LogoTPS 320i, TPS 400i, TPS 500i, TPS 600i
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    • Imprint
    • Terms and Conditions
    • Data privacy statement
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    • 044-05122024
    • Safety rules
      • Explanation of safety notices
      • General
      • Proper use
      • Mains connection
      • Environmental conditions
      • Obligations of the operator
      • Obligations of personnel
      • Residual current protective device
      • Protecting yourself and others
      • Noise emission values
      • Danger from toxic gases and vapours
      • Danger from flying sparks
      • Risks from mains current and welding current
      • Meandering welding currents
      • EMC Device Classifications
      • EMC measures
      • EMF measures
      • Specific hazards
      • Requirement for the shielding gas
      • Danger from shielding gas cylinders
      • Danger from escaping shielding gas
      • Safety measures at the installation location and during transport
      • Safety measures in normal operation
      • Commissioning, maintenance and repair
      • Safety inspection
      • Safety symbols
      • Data security
      • Copyright
    • General information
      • General
        • Device concept
        • Power source = welding machine
        • How it works
        • Application areas
        • Conformities
        • Bluetooth trademarks
        • Warning notices on the device
      • System components
        • General
        • Overview
        • Options
        • OPT/i Safety Stop PL d option
    • Welding packages, welding characteristics and welding processes
      • Welding packages
        • General
        • Welding packages
      • Welding characteristics
        • Welding characteristics
      • Welding methods and processes
        • MIG/MAG pulse synergic welding
        • MIG/MAG standard synergic welding
        • PMC process
        • LSC process
        • SynchroPulse welding
        • CMT process
        • CMT Cycle Step welding process
        • SlagHammer
        • Stitch welding
        • WireSense
        • ConstantWire
        • Gouging (arc air gouging)
    • Controls, connections and mechanical components
      • Control panel
        • General
        • Safety
        • Control panel
        • Input options
      • Display and status line
        • Display
        • Status bar
        • Status bar – Current limit reached
        • Switching to full screen
        • Next page - Previous page
        • Animated graphics
        • Greyed out parameters
      • Connections, switches and mechanical components
        • TPS 320i / 400i / 500i / 600i welding machine
    • Installation and commissioning
      • Minimum equipment needed for welding task
        • General
        • MIG/MAG gas-cooled welding
        • MIG/MAG water-cooled welding
        • MIG/MAG automated welding
        • Manual CMT welding
        • Automated CMT welding
        • TIG DC welding
        • Manual metal arc welding
        • Arc air gouging
      • Before installation and commissioning
        • Safety
        • Intended use
        • Setup regulations
        • Mains connection
        • Generator-powered operation
        • Information on system components
      • Connecting the mains cable
        • General
        • Stipulated mains cables
        • Safety
        • Connecting the mains cable - general
      • Commissioning the TPS 320i / 400i / 500i / 600i
        • Safety
        • General
        • TPS 320i / 400i / 500i / 600i:
          Assembling the system components (overview)
        • Fixing the strain-relief device for the interconnecting hosepack
        • Connecting the interconnecting hosepack
        • Correct arrangement of the interconnecting hosepack
        • Connecting the gas cylinder
        • Establishing a ground earth connection
        • Connecting MIG/MAG welding torches to the wirefeeder
        • Other tasks
        • Notes on wire threading
      • Locking and unlocking the welding machine using the NFC key
        • General
        • Locking and unlocking the welding machine using the NFC key
    • Welding
      • MIG/MAG modes
        • General
        • Symbols and their explanations
        • 2-step mode
        • 4-step mode
        • Special 4-step mode
        • Special 2-step mode
        • Spot welding
      • MIG/MAG and CMT welding
        • Safety
        • MIG/MAG and CMT welding – overview
        • Switching on the welding machine
        • Setting the welding process and operating mode via the status bar
        • Setting the welding process and operating mode via the menu bar
        • Selecting the filler metal and shielding gas
        • Setting the welding parameters
        • Set the shielding gas flow rate
        • MIG/MAG or CMT welding
      • Spot and stitch welding
        • Spot welding
        • Stitch welding
      • MIG/MAG and CMT welding parameters
        • Welding parameters for MIG/MAG pulse synergic welding and PMC welding
        • Welding parameters for MIG/MAG standard synergic welding, LSC welding and CMT welding
        • Welding parameters for MIG/MAG standard manual welding
        • Explanation of footnotes
      • EasyJob mode
        • General
        • Activating EasyJob mode
        • Storing EasyJob operating points
        • Retrieving EasyJob operating points
        • Deleting EasyJob operating points
        • Loading more EasyJobs
      • Job mode
        • General
        • Storing settings as a job
        • Job welding - retrieving a job
        • Renaming a job
        • Deleting a job
        • Loading a job
        • Optimizing a job
        • Setting correction limits for a job
        • Pre-settings for "Save as Job"
        • Job Mode with WF 25i Dual
      • TIG welding
        • Safety
        • Preparation
        • TIG welding
        • Igniting the arc
        • Finishing welding
      • MMA welding
        • Safety
        • Preparation
        • Manual metal arc welding
        • Welding parameters for manual metal arc welding
      • Arc Air Gauging
        • Safety
        • Preparation
        • Arc air gouging
    • Process parameters
      • Overview
        • Overview
      • Process parameters, General
        • Common process parameters
        • Process parameters for start of welding/end of welding
        • Process parameters for Gas-Setup
        • Process parameters for process control
        • Penetration stabilizer
        • Arc length stabilizer
        • Combination of penetration stabilizer and arc length stabilizer
        • Process parameters for SynchroPulse
        • Process parameters for process mix
        • Process parameters for TWIN process control
        • Process parameters for CMT Cycle Step
        • Process parameters for ConstantWire
        • Process parameters for spot welding
        • Process parameters for interval
        • Process parameters for manual setup
        • R/L-check / alignment
        • Process parameters for TIG / electrode setup
      • Components and monitoring process parameters
        • Process parameters - Components and monitoring
        • Process parameters for components
        • System adjust
        • Arc break monitoring
        • Wire stick contact tip
        • Wire stick work piece
        • Welding circuit coupling
        • Wire end monitoring
        • Gas monitoring
        • Motor force monitoring
        • Wire buffer monitoring
      • Process parameters, Job
        • Overview – Process parameters, Job
        • Optimising job process parameters
        • Process parameters for correction limits
        • Process parameters for "Save as Job" pre-settings
    • Defaults
      • Defaults
        • General
        • Overview
      • Defaults - view
        • Defaults view
        • Setting the language
        • Setting units / standards
        • Setting the time and date
        • Retrieving system data
        • Displaying characteristics
        • MIG/MAG parameter display
        • JobMaster MIG/MAG display
      • Defaults - System
        • Defaults - System
        • Retrieving device information
        • Restore factory settings
        • Restoring the website password
        • Mode Setup: Setting the special 4-step "Guntrigger", special display for JobMaster, spot welding and torch trigger job selection
        • Service Connect
        • Network settings
        • Setting network parameters manually
        • WLAN
        • Bluetooth settings
        • WeldCube Air
        • Client authorization
        • USB port
        • Welding machine configuration
        • Wire feeder setup
        • Interface setup
        • TWIN setup
      • Defaults - Documentation
        • Defaults - Documentation
        • Setting the sampling rate
        • Viewing the logbook
        • Activating/deactivating limit value monitoring
      • Defaults - Administration
        • Defaults - Administration
        • General
        • Explanation of terms used
        • Pre-defined roles and users
        • User management overview
      • Administrator and creating roles
        • Recommendation for creating roles and users
        • Creating an administrator key
        • Creating roles
        • Copy roles
      • Creating a user
        • Creating a user
        • Copying users
      • Editing roles / users, deactivating user management
        • Editing roles
        • Deleting roles
        • Editing users
        • Deleting users
        • Deactivating user management
        • Lost NFC administrator key?
      • CENTRUM - Central User Management
        • Activating the CENTRUM server
    • SmartManager - the welding machine website
      • SmartManager - the welding machine website
        • General
        • Call up the welding machine SmartManager and log in
        • Help function, should you be unable to log in
        • Changing password / logging off
        • Settings
        • Language selection
        • Status indicator
        • Fronius
      • Current system data
        • Current system data
      • Documentation, logbook
        • Logbook
        • Basic settings
      • Job-Data
        • Job data
        • Job overview
        • Editing a job
        • Importing a job
        • Exporting a job
        • Exporting job(s) as…
      • Welding machine settings
        • Process parameters
        • Name & location
        • Parameter display
        • Date & time
        • Network settings
        • MQTT settings
        • OPC UA settings
      • Backup & Restore
        • General remarks
        • Backup & Restore
        • Automatic backup
      • Signal visualisation
        • Signal visualisation
      • User management
        • General
        • Users
        • User roles
        • Export & import
        • CENTRUM server
      • Overview
        • Overview
        • Expanding / reducing all groups
        • Export component overview as ...
      • Update
        • Update
        • Searching for an update file (performing the update)
        • Information on open source licensing
        • Fronius WeldConnect
      • Function Packages
        • Function Packages
        • Installing a function package
      • Synergic lines overview
        • Characteristics overview
        • Show filter
      • Screenshot
        • Screenshot
      • Interface
        • Interface
    • Troubleshooting and maintenance
      • Troubleshooting
        • General
        • Safety
        • MIG/MAG welding - current limit
        • Troubleshooting the welding machine
      • Care, maintenance and disposal
        • General
        • Safety
        • At every start-up
        • Every 2 months
        • Every 6 months
        • Updating firmware
        • Disposal
    • Appendix
      • Average consumption values during welding
        • Average wire electrode consumption during MIG/MAG welding
        • Average shielding gas consumption during MIG/MAG welding
        • Average shielding gas consumption during TIG welding
      • Technical data
        • Explanation of the term "duty cycle"
        • Special voltages
        • Overview with critical raw materials, year of production of the device
        • TPS 320i
        • TPS 320i /nc
        • TPS 320i /600V/nc
        • TPS 320i /MV/nc
        • TPS 400i
        • TPS 400i /nc
        • TPS 400i /600V/nc
        • TPS 400i /MV/nc
        • TPS 500i
        • TPS 500i /nc
        • TPS 500i /600V/nc
        • TPS 500i /MV/nc
        • TPS 600i
        • TPS 600i /nc
        • TPS 600i /600V/nc
        • China Energy Label
        • Radio parameters
        • Catalogue C
      • Hazardous Substances

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

    Controls
    Input options
    Commissioning
    MIG/MAG welding
    MIG/MAG welding parameters
    Process parameters
    Defaults
    SmartManager
    Technical data

    Safety rules

    Explanation of safety notices

    DANGER!

    Indicates immediate danger.

    If not avoided, death or serious injury will result.

    WARNING!

    Indicates a potentially hazardous situation.

    If not avoided, death or serious injury may result.

    CAUTION!

    Indicates a situation where damage or injury could occur.

    If not avoided, minor injury and/or damage to property may result.

    NOTE!

    Indicates a risk of flawed results and possible damage to the equipment.

    1. Safety rules

    Explanation of safety notices

    DANGER!

    Indicates immediate danger.

    If not avoided, death or serious injury will result.

    WARNING!

    Indicates a potentially hazardous situation.

    If not avoided, death or serious injury may result.

    CAUTION!

    Indicates a situation where damage or injury could occur.

    If not avoided, minor injury and/or damage to property may result.

    NOTE!

    Indicates a risk of flawed results and possible damage to the equipment.

    1. Safety rules

    General

    The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause:
    • injury or death to the operator or a third party,
    • damage to the device and other material assets belonging to the operating company,
    • inefficient operation of the device.
    All persons involved in commissioning, operating, maintaining and servicing the device must:
    • be suitably qualified,
    • have sufficient knowledge of welding and
    • read and follow these operating instructions carefully.

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

    All safety and danger notices on the device
    • must be in a legible state,
    • must not be damaged,
    • must not be removed,
    • must not be covered, pasted or painted over.

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

    1. Safety rules

    Proper use

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

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

    Proper use includes:
    • carefully reading and following all the instructions given in the operating instructions
    • studying and obeying all safety and danger notices carefully
    • performing all stipulated inspection and maintenance work.
    Never use the device for the following purposes:
    • Thawing out pipes
    • Charging batteries
    • Starting engines

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

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

    1. Safety rules

    Mains connection

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

    This may affect a number device types in terms of:
    • Connection restrictions
    • Criteria with regard to the maximum permissible mains impedance *)
    • Criteria with regard to the minimum short-circuit power requirement *)

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

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

    IMPORTANT! Ensure that the mains connection is earthed properly

    1. Safety rules

    Environmental conditions

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

    Ambient temperature range:
    • during operation: -10 °C to + 40 °C (14 °F to 104 °F)
    • during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
    Relative humidity:
    • up to 50% at 40 °C (104 °F)
    • up to 90% at 20 °C (68 °F)

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

    1. Safety rules

    Obligations of the operator

    The operator must only allow persons to work with the device who:
    • are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device
    • have read and understood these operating instructions, especially the 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

    Obligations of personnel

    Before using the device, all persons instructed to do so undertake:
    • 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

    Residual current protective device

    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

    Protecting yourself and others

    Anyone working with the device exposes themselves to numerous risks, e.g.
    • flying sparks and hot pieces of metal
    • Arc radiation, which can damage eyes and skin
    • Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
    • Risk of electrocution from mains current and welding current
    • Greater noise pollution
    • Harmful welding fumes and gases
    Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:
    • Flame-resistant
    • Insulating and dry
    • Covers the whole body, is undamaged and in good condition
    • Safety helmet
    • Trousers with no turn-ups
    Protective clothing refers to a variety of different items. Operators should:
    • Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
    • Wear regulation protective goggles with side protection behind the 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
    Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
    • Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)
    • Provide suitable protective equipment
    • Alternatively, erect suitable safety screens/curtains.
    1. Safety rules

    Noise emission values

    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

    Danger from toxic gases and vapours

    The fumes produced during welding contain harmful gases and vapours.

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

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

    Keep your face away from welding fumes and gases.

    Fumes and hazardous gases
    • must not be breathed in
    • must be extracted from the working area using appropriate methods.

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

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

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

    The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:
    • Metals used for the workpiece
    • Electrodes
    • Coatings
    • Cleaners, degreasers, etc.
    • Welding process used

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

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

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

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

    1. Safety rules

    Danger from flying sparks

    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

    Risks from mains current and welding current

    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.

    The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
    • 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.

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

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

    1. Safety rules

    Meandering welding currents

    If the following instructions are ignored, meandering welding currents can develop with the following consequences:
    • Fire hazard
    • Overheating of parts connected to the workpiece
    • Damage to ground conductors
    • Damage to device and other electrical equipment

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

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

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

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

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

    1. Safety rules

    EMC Device Classifications

    Devices in emission class A:
    • Are only designed for use in industrial settings
    • Can cause line-bound and radiated interference in other areas
    Devices in emission class B:
    • Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

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

    1. Safety rules

    EMC measures

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

    Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interference from the device include:
    • Safety devices
    • Network, signal and data transfer lines
    • IT and telecommunications devices
    • Measuring and calibrating devices
    Supporting measures for avoidance of EMC problems:
    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

    EMF measures

    Electromagnetic fields may pose as yet unknown risks to health:
    • Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
    • Individuals with pacemakers must seek advice from their doctor before 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

    Specific hazards

    Keep hands, hair, clothing and tools away from moving parts. For example:
    • 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 may only be opened/removed while maintenance or repair work is being carried out.

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

    The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
    Therefore, always keep the welding torch facing 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 machines for work in areas with increased electrical risk (e.g. near boilers) must carry the 'Safety' sign. However, the welding machine 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 suitable load-carrying equipment.
    • Chains or 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).

    Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

    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

    Requirement for the shielding gas

    Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality.
    Meet the following requirements regarding shielding gas quality:
    • Solid particle size < 40 µm
    • Pressure condensation point < -20 °C
    • Max. oil content < 25 mg/m³

    Use filters if necessary.

    1. Safety rules

    Danger from shielding gas cylinders

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

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

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

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

    Never hang a welding torch on a shielding gas cylinder.

    Never touch a shielding gas cylinder with an electrode.

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

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

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

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

    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

    Danger from escaping shielding gas

    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

    Safety measures at the installation location and during transport

    A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable
    • The maximum permissible tilt angle is 10°.
    Special regulations apply in rooms at risk of fire or explosion
    • Observe relevant national and international regulations.

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

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

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

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

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

    Before transporting the device, allow coolant to drain completely and detach the following components:
    • Wirefeeder
    • Wirespool
    • Shielding gas cylinder

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

    1. Safety rules

    Safety measures in normal operation

    Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
    • injury or death to the operator or a third party
    • damage to the device and other material assets belonging to the operator
    • inefficient operation of the device

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

    Never bypass or disable safety devices.

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

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

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

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

    Only use suitable original coolant from the manufacturer.

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

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

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

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

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

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

    1. Safety rules

    Commissioning, maintenance and repair

    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

    Safety inspection

    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.

    A safety inspection should be carried out by a qualified electrician
    • after any changes are made
    • after any additional parts are installed, or after any conversions
    • after repair, care and maintenance 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

    Safety symbols

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

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

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

    1. Safety rules

    Data security

    With regard to data security, the user is responsible for:
    • backing up any changes made to the factory settings
    • saving and retaining personal settings
    1. Safety rules

    Copyright

    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.

    General information

    General

    Device concept

    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

    General

    Device concept

    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

    Device concept

    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

    Power source = welding machine

    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

    How it works

    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.

    This results in:
    • A precise welding process
    • Exact reproducibility of all results
    • Excellent weld properties
    1. General information
    2. General

    Application areas

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

    The 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

    Conformities

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

    FCC ID: QKWSPBMCU2

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

    (1)
    The device must not cause any harmful interference.
    (2)
    The device must be able to cope with any interference, including that which could adversely affect its operation.

    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:

    (1)
    The device must not cause any harmful interference.
    (2)
    This device must accept any interference received, including interference that may cause undesired operation.

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

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

    Article 14
    The use of low-power radio frequency devices must not adversely affect flight safety and communications.
    A detected malfunction must be deactivated and corrected immediately until no malfunction is present.
    The notice in the preceding paragraph refers to radio communications operated in accordance with the provisions of the Telecommunications Act. Low-power 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

    Bluetooth trademarks

    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 on the device

    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

    System components

    General

    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

    General

    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

    Overview

    (1)
    Cooling units
    (2)
    Welding machines
    (3)
    Robot accessories
    (4)
    Interconnecting hosepacks (max. 50 m)*
    (5)
    Wirefeeders
    (6)
    Wirefeeder holder
    (7)
    Trolleys and gas cylinder holders
    *
    Interconnecting hosepacks > 50 m only in combination with optional
    OPT/i SpeedNet Repeater

    Also:

    • Welding torches
    • Grounding cable and electrode cable
    • Dust filter
    • Additional current sockets
    1. General information
    2. System components

    Options

    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

    OPT/i Safety Stop PL d option

    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.

    Welding packages, welding characteristics and welding processes

    Welding packages

    General

    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

    Welding packages

    General

    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

    General

    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

    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)

     

    *
    Only in conjunction with the Standard Welding Package
    **
    Only in conjunction with the Pulse Welding Package
    ***
    Only in conjunction with the Standard Welding Package and the Pulse Welding Package

    IMPORTANT! A TPSi 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

    Welding characteristics

    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)
    Can only be used with iWave AC/DC multiprocess welding machines
    2)
    Welding characteristics with special properties provided by additional hardware
    3)
    Mixed process characteristics
    1. Welding packages, welding characteristics and welding processes
    2. Welding characteristics

    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)
    Can only be used with iWave AC/DC multiprocess welding machines
    2)
    Welding characteristics with special properties provided by additional hardware
    3)
    Mixed process characteristics
    1. Welding packages, welding characteristics and welding processes

    Welding methods and processes

    MIG/MAG pulse synergic welding

    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

    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 standard synergic welding

    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 process

    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 process

    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 welding

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

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

    CMT process

    CMT = Cold Metal Transfer

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

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

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

    The CMT process is suitable for:

    • Joint welding, cladding and brazing – particularly in the case of high 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

    NOTE!

    A CMT reference book is available complete with typical applications;
    see ISBN 978-3-8111-6879-4.

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

    CMT Cycle Step welding process

    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

    SlagHammer

    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

    Stitch welding

    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

    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

    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

    Gouging (arc air gouging)

    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!

    Controls, connections and mechanical components

    Control panel

    General

    Welding parameters can be easily changed and selected using the adjusting dial.
    The parameters are shown on the display while welding is in progress.

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

    NOTE!

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

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

    1. Controls, connections and mechanical components

    Control panel

    General

    Welding parameters can be easily changed and selected using the adjusting dial.
    The parameters are shown on the display while welding is in progress.

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

    NOTE!

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

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

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

    General

    Welding parameters can be easily changed and selected using the adjusting dial.
    The parameters are shown on the display while welding is in progress.

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

    NOTE!

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

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

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

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

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

    Control panel

    43,0001,3547
    No.Function
    (1)
    USB port for servicing purposes
    For connecting TPS/i Licence Key, TPS/i Demonstrator Dongle und TPS/i Service Dongle
    For details on the function of the USB port, see page (→).
    IMPORTANT! The USB port is not electrically isolated from the welding circuit. Devices that establish an electrical connection with another device must therefore not be connected to the USB port.
    (2)
    Adjusting dial with turn/press function
    To select elements, set values and scroll through lists
    (3)
    Display (touchscreen)
    • For operating the welding machine by touching the display
    • For displaying values
    • For navigating in the menu
    (4)
    Key card reader for NFC keys
    • For locking/unlocking the welding machine using NFC keys
    • For logging on different users (with active user management and assigned NFC keys)
    NFC key = NFC card or NFC key ring
    (5)
    Wire threading button
    To thread the wire electrode into the torch hosepack with no accompanying flow of gas or current
    (6)
    Gas-test button
    For setting the required gas flow rate on the gas pressure regulator.
    After pressing this button, gas flows for 30 seconds. Press the button again to stop the gas flow prematurely.
    1. Controls, connections and mechanical components
    2. Control panel

    Input options

    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

    Display and status line

    Display

    No.Function
    (1)
    Status bar
    The status bar provides information on:
    • Current welding data
    • Bluetooth or WLAN status
    • Logged-on user/locked state of the welding machine
    • Active faults
    • Time and date
    • and more
    For details, see from page (→)
    (2)
    Left-hand menu bar
    The left-hand menu bar contains the menus:
    • Welding
    • Welding process
    • Process parameters
    • Defaults
    The buttons in the left-hand menu bar are actuated by touching the display.
    (3)
    Main area
    The welding parameters, graphics, lists or navigation elements are shown in the main area. The structure of the main area and the elements shown in it vary according to the application.
    (3a)
    Available welding parameters
    The main area is operated via the adjusting dial or by touching the display.
    (4)
    Right-hand menu bar
    Depending on the menu selected in the left-hand menu bar, the right-hand menu bar may be used as follows:
    • As a function ribbon containing application and function buttons
    • For navigating through the 2nd menu level
    The buttons in the right-hand menu bar are actuated by touching the display.
    (5)
    Welding data display
    Welding current, welding voltage, wire speed, welding power (in kW)
    Different values are displayed here depending on the situation:
    • When setting the standard value
    • The actual value during welding
    • After welding, the hold value or average value - depending on the setting in the default settings (see also from page (→))
    1. Controls, connections and mechanical components
    2. Display and status line

    Display

    No.Function
    (1)
    Status bar
    The status bar provides information on:
    • Current welding data
    • Bluetooth or WLAN status
    • Logged-on user/locked state of the welding machine
    • Active faults
    • Time and date
    • and more
    For details, see from page (→)
    (2)
    Left-hand menu bar
    The left-hand menu bar contains the menus:
    • Welding
    • Welding process
    • Process parameters
    • Defaults
    The buttons in the left-hand menu bar are actuated by touching the display.
    (3)
    Main area
    The welding parameters, graphics, lists or navigation elements are shown in the main area. The structure of the main area and the elements shown in it vary according to the application.
    (3a)
    Available welding parameters
    The main area is operated via the adjusting dial or by touching the display.
    (4)
    Right-hand menu bar
    Depending on the menu selected in the left-hand menu bar, the right-hand menu bar may be used as follows:
    • As a function ribbon containing application and function buttons
    • For navigating through the 2nd menu level
    The buttons in the right-hand menu bar are actuated by touching the display.
    (5)
    Welding data display
    Welding current, welding voltage, wire speed, welding power (in kW)
    Different values are displayed here depending on the situation:
    • When setting the standard value
    • The actual value during welding
    • After welding, the hold value or average value - depending on the setting in the default settings (see also from page (→))
    1. Controls, connections and mechanical components
    2. Display and status line

    Status bar

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

    (1)
    Current welding process
    (2)
    Current operating mode
    (3)
    Current welding program
    (material, shielding gas, characteristic and wire diameter)
    (4)
    Process functions display

     

    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
    (6)
    TWIN mode only:
    Welding machine number, LEAD / TRAIL / SINGLE

    Only in operation with WF 25i Dual double-head wirefeeder:
    Currently selected welding process line

    During Teaching, Touchsensing and WireSense:

     

    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

    NOTE!

    The following functions can be selected and set directly in the status bar:

    (1) Welding process
    (2) Operating mode
    (3) Characteristic (e.g. dynamic, root, universal, etc.)
    (4) SynchroPulse, Spatter Free Ignition, Interval, CMT Cycle Step, Penetration stabilizer, Arc length stabilizer

    Touch the desired function in the status bar and set it in the window that opens.

    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

    Status bar – Current limit reached

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

    1For detailed information, select the status bar

    The information appears.

    2Select "Hide information" to exit
    3Reduce the wire speed, welding current, welding voltage or material thickness

    or

    Increase the distance between the contact tip and the workpiece

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

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

    Switching to full screen

    1

    The display is shown in full screen mode:

    2Exit full screen mode:

    NOTE!

    Hiding the EasyJobs produces the optimal full-screen display:

    Defaults / View / EasyJobs / EasyJobs Off

    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

    Next page - Previous page

    NOTE!

    The number and sequence of the displayed parameters may vary depending on the device type, equipment and available Welding Packages.

    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

    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

    Greyed out parameters

    NOTE!

    In the menus, certain parameters are greyed out because they have no function with the currently selected settings.

    Greyed-out parameters can be selected and changed, but have no influence on the current welding process or the welding result.

    (a)
    Greyed out parameter (e.g. penetration stabilizer)
    (b)
    Greyed out parameter selected
    (c)
    Value of the greyed out parameter is changed
    (d)
    Greyed out parameter with changed value - no effect with current settings
    1. Controls, connections and mechanical components

    Connections, switches and mechanical components

    TPS 320i / 400i / 500i / 600i welding machine

    Front
    Rear
    No.Function
    (1)
    Mains switch
    For switching the welding machine on and off
    (2)
    Control panel cover
    For protecting the control panel
    (3)
    Control panel with display
    For operating the welding machine
    (4)
    (-) current socket with bayonet latch
    For connecting the return lead cable during MIG/MAG welding
    (5)
    Blanking cover
    Reserved for the second (+) current socket option with bayonet latch
    (6)
    Blanking cover
    Reserved for the second SpeedNet connection socket option
    (7)
    Blanking cover
    Reserved for the second SpeedNet connection socket option
    (8)
    (+) current socket with fine-pitch thread (Power Connector)
    For connecting the power cable from the interconnecting hosepack during MIG/MAG welding
    (9)
    SpeedNet connection socket
    For connecting the interconnecting hosepack
    (10)
    Ethernet port
    (11)
    Mains cable with strain relief
    (12)
    Blanking cover
    Reserved for the second (-) current socket option with bayonet latch

    The second (-) current socket is used to connect the interconnecting hosepack during MIG/MAG welding for polarity reversal (e.g. for flux-cored wire welding)
    (13)
    Blanking cover
    Reserved for the second SpeedNet connection socket option or robot interface
    RI FB Inside/i

    Fitted on the TPS 600i is another cover plate, containing the system bus connection for the OPT/i TPS 4x Switch SpeedNet option.
    1. Controls, connections and mechanical components
    2. Connections, switches and mechanical components

    TPS 320i / 400i / 500i / 600i welding machine

    Front
    Rear
    No.Function
    (1)
    Mains switch
    For switching the welding machine on and off
    (2)
    Control panel cover
    For protecting the control panel
    (3)
    Control panel with display
    For operating the welding machine
    (4)
    (-) current socket with bayonet latch
    For connecting the return lead cable during MIG/MAG welding
    (5)
    Blanking cover
    Reserved for the second (+) current socket option with bayonet latch
    (6)
    Blanking cover
    Reserved for the second SpeedNet connection socket option
    (7)
    Blanking cover
    Reserved for the second SpeedNet connection socket option
    (8)
    (+) current socket with fine-pitch thread (Power Connector)
    For connecting the power cable from the interconnecting hosepack during MIG/MAG welding
    (9)
    SpeedNet connection socket
    For connecting the interconnecting hosepack
    (10)
    Ethernet port
    (11)
    Mains cable with strain relief
    (12)
    Blanking cover
    Reserved for the second (-) current socket option with bayonet latch

    The second (-) current socket is used to connect the interconnecting hosepack during MIG/MAG welding for polarity reversal (e.g. for flux-cored wire welding)
    (13)
    Blanking cover
    Reserved for the second SpeedNet connection socket option or robot interface
    RI FB Inside/i

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

    Installation and commissioning

    Minimum equipment needed for welding task

    General

    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

    Minimum equipment needed for welding task

    General

    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

    General

    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

    MIG/MAG gas-cooled welding

    • 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

    MIG/MAG water-cooled welding

    • 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

    MIG/MAG automated welding

    • 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

    Manual CMT welding

    • 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

    Automated CMT welding

    • 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

    TIG DC welding

    • 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

    Manual metal arc welding

    • 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

    Arc air gouging

    • 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

    Before installation and commissioning

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

    1. Installation and commissioning
    2. Before installation and commissioning

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

    1. Installation and commissioning
    2. Before installation and commissioning

    Intended use

    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.

    Intended use also includes:
    • 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

    Setup regulations

    The device has been tested according to degree of protection IP23. This means:
    • 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.

    WARNING!

    Danger from machines toppling over or falling.

    This can result in serious personal injury and damage to property.

    Set up the device securely on an even, solid surface.

    Check all screw connections are tightly fastened after installation.

    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

    Mains connection

    • 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.

    CAUTION!

    An inadequately dimensioned electrical installation can cause serious damage to property.

    The mains lead and its fuse protection must be dimensioned to suit the local power supply.
    The technical data shown on the rating plate applies.

    1. Installation and commissioning
    2. Before installation and commissioning

    Generator-powered operation

    The welding machine is generator-compatible.

    The maximum apparent power S1max of the welding machine must be known in order to select the correct generator output.
    The maximum apparent power S1max of the welding machine is calculated for 3-phase devices as follows:

    S1max = I1max x U1 x √3

    See device rating plate or technical data for I1max and U1 values

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

    SGEN = S1max x 1.35

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

    IMPORTANT! The generator apparent power SGEN must always be higher than the maximum apparent power S1max of the welding machine.

    NOTE!

    The voltage delivered by the generator must never violate the upper or lower limits of the mains voltage tolerance range.

    Details of the mains voltage tolerance can be found in the "Technical data" section.

    1. Installation and commissioning
    2. Before installation and commissioning

    Information on system components

    The steps and activities described below include references to various system components, including:
    • Trolleys
    • Cooling units
    • Wire-feed unit holders
    • Wire-feed units
    • Interconnecting hosepacks
    • Welding torches
    • etc.

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

    1. Installation and commissioning

    Connecting the mains cable

    General

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

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

    1. Installation and commissioning
    2. Connecting the mains cable

    General

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

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

    1. Installation and commissioning
    2. Connecting the mains cable

    Stipulated mains cables

    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 | -

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

    AWG = American wire gauge

    1. Installation and commissioning
    2. Connecting the mains cable

    Safety

    WARNING!

    Danger due to work that has been carried out incorrectly.

    This can result in serious injury and damage to property.

    The work described below must only be carried out by trained and qualified personnel.

    Observe national standards and directives.

    CAUTION!

    Danger due to improperly prepared mains cable.

    This can result in short circuits and damage to property.

    Fit ferrules to all phase conductors and the ground conductor of the stripped mains cable.

    1. Installation and commissioning
    2. Connecting the mains cable

    Connecting the mains cable - general

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

    1
    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

    Commissioning the TPS 320i / 400i / 500i / 600i

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all the devices and components involved to prevent unintentional restarting.

    WARNING!

    Danger from electrical current due to electrically conductive dust in the device.

    This can result in serious injury and damage to property.

    Only operate the device with an air filter fitted. The air filter is a very important safety device for achieving IP 23 protection.

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

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all the devices and components involved to prevent unintentional restarting.

    WARNING!

    Danger from electrical current due to electrically conductive dust in the device.

    This can result in serious injury and damage to property.

    Only operate the device with an air filter fitted. The air filter is a very important safety device for achieving IP 23 protection.

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

    General

    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

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

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

    Fixing the strain-relief device for the interconnecting hosepack

    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

    Connecting the interconnecting hosepack

    NOTE!

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

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

    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

    CAUTION!

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

    Lay the interconnecting hosepack without loops

    Do not put anything on top of the interconnecting hosepack

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

    Correct arrangement of the interconnecting hosepack

    IMPORTANT!

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

    Connecting the gas cylinder

    WARNING!

    Danger from falling gas cylinders.

    This can result in serious injury and damage to property.

    Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

    Observe the safety rules of the gas cylinder manufacturer.

    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

    Establishing a ground earth connection

    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.

    CAUTION!

    A shared ground earth connection for multiple welding machines will have an adverse effect on welding results!

    If multiple welding machines are being used to weld a component, a shared ground earth connection can have a massive impact on the welding results.

    Separate the welding circuits!

    Provide a different ground earth connection for each welding circuit!

    Do not use a single, shared return (ground) lead!

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

    Connecting MIG/MAG welding torches to the wirefeeder

    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

    Other tasks

    Carry out the following steps in accordance with the wirefeeder Operating Instructions:
    1Insert the feed rollers in the wirefeeder
    2Insert the wirespool or basket-type spool with adapter in the wirefeeder
    3Feeding in the wire electrode

    The wire electrode can be fed in by pressing a wire threading button in the welding system or by pressing the torch trigger.
    The dialogue window "Wire threading" is shown on the display.
    4Setting the contact pressure
    5Adjusting the brake

    IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made 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

    Notes on wire threading

    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

    Locking and unlocking the welding machine using the NFC key

    General

    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

    General

    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 and unlocking the welding machine using the NFC key

    Locking the welding machine

    1Hold the NFC key on the NFC key reader

    The key symbol appears on the display.

    The key symbol is then displayed in the status bar.

    The 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

    1Hold the NFC key on the NFC key reader

    The crossed-out key symbol appears on the display.

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

    NOTE!

    More information about locking and unlocking the welding machine can be found in the "Defaults - Management / Administration" chapter from page (→).

    Welding

    MIG/MAG modes

    General

    WARNING!

    Danger from incorrect operation.

    Possible serious injury and damage to property.

    Do not use the functions described here until you have read and completely understood these Operating Instructions.

    Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!

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

    1. Welding

    MIG/MAG modes

    General

    WARNING!

    Danger from incorrect operation.

    Possible serious injury and damage to property.

    Do not use the functions described here until you have read and completely understood these Operating Instructions.

    Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!

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

    1. Welding
    2. MIG/MAG modes

    General

    WARNING!

    Danger from incorrect operation.

    Possible serious injury and damage to property.

    Do not use the functions described here until you have read and completely understood these Operating Instructions.

    Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules!

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

    1. Welding
    2. MIG/MAG modes

    Symbols and their explanations

    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

    2-step mode

    "2-step mode" is suitable for
    • Tacking work
    • Short weld seams
    • Automated and robot welding
    1. Welding
    2. MIG/MAG modes

    4-step mode

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

    1. Welding
    2. MIG/MAG modes

    Special 4-step mode

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

    1. Welding
    2. MIG/MAG modes

    Special 2-step mode

    "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

    Spot welding

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

    1. Welding

    MIG/MAG and CMT welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. MIG/MAG and CMT welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. MIG/MAG and CMT welding

    MIG/MAG and CMT welding – overview

    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

    NOTE!

    If using a cooling unit, follow the safety rules and note the operating conditions in the cooling unit operating instructions.

    1. Welding
    2. MIG/MAG and CMT welding

    Switching on the welding machine

    1Connect the mains cable
    2Move the mains switch to the "I" position

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

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

    1. Welding
    2. MIG/MAG and CMT welding

    Setting the welding process and operating mode via the status bar

    1In the status bar, select the symbol for the welding process

    An overview of the welding processes is displayed.

    NOTE!

    The number and sequence of the displayed welding processes may vary depending on the device type, equipment and available Welding Packages.

    2Select the desired welding process
    3In the status bar, select the symbol for the operating mode

    An overview of the operating modes is displayed.

    NOTE!

    The number and sequence of the displayed operating modes may vary depending on the device type, equipment and available Welding Packages.

    4Select the desired operating mode
    1. Welding
    2. MIG/MAG and CMT welding

    Setting the welding process and operating mode via the menu bar

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

    NOTE!

    The number and sequence of the displayed welding processes may vary depending on the device type, equipment and available welding packages.

    1Select "Welding process"
    2Select "Process"

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

    3Select the desired welding process
    4Select "Mode"

    An overview of the operating modes is displayed:

    • 2-step mode
    • 4-step mode
    • Special 2-step mode
    • Special 4-step mode
    • Spot welding
    5Select the desired operating mode
    1. Welding
    2. MIG/MAG and CMT welding

    Selecting the filler metal and shielding gas

    1Select "Welding process"
    2Select "Filler metal"
    3Select "Change material settings"
    4Turn the adjusting dial and select the desired filler metal
    5Select "Next" / press the adjusting dial
    6Turn the adjusting dial and select the desired wire diameter
    7Select "Next" / press the adjusting dial
    8Turn the adjusting dial and select the desired shielding gas
    9Select "Next" / press the adjusting dial

    NOTE!

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

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

    10Turn the adjusting dial and select the desired welding process
    11To select the desired characteristic, press the adjusting dial (blue background)
    12Turn the adjusting dial and select the desired characteristic
    13Press the adjusting dial and apply the selected characteristic (white background)
    14Select "Next"

    The confirmation step of the filler metal wizard is displayed:

    15Select "Save" / press the adjusting dial

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

    1. Welding
    2. MIG/MAG and CMT welding

    Setting the welding parameters

    1Select "Welding"
    2Select the desired welding parameter by turning the adjusting dial
    3Press the adjusting dial to change the parameter

    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.

    4Turn the adjusting dial to change the parameter

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

    5Press the adjusting dial to call up the welding parameters overview
    6Adjust the process parameters accordingly to make user or application-specific settings on the welding system

    NOTE!

    If there is a WF 25i Dual double-head wirefeeder in the welding system, set welding parameters and process parameters for both welding process lines separately.

    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

    Set the shielding gas flow rate

    1Open the gas cylinder valve
    2Press the gas-test button

    Gas flows out.
    The "Gas purging" dialogue window appears on the display, indicating the remaining gas purging time. If there is a gas regulator or gas sensor in the welding system, the actual gas value is also displayed.
    3Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the required shielding gas flow rate
    4Press the gas-test button
    The flow of gas stops.
    1. Welding
    2. MIG/MAG and CMT welding

    MIG/MAG or CMT welding

    1Select "Welding" to display the welding parameters

    CAUTION!

    Danger from emerging wire electrode.

    This can result in personal injury.

    Hold the welding torch with the end directed away from the face and body.

    Wear suitable protective goggles.

    Do not point the welding torch at people.

    Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.

    2Press the torch trigger and start 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 (→)).

    NOTE!

    Under certain circumstances, it may not be possible to change welding parameters that have been set on a system component (such as wirefeeder or remote control) from the control panel of the welding machine.

    1. Welding

    Spot and stitch welding

    Spot welding

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

    1Select the desired welding process:
    • Via the status bar / Operating mode - see from page (→), work step 3
      or
    • Via the menu bar - see from page (→)
    2Activate spot welding:
    1. In the status bar, select the symbol for the operating mode
    2. Select Spot welding
      or
    1. Select Welding process / Operating mode / Spot welding
    3Select "Process parameters"
    4Select "Common"
    5Select "Spot welding"

    The spot welding time parameter is displayed.
    6Enter the desired value for the spot welding time: Press and turn the dial

    Setting range: 0.1 - 10.0 s
    Factory setting: 1.0 s
    7Apply value by pressing OK

    NOTE!

    4-step mode is assigned as standard for spot welding.

    Press the torch trigger - Spot welding process runs until the end of the spot welding time - Press again to stop the spot welding time prematurely

    The spot welding parameter can be changed to 2-step under Defaults / System / Mode Setup
    (more information on 2-step and 4-step mode in spot welding starts on page (→))

    8Select the filler metal, wire diameter and shielding gas
    9Open the gas cylinder valve
    10Set the shielding gas flow rate

    WARNING!

    Danger due to emerging wire electrode.

    This can result in serious personal injuries.

    Hold the welding torch so that the tip of the welding torch points away from the face and body.

    Wear suitable protective goggles.

    Do not point the welding torch at people.

    Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.

    11Spot welding

    Procedure for producing a welding spot:

    1Hold the welding torch vertical
    2Press and release the torch trigger
    3Keep the welding torch in the same position
    4Wait for the gas post-flow time
    5Raise the welding torch

    NOTE!

    Pre-set start of welding and end of welding parameters are also active for spot welding.

    Start of welding / end of welding treatment for spot welding can be assigned under Process parameters / General MIG/MAG / Weld-Start/Weld-End.

    If the final current time is active, the end of welding is not after the pre-set spot welding time, but only once the pre-set slope and final current times have ended.

    1. Welding
    2. Spot and stitch welding

    Spot welding

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

    1Select the desired welding process:
    • Via the status bar / Operating mode - see from page (→), work step 3
      or
    • Via the menu bar - see from page (→)
    2Activate spot welding:
    1. In the status bar, select the symbol for the operating mode
    2. Select Spot welding
      or
    1. Select Welding process / Operating mode / Spot welding
    3Select "Process parameters"
    4Select "Common"
    5Select "Spot welding"

    The spot welding time parameter is displayed.
    6Enter the desired value for the spot welding time: Press and turn the dial

    Setting range: 0.1 - 10.0 s
    Factory setting: 1.0 s
    7Apply value by pressing OK

    NOTE!

    4-step mode is assigned as standard for spot welding.

    Press the torch trigger - Spot welding process runs until the end of the spot welding time - Press again to stop the spot welding time prematurely

    The spot welding parameter can be changed to 2-step under Defaults / System / Mode Setup
    (more information on 2-step and 4-step mode in spot welding starts on page (→))

    8Select the filler metal, wire diameter and shielding gas
    9Open the gas cylinder valve
    10Set the shielding gas flow rate

    WARNING!

    Danger due to emerging wire electrode.

    This can result in serious personal injuries.

    Hold the welding torch so that the tip of the welding torch points away from the face and body.

    Wear suitable protective goggles.

    Do not point the welding torch at people.

    Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.

    11Spot welding

    Procedure for producing a welding spot:

    1Hold the welding torch vertical
    2Press and release the torch trigger
    3Keep the welding torch in the same position
    4Wait for the gas post-flow time
    5Raise the welding torch

    NOTE!

    Pre-set start of welding and end of welding parameters are also active for spot welding.

    Start of welding / end of welding treatment for spot welding can be assigned under Process parameters / General MIG/MAG / Weld-Start/Weld-End.

    If the final current time is active, the end of welding is not after the pre-set spot welding time, but only once the pre-set slope and final current times have ended.

    1. Welding
    2. Spot and stitch welding

    Stitch welding

    1Select the desired welding process:
    • Via the status bar - see from page (→)
      or
    • Via the menu bar - see from page (→)
    2Select the operating mode for stitch welding:
    • Via the status bar - see from page (→)
      or
    • Via the menu bar - see from page (→)
    3Select the filler metal, wire diameter and shielding gas
    4Set the desired welding parameters depending on the selected welding process
    5Activating stitch welding mode:
    1. Select the process functions display in the status bar
    2. Select interval
      or
    1. Under Process parameters / Common / Interval, set the Interval parameter to "on"

      Stitch welding is activated, the interval indicator lights up in the status bar.
    6Set the other parameters for stitch welding:
    stitch welding time, interval pause time, interval cycles
    7Open the gas cylinder valve
    8Set the shielding gas flow rate

    WARNING!

    Danger due to emerging wire electrode.

    This can result in serious personal injuries.

    Hold the welding torch so that the tip of the welding torch points away from the face and body.

    Wear suitable protective goggles.

    Do not point the welding torch at people.

    Ensure that the wire electrode can only intentionally make contact with electrically conductive objects.

    9Stitch welding

    Procedure for stitch welding:

    1Hold the welding torch vertical
    2Depending on the selected mode:
    press and hold the torch trigger (2-step mode)
    press and release the torch trigger (4-step mode)
    3Keep the welding torch in the same position
    4Wait for the welding interval
    5Position the welding torch at the next point
    6To end stitch welding, depending on the selected mode:
    release the torch trigger (2-step mode)
    press and release the torch trigger (4-step mode)
    7Wait for the gas post-flow time
    8Raise the welding torch

    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

    MIG/MAG and CMT welding parameters

    Welding parameters for MIG/MAG pulse synergic welding and PMC 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.

    NOTE!

    For certain PMC characteristics, the arc length correction cannot be adjusted when the arc length stabilizer is active.

    The arc length correction is then not displayed in the welding parameters.

    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

    NOTE!

    SynchroPulse can be activated via the status bar.

    (See page (→))

    If SynchroPulse is activated, the SynchroPulse parameters are also displayed with the welding parameters.

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

    Welding parameters for MIG/MAG pulse synergic welding and PMC 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.

    NOTE!

    For certain PMC characteristics, the arc length correction cannot be adjusted when the arc length stabilizer is active.

    The arc length correction is then not displayed in the welding parameters.

    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

    NOTE!

    SynchroPulse can be activated via the status bar.

    (See page (→))

    If SynchroPulse is activated, the SynchroPulse parameters are also displayed with the welding parameters.

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

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

    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.

    NOTE!

    For certain PMC characteristics, the arc length correction cannot be adjusted when the arc length stabilizer is active.

    The arc length correction is then not displayed in the welding parameters.

    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)

    NOTE!

    SynchroPulse can be activated via the status bar.

    (See page (→))

    If SynchroPulse is activated, the SynchroPulse parameters are also displayed with the welding parameters.

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

    Welding parameters for MIG/MAG standard manual welding

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

    Voltage 1) [V]

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

    Before the start of welding, the 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

    Explanation of footnotes

    1)
    Synergic parameter
    When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.

    The actual setting range depends on the welding machine and wirefeeder used and on the welding program selected.
    2)
    The actual setting range depends on the welding program selected.
    3)
    The maximum value depends on the wirefeeder used.
    1. Welding

    EasyJob mode

    General

    If EasyJob mode has been activated, 5 additional buttons appear on the display. These enable up to 5 operating points to be saved at the touch of a button.
    The current welding settings are saved.

    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

    General

    If EasyJob mode has been activated, 5 additional buttons appear on the display. These enable up to 5 operating points to be saved at the touch of a button.
    The current welding settings are saved.

    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

    Activating EasyJob mode

    1Select Defaults / View / EasyJobs

    The overview to activate/deactivate EasyJob mode is displayed.

    4Select "EasyJobs on"
    5Select "OK"

    EasyJob mode is activated and the default settings are displayed.

    6Select "Welding"

    Five EasyJob buttons are displayed for the welding parameters.

    1. Welding
    2. EasyJob mode

    Storing EasyJob operating points

    NOTE!

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


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

    1To store the current welding settings, touch one of the EasyJob buttons for about three seconds

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

    The settings have now been stored. The most recently stored settings will be active. An active EasyJob is 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

    Retrieving EasyJob operating points

    1To retrieve a saved EasyJob operating point, touch the corresponding EasyJob button briefly (< 3 seconds)

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

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

    1. Welding
    2. EasyJob mode

    Deleting EasyJob operating points

    1To delete an EasyJob operating point, touch the relevant EasyJob button for approximately 5 seconds

    The button

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

    The EasyJob operating point has been deleted.

    * ... highlighted in red

    1. Welding
    2. EasyJob mode

    Loading more EasyJobs

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

    1Select Defaults / View / EasyJobs

    The overview to activate/deactivate EasyJob mode is displayed.

    2Select "Load more EasyJobs"
    3Select "OK"

    EasyJob mode is activated and the default settings are displayed.

    4Select "Welding"

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

    5Select "Load Job"

    The list of stored jobs is displayed.

    6Use the adjusting dial to select the desired job
    7Select "Load" or press the adjusting dial

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

    1. Welding

    Job mode

    General

    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

    General

    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

    Storing settings as a job

    1Set the parameters that are to be stored as a job:
    • Welding parameters
    • Welding process
    • Process parameters
    • Machine defaults (if necessary)
    2Select "Save as Job"

    The job list is displayed.

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

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

    3Press the adjusting dial / select "Next"

    The next free job number is displayed.

    4Turn the adjusting dial and select the desired storage location
    5Press the adjusting dial / select "Next"

    The keyboard is displayed.

    6Enter a job name
    7Select "OK" and confirm the job name / press the adjusting dial

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

    8To exit, select "Finish" / press the adjusting dial
    1. Welding
    2. Job mode

    Job welding - retrieving a job

    NOTE!

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

    1Select "Welding process"
    2Select "Process"
    Alternatively, the welding process can also be selected via the status bar (compare with the selection described from page (→) ).
    3Select "Job mode"

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

    4Select "Job welding"
    5Press the adjusting dial twice or touch the job number displayed under the status bar (white background, job number is highlighted in blue)
    6Turn the adjusting dial and select the desired job
    7Press the adjusting dial and apply the selected job (white background)
    8Start welding

    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

    Renaming a job

    1Select "Save as Job"
    (also works in Job Mode)

    The job list is displayed.

    2Turn the adjusting dial and select the job to be renamed
    3Select "Rename Job"

    The keyboard is displayed.

    4Change the job name using the keyboard
    5Select "OK" and confirm the amended job name / press the adjusting dial

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

    6To exit, select "Cancel"

    NOTE!

    As an alternative to the procedure described above, the job can also be renamed in the process parameters:

    Process parameters / Job / Optimize job / Rename job

    1. Welding
    2. Job mode

    Deleting a job

    1Select "Save as Job"
    (also works in Job Mode)

    The job list is displayed.

    2Turn the adjusting dial and select the job to be deleted
    3Select "Delete Job"

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

    4Select "Yes" to delete the selected job

    The job is deleted, the job list is displayed.

    5To exit, select "Cancel"

    NOTE!

    As an alternative to the procedure described above, the job can also be deleted in the process parameters:

    Process parameters / Job / Optimize job / Delete job

    1. Welding
    2. Job mode

    Loading a job

    The load job function can be used to load the data for a saved job or an EasyJob to the welding screen. The relevant data from the job is displayed in the welding parameters and can be changed, saved as a new job or EasyJob, or used to start welding.

    1Select "Save as Job"
    (also works in Job Mode)

    The job list is displayed.

    2Turn the adjusting dial and select the job to be loaded
    3Select "Load job"

    The load job information is shown.

    4Select "Yes"

    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

    Optimizing a job

    1Select "Process parameters"
    2Select "JOB"

    An overview of the job functions is displayed.

    3Select "Optimize Job"

    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
    5Select "Finish"
    1. Welding
    2. Job mode

    Setting correction limits for a job

    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.

    1Select "Process parameters"
    2Select "JOB"

    An overview of the job functions is displayed.

    3Select "Correction limits"

    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
    5Select "Finish"
    1. Welding
    2. Job mode

    Pre-settings for "Save as Job"

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

    1Select "Process parameters"
    2Select "JOB"

    An overview of the job functions is displayed.

    3Select "Pre-settings for "Save as Job""
    4Confirm the displayed information

    The default settings for saving new jobs are displayed.

    5Turn the adjusting dial and select the desired parameter
    6Press the adjusting dial
    7Turn the adjusting dial and change the value
    8Press the adjusting dial
    9Select "Finish"
    1. Welding
    2. Job mode

    Job Mode with WF 25i Dual

    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.

    NOTE!

    A Jobmaster welding torch is recommended for Job Mode with a WF 25i Dual.

    1. Welding

    TIG welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. TIG welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. TIG welding

    Preparation

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

    1Move the mains switch to the "O" position
    2Disconnect the mains plug
    3Remove the MIG/MAG welding torch
    4Disconnect the return lead cable from the (-) current socket
    5Plug the return lead cable into the 2nd (+) current socket and twist to fasten it
    6Use the other end of the return lead cable to establish a connection to the workpiece
    7Plug the bayonet current plug on the TIG gas-valve torch into the (-) current socket and twist it clockwise to fasten it
    8Screw the pressure regulator onto the (argon) gas cylinder and tighten it
    9Connect the gas hose of the TIG gas-valve torch to the pressure regulator
    10Plug in the mains plug
    1. Welding
    2. TIG welding

    TIG welding

    CAUTION!

    Risk of injury and damage from electric shock.

    As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is live.

    Ensure that the tungsten electrode does not touch any persons or electrically conductive or earthed parts (e.g. housing, etc.).

    1Move the mains switch to the "I" position
    2Select "Welding process"
    3Select "Process"

    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.

    4Select TIG

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

    NOTE!

    Under certain circumstances, it may not be possible to change welding parameters that have been set on a control panel of a system component (such as remote control or wirefeeder) from the control panel of the welding machine.

    5Select "TIG welding"

    The TIG welding parameters are displayed.

    6Press the adjusting dial to change the welding parameter

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

    The value of the selected parameter can now be changed.

    7Turn the adjusting dial and change the parameter
    8Adjust the process parameters accordingly to make user or application-specific settings on the welding system
    9Open the gas stop valve on the TIG gas-valve torch
    10Set the desired shielding gas flow rate on the pressure regulator
    11Start welding (ignite the arc)
    1. Welding
    2. TIG welding

    Igniting the arc

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

    1Place the gas nozzle on the ignition location so that there is 2-3 mm (0.08 - 0.12 in.) between the tip of the tungsten electrode and the workpiece. Keep a distance
    2Gradually tilt the welding torch up until the tungsten electrode touches the workpiece
    3Raise the welding torch and tilt it into the normal position - the arc now ignites
    4Carry out welding
    1. Welding
    2. TIG welding

    Finishing welding

    1Lift the TIG gas-valve torch away from the workpiece until the arc goes out.

    IMPORTANT! To protect the tungsten electrode, ensure that the shielding gas at the end of welding flows for long enough to allow the tungsten electrode to cool sufficiently.
    2Close the gas stop valve on the TIG gas-valve torch
    1. Welding

    MMA welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. MMA welding

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. MMA welding

    Preparation

    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.

    1Move the mains switch to the "O" position
    2Disconnect the mains plug
    3Remove the MIG/MAG welding torch

    NOTE!

    Check the rod electrode packaging or labelling to determine whether the rod electrodes are for positive pole or negative pole welding

    4Plug the return lead cable into either the (-) or the (+) current socket, depending on the type of electrode, and twist to fasten it
    5Use the other end of the return lead cable to establish a connection to the workpiece
    6Plug the bayonet current plug of the electrode holder cable into the free current socket with the opposite polarity, according to the type of electrode, and twist it clockwise to fasten it
    7Plug in the mains plug
    1. Welding
    2. MMA welding

    Manual metal arc welding

    CAUTION!

    Risk of injury and damage from electric shock.

    As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is live.

    Make sure that the rod electrode does not touch any persons or electrically conductive or earthed parts (e.g. the housing, etc.)

    1Move the mains switch to the "I" position
    2Select "Welding process"
    3Select "Process"

    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.

    4Select the MMA/SMAW welding process

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

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

    NOTE!

    Under certain circumstances, it may not be possible to change welding parameters that have been set on a control panel of a system component (such as remote control or wirefeeder) from the control panel of the welding machine.

    5Select "MMA/SMAW welding"

    The MMA welding parameters are displayed.

    6Turn the adjusting dial and select the desired welding parameter
    7Press the adjusting dial to change the welding parameter

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

    The value of the selected parameter can now be changed.

    8Turn the adjusting dial and change the parameter
    9Adjust the process parameters accordingly to make user or application-specific settings on the welding system
    10Start welding
    1. Welding
    2. MMA welding

    Welding parameters for manual metal arc 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

    Arc Air Gauging

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. Arc Air Gauging

    Safety

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this equipment and all system components.

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Welding
    2. Arc Air Gauging

    Preparation

    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.

    1Move the mains switch to the "O" position
    2Disconnect the mains plug
    3Remove the MIG/MAG welding torch
    4Plug the return lead cable into the (-) current socket and twist to fasten it
    5Use the other end of the return lead cable to establish a connection to the workpiece
    6Attach PowerConnector - Dinse adapter to the (+) current socket
    7Plug the bayonet current plug on the arc air gouging torch into the (+) current socket and twist it clockwise to fasten it
    8Connect the compressed air connection of the arc air gouging torch to the compressed air supply
    Working pressure: 5-7 bar (constant)
    9Clamp the carbon electrode so that the electrode tip protrudes approximately 100 mm out of the arc air gouging torch;
    the air outlet openings of the arc air gouging torch must be located at the bottom
    10Plug in the mains plug
    1. Welding
    2. Arc Air Gauging

    Arc air gouging

    CAUTION!

    Risk of injury and damage from electric shock.

    As soon as the mains switch is in the "I" position, the electrode in the arc air gouging torch is live.

    Make sure the electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing, etc.).

    CAUTION!

    Risk of personal injury due to loud operating noise.

    Use suitable ear protection during arc air gouging!

    1Move the mains switch to the "I" position
    2Under Process parameters / Common / TIG/MMA/SMAW Setup, set the "Characteristic" parameter to "Arc gouging" (last entry)

    NOTE!

    Settings for the break voltage and the starting current time are ignored.

    3Select OK
    4Select Welding process / Process / MMA/SMAW

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

    NOTE!

    Under certain circumstances, it may not be possible to change welding parameters that have been set on a system component (such as wirefeeder or remote control) from the control panel of the welding machine.

    5Select "MMA/SMAW welding"

    The arc air gouging parameters are displayed.

    6Adjust the main current according to the electrode diameter as indicated on the electrode packaging

    NOTE!

    At higher amperages, guide the arc air gouging torch with both hands!

    Use a suitable welding helmet.

    7Open the compressed air valve on the handle of the arc air gouging torch
    8Initiate processing

    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

    Overview

    Overview

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

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

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

    1. Process parameters

    Overview

    Overview

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

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

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

    1. Process parameters
    2. Overview

    Overview

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

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

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

    1. Process parameters

    Process parameters, General

    Common process parameters

    NOTE!

    Depending on the device type, equipment or Welding Packages available, the display and sequence of process parameters may vary.

    1. Process parameters
    2. Process parameters, General

    Common process parameters

    NOTE!

    Depending on the device type, equipment or Welding Packages available, the display and sequence of process parameters may vary.

    1. Process parameters
    2. Process parameters, General

    Process parameters for start of welding/end of welding

    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

    NOTE!

    SFI is permanently integrated in certain welding processes and cannot be deactivated.

    If SH is displayed in the status line for SFI, the SlagHammer function is active in addition to SFI.
    SFI and SH cannot be deactivated.

    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

    Process parameters for Gas-Setup

    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

    NOTE!

    For the gas controller to function correctly, the supply pressure at the wirefeeder must be at least 4.5 bar / 65 psi when the target flow rate is maintained.

    Uninstall existing flow controllers if necessary to achieve the minimum supply pressure of 4.5 bar / 65 psi.


    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

    Process parameters for process control

    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

    Penetration stabilizer

    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 vD  ... Wire speed

    1. Process parameters
    2. Process parameters, General

    Arc length stabilizer

    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.

    NOTE!

    If the arc length stabilizer is activated, the normal arc length correction is only effective at the start of welding.

    The arc length correction is then no longer displayed in the welding parameters.

    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 vD ... Wire speed U ... Welding voltage

    * ... Number of short circuits

    1. Process parameters
    2. Process parameters, General

    Combination of penetration stabilizer and arc length stabilizer

    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 vD ... Wire speed U ... Welding voltage

    * ... Number of short circuits Δs ... Stick out change

    1. Process parameters
    2. Process parameters, General

    Process parameters for SynchroPulse

    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

    NOTE!

    The maximum adjustable Delta wire feed of 6 m/min (235 ipm) is only possible up to a frequency of approx. 3 Hz.

    In the frequency range of 3-10 Hz, the adjustable Delta wire feed decreases.

    (4) Frequency
    for setting the frequency for SynchroPulse

    0.5-10.0 Hz
    Factory setting: 3.0 Hz

    NOTE!

    In TWIN mode, the setting of the frequency on the lead welding machine also affects the trail welding machine.

    The setting of the frequency on the trail welding machine has no effect.

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

    10-90%
    Factory setting: 50 Hz

    NOTE!

    In TWIN mode, the setting of the duty cycle (high) on the lead welding machine also affects the trail welding machine.

    The setting of the duty cycle (high) on the trail welding machine has no effect.

    (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

    - .... short arc
    0 ... uncorrected arc length
    + ... longer arc

    NOTE!

    If SynchroPulse is activated, the normal arc length correction has no effect on the welding process.

    The arc length correction is then no longer displayed in the welding parameters.

    (7) Arc correction low
    for correcting the arc length for SynchroPulse in the lower operating point (= average wire speed less Delta wire speed)

    -10.0-+10.0
    Factory setting: 0.0

    - .... short arc
    0 ... uncorrected arc length
    + ... longer arc

    SynchroPulse example, duty cycle (high) = 25%
    1. Process parameters
    2. Process parameters, General

    Process parameters for process mix

    The following process parameters for mixed processes can be set under "Process mix":

    Wire speed vD *
    Wire speed

    1.0-25.0 m/min / 40-985 ipm

    The wire speed value is applied or can be specified and changed in the Process mix parameters.

    Arclength correction

    -10.0-+10.0

    The arc length correction value is applied or can be specified and changed in the process mix parameters.

    Pulse correction
    for changing the pulse energy in the pulsed arc process phase

    -10.0-+10.0

    The pulse correction value is applied or can be specified and changed in the process mix parameters.

    Upper power time correction (3) *
    to set the duration of the hot process phase in a mixed process

    -10.0-+10.0
    Factory setting: 0

    Upper and lower power time correction is used to define the relationship between hot and cold process phases.

    If the upper power time correction is increased, the process frequency reduces and the PMC process phase becomes longer.

    If the upper power time correction is reduced, the process frequency increases and the PMC process phase becomes shorter.

    Lower power time correction (2) *
    to set the duration of the cold process phase in a mixed process

    -10.0-+10.0 / 1-100 CMT cycles (for CMT mix characteristics)
    Factory setting: 0

    Upper and lower power time correction is used to define the relationship between hot and cold process phases.

    If the lower power time correction is increased, the process frequency reduces and there is a longer LSC process phase or a longer CMT process phase for CMT mix.

    If the lower power time correction is reduced, the process frequency increases and there is a shorter LSC process phase or a shorter CMT process phase for CMT mix.

    Lower power correction (1) *
    to set the energy input in the cold process phase in a mixed process

    -10.0-+10.0
    Factory setting: 0

    If the lower power correction is increased, this results in a higher wire speed and therefore higher energy input in the cold LSC process phase or in the cold CMT process phase.


    * Representation of the parameters in the following graphics

    Mixed process between PMC and LSC welding process. A cold LSC process phase follows a hot PMC process phase as part of a cycle.
    Mixed process between PMC and wire movement reversal using a PushPull drive unit. A cold low power phase with calibration movement follows a hot PMC process phase.
    Mixed process between CMT and PMC welding process. Cold CMT process phases follow hot PMC process phases.
    (1)
    Lower power correction
    (2)
    Low power time corr.
    (3)
    High power time corr.
    vD
    Wire speed
    1. Process parameters
    2. Process parameters, General

    Process parameters for TWIN process control

    The process parameters for TWIN process control are only available in TWIN mode.

    Wire speed
    Wire speed

    1.0-25.0 m/min / 40-985 ipm

    The wire speed value is applied or can be specified and changed in the TWIN parameters.

    Arclength correction

    -10.0-+10.0

    The arc length correction value is applied or can be specified and changed in the TWIN parameters.

    Pulse correction or dynamic correction
    (depending on the selected welding process)

    • For changing the pulse energy in the pulsed arc process phase
    • For changing the short circuit current and the current to short-circuit break-up

    -10.0-+10.0
    Factory setting: 0.0

    The pulse correction or dynamic correction value is applied or can be specified and changed in the TWIN parameters.

    Penetration stabilizer
    For details see page (→)

    0.0 / auto / 0.1-10.0 m/min
    Factory setting: 0 m/min

    Arc length stabilizer
    For details see page (→)

    auto / 0.0-10.0
    Factory setting: 0

    Pulse synchronisation ratio
    for setting the vastly different wire speeds between the leading and trailing arc

    auto, 1/1, 1/2, 1/3
    Factory setting: auto

    Lead/trail phase shift
    for setting a time offset between leading droplet detachment and trailing droplet detachment

    auto, 0-95%
    Factory setting: auto

    Trail ignition delay
    for setting an ignition delay between the leading and trailing arc

    auto / off / 0-2 s
    Factory setting: auto

    1. Process parameters
    2. Process parameters, General

    Process parameters for CMT Cycle Step

    CMT Cycle Step
    for activating/deactivating the CMT Cycle Step function

    On / Off

    Wire speed
    Wire speed, determines the deposition rate during the welding process phase and therefore the size of the welding spot;

    Setting range: in m/min (ipm), dependent on the welding characteristic

    The wire speed value is applied or can also be specified or changed in the CMT Cycle Step parameters.

    Cycles (welding spot size)
    for setting the number of CMT cycles (weld droplets) for a welding spot;
    the number of CMT cycles and the set wire speed determine the size of the welding spot.

    1 - 2000

    Pause time interval
    for setting the time between each welding spot

    0.01 - 2.00 s

    The higher the value for the pause time interval, the cooler the welding process is (heavier flaking).

    Cycles interval
    for setting the number of repeated CMT cycles including pauses until the end of welding

    constant / 1 - 2000

    constant
    The repetitions are carried out continuously;
    end of welding, for example using "Arc Off"

    1. Process parameters
    2. Process parameters, General

    Process parameters for ConstantWire

    Wire speed

    0.0-max. m/min (depending on the wirefeeder used)
    Factory setting: 5.0 m/min

    Current

    0-max. A (depending on the welding machine used)
    Factory setting: 50 A

    Voltage limitation

    auto / 1-50 V
    Factory setting: auto

    With the auto setting, the voltage limitation is defined by the set characteristic.

    Contact stabilizer

    off / on
    Factory setting: off

    If the welding wire is undesirably lifted from the solder/weld pool, the welding wire is accelerated to immediately re-establish contact.
    This stabilises the soldering process and compensates for short-term process errors.

    Ground earth connection

    yes / no
    Factory setting: yes

    When set to yes, the circuit is closed by means of ground earth connection, for example for hot wire applications and to enable the extended process signals.

    Wire burn-back
    Distance travelled during backward movement of the welding wire

    0.0-10.0
    Factory setting: 0.0

    Adjusting the distance travelled during the backward movement of the welding wire prevents sticking of the welding wire at the end of the process.

    1. Process parameters
    2. Process parameters, General

    Process parameters for spot welding

    Spot welding time 

    0.1 - 10.0  s
    Factory setting: 1.0 s

    1. Process parameters
    2. Process parameters, General

    Process parameters for interval

    Interval
    to activate / deactivate stitch welding

    off / on
    Factory setting: off

    Wire speed

    0.0 - max. m/min (depending on the wirefeeder used)

    Stitch welding time

    0.01 - 9.9 s
    Factory setting: 0.3 s

    Interval break time

    off / 0.01 - 9.9 s
    Factory setting: 0.3 s

    Interval cycles

    constant / 1 - 99
    Factory setting: constant

    1. Process parameters
    2. Process parameters, General

    Process parameters for manual setup

    Ignition current
    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
    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

    Characteristic slope

    auto / U constant / 1000 - 8 A/V
    Factory setting: auto

    1. Process parameters
    2. Process parameters, General

    R/L-check / alignment

    Align the welding circuit resistance (R) and welding circuit inductivity (L) if one of the following components of the welding system is changed:

    • Torch hosepacks
    • Interconnecting hosepacks
    • Grounding cables, welding power-leads
    • Wirefeeders
    • Welding torches, electrode holders
    • PushPull units

    Prerequisites for R/L alignment:

    The welding system must be complete: closed welding circuit with welding torch and torch hosepack, wirefeeders, grounding cable, interconnecting hosepacks.

    Performing R/L alignment:

    1Select Process parameters / General / R/L-check / alignment

    The current welding circuit inductivity and welding circuit resistance values are displayed.

    2Select "Next" / press the adjusting dial / press the torch trigger

    The second step of the R/L alignment wizard appears.

    3Follow the displayed instructions

    IMPORTANT! Contact between the earthing clamp and workpiece must be established on a cleaned area of the workpiece.
    4Select "Next" / press the adjusting dial / press the torch trigger

    The third step of the R/L alignment wizard appears.

    5Follow the displayed instructions
    6Select "Next" / press the adjusting dial / press the torch trigger

    The fourth step of the R/L alignment wizard appears.

    7Follow the displayed instructions
    8Press the torch trigger / select "Next" / press the adjusting dial

    After a successful measurement, the current values are displayed.

    9Select "Finish" / press the adjusting dial

    Alternatively, R/L alignment can also be carried out via a Jobmaster welding torch.

    1. Process parameters
    2. Process parameters, General

    Process parameters for TIG / electrode setup

    The following process parameters can be set and displayed for the TIG and MMA welding processes:

    Process parameters for MMA welding:

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

    0.0-2.0 s
    Factory setting: 0.5 s

    Characteristic
    for selecting the electrode characteristic

    I-constant / 0.1-20.0 A/V / P-constant / Arc air gouging
    Factory setting: I-constant

    (1)
    Load line for rod electrode
    (2)
    Load line for rod electrode where arc length is increased
    (3)
    Load line for rod electrode where arc length is reduced
    (4)
    Characteristic where "I-constant" parameter is selected (constant welding current)
    (5)
    Characteristic where "0.1-20" parameter is selected (drooping characteristic with adjustable slope)
    (6)
    Characteristic where "P-constant" parameter is selected (constant welding power)
    (7)
    Example of pre-set arc-force dynamic where characteristic (4) is selected
    (8)
    Example of pre-set arc-force dynamic where characteristic (5) or (6) is selected

    I-constant (constant welding current)

    • If the "I-constant" parameter is set, the welding current will be kept constant, irrespective of the welding voltage. This results in a vertical characteristic (4).
    • The "I-constant" parameter is particularly suitable for rutile electrodes and basic electrodes.

    0.1-20.0 A/V (drooping characteristic with adjustable slope)

    • Parameter "0.1-20" is used to set a drooping characteristic (5). The setting range extends from 0.1 A / V (very steep) to 20 A / V (very flat).
    • Setting a flat characteristic (5) is only advisable for cellulose electrodes.

    P-constant (constant welding power)

    • If the "P-constant" parameter is set, the welding power is kept constant, irrespective of the welding voltage and welding current. This results in a hyperbolic characteristic (6).
    • The "P-constant" parameter is particularly suitable for cellulose electrodes.

    Arc air gouging

    • Special characteristic for arc air gouging with a carbon electrode
    (1)
    Load line for rod electrode
    (2)
    Load line for rod electrode where arc length is increased
    (3)
    Load line for rod electrode where arc length is reduced
    (4)
    Characteristic where "I-constant" parameter is selected (constant welding current)
    (5)
    Characteristic where "0.1-20" parameter is selected (drooping characteristic with adjustable slope)
    (6)
    Characteristic where "P-constant" parameter is selected (constant welding power)
    (7)
    Example of pre-set arc-force dynamic where characteristic (5) or (6) is selected
    (8)
    Possible change in the current where characteristic (5) or (6) is selected, as a function of the welding voltage (arc length)
    (a)
    Operating point where arc length is long
    (b)
    Operating point where welding current IH is set
    (c)
    Operating point where arc length is short

    The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose characteristic corresponds - at a given arc length - to the load line (1).

    Depending on what welding current (I) has been set, the point of intersection (operating point) of characteristics (4), (5) and (6) will be displaced along the load line (1). The operating point provides information on the actual welding voltage and the actual welding current.

    Where the welding current (IH) is permanently set, the operating point may migrate along the characteristics (4), (5) and (6) according to the welding voltage at a given moment. The welding voltage U is dependent upon the arc length.

    If the arc length changes (e.g. in accordance with the load line (2)) the resulting operating point will be the point where the corresponding characteristic (4), (5) or (6) intersects with the load line (2).

    Applies to characteristics (5) and (6): Depending upon the welding voltage (arc length), the welding current (I) will also become either smaller or larger, even though the value set for IH remains the same.

    Anti-stick 
    to activate/deactivate the anti-stick function

    off / on
    Factory setting: on

    As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to stick. This may also cause the rod electrode to burn out.

    The anti-stick function prevents the electrode from burning out. If the rod electrode begins to stick, the welding machine switches the welding current off after 1.5 seconds. After the rod electrode has been lifted off the workpiece, the welding process can be continued without any problems.

    Break voltage
    for setting a voltage, at which the welding process can be ended by slightly lifting the rod electrode.

    20-90 V
    Factory setting: 90 V

    The arc length depends on the welding voltage. To end the welding process, it is usually necessary to significantly lift the rod electrode away from the workpiece. With the break voltage parameter, the welding voltage can be limited to a value that makes it possible to end the welding process simply by lifting the rod electrode slightly.

    IMPORTANT! If, during welding, you often find that the welding process is ended unintentionally, increase the value of the break voltage.

    Process parameters for TIG welding:

    Break voltage
    for setting a voltage, at which the welding process can be ended by slightly lifting the TIG welding torch.

    10.0-30.0 V
    Factory setting: 14 V

    Comfort Stop Sensitivity
    to activate/deactivate the TIG Comfort Stop function

    off / 0.1 - 1.0 V
    Factory setting: 0.8 V

    At the end of the welding process, the welding current is switched off automatically if the arc length increases by more than a defined amount. This prevents the arc being unnecessarily elongated when the TIG gas-valve torch is lifted off the workpiece.

    Sequence:

    1Welding
    2At the end of the welding action, briefly raise the welding torch

    The arc length is increased significantly.
    3Lower the welding torch
    • The arc length is reduced significantly
    • The TIG Comfort Stop function is triggered
    4Keep the welding torch at the same height
    • The welding current is continuously decreased (downslope).
    • The arc goes out.
    IMPORTANT! The downslope is pre-set and cannot be adjusted.
    5 Raise the welding torch from the workpiece
    1. Process parameters

    Components and monitoring process parameters

    Process parameters - Components and monitoring

    NOTE!

    Depending on the device type, equipment or WeldingPackages available, the display and sequence of process parameters may vary.

    1. Process parameters
    2. Components and monitoring process parameters

    Process parameters - Components and monitoring

    NOTE!

    Depending on the device type, equipment or WeldingPackages available, the display and sequence of process parameters may vary.

    1. Process parameters
    2. Components and monitoring process parameters

    Process parameters for components

    The following process parameters can be set and displayed for the system components of a welding system:

    Cooling unit

    Cooling unit mode 
    to determine whether a cooling unit is to be switched on or off, or operated automatically

    eco / auto / on / off (depending on the cooling unit)
    Factory setting: auto

    Delay time flow sensor
    for setting the time from when the flow sensor responds until a warning message is output

    5-25 s
    Factory setting: 5 s

    Coolant flow warning level
    (only if the flow temperature sensor option is present on the cooling unit)
    If the parameter is activated, a warning is generated if the value entered is not reached.

    off / 0.75-0.95 l/min
    Factory setting: off

    Wire speed

    Inching value
    for setting the wire speed at which the wire electrode is threaded into the torch hosepack

    e.g. 2-25 m/min / 20-3,935 ipm
    (depending on the wire speed)
    Factory setting: 10 m/min

    NOTE!

    The feeder inching speed can also be set in the window that opens when the wire threading button is pressed:

    Press wire threading button

    Press and turn the adjusting dial to change the value of the feeder inching speed

    Select "Close" or press the adjusting dial to accept the value

    Welding machine

    Ignition timeout
    Length of wire that is fed before the safety cut-out trips

    off / 5-100 mm (0.2-3.94 in.)
    Factory setting: off

    NOTE!

    The ignition time-out process parameter is a safety function.

    The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire speeds.

    How it works:
    Once the torch trigger is pressed, gas pre-flow begins immediately. Wirefeeding then begins, followed by ignition. If no current starts flowing before the specified length of wire has been fed, the system shuts down automatically.
    To try again, press the torch trigger again.

    Sense lead
    to activate/deactivate the sense lead function

    off / on
    Factory setting: on

    The sense lead is additional hardware for direct voltage measurement on the workpiece. The function is used to determine the correct actual value when several welding processes are welding on one component at the same time and there is a risk of coupled interference voltages due to unfavourable hosepack routing or shared return (ground) leads.

    Robot settings

    TouchSensing sensitivity
    for setting the sensitivity for TouchSensing in conjunction with the OPT/i WF gas nozzle position search option built into the wirefeeder for different component surfaces and external interferences

    Setting the TouchSensing sensitivity has no effect on the OPT/i Touch Sense Adv option.

    TouchSensing = finding the seam position by means of applied sensor voltage during automated welding
    TouchSensing takes place via the gas nozzle or the wire electrode.

    TouchSensing by means of a gas nozzle only works if:

    • The OPT/i WF gas nozzle position search option is installed in the robot wirefeeder
      or
    • The OPT/i Touch Sense Adv. option is installed in the robot wirefeeder or in the welding machine.
    • There is an existing robot interface.

    0-10
    Factory setting: 1

    0
    for bare surfaces, long and bolted short circuit, robust and not susceptible to interference

    10
    for oxidised surfaces, high measurement-related susceptibility to interference
    Not suitable for welding on a component with multiple welding machines!

    Insulated surfaces cannot be detected.

    Procedure for determining TouchSensing sensitivity:

    • Start with the factory setting value 1
    • If no triggering signal is detected, increase TouchSensing sensitivity

    IMPORTANT! A higher TouchSensing sensitivity also increases the susceptibility to interference!

    "WireSense" edge detection
    for activating/determining edge detection using WireSense (option)

    off / 0.5-20.0 mm
    Factory setting: off

    The "WireSense" edge detection only works

    • With automated applications
    • If the OPT/i WireSense is present on the welding machine (enabled in the software)
    • In conjunction with CMT system components WF 60i Robacta Drive CMT, SB 500iR with wire buffer or SB 60i R and WFi Reel

    WireSense is usually activated via a robot control. As soon as a value > 0.5 mm is specified by the robot control, the value set manually on the welding machine is overwritten.

    If the ignition timeout parameter is activated, this also applies to WireSense.

    In the case of higher-level robot controls with a low signal range (e.g. in the case of linear undercarriages), WireSense can be set manually on the welding machine.

    Economy image example:

    • Start/stop is performed via the control.
    • The edge height is specified on the welding machine.
    1. Process parameters
    2. Components and monitoring process parameters

    System adjust

    If two motors are used in a welding system, they need to be calibrated to maintain process stability.

    System calibration must be carried out on welding systems with PushPull units or unreeling wirefeeders following successful installation or replacement of a wirefeeder.

    A notification will be displayed.

    1Select "OK" and start system calibration

    The system calibration wizard starts.

    2Follow the instructions shown

    System calibration can also be started manually here.

    Perform system calibration:

    1Select Process parameters / Components & monitoring / System adjust

    If system calibration is required, the system calibration wizard starts. The first step in the system calibration wizard is displayed:

    2Follow the displayed instructions
    3To move to the next step in the wizard, select "Next" / press the adjusting dial

    When system calibration has been completed successfully, a confirmation to this effect is displayed.

    4To close the system calibration wizard, select "Finish" / press the adjusting dial
    1. Process parameters
    2. Components and monitoring process parameters

    Arc break monitoring

    1Select Process parameters / Components & Monitoring / Arc break watchdog settings

    The "Arc break watchdog settings" overview is displayed.

    2Turn the adjusting dial and select the desired parameter
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial and change the value of the parameter (blue background)

    Arc break reaction = ignorieren (deactivated):
    The welding machine remains active and no error message appears on the display.

    Arc break reaction = Fehler (activated):
    If the arc break fractures off and no current flow is detected within a set arc break period, the system shuts down automatically and an error message appears on the display.

    Factory setting = ignorieren

    Arc break time = 0-2.00 s
    An error is output if the set period is exceeded.

    Factory setting = 0.2 s
    5Select "OK" to activate arc break monitoring (arc break watchdog)
    1. Process parameters
    2. Components and monitoring process parameters

    Wire stick contact tip

    1Select Process parameters / Components & Monitoring / Wire stick contact tip

    The overview "Wire stick contact tip - setup menu" is displayed.

    2Turn the adjusting dial and select the desired parameter
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial and change the value of the parameter (blue background)

    Wire stick on contact tip = ignore:
    The wire stick check on the contact tip is deactivated.

    Wire stick on contact tip = Fehler (activated):
    The welding process will be interrupted in the event of wire stick on the contact tip.

    IMPORTANT! Monitoring is only possible during dip transfer arc processes.

    Factory setting = ignorieren

    Filter time = 0.5 - 5.0 s
    Maximum duration without arc short circuit until welding is interrupted.

    Factory setting = 0.5 s
    5Select "OK" to conclude the settings
    1. Process parameters
    2. Components and monitoring process parameters

    Wire stick work piece

    1Select Process parameters / Components & Monitoring / Wire stick work piece

    The overview "Wire stick work piece - setup menu" is displayed.

    2Turn the adjusting dial and select the desired parameter
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial and change the value of the parameter (blue background)

    Wire stick on workpiece = ignorieren:
    Wire stick monitoring on the workpiece is deactivated.

    Wire stick on workpiece = Fehler (activated):
    The welding process will be interrupted if the wire sticks on the workpiece.

    Factory setting = ignorieren
    5Select "OK" to conclude the settings
    1. Process parameters
    2. Components and monitoring process parameters

    Welding circuit coupling

    This function can be used to measure the inductances present in the welding circuit.
    Inductances can lead to welding problems, for example when several systems weld on one component.

    With the help of inductance measurement and appropriate cable management, welding problems can be prevented early on during the commissioning of a welding system.

    Selecting the "Welding circuit coupling" button starts a corresponding wizard.

    1To measure the inductances in the welding circuit, follow the instructions issued by the wizard.

    Measuring results:

    Result

    Rcoupling
    (common ground)

    Kcoupling
    (inductive coupling)

    Very good

    0 mOhm

    0%

    Good

    1 - 2.5 mOhm

    2-15%

    Average

    3 - 15 mOhm

    16-30%

    Poor

    16 - 100 mOhm

    31-100%

    The measurement results are stored in the logbook.

    Details on the welding circuit coupling are described in the Operating Instructions "Cable Management Guide" - 42.0426,0420,xx.
    The Operating Instructions are available as HTML under the following link:

    https://manuals.fronius.com/html/4204260420

    1. Process parameters
    2. Components and monitoring process parameters

    Wire end monitoring

    1Select Process parameters / Components & Monitoring / Wire end monitoring

    The overview "Wire end monitoring setup menu" is displayed.

    2Turn the adjusting dial and select the desired parameter, depending on the type of wire end monitoring:
    (1)
    Wire end reaction for
    OPT/i WF R WE ring sensor
    4,100,878,CK
    (2)
    Wire end reaction for
    OPT/i WF R WE drum
    4,100,879,CK
    (3)
    Wire end reaction for
    OPT/i WF R WE wire end
    4,100,869,CK
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial and change the value of the parameter (blue background)

    Reaction = error:
    Wire end fault, welding will be interrupted immediately. The fault will be shown on the display.

    Reaction = after seam end:
    The wire end fault will show on the display after the current welding process has ended.

    Reaction= ignore (deactivated):
    No reaction at the wire end

    Factory setting = error
    5Select "OK" to conclude the settings
    1. Process parameters
    2. Components and monitoring process parameters

    Gas monitoring

    The parameters for gas monitoring are only available if the OPT/i gas flow rate sensor option is present on the wirefeeder or on the SplitBox.

    A lower limit for the gas flow rate can be set using gas monitoring. If the gas flow rate drops below this limit for a defined period of time, an error message is immediately issued and the welding operation is halted.

    1Select Process parameters / Components & Monitoring / Gas monitoring

    The "Gas monitoring" overview is displayed.

    2Turn the adjusting dial and select the desired parameter:

    Lower gas flow limit
    Setting range: 0.5 - 30.0 l/min
    Factory setting: 7.0 l/min

    Max. time of gas deviation
    Setting range: off / 0.1 - 10.0 s
    Factory setting: 2.0 s

    Gas factor sensor
    Setting range: auto / 0.90 - 20.00
    Overview of important gas factors:
    1.00 - C1 (CO2)
    1.52 - M21 ArC-18
    1.69 - M12 ArC-2.5
    1.72 - I1 (Argon)
    11.8 - I2 (Helium)

    Factory setting: auto

    NOTE!

    If the wrong gas factor is set, this can have a massive impact on the gas flow rate and therefore the welding result.

    All the standard gases from the Fronius welding database are considered under the "auto" setting.

    Setting the gas factor manually is only advisable for special gases, and only after consultation.

    3Press the adjusting dial (blue background)
    4Turn the adjusting dial to change the parameter value (blue background)
    5Select "OK" to conclude the settings
    1. Process parameters
    2. Components and monitoring process parameters

    Motor force monitoring

    1Select Process parameters / Components & Monitoring / Motor force monitoring

    The "Motor force monitoring" overview is displayed.

    2Turn the adjusting dial and select the desired parameter:

    Wire feed force monitoring

    Setting range:
    Ignore (no response)
    Warning (a warning is displayed)
    Error (welding process is interrupted, an error message is displayed
    )Factory setting: Ignore

    Maximum force
    Setting range: 0 - 999 N
    Factory setting: 0 N

    Max. time of force deviation
    Setting range: 0.1 - 10.0 s
    Factory setting: 3 s
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial to change the parameter value (blue background)
    5Select "OK" to conclude the settings
    1. Process parameters
    2. Components and monitoring process parameters

    Wire buffer monitoring

    The parameters for wire buffer monitoring are available if there is a wire buffer in the welding system.

    1Select Process parameters / Components & Monitoring / Wire buffer monitoringIt is possible to set the reaction in case of an empty wire buffer:Error / After seam end / Ignore
    Factory setting: Error
    Error
    If the wire buffer is empty, welding is interrupted and an error message is displayed.
    After seam end
    An error message is displayed after the current weld is completed, and a further weld start is prevented.
    Ignore
    No reaction when wire buffer is empty
    2Push and turn the adjusting dial and select the desired parameter
    3Select "OK" to conclude the settings
    1. Process parameters

    Process parameters, Job

    Overview – Process parameters, Job

    1. Process parameters
    2. Process parameters, Job

    Overview – Process parameters, Job

    1. Process parameters
    2. Process parameters, Job

    Optimising job process parameters

    The following process parameters can be set for job optimisation:

    Job parameter

    Wire Feed Speed
    for adjusting the wire speed

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

    Arclength correction
    for correcting the arc length

    -10.0-+10.0

    - .... short arc
    0 ... uncorrected arc length
    + ... longer arc

    Pulse correction
    for MIG/MAG pulse synergic welding, PMC welding for correction of the pulse energy

    -10.0-+10.0

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

    or

    Dynamic correction
    for MIG/MAG standard synergic welding, LSC welding and CMT welding to adjust the short circuit current and the current to short-circuit break-up

    -10.0-+10.0

    -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)

    Welding process parameters

    Change characteristic - current ID: xxxx
    The ID no. of the currently stored characteristic is displayed.

    After pressing the dial, the method and property of the characteristic can be changed.

    Process
    The process assigned to the characteristic is displayed.

    Property
    The property assigned to the characteristic is displayed.

    Trigger mode
    for setting the operating mode

    2-step / 4-step / S2-step / S4-step / spot welding


    The other adjustable process parameters correspond to the process parameters already described:

    TWIN process control ... see page (→)
    (only if there is a TWIN interface in the welding system)

    • Pulse synchronisation ratio
    • Lead/trail phase shift
    • Trail ignition delay

    Weld-Start/ Weld-End ... see page (→)

    • Starting current
    • Start arc length correction
    • Start current time
    • Slope 1
    • Slope 2
    • Final current
    • End arc length correction
    • End current time
    • SFI
    • SFI HotStart
    • Wire retract

    Spot welding ... see page (→)

    • Spot welding time

    Process control ... see page (→)

    • Penetration stabilizer
    • Arc length stabilizer

    SynchroPulse ... see page (→)

    • SynchroPulse
    • Delta wire feed
    • Frequency
    • Duty cycle (high)
    • Arc length correction high
    • Arc length correction low

    Process mix settings ... see page (→)

    • High power time corr.
    • Low power time corr.
    • Low power corr.

    CMT Cycle Step ... see page (→)
    Only if the OPT/i CMT Cycle Step option is present on the welding machine.

    • CMT Cycle Step
    • Cycles (Spot size)
    • Interval break time
    • Interval cycles

    Gas-Setup ... see page (→)

    • Gas pre-flow
    • Gas post-flow
    • Command value gas
    • Gas factor

    Power

    • Upper power correction limit
    • Lower power correction limit

    Arc length correction ... see page (→)

    • Upper arc length correction limit
    • Lower arc length correction limit

    Job slope ... see page (→)

    • Job slope

    Documentation ... see page (→)

    • Sampling rate

    Limit monitoring ... see page (→)
    (only in conjunction with the OPT/i Limit Monitoring option)

    • Voltage command value
    • Lower voltage limit
    • Upper voltage limit
    • Max. time of voltage deviation
    • Current command value
    • Lower current limit
    • Upper current limit
    • Max. time of current deviation
    • Wfs command value
    • Lower wfs limit
    • Upper wfs limit
    • Max. time of wfs deviation
    • Welding duration command value
    • Lower welding duration limit
    • Upper welding duration limit
    • Welding time monitoring
    • Energy command value
    • Lower energy limit
    • Upper energy limit
    • Energy monitoring
    • Limit reaction

    Components ... see page (→)

    • Feeder inching speed

    NOTE!

    In addition to setting the parameters, jobs can also be renamed, copied and deleted under "Optimize Job" with the help of the corresponding buttons.

    Further information on optimising jobs can be found in the Welding mode section, under Job Mode on page (→).

    1. Process parameters
    2. Process parameters, Job

    Process parameters for correction limits

    The following process parameters can be set for the job correction limits:

    Power

    Upper power limit
    For setting the upper power limit for a job

    0 - 20%
    Factory setting: 0%

    Lower power limit
    For setting the lower power limit for a job

    -20 - 0%
    Factory setting: 0%


    Arc length correction

    Upper arc length correction Limit
    for setting the upper arc length correction limit for a job

    0.0 - 10.0
    Factory setting: 0

    Lower arc length correction Limit
    for setting the lower arc length correction limit for a job

    -10.0 - 0.0
    Factory setting: 0


    Further information on optimising jobs can be found in the Job correction limits section, under Job Mode on page (→).

    1. Process parameters
    2. Process parameters, Job

    Process parameters for "Save as Job" pre-settings

    After confirming the displayed information, the following process parameters can be set for the "Save as Job" pre-settings:

    Job slope

    Job slope
    defines the time between the job that is currently selected and the next job

    0.0 - 10.0 s
    Factory setting: 0 s

    MIG/MAG job correction limit

    Upper power correction limit

    0 - 20%
    Factory setting: 0%

    Lower power correction limit

    0 - -20%
    Factory setting: 0%

    Upper arc length correction limit

    0.0 - 10.0
    Factory setting: 0.0

    Lower arc length correction limit

    0.0 - -10.0
    Factory setting: 0.0


    Limit Monitoring
    (only in conjunction with the OPT/i Limit Monitoring option)

    Lower voltage limit
    for setting the lower voltage limit as a function of the set value

    -10.0 - 0.0 V
    Factory setting: 0 V

    Upper voltage limit
    for setting the upper voltage limit as a function of the set value

    0.0 - 10.0 V
    Factory setting: 0 V

    Maximum duration of voltage deviation
    for setting the maximum duration of a voltage deviation

    off / 0.1 - 10.0 s
    Factory setting: off

    Lower current limit
    for setting the lower current limit as a function of the set value

    -100.0 - 0.0 A
    Factory setting: 0

    Upper current limit
    for setting the upper current limit as a function of the set value

    0.0 - 100.0 A
    Factory setting: 0

    Maximum duration of current deviation
    for setting the maximum duration of a current deviation

    off / 0.1 - 10.0 s
    Factory setting: off

    Lower wire speed limit
    for setting the lower wire speed limit

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

    Upper wire speed limit
    for setting the upper wire speed limit

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

    Maximum duration of wire speed deviation
    for setting the maximum duration of a wire speed deviation

    off / 0.1 - 10.0 s
    Factory setting: off

    Lower welding duration limit
    for setting the lower welding duration limit

    0.0 ... -50.0 s
    Factory setting: 1.0

    Upper welding duration limit
    for setting the upper welding duration limit

    0.0 - 50.0 s
    Factory setting: 1.0

    Welding duration monitoring
    to enable/disable welding duration monitoring

    on / off
    Factory setting: on

    Lower energy limit
    for setting the lower energy limit

    0.0 ... -max
    Factory setting: -1.0

    Upper energy limit
    for setting the upper energy limit

    0.0 - max
    Factory setting: 1.0

    Energy monitoring
    to enable/disable energy monitoring

    on / off
    Factory setting: on

    Limit reaction
    for setting the reaction if the limit values are exceeded or undercut

    Ignore / Warning / Error
    Factory setting: Ignore

    Ignore
    Limit values will not be monitored or logged in the logbook

    Warning
    If the limit values are exceeded or undercut, a warning will show on the display and the welding process will not be interrupted.

    Error
    If the limit values are exceeded or undercut, the welding process will stop immediately and an error message will show on the display.

    Defaults

    Defaults

    General

    NOTE!

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

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

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

    1. Defaults

    Defaults

    General

    NOTE!

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

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

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

    1. Defaults
    2. Defaults

    General

    NOTE!

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

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

    WARNING!

    Danger from incorrect operation and work that is not carried out properly.

    This can result in serious personal injury and damage to property.

    All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

    Read and understand this document in full.

    Read and understand all safety rules and user documentation for this device and all system components.

    1. Defaults
    2. Defaults

    Overview

    "Defaults" contains the following options:

    • View
    • System
    • Documentation
    • Administration
    1. Defaults

    Defaults - view

    Defaults view

    1. Defaults
    2. Defaults - view

    Defaults view

    1. Defaults
    2. Defaults - view

    Setting the language

    1Select Defaults / View / Language
    2Turn the adjusting dial and select the desired language
    3Select OK / press the adjusting dial
    1. Defaults
    2. Defaults - view

    Setting units / standards

    1Select Defaults / View / Units / Standards
    2Select the desired unit
    3Select the desired standard:

    EN
    Name of filler metal according to European standards
    (e.g. AlMg 5, CuSi3, Steel, etc.)
    AWS
    Name of filler metal according to the American Welding Standard
    (e.g. ER 5356, ER CuSi-A, ER 70 S-6, etc.)
    4Select the desired display of the welding data at the end of welding

    Hold
    The current actual values at the end of welding are displayed.

    Mean
    The average values over the entire main current phase are displayed.
    5Select "OK"

    An overview of units and standards is displayed.

    1. Defaults
    2. Defaults - view

    Setting the time and date

    The time and date can either be set using the NTP (Network Time Protocol) or manually.

    1Select "Defaults / Display / Time & Date"

    Setting the time and date using the NTP
    A DNS server must be available, or the network parameters must be configured correctly if setting the time and date manually (see "Setting network parameters manually", page (→)).

    2Select "Automatic Time & Date"
    3Enter the address of the local time server
    Ask your IT administrator for the address of the local time server or use the internet (e.g. pool.ntb.org).
    4Enter the time zone
    The time zone must correspond to the location of the welding machine.
    5Select "Time server test" to start the time synchronisation

    The welding machine is synchronised with the time on the NTP server. If the NTP has been set up, the time will be synchronised each time the welding machine is started, as long as a connection to the time server can be established.

    6Select "Apply"

    Setting the time and date manually
    In order to be able to set the time and date manually, "Automatic Time & Date" must not be selected.

    2Turn the adjusting dial and select the desired parameter:
    Year / Month / Day / Hour / Minute
    (white background)
    3Press the adjusting dial to change the parameter (blue background)
    4Turn the adjusting dial and set the desired value (blue background)
    5Press the adjusting dial and apply the set value (white background)
    6Select "OK" / press the adjusting dial

    The default view settings are displayed.

    1. Defaults
    2. Defaults - view

    Retrieving system data

    1Select Defaults / View / System data

    The current system data is displayed.

    Arc power from real-time values in kW

    IP delivers the correct mean value of the arc power due to the high sample measuring rate during non-continuous welding processes.

    If the welding speed is known, the electrical energy per unit length can be calculated:

    E = IP / vs

    E
    Electrical energy per unit length in kJ/cm
    IP
    Arc power in kW
    vs
    Welding speed in cm/s

    Arc energy in kJ

    IE delivers the correct total arc energy due to the high sample measuring rate during non-continuous welding processes.
    The arc energy is total arc power during the entire welding time.
    If the weld seam length is known, the electrical energy per unit length can be calculated:

    E = IE / L

    E
    Electrical energy per unit length in kJ/cm
    IE
    Arc energy in kJ
    L
    Length of the weld seam in cm

    The arc energy is preferably used during manual welding to calculate the energy per unit length.

    Current welding speed in cm/min

    Job currently set

    Current weld seam

    Duration of the current weld seam in s

    Current motor current in A, wirefeeder 1
    (wirefeeder next to the arc)

    Current motor current in A, wirefeeder 2
    (e.g. the rear wirefeeder in a push-pull system)

    Current motor current in A, wirefeeder 3
    (e.g. an unreeling wirefeeder in a push-pull system with unreeling wirefeeder)

    Current motor force in N, wirefeeder motor 1

    Current motor force in N, wirefeeder motor 2

    Current motor force in N, wirefeeder motor 3

    Current flow rate in l/min on the cooling unit
    (with built-in OPT/i CU flow temperature sensor option)

    Error output if flow rate < 0.7 l/min

    Current shielding gas flow rate
    (if OPT/i gas controller option is available)

    Total shielding gas consumption
    (if OPT/i gas controller option is available)

    Current coolant temperature in °C on the cooling unit
    (with built-in OPT/i CU flow temperature sensor option)

    Error output if coolant temperature > 70 °C
    (measured during coolant return)

    Arc time in h

    Total welding machine operating hours in h

    2Select "OK" to exit the system data

    The default view settings are displayed.

    1. Defaults
    2. Defaults - view

    Displaying characteristics

    1Select Defaults / View / Synergic lines

    The options for displaying the characteristics are displayed.

    2Select desired display option

    Display current characteristics:
    Only the current characteristics are displayed in the material settings.

    Display replaced characteristics:
    Older characteristics that have been replaced are also displayed in the material settings, as well as the current characteristics. These can also be selected while setting the material settings.
    3Select "OK"

    The default view settings are displayed.

    1. Defaults
    2. Defaults - view

    MIG/MAG parameter display

    In the case of the MIG/MAG welding parameters, this function enables additional parameters or settings to be displayed.

    Job parameters
    Current, voltage, material thickness, power, arc length correction, pulse correction or dynamic correction

    SFI parameters
    SFI, SFI HotStart

    Process control
    Penetration stabilizer, arc length stabilizer

    SynchroPulse settings
    SynchroPulse, Delta wire speed, frequency, duty cycle (high), arc correction high, arc correction low

    Interval settings
    Interval, interval cycles, interval pause time, stitch welding time

    Process mix
    Upper power duration correction, lower power duration correction, lower power correction

    Cycle Step
    CMT Cycle Step, cycles (welding spot size), interval pause time, interval cycles

    AC settings
    AC power balance, AC cycles negative, AC cycles positive

    Start/end of welding settings
    Starting current, starting arc length correction, starting current time, slope 1, slope 2, final current, end arc length correction, end current time

    Spot welding settings
    Spot welding time

    Gas defaults
    Command value gas, gas pre-flow, gas post-flow

    TWIN process control
    Pulse synchronisation ratio, lead/trail phase shift, trail ignition delay


    Display additional parameters:

    1Select Defaults / Display / MIG/MAG parameter display
    2Turn the adjusting dial and select the desired parameter
    3Press the adjusting dial
    4Select "OK" to exit the MIG/MAG parameter display setup

    The parameter is displayed in the welding parameters, where it can now also be modified.

    1. Defaults
    2. Defaults - view

    JobMaster MIG/MAG display

    This function is used to set the functions and parameters available on a JobMaster welding torch.

    Job parameters
    Job number, EasyJobs, current, wire speed, voltage, material thickness, power, arc length correction, pulse correction or dynamic correction

    Welding process parameters
    Process, characteristic property, welding torch operating mode

    SFI parameters
    SFI, SFI HotStart

    Process control
    Penetration stabilizer, arc length stabilizer

    SynchroPulse settings
    SynchroPulse, Delta wire speed, frequency, duty cycle (high), arc correction high, arc correction low

    Interval settings
    Interval, interval cycles, interval pause time, stitch welding time

    Process mix
    Upper power duration correction, lower power duration correction, lower power correction

    Cycle Step
    CMT Cycle Step, cycles (welding spot size), interval pause time, interval cycles

    AC settings
    AC power balance, AC cycles negative, AC cycles positive

    Start/end of welding settings
    Starting current, starting arc length correction, starting current time, slope 1, slope 2, final current, end arc length correction, end current time

    Spot welding settings
    Spot welding time

    Gas defaults
    Command value gas, gas pre-flow, gas post-flow

    General settings
    R/L alignment, wire forwards/backwards, gas test


    Setting parameters for the JobMaster welding torch:

    1Select Defaults / Display / JobMaster MIG/MAG display
    2Turn the adjusting dial and select the desired parameter
    3Press the adjusting dial
    4Select OK to exit the iJob parameter display

    The parameter is displayed on the JobMaster welding torch, where it can now also be modified.

    1. Defaults

    Defaults - System

    Defaults - System

    NOTE!

    Depending on the device type, equipment or WeldingPackages available, the display and sequence of system defaults may vary.

    1. Defaults
    2. Defaults - System

    Defaults - System

    NOTE!

    Depending on the device type, equipment or WeldingPackages available, the display and sequence of system defaults may vary.

    1. Defaults
    2. Defaults - System

    Retrieving device information

    1Select Defaults / System / Information

    The device information is displayed.

    2Select "OK"
    1. Defaults
    2. Defaults - System

    Restore factory settings

    1Select Defaults / System / Restore factory settings

    A confirmation prompt for the factory settings is displayed.

    2Select "Yes" to reset the values to their factory settings

    The process parameters and machine preset values are reset to the factory settings, an overview of the machine presets is displayed.

    1. Defaults
    2. Defaults - System

    Restoring the website password

    1Select Defaults / System / Website password

    A confirmation prompt asking whether you really want to reset the website password is displayed.

    2Select "Yes" to reset the website password

    The website password is reset to the factory setting:
    User name = admin
    Password = admin

    The system overview of the default settings is displayed.

    1. Defaults
    2. Defaults - System

    Mode Setup: Setting the special 4-step "Guntrigger", special display for JobMaster, spot welding and torch trigger job selection

    In the default settings, the following special functions can be set under "Mode Setup":

    • Special 4-step "Guntrigger" for a JobMaster welding torch *
    • JobMaster special display for a JobMaster welding torch *
    • 2-step or 4-step mode for spot welding
    • Torch trigger job selection for a welding torch
    *
    Only if the OPT/i GUN Trigger option is available on the welding machine.
    1Select Defaults / System / Mode Setup
    2Turn the adjusting dial and select the desired special function (white background)
    3Press the adjusting dial (blue background)
    4Turn the adjusting dial to activate/deactivate the special function
    5Select OK

    Special 4-step = Guntrigger

    With a JobMaster welding torch and with special 4-step mode selected, this function allows you to change jobs via the torch trigger during welding. Job changing takes place within defined job groups.
    A job group is defined by the next non-programmed job.

    Example:
    Job group 1: Job no. 3 / 4 / 5
    Job no. 6 is not assigned ==> End of job group 1
    Job group 2: Job no. 7 / 8 / 9

    • When welding starts, the job with the lowest number within the job group is automatically selected.
    • To change to the job with the next highest number within a job group, press the torch trigger briefly (< 0.5 seconds).
    • To stop welding, press the torch trigger for more than 0.5 seconds.
    • To change to the next job group, press the parameter setting button on the JobMaster welding torch for more than 5 seconds.

    Special JobMaster display = on

    The following can now be set and carried out on the JobMaster welding torch:

    • Operating mode
    • SynchroPulse
    • Gas test

    NOTE!

    The parameter "Special JobMaster display" is no longer available as of firmware version 4.0.0.

    The corresponding settings can be implemented as follows:

    Defaults / Display / JobMaster MIG/MAG display
    (see page (→))

    Spot welding

    2-step = spot welding in 2-step mode:
    The spot welding process runs for as long as the torch trigger is kept pressed and ends no later than at the expiry of the spot welding time.
    Releasing the torch trigger stops the spot welding process before the spot welding time expires.

    4-step = spot welding in 4-step mode:
    The spot welding process starts once the torch trigger is pressed and ends no later than at the expiry of the spot welding time.
    Press the torch trigger again to stop the spot welding process before the spot welding time expires.

    More information on spot welding:

    • Page (→) (spot welding in general)
    • Page (→) (spot welding time)

    Torch trigger job selection = on

    This function allows the user to change to the next job using the torch trigger. Job changing takes place within defined job groups.
    A job group is defined by the next non-programmed job.

    Example:
    Job group 1: Job no. 3 / 4 / 5
    Job no. 6 is not assigned ==> End of job group 1
    Job group 2: Job no. 7 / 8 / 9

    • When welding starts, the job with the lowest number within the job group is automatically selected.
    • To change to the job with the next highest number within a job group, press the torch trigger briefly (< 0.5 seconds).
    • To stop welding, press the torch trigger for more than 0.5 seconds.
    • To switch to the next job group, press the torch trigger briefly twice
      (< 0.3 s, 2 x).

    You can switch jobs when the device is in standby or during welding.

    1. Defaults
    2. Defaults - System

    Service Connect

    Service Connect is a remote maintenance tool for fault diagnosis and troubleshooting, data analysis and process optimisation on the welding machine.
    After accepting the terms of use directly on the control panel of the welding machine, a Fronius technician can access the welding machine remotely.

    Procedure when a problem arises on the welding machine for which remote diagnostics are requested from Fronius:

    1Select Defaults / System / Service Connect
    2Follow the displayed instructions and select "Next"

    The welding machine establishes a secure VPN connection to Fronius.
    Once the connection has been successfully established, a code is shown on the display and the green double arrow symbol is shown in the status bar.
    3Pass this code on to Fronius by telephone
    4Select "Finish"

    Fronius support can begin.
    The remote operation carried out by the Fronius technician is recorded by Fronius using a video log.

    End remote operation:

    1Select Defaults / System / Service Connect

    The prompt to disconnect the connection is displayed.
    2Select "Next"

    The connection is disconnected, the Fronius technician no longer has access to the welding machine.

    A confirmation about the disconnection of the network connection is displayed, the double arrow symbol in the status bar is no longer displayed.
    1. Defaults
    2. Defaults - System

    Network settings

    The network settings contain the following entries:

    • Network
    • WLAN
    • Bluetooth settings
    • WeldCube Air
    • Client authorization
    • USB port
    1. Defaults
    2. Defaults - System

    Setting network parameters manually

    1Select Defaults / System / Network settings / Network

    If DHCP is enabled, the IP address, Network mask, Standard gateway, DNS Server 1 and DNS Server 2 network parameters are greyed out and cannot be adjusted.

    2Turn the adjusting dial and select "DHCP"
    3Press the adjusting dial

    DHCP is disabled, the network parameters can now be set.

    4Turn the adjusting dial and select the desired network parameter
    5Press the adjusting dial

    The numerical pad for the selected parameter is displayed.

    6Enter a value for the network parameter
    7Select "OK" and confirm the value for the network parameter / press the adjusting dial
    8Select "Store" to apply changes to the network

    The value for the network parameter is applied, the network settings are displayed.

    1. Defaults
    2. Defaults - System

    WLAN

    1Select Defaults / System / Network settings / WLAN

    The WLAN setup overview is displayed.

    Setup country code

    1Select "Setup country code"
    2Press the adjusting dial
    3Turn the adjusting dial and select the corresponding country
    4Select "OK"

    Activating WLAN

    1Select "Enable WI-Fi"

    When WLAN is enabled, a check mark appears in the button and the "Add network" and "Delete network" buttons are active.

    Adding a network

    1Select "Add network"

    The available WLAN networks are displayed.

    2Turn the adjusting dial and select the desired WLAN network
    3Press the adjusting dial or select "Insert"
    4Enter data:
    • Enable DHCP
      or
    • Manually enter IP address, network mask, default gateway, DNS Server 1 and DNS Server 2:
      Turn the dial and select the desired element,
      press the setting dial,
      enter the data using the numeric keypad,
      confirm with "OK"
    5Select "OK" and add as WLAN network

    Deleting a network

    1Turn the adjusting dial and select the WLAN network to be deleted
    2Select "Delete network"
    3Confirm security prompt

    The WLAN network will be deleted.
    1. Defaults
    2. Defaults - System

    Bluetooth settings

    General

    Each Bluetooth device has its own MAC address. This MAC address can be used to assign the devices to specific welding machines, preventing mix-ups.

    The welding machine is able to communicate with the following Bluetooth devices:

    • Remote control RC Panel Basic /BT
    • Pedal remote control RC Pedal TIG /BT
    • Welding helmet Vizor Connect /BT

    An active Bluetooth connection is indicated in the status bar on the display when the Bluetooth symbol lights up blue.

    For safety reasons, when using Bluetooth devices of the same type, only one device can be actively connected to the welding machine.
    It is possible to establish multiple active Bluetooth connections when using Bluetooth devices of different types.

    An existing, active Bluetooth connection cannot be interrupted or influenced by another Bluetooth device.

    Bluetooth remote controls have priority over wired remote controls or welding torches with control functions.

    If the connection between a wired or Bluetooth remote control and the welding machine is interrupted during the welding process, the welding process is ended.

    Running Bluetooth setup

    1Select Defaults / System / Network settings / Bluetooth setting

    The overview of the Bluetooth devices is displayed.

    Activating or deactivating the welding machine Bluetooth function

    • Select the "Activate Bluetooth" button

    Adding a Bluetooth device

    • Switch on the Bluetooth device
    • Select the "Add device" button

      All Bluetooth devices detected are displayed in a list along with their names, MAC addresses and additional information.
    • Use the adjusting dial to select the desired Bluetooth device
    • Compare the MAC address displayed with the MAC address on the device
      Select the "Add" button to establish an active connection to the selected device
    • Select the "Save" button

      The active connection is displayed under Info.

    Symbols displayed under Info:

    Active Bluetooth connection
    An active change can be made to the welding machine via the Bluetooth device.
    Depending on the availability of the data, additional information is also displayed, such as the battery status, signal strength, etc. of the Bluetooth device.

    Paired
    The Bluetooth device has already been actively connected to a welding machine at least once and appears in the list of the Bluetooth devices.

    Inactive
    A new Bluetooth device has been detected or the Bluetooth device was removed by the user.

    Deleting the Bluetooth device

    • Use the adjusting dial to select the Bluetooth device to be deleted
    • Select the "Delete device" button
    • When prompted, confirm that you want to delete the device with "OK"
    2Select "OK" to exit Bluetooth setup
    1. Defaults
    2. Defaults - System

    WeldCube Air

    WeldCube Air is a cloud-based centralised collection of welding data, process metrics and other functionalities.
    WeldCube Air is available as an online service.

    NOTE!

    Knowledge of network technology is required to set up WeldCube Air. Contact your IT department.

    Before connecting to WeldCube Air:

    Unlock the following ports and domains
    https://dps.prod.air.az.weldcube.com/ Port 443 (HTTPS)
    https://stpwwcpcprod001.blob.core.windows.net/ Port 443 (HTTPS)
    https://stpwwcashared.blob.core.windows.net/ Port 443 (HTTPS)
    Port 8883 (MQTT)

    Activate the time server
    Select Defaults / Display / Date & Time / Automatic Time & Date
    With manual time setting, the time deviation must not exceed 2 minutes.

    1Select Defaults / System / Network settings / WeldCube Air
    2Select Enable WeldCube Air
    3Confirm consent for data transfer

    The device code and the QR code are displayed:
    4Scan the QR code
    or
    go to the air.weldcube.com web page and select Add machine / Continue and enter the device machine code

    The welding machine is connected to WeldCube Air.

    Disable WeldCube Air
    Pairing between welding machine and WeldCube Air remains unaffected, no data is sent.

    Unpair device
    The welding machine is disconnected from WeldCube Air - no data transfer, no pairing.

    Further information on WeldCube Air is available at:
    https://www.weldcube.com

    1. Defaults
    2. Defaults - System

    Client authorization

    Increased connection security
    To increase the connection security between WeldCube Premium and the welding system, an existing connection to WeldCube Premium can be confirmed under Client authorization.

    Confirm connection:

    1Select Defaults / System / Network settings / client authorization

    The existing connections to WeldCube Premium are displayed with WeldCube Premium ID, URL and the connection security status.

     

    Status of the extended connection unknown

    Extended connection pending

    Extended connection permitted

    2Select the desired WeldCub Premium connection by turning the adjusting dial
    3Press the adjusting dial or select "OK"
    4Confirm when prompted
    1. Defaults
    2. Defaults - System

    USB port

    1Select Defaults / System / Network settings / USB port
    2Press the adjusting dial
    3Select the desired setting for the USB port on the control panel by turning the adjusting dial:

    off:
    No data exchange possible on the USB port.

    restricted:
    Licence-Key and Service-Dongle possible

    on:
    No restriction on the USB port
    4Press the adjusting dial or select "OK"

    The setting is applied.

    1. Defaults
    2. Defaults - System

    Welding machine configuration

    Power source = welding machine

    1Select Defaults / System / Welding machine configuration

    The welding machine configuration is displayed.

    2Turn the adjusting dial and select a configuration location
    3Press the adjusting dial

    The keyboard is displayed.

    4Use the keyboard to enter the desired text (max. 20 characters)
    5Select "OK" to confirm the text / press the adjusting dial

    The text is applied and the welding machine configuration is displayed.

    6Select "Store" to apply changes
    1. Defaults
    2. Defaults - System

    Wire feeder setup

    Use "Wire feeder setup" to activate or deactivate potentiometers on a wirefeeder.

    1Select Defaults / System / Wire feeder setup
    2Set the "Wirefeeder Potentiometer" parameter to either "off" or "on" 

    off
    The potentiometers on the wirefeeder are deactivated.

    on:
    The potentiometers on the wirefeeder are activated.

    Factory setting:
    on
    1. Defaults
    2. Defaults - System

    Interface setup

    Interface setup can be used to specify whether the welding parameters will be determined externally by the robot control or internally by the welding machine.

    1Select Defaults / System / Interface setup
    2Set the "Welding parameter" to "External" or "Internal"

    External:
    All parameter settings are controlled using the robot control (even the welding parameters).

    Internal:
    The welding parameters are set using the welding machine, the control signals are routed through the robot control.

    Factory setting:
    External
    1. Defaults
    2. Defaults - System

    TWIN setup

    Welding lines 1 and 2 are assigned to welding machines in TWIN setup.

    1Switch on welding machine 2, leave welding machine 1 switched off
    2Attach sticker 2 to welding machine 2 where it is clearly visible
    3For welding machine 2, select Defaults / System / TWIN Setup
    4Change the parameter to 2, select "Next"
    5Switch on welding machine 1
    6Attach sticker 1 to welding machine 1 where it is clearly visible
    7In the welding machine 1 Setup menu, check under Defaults / System / TWIN Setup that the parameter is set to 1
    1. Defaults

    Defaults - Documentation

    Defaults - Documentation

    1. Defaults
    2. Defaults - Documentation

    Defaults - Documentation

    1. Defaults
    2. Defaults - Documentation

    Setting the sampling rate

    1Select Defaults / Documentation / Basic settings
    2Press the adjusting dial
    3Turn the adjusting dial and change the sampling rate value:

    off
    Sampling rate is deactivated; only average values are stored.

    0.1–100.0 s
    Documentation is stored with the set sampling rate.
    4Select "OK" to confirm the sampling rate
    1. Defaults
    2. Defaults - Documentation

    Viewing the logbook

    1Select Defaults / Documentation / Logbook

    The logbook is displayed.
    Welding operations, events, errors, warnings or notifications can be displayed using the respective buttons.

    The following data is also logged:

    (1)
    Welding operation number
    (2)
    Date (ddmmyy)
    (3)
    Time (hhmmss)
    (4)
    Welding duration in s
    (5)
    Welding current in A (average value)
    (6)
    Welding voltage in V (average value)
    (7)
    Wire speed in m/min
    (8)
    Arc energy in kJ (for details see page (→))
    (9)
    Job no.

    Turn the adjusting dial to scroll through the list.
    Pressing the adjusting dial displays details of a logbook entry.

    Details for welds:

    (10)
    Welding section number
    (11)
    Duration of the welding section in s
    (12)
    Welding current in A (average value)
    (13)
    Welding voltage in V (average value)
    (14)
    Wire speed in m/min
    (15)
    Welding speed (cm/min)
    (16)
    Arc power from real-time values in W (for details see page (→))
    (17)
    Arc energy in kJ (for details see page (→))
    (18)
    Job no.
    (19)
    Process
    2Select "Close" to exit the detailed view
    3Select "OK" to exit the logbook
    1. Defaults
    2. Defaults - Documentation

    Activating/deactivating limit value monitoring

    1Select Defaults / Documentation / Limit monitoring

    The settings for limit value monitoring are displayed.

    2Press the adjusting dial
    3Turn the adjusting dial and change the value for limit monitoring:

    off:
    The limit value monitoring is deactivated.

    on:
    The limit values will be monitored according to the settings

    Factory setting:
    off
    4Select "OK" to apply the settings for limit value monitoring

    The documentation overview is displayed.

    1. Defaults

    Defaults - Administration

    Defaults - Administration

    1. Defaults
    2. Defaults - Administration

    Defaults - Administration

    1. Defaults
    2. Defaults - Administration

    General

    User management is advisable if several users work with the same welding machine.
    User management works with different roles and the help of NFC keys.

    Users are assigned different roles depending on their level of training or qualifications.

    1. Defaults
    2. Defaults - Administration

    Explanation of terms used

    Administrator
    An administrator has unlimited access rights to all functions on the welding machine. The administrator's duties include:
    • Creating roles
    • Editing and managing user data
    • Assigning access rights
    • Updating the firmware
    • Backing up data, etc.

    User management
    User management encompasses all users registered on the welding machine. Users are assigned different roles depending on their level of training or qualifications.

    NFC card
    An NFC card or an NFC key ring is assigned to a certain user who is registered on the welding machine.
    NFC cards and NFC key rings will both be referred to under the general term NFC key for the purpose of these Operating Instructions.

    IMPORTANT! Each user should be assigned their own NFC key.

    Roles
    Roles are used for managing registered users (= user management). Users' access rights and permitted activities are defined by their roles.

    1. Defaults
    2. Defaults - Administration

    Pre-defined roles and users

    Under Defaults / Administration / User management, 2 roles are predefined as factory settings:

    Administrator
    with full rights and options

    The "Administrator" role cannot be deleted, renamed or edited.

    The "Administrator" role is assigned the pre-defined "Admin" user, which cannot be deleted. The "Admin" user can assign names, languages, units, web passwords and NFC keys.
    As soon as "Admin" assigns an NFC key, user management is activated.

    Locked
    Factory-set with access to welding processes, but not to process parameters and defaults

    The "Locked" role

    • Cannot be deleted or renamed
    • Can be edited to approve different functions according to demand

    The "Locked" role cannot have any NFC keys assigned to it.

    If no NFC key is assigned to the pre-defined user "Admin", every NFC key will work to lock and unlock the welding machine (no user management, see "Locking and unlocking the welding machine using the NFC key", page (→)).

    1. Defaults
    2. Defaults - Administration

    User management overview

    User management consists of the following sections:

    • Creating the administrator and roles
    • Creating a user
    • Editing roles / users, deactivating user management
    1. Defaults

    Administrator and creating roles

    Recommendation for creating roles and users

    Please proceed systematically when creating roles and NFC keys.

    Fronius recommends creating one or two administrator keys. In the worst case, a welding machine can no longer be operated without administrator rights.

    Procedure

    NOTE!

    Losing an NFC administrator key can lead to the welding machine becoming unusable, depending on the settings. Keep one of the two NFC administrator keys in a safe place.

    1Create two equivalent users in the "Administrator" role

    This means that you will still have access to administrative functions should you lose one of the NFC administrator keys.
    2Consider further roles:
    • How many roles are needed?
    • Which rights will be assigned to each role?
    • How many users are there?
    3Create roles
    4Assign users to roles
    5Check that the created users have access to their respective roles with their NFC keys.
    1. Defaults
    2. Administrator and creating roles

    Recommendation for creating roles and users

    Please proceed systematically when creating roles and NFC keys.

    Fronius recommends creating one or two administrator keys. In the worst case, a welding machine can no longer be operated without administrator rights.

    Procedure

    NOTE!

    Losing an NFC administrator key can lead to the welding machine becoming unusable, depending on the settings. Keep one of the two NFC administrator keys in a safe place.

    1Create two equivalent users in the "Administrator" role

    This means that you will still have access to administrative functions should you lose one of the NFC administrator keys.
    2Consider further roles:
    • How many roles are needed?
    • Which rights will be assigned to each role?
    • How many users are there?
    3Create roles
    4Assign users to roles
    5Check that the created users have access to their respective roles with their NFC keys.
    1. Defaults
    2. Administrator and creating roles

    Creating an administrator key

    NOTE!

    Once an NFC key is assigned to the pre-defined "Admin" user under Defaults / Administration / User management / Administrator, user management becomes active.

    1Select Defaults / Administration / User management

    User management is displayed, "Administrator" is selected.

    2Press the adjusting dial
    3Turn the adjusting dial and select "Admin"
    4Press the adjusting dial
    5Turn the adjusting dial and select "NFC card"
    6Press the adjusting dial

    The information to be transferred to the NFC card is displayed.

    7Follow the instructions displayed
    (hold the new NFC key on the NFC key reader and wait for confirmation of identification)
    8Select "OK"

    A note concerning the activated user management is displayed.

    9Select "OK"

    Under Admin / NFC card, the number of the assigned NFC key is displayed.

    To create a second administrator key:

    • Copy "Admin" (to create "new from" see page (→))
    • Enter user name
    • Assign new NFC card
    1. Defaults
    2. Administrator and creating roles

    Creating roles

    1Select Defaults / Administration / User management

    User management appears.

    2Select "create role"

    The keyboard is displayed.

    3Use the keyboard to enter the desired role name (max. 20 characters)
    4Select "OK" to apply the role name / press the adjusting dial

    The functions that can be executed within a role are displayed.

    Symbols:

    ... hidden

    ... read only

    ... read and write

    5Specify the functions that a user can carry out in this role
    • Select functions by turning the adjusting dial
    • Press the adjusting dial
    • Select settings from the list
    • Press the adjusting dial
    6Select "OK"
    1. Defaults
    2. Administrator and creating roles

    Copy roles

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the role to be copied
    3Select "new from"
    4Enter a name for the new role using the keyboard
    5Select "OK"
    6Specify executable functions for the role
    • Select function by turning the adjusting dial
    • Press the adjusting dial
    • Select the settings for the functions from the list
    7Select "OK"
    1. Defaults

    Creating a user

    Creating a user

    NOTE!

    For privacy reasons, only person identity numbers and not full names should be entered when creating users.

    1Select Defaults / Administration / User management

    User management appears.

    2Select "create user"

    The keyboard is displayed.

    3Use the keyboard to enter the desired user name (max. 20 characters)
    4Select "OK" to confirm the user name / press the adjusting dial
    5Enter further user data
    - Select parameters by turning the adjusting dial
    - Press the adjusting dial
    - Select role, language, unit and standard (norm) from the list
    - Enter first name, last name and web password by using the keyboard
    6Turn the adjusting dial and select "NFC card"
    7Press the adjusting dial

    The information to be transferred to the NFC card is displayed.

    8Follow the instructions displayed
    (hold the new NFC key on the NFC key reader and wait for confirmation of identification)
    1. Defaults
    2. Creating a user

    Creating a user

    NOTE!

    For privacy reasons, only person identity numbers and not full names should be entered when creating users.

    1Select Defaults / Administration / User management

    User management appears.

    2Select "create user"

    The keyboard is displayed.

    3Use the keyboard to enter the desired user name (max. 20 characters)
    4Select "OK" to confirm the user name / press the adjusting dial
    5Enter further user data
    - Select parameters by turning the adjusting dial
    - Press the adjusting dial
    - Select role, language, unit and standard (norm) from the list
    - Enter first name, last name and web password by using the keyboard
    6Turn the adjusting dial and select "NFC card"
    7Press the adjusting dial

    The information to be transferred to the NFC card is displayed.

    8Follow the instructions displayed
    (hold the new NFC key on the NFC key reader and wait for confirmation of identification)
    1. Defaults
    2. Creating a user

    Copying users

    NOTE!

    For privacy reasons, only person identity numbers and not full names should be entered when creating users.

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the role to which the user to be copied is assigned
    3Press the adjusting dial
    4Turn the adjusting dial and select the user to be copied
    5Select "new from"
    6Enter a name for the new user using the keyboard
    7Select "OK"
    8Specify further user data
    9Assign new NFC key
    10Select "OK"
    1. Defaults

    Editing roles / users, deactivating user management

    Editing roles

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the desired role
    3Select "Edit user/role"

    The role will open, the functions can be adjusted:

    • Select function by turning the adjusting dial
    • Press the adjusting dial
    • Change the role name using the keyboard
    • Select the settings for the functions from the list
    4Select "OK"

    If no user is assigned to a role, then the it is possible to start editing the role by pressing the adjusting dial.

    1. Defaults
    2. Editing roles / users, deactivating user management

    Editing roles

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the desired role
    3Select "Edit user/role"

    The role will open, the functions can be adjusted:

    • Select function by turning the adjusting dial
    • Press the adjusting dial
    • Change the role name using the keyboard
    • Select the settings for the functions from the list
    4Select "OK"

    If no user is assigned to a role, then the it is possible to start editing the role by pressing the adjusting dial.

    1. Defaults
    2. Editing roles / users, deactivating user management

    Deleting roles

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the role to be deleted
    3Select "Delete user/role"
    4Confirm when prompted

    The role and all assigned users will be deleted.

    1. Defaults
    2. Editing roles / users, deactivating user management

    Editing users

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the role to which the user to be edited is assigned
    3Press the adjusting dial

    The users assigned to the role are displayed.

    4Turn the adjusting dial and select the user to be edited
    5Select "Edit user/role" (or press the adjusting dial)
    • Select parameters by turning the adjusting dial
    • Press the adjusting dial
    • Change the name and web password using the keyboard
    • Select other settings from the list
    Replace NFC card:
    • Turn the adjusting dial and select "NFC card"
    • Press the adjusting dial
    • Select "replace"
    • Hold the new NFC key on the NFC key reader and wait for confirmation of identification
    • Select "OK"
    6Select "OK"
    1. Defaults
    2. Editing roles / users, deactivating user management

    Deleting users

    1Select Defaults / Administration / User management

    User management appears.

    2Turn the adjusting dial and select the role to which the user to be deleted is assigned
    3Press the adjusting dial
    4Turn the adjusting dial and select the user to be deleted
    5Select "Delete user/role"
    6Confirm when prompted

    The user is deleted.

    1. Defaults
    2. Editing roles / users, deactivating user management

    Deactivating user management

    1Select the pre-defined "Admin" user under Defaults / Administration / User management / Administrator
    2Turn the adjusting dial and select "NFC card"
    3Press the adjusting dial

    A confirmation prompt asking whether you want to delete or replace the NFC card is displayed.

    NOTE!

    If the NFC card is deleted by the predefined "Admin" user, user management is deactivated.

    4Select delete

    User management is deactivated, the welding machine is locked.
    The welding machine can be locked and unlocked again with any NFC key (see page (→)).

    1. Defaults
    2. Editing roles / users, deactivating user management

    Lost NFC administrator key?

    Procedure when

    • User management is active
    • The welding machine is locked
      and
    • The NFC administrator key has been lost:
    1Touch the key symbol in the status bar on the display

    Information on the loss of the administrator card is displayed.
    2Note the IP address of the welding machine
    3Open the welding machine SmartManager (enter the IP address of the welding machine in a browser)
    4Contact Fronius After-Sales Service
    1. Defaults

    CENTRUM - Central User Management

    Activating the CENTRUM server

    CENTRUM is a piece of software for the central management of users. Detailed information is available in the CENTRUM Operating Instructions (42,0426,0338,xx).

    The CENTRUM server can also be activated directly on the welding machine, as follows:

    1Select Defaults / Administration / CENTRUM Server

    The Central User Management Server is displayed.

    2Activate the CENTRUM server (press the adjusting dial)
    3Select CENTRUM server, press the adjusting dial and use the keyboard to enter the address of the CENTRUM server
    4Select the verify CENTRUM button
    5Save
    1. Defaults
    2. CENTRUM - Central User Management

    Activating the CENTRUM server

    CENTRUM is a piece of software for the central management of users. Detailed information is available in the CENTRUM Operating Instructions (42,0426,0338,xx).

    The CENTRUM server can also be activated directly on the welding machine, as follows:

    1Select Defaults / Administration / CENTRUM Server

    The Central User Management Server is displayed.

    2Activate the CENTRUM server (press the adjusting dial)
    3Select CENTRUM server, press the adjusting dial and use the keyboard to enter the address of the CENTRUM server
    4Select the verify CENTRUM button
    5Save

    SmartManager - the welding machine website

    SmartManager - the welding machine website

    General

    The welding machines have their own website: SmartManager.
    As soon as the welding machine is connected to a computer using a network cable, or is on a network, the welding machine's SmartManager can be retrieved using the welding machine's IP address.
    At least IE 10 or a similar modern browser is required to access SmartManager.

    The entries displayed on SmartManager may vary depending on system configuration, software upgrades and available options.

    Examples of entries displayed:

    • Current system data
    • Documentation Logbook
    • Job data
    • Power source settings
    • Backup & Restore
    • User management
    • Signal visualisation
    • Overview
    • Update
    • Function Packages
    • Characteristics overview
    • Screenshot
    • Robot interface *
    *
    Depending on the available robot interface, the name of the interface will be displayed as an entry on the website.
    1. SmartManager - the welding machine website

    SmartManager - the welding machine website

    General

    The welding machines have their own website: SmartManager.
    As soon as the welding machine is connected to a computer using a network cable, or is on a network, the welding machine's SmartManager can be retrieved using the welding machine's IP address.
    At least IE 10 or a similar modern browser is required to access SmartManager.

    The entries displayed on SmartManager may vary depending on system configuration, software upgrades and available options.

    Examples of entries displayed:

    • Current system data
    • Documentation Logbook
    • Job data
    • Power source settings
    • Backup & Restore
    • User management
    • Signal visualisation
    • Overview
    • Update
    • Function Packages
    • Characteristics overview
    • Screenshot
    • Robot interface *
    *
    Depending on the available robot interface, the name of the interface will be displayed as an entry on the website.
    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    General

    The welding machines have their own website: SmartManager.
    As soon as the welding machine is connected to a computer using a network cable, or is on a network, the welding machine's SmartManager can be retrieved using the welding machine's IP address.
    At least IE 10 or a similar modern browser is required to access SmartManager.

    The entries displayed on SmartManager may vary depending on system configuration, software upgrades and available options.

    Examples of entries displayed:

    • Current system data
    • Documentation Logbook
    • Job data
    • Power source settings
    • Backup & Restore
    • User management
    • Signal visualisation
    • Overview
    • Update
    • Function Packages
    • Characteristics overview
    • Screenshot
    • Robot interface *
    *
    Depending on the available robot interface, the name of the interface will be displayed as an entry on the website.
    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Call up the welding machine SmartManager and log in

    1Defaults / System / Information ==> note down the IP address of the welding machine
    2Enter the IP address in the browser search field
    3Enter user name and password

    Factory setting:
    User name = admin
    Password = admin
    4Confirm the displayed message

    The welding machine SmartManager is displayed.

    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Help function, should you be unable to log in

    There are two auxiliary functions when logging on to SmartManager:

    • Start unlocking function?
    • Forgotten password?

    Start unlocking function?

    An unintentionally locked welding machine can be unlocked with this function and all its functions made available.

    1Click "Start unlocking function"?
    2Create verification file:
    Click on "Save"

    A TXT file with the following name will be saved to the computer's "Downloads" folder:

    unlock_SN[serial number]_YYYY_MM_DD_hhmmss.txt

    3Send this verification file to Fronius Technical Support by e-mail:
    welding.techsupport@fronius.com

    Fronius will respond to each e-mail with a one-time unlocking file named as follows:

    response_SN[serial number]_YYYY_MM_DD_hhmmss.txt

    4Save the unlocking file to your computer
    5Click on "Search unlocking file"
    6Apply unlocking file
    7Click on "Install unlocking file"

    This will work just once to unlock the welding machine.

    Forgotten password?

    After clicking "Forgotten password?" a notice will be displayed explaining that the password can be reset on the welding machine (see also "Resetting the website password", page (→)).

    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Changing password / logging off

    By clicking this symbol

    • the user password can be changed
    • you can log out of SmartManager

    Changing the password for the SmartManager:

    1Enter the old password
    2Enter the new password
    3Repeat the new password
    4Click on "Save"
    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Settings

    Clicking on this symbol expands the display of characteristics, material specifications and certain welding parameters for the welding machine's SmartManager.

    The settings depend on which user is currently logged on.

    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Language selection

    The languages available for SmartManager can be displayed by clicking on the language abbreviation.

    To change the language, click on the one you would like.

    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Status indicator

    The current status of the welding machine is shown between the Fronius logo and displayed welding machine.

    Attention / Warning

    Fault on welding machine *

    Welding machine is welding

    The welding machine is ready (online)

    The welding machine is not ready (offline)

     

    *
    In the event of an error, a red error line complete with error number will be displayed above the line with the Fronius logo.
    Clicking on the error line will reveal a description of the error.
    1. SmartManager - the welding machine website
    2. SmartManager - the welding machine website

    Fronius

    A click on the Fronius logo opens the homepage of Fronius: www.fronius.com.

    1. SmartManager - the welding machine website

    Current system data

    Current system data

    The welding system's current data is displayed.

    NOTE!

    The system data displayed will vary depending on the welding process, equipment and existing WeldingPackages.

    e.g. system data for MIG/MAG:

    (1)
    Device type
    (2)
    Device name
    (3)
    TWIN info
    (4)
    Plant
    (5)
    Production building (hall)
    (6)
    Cell
    (7)
    Filler (addition)
    (8)
    Welding process
    (9)
    Actual values / HOLD or average values (depending on setting)
    (10)
    Welding current
    (11)
    Welding voltage
    (12)
    Wire speed
    (13)
    Arc time
    (14)
    Arc energy
    (15)
    Arc power
    (16)
    Welding current command value
    (17)
    Welding voltage command value
    (18)
    Wire feed speed command value
    (19)
    Arc length correction
    (20)
    Pulse/dynamic correction
    (21)
    Arc power
    (22)
    Arc length stabilizer
    (23)
    Penetration stabilizer
    (24)
    Total shielding gas consumption
    (25)
    Total arc time
    (26)
    Total operating hours of the welding machine
    (27)
    Operating mode
    (28)
    Filler metal, shielding gas, characteristic, diameter, ID
    (29)
    Process functions
    (30)
    TWIN or WF Dual information
    (31)
    Full-screen mode
    1. SmartManager - the welding machine website
    2. Current system data

    Current system data

    The welding system's current data is displayed.

    NOTE!

    The system data displayed will vary depending on the welding process, equipment and existing WeldingPackages.

    e.g. system data for MIG/MAG:

    (1)
    Device type
    (2)
    Device name
    (3)
    TWIN info
    (4)
    Plant
    (5)
    Production building (hall)
    (6)
    Cell
    (7)
    Filler (addition)
    (8)
    Welding process
    (9)
    Actual values / HOLD or average values (depending on setting)
    (10)
    Welding current
    (11)
    Welding voltage
    (12)
    Wire speed
    (13)
    Arc time
    (14)
    Arc energy
    (15)
    Arc power
    (16)
    Welding current command value
    (17)
    Welding voltage command value
    (18)
    Wire feed speed command value
    (19)
    Arc length correction
    (20)
    Pulse/dynamic correction
    (21)
    Arc power
    (22)
    Arc length stabilizer
    (23)
    Penetration stabilizer
    (24)
    Total shielding gas consumption
    (25)
    Total arc time
    (26)
    Total operating hours of the welding machine
    (27)
    Operating mode
    (28)
    Filler metal, shielding gas, characteristic, diameter, ID
    (29)
    Process functions
    (30)
    TWIN or WF Dual information
    (31)
    Full-screen mode
    1. SmartManager - the welding machine website

    Documentation, logbook

    Logbook

    The last 100 entries in the logbook are shown in the Documentation entry. These logbook entries can be welding operations, errors, warnings, notifications and events.
    Press the "Time filter" button to restrict the data to a specific period of time. To do so, the date (yyyy mm dd) and time (hh mm) are entered in the format from – to in each case.
    A blank filter loads the latest welding operations again.
    The option to show welding operations, errors, warnings, notifications and events can be deactivated.

    The following data is displayed:

    (1)
    Welding operation number
    (2)
    Start time (date and time)
    (3)
    Welding duration in s
    (4)
    Welding current in A (average value)
    (5)
    Welding voltage in V (average value)
    (6)
    Wire speed in m/min
    (7)
    IP - arc power in W (from real-time values in accordance with ISO/TR 18491)
    (8)
    IE - arc energy in kJ (in total across the entire weld in accordance with ISO/TR 18491)

    Robot speed and jobs are also displayed if present in the system.

    Clicking on a logbook entry will display details.

    Details for welds:

    Section no.

    (9)
    Duration of the welding section in s
    (10)
    Welding current in A (average value)
    (11)
    Welding voltage in V (average value)
    (12)
    Wire speed in m/min
    (13)
    Welding speed (cm/min)
    (14)
    Arc power from real-time values in W (for details see page (→))
    (15)
    Arc energy in kJ (for details see page (→))
    (16)
    Job no.
    (17)
    Process

    Further values can be displayed by clicking on the "Insert column" button:

    • I max / I min: maximum/minimum welding current in A
    • Max power / Min power: maximum/minimum arc power in W
    • Start time (welding machine time); date and time
    • U max / U min: maximum/minimum welding voltage in V
    • Vd max / Vd min: maximum/minimum wire speed in m/min

    If the OPT/i documentation option is available on the welding machine, individual welding sections can also be displayed.

    This documentation can be exported in the desired format using the "PDF" and "CSV" buttons.
    In order to create CSV exports, the OPT/i documentation option must be available on the welding machine.

    1. SmartManager - the welding machine website
    2. Documentation, logbook

    Logbook

    The last 100 entries in the logbook are shown in the Documentation entry. These logbook entries can be welding operations, errors, warnings, notifications and events.
    Press the "Time filter" button to restrict the data to a specific period of time. To do so, the date (yyyy mm dd) and time (hh mm) are entered in the format from – to in each case.
    A blank filter loads the latest welding operations again.
    The option to show welding operations, errors, warnings, notifications and events can be deactivated.

    The following data is displayed:

    (1)
    Welding operation number
    (2)
    Start time (date and time)
    (3)
    Welding duration in s
    (4)
    Welding current in A (average value)
    (5)
    Welding voltage in V (average value)
    (6)
    Wire speed in m/min
    (7)
    IP - arc power in W (from real-time values in accordance with ISO/TR 18491)
    (8)
    IE - arc energy in kJ (in total across the entire weld in accordance with ISO/TR 18491)

    Robot speed and jobs are also displayed if present in the system.

    Clicking on a logbook entry will display details.

    Details for welds:

    Section no.

    (9)
    Duration of the welding section in s
    (10)
    Welding current in A (average value)
    (11)
    Welding voltage in V (average value)
    (12)
    Wire speed in m/min
    (13)
    Welding speed (cm/min)
    (14)
    Arc power from real-time values in W (for details see page (→))
    (15)
    Arc energy in kJ (for details see page (→))
    (16)
    Job no.
    (17)
    Process

    Further values can be displayed by clicking on the "Insert column" button:

    • I max / I min: maximum/minimum welding current in A
    • Max power / Min power: maximum/minimum arc power in W
    • Start time (welding machine time); date and time
    • U max / U min: maximum/minimum welding voltage in V
    • Vd max / Vd min: maximum/minimum wire speed in m/min

    If the OPT/i documentation option is available on the welding machine, individual welding sections can also be displayed.

    This documentation can be exported in the desired format using the "PDF" and "CSV" buttons.
    In order to create CSV exports, the OPT/i documentation option must be available on the welding machine.

    1. SmartManager - the welding machine website
    2. Documentation, logbook

    Basic settings

    In the basic settings, the sampling rate for documentation can be activated and set.
    In addition, motor force M1 - M3, gas flow actual value and welding speed can be activated for documentation.

    1. SmartManager - the welding machine website

    Job-Data

    Job data

    If the OPT/i Jobs option is available on the welding machine, the following is possible in the Job data entry:

    • Existing welding system jobs can be viewed *
    • Existing welding system jobs can be optimised
    • Jobs stored externally can be transferred to the welding system
    • Existing jobs in the welding system can be exported as a PDF * or CSV file
    *
    Viewing and exporting as PDF also works when the OPT/i Jobs option is not available on the welding machine.
    1. SmartManager - the welding machine website
    2. Job-Data

    Job data

    If the OPT/i Jobs option is available on the welding machine, the following is possible in the Job data entry:

    • Existing welding system jobs can be viewed *
    • Existing welding system jobs can be optimised
    • Jobs stored externally can be transferred to the welding system
    • Existing jobs in the welding system can be exported as a PDF * or CSV file
    *
    Viewing and exporting as PDF also works when the OPT/i Jobs option is not available on the welding machine.
    1. SmartManager - the welding machine website
    2. Job-Data

    Job overview

    The job overview lists all jobs stored in the welding system.
    Clicking on a job displays the data and parameters stored for this job.
    Job data and parameters can only be viewed in the job overview. The column width for parameters and values can be easily dragged and adjusted with the mouse pointer.
    Other jobs can easily be added to the list with the data listed by clicking on the "Add column" button.

    All added jobs are compared to the job that is currently selected.

    1. SmartManager - the welding machine website
    2. Job-Data

    Editing a job

    Existing welding system jobs can be optimised, provided the OPT/i Jobs option is present on the welding machine.

    1Click on "Edit job"
    2Click on the job to be amended in the list of available jobs

    The selected job is opened and the following job data is shown:
    • Parameter
      The parameter currently stored in the job
    • Value
      The values of the parameter currently stored in the job
    • Change value to
      To enter the new parameter value
    • Setting range
      Possible setting range for the new parameter values
    3Amend the values accordingly
    4Save / Delete adjustments, Save as / Delete job

    As an aid when editing a job, other jobs can be added with ease to the list with the data displayed by clicking on "Add job".

    Creating a new job

    1Click on "Create new job"
    2Enter job data
    3Click on "OK" to apply the new job
    1. SmartManager - the welding machine website
    2. Job-Data

    Importing a job

    This function allows jobs stored externally to be transferred to the welding system, provided the OPT/i Jobs option is available on the welding machine.

    1Click on "Search Job-file"
    2Select desired job file

    Individual jobs can be selected and new job numbers assigned in the preview of the job import list.
    3Click on "Import Job"

    If the import is successful, a corresponding confirmation is displayed and the imported jobs appear in the list.
    1. SmartManager - the welding machine website
    2. Job-Data

    Exporting a job

    This function allows jobs from the welding machine to be stored externally, provided the OPT/i Jobs option is available on the welding machine.

    1Select jobs to be exported
    2Click on "Export Job"

    The jobs are exported as an XML file into the computer's Download folder.

    1. SmartManager - the welding machine website
    2. Job-Data

    Exporting job(s) as…

    Under "Job overview" and "Edit job", existing jobs in the welding system can be exported as PDF or CSV files.
    For CSV exports, the OPT/i Jobs option must be available on the welding machine.

    1Click on "Export job(s) as..."

    The PDF or CSV settings are displayed.

    2Select the job(s) to be exported:
    current job / all jobs / job numbers
    3Click on "Save PDF" or "Save CSV"

    A PDF or CSV file containing the selected jobs is created and saved according to the settings of the browser in question.

    1. SmartManager - the welding machine website

    Welding machine settings

    Process parameters

    General process parameters and process parameters for welding machine components and monitoring can be viewed and changed under Process parameters.

    Changing process parameters

    1Click parameter group / welding parameter
    2Alter the parameter value directly in the display field
    3Save changes
    1. SmartManager - the welding machine website
    2. Welding machine settings

    Process parameters

    General process parameters and process parameters for welding machine components and monitoring can be viewed and changed under Process parameters.

    Changing process parameters

    1Click parameter group / welding parameter
    2Alter the parameter value directly in the display field
    3Save changes
    1. SmartManager - the welding machine website
    2. Welding machine settings

    Name & location

    The welding machine configuration can be viewed and changed under name & location.

    1. SmartManager - the welding machine website
    2. Welding machine settings

    Parameter display

    Welding parameters and special functions for the welding machine and JobMaster welding torch can be set under Parameter display.

    1Select parameter / function (tick)
    2Save changes

    The selected parameters / functions are:

    • Shown under the welding parameters on the welding machine display
    • Available on the JobMaster welding torch
    1. SmartManager - the welding machine website
    2. Welding machine settings

    Date & time

    The date & time can be set automatically or manually.

    1. SmartManager - the welding machine website
    2. Welding machine settings

    Network settings

    The following parameters can be set under Network settings:

    Management

    • MAC address and current IP address are displayed.
    • If DHCP is not selected, the IP address, network mask, standard gateway, DNS server 1 and 2 can be set manually.

    WLAN

    • MAC address and current IP address are displayed.
    • The WLAN country code can be set.
    • Configured networks are displayed.
    • Available networks are displayed.

    WeldCube Air
    Connect the welding machine to WeldCubeAir
    (alternatively, click on the cloud icons in the upper right corner)

    1. SmartManager - the welding machine website
    2. Welding machine settings

    MQTT settings

    Only displayed if the OPT/i MQTT option is installed on the welding machine.

    MQTT - Message Queuing Telemetry Transport
    (standardised data interface protocol)

    Supported functions:

    • Provides the real-time data to be transferred to other systems
    • Fixed amount of data
    • Reads

    Defining MQTT settings

    1Activate MQTT
    2Enter broker, port and device topic
    3Select safety certificate
    4Enter authentication
    5Save changes
    1. SmartManager - the welding machine website
    2. Welding machine settings

    OPC UA settings

    Only displayed if the OPT/i OPC UA option is installed on the welding machine.

    OPC-UA - Open Platform Communications - Unified Architecture
    (standardised data interface protocol)

    Supported functions:

    • Provides the real-time data to be transferred to other systems
    • Possible to copy data from other systems
    • Fixed amount of data
    • Reads & writes

    Defining OPC UA settings

    1Activate OPC UA server
    2Select safety directive
    3Enter authentication
    4Save changes
    1. SmartManager - the welding machine website

    Backup & Restore

    General remarks

    In the backup & restore entry

    • all welding system data can be saved as a backup (e.g. current parameter settings, jobs, user characteristics, defaults, etc.),
    • any backups will be restored to the welding system
    • You can select which data you would like to be backed up automatically.
    1. SmartManager - the welding machine website
    2. Backup & Restore

    General remarks

    In the backup & restore entry

    • all welding system data can be saved as a backup (e.g. current parameter settings, jobs, user characteristics, defaults, etc.),
    • any backups will be restored to the welding system
    • You can select which data you would like to be backed up automatically.
    1. SmartManager - the welding machine website
    2. Backup & Restore

    Backup & Restore

    Starting backup

    1Click on "Start backup" to save a backup of the welding system data

    The data is saved in a selected location in the default format MCU1-YYYYMMDDHHmm.fbc.

    YYYY = Year
    MM = Month
    DD = Day
    HH = Hour
    mm = Minute

    The date and time correspond to the welding machine settings.

    Searching for a restore file

    1Click on "Search restore file" to transfer an existing backup to the welding machine
    2Select the file and click on "Open"

    The selected backup file is displayed on the welding machine's SmartManager under "Restore".
    3Click on "Start recovery"

    Once the data has been successfully restored, a confirmation to this effect is displayed.
    1. SmartManager - the welding machine website
    2. Backup & Restore

    Automatic backup

    1Enable interval settings
    2Enter the intervals at which the automatic backup should take place:
    • Interval:
      daily / weekly / monthly
    • At:
      time (hh:mm)
    3Enter the data for the backup destination:
    • Protocol:
      SFTP (Secure File Transfer Protocol) / SMB (Server Message Block)
    • Server:
      Enter IP address of the destination server
    • Port:
      Enter port number; if no port number is entered, the default port 22 is automatically used.
      If SMB is set under Protocol, leave the Port field blank.
    • Storage location:
      This configures the subfolder where the backup will be stored.
      If no storage location is entered, the backup is stored in the root directory of the server.

      IMPORTANT! For SMB and SFTB, always enter the storage location with a slash "/".
    • Domain/user, password:
      User name and password - as configured on the server;
      When entering a domain, first enter the domain, then backslash "\" and then the user name (DOMAIN\USER)
    4If a connection via proxy server is required, activate and enter the proxy settings:
    • Server
    • Port
    • Users
    • Password
    5Save changes
    6Trigger automatic backup

    If you have any questions about the configuration, contact your network administrator.

    1. SmartManager - the welding machine website

    Signal visualisation

    Signal visualisation

    Signal visualisation is only available if a robot interface is present.
    To display the signal visualisation correctly, IE 10 or another modern browser is required.

    The signals and commands transferred via a robot interface are displayed.

    IN ... Signals from the robot control to the welding machine
    OUT ... Signals from the welding machine to the robot control

    You can search for, sort and filter the displayed signals at any time.
    To sort the characteristics in ascending or descending order, click on the arrow next to the respective information. The column widths can be easily dragged and adjusted with the cursor.

    The following information is required for a detailed description of the signals:

    • Bit position
    • Signal name
    • Value
    • Data type
    1. SmartManager - the welding machine website
    2. Signal visualisation

    Signal visualisation

    Signal visualisation is only available if a robot interface is present.
    To display the signal visualisation correctly, IE 10 or another modern browser is required.

    The signals and commands transferred via a robot interface are displayed.

    IN ... Signals from the robot control to the welding machine
    OUT ... Signals from the welding machine to the robot control

    You can search for, sort and filter the displayed signals at any time.
    To sort the characteristics in ascending or descending order, click on the arrow next to the respective information. The column widths can be easily dragged and adjusted with the cursor.

    The following information is required for a detailed description of the signals:

    • Bit position
    • Signal name
    • Value
    • Data type
    1. SmartManager - the welding machine website

    User management

    General

    In the user management entry

    • Users can be viewed, changed and created.
    • User roles can be viewed, changed and created.
    • Users and user roles can be exported or imported on the welding machine.
      User management data present on the welding machine is overwritten by importing.
    • A CENTRUM server can be activated.

    User management is created on a welding machine and can then be saved with the export/import function and transferred to another welding machine.

    1. SmartManager - the welding machine website
    2. User management

    General

    In the user management entry

    • Users can be viewed, changed and created.
    • User roles can be viewed, changed and created.
    • Users and user roles can be exported or imported on the welding machine.
      User management data present on the welding machine is overwritten by importing.
    • A CENTRUM server can be activated.

    User management is created on a welding machine and can then be saved with the export/import function and transferred to another welding machine.

    1. SmartManager - the welding machine website
    2. User management

    Users

    Existing users can be viewed, changed and deleted; new users can be created.

    Viewing/changing a user:

    1Select user
    2Alter the user data directly in the display field
    3Save changes

    Deleting a user:

    1Select user
    2Click the "Delete user" button
    3When prompted, confirm with OK

    Creating a user:

    1Click the "Create new user" button
    2Enter user data
    3Confirm with OK
    1. SmartManager - the welding machine website
    2. User management

    User roles

    Existing user roles can be viewed, changed and deleted, new user roles can be created

    Viewing/changing a user role:

    1Select user role
    2Alter the user role directly in the display field
    3Save changes

    The "Administrator" role cannot be changed.

    Deleting a user role:

    1Select user role
    2Click the "Delete user role" button
    3When prompted, confirm with OK

    The "Administrator" and "Locked" roles cannot be deleted.

    Creating a user role:

    1Click the "Create new user role" button
    2Enter a role name, apply values
    3Confirm with OK
    1. SmartManager - the welding machine website
    2. User management

    Export & import

    Exporting users and user roles from a welding machine

    1Click on "Export"

    The user management data from the welding machine will be saved to the "Downloads" folder on the computer.
    File format: userbackup_SNxxxxxxxx_YYYY_MM_DD_hhmmss.user

    SN = Serial number, YYYY = Year, MM = Month, DD = Day
    hh = hour, mm = minute, ss = second

    Importing users and user roles to a welding machine

    1Click on "Search user data file"
    2Select the file and click "Open"
    3Click on "Import"

    The user management data will be saved to the welding machine.

    1. SmartManager - the welding machine website
    2. User management

    CENTRUM server

    For activating a CENTRUM server
    (CENTRUM = Central User Management)

    1Activate CENTRUM server
    2In the input field, enter the domain name or IP address of the server where Central User Management has been installed.

    A valid DNS server must be configured in the welding machine network settings if using a domain name.
    3Click the "Verify server" button

    This checks the availability of the specified server.
    4Save changes
    1. SmartManager - the welding machine website

    Overview

    Overview

    In the overview entry, welding system components and options are displayed with all available information, e.g. firmware version, item number, serial number, production date, etc.

    1. SmartManager - the welding machine website
    2. Overview

    Overview

    In the overview entry, welding system components and options are displayed with all available information, e.g. firmware version, item number, serial number, production date, etc.

    1. SmartManager - the welding machine website
    2. Overview

    Expanding / reducing all groups

    Clicking on the button "Expand all groups" displays further details for the individual system components.

    Welding machine example:

    • TPSi Touch: Item number
      MCU1: Item number, version, serial number, production date
      Bootloader: Version
      Image: Version
      Licences: WP Standard, WP Pulse, WP LSC, WP PMC, OPT/i Guntrigger, etc.
    • SC2: Item number
      Firmware: Version

    Clicking on the button "Reduce all groups" hides the details for the system components.

    1. SmartManager - the welding machine website
    2. Overview

    Export component overview as ...

    Click the "Export component overview as ..." button to create an XML file of the system component details. This XML file can either be opened or saved.

    1. SmartManager - the welding machine website

    Update

    Update

    The welding machine firmware can be updated in the "Update" entry.

    The current version of the firmware on the welding machine is displayed.

    Update welding machine firmware:

    Firmware link:
    The update file can be downloaded via the link provided:
    Firmware TPS/i_iWAVE

    1Organise and save the update file
    2Click on "Search update file" to start the update process
    3Select update fileClick on "Update"

    Once the update has been successfully completed, the welding machine may need to be restarted.

    When an update has been completed successfully, a confirmation to this effect is displayed.

    1. SmartManager - the welding machine website
    2. Update

    Update

    The welding machine firmware can be updated in the "Update" entry.

    The current version of the firmware on the welding machine is displayed.

    Update welding machine firmware:

    Firmware link:
    The update file can be downloaded via the link provided:
    Firmware TPS/i_iWAVE

    1Organise and save the update file
    2Click on "Search update file" to start the update process
    3Select update fileClick on "Update"

    Once the update has been successfully completed, the welding machine may need to be restarted.

    When an update has been completed successfully, a confirmation to this effect is displayed.

    1. SmartManager - the welding machine website
    2. Update

    Searching for an update file (performing the update)

    1After clicking on "Search update file", select the desired firmware (*.ffw)
    2Click on "Open"

    The selected update file is displayed on the welding machine's SmartManager under "Update".
    3Click on "Update"

    A progress bar is displayed above the update process.
    When this reaches 100%, you will be prompted to restart the welding machine.

    SmartManager is not available during the restart.
    After the restart, SmartManager may not be available any more.
    If you select "No", the new software functions are activated when you next switch the device on/off.

    4To restart the welding machine, click on "Yes"

    The welding machine restarts; the display goes black for a short time.
    The Fronius logo is shown on the welding machine display during the restart.

    Once the update has been completed successfully, confirmation and the current firmware version are displayed.
    Finally, log back on to SmartManager.
    1. SmartManager - the welding machine website
    2. Update

    Information on open source licensing

    Clicking on the link displays information on open source licensing.

    1. SmartManager - the welding machine website
    2. Update

    Fronius WeldConnect

    The mobile application Fronius WeldConnect can also be called up in the "Update" entry.
    WeldConnect is an app for wireless interaction with the welding system.

    The following functions can be performed with WeldConnect:

    • Current unit configuration at a glance
    • Mobile access to the welding machine's SmartManager
    • Automatic determination of the output parameters for MIG/MAG and TIG
    • Cloud storage and wireless transmission to the welding machine
    • Part identification
    • Logging in and out of the welding machine without an NFC card
    • Saving and sharing parameters and jobs
    • Data transfer from one welding machine to another via backup, restore
    • Firmware update

    Fronius WeldConnect is available in the following forms:

    • As an Android app
    • As an Apple/iOS app

    Further information on Fronius WeldConnect is available at:

    https://www.fronius.com/en/welding-technology/innovative-solutions/weldconnect
    1. SmartManager - the welding machine website

    Function Packages

    Function Packages

    The following data can be displayed under Function Packages:

    • Welding packages available on the welding machine
      (e.g. WP STANDARD, WP PULSE, WP LSC, etc.)
    • DB /i (databases)
    • Options available on the welding machine (OPT/i, etc.)
    • CFG /i (robot interface configurations)
    1. SmartManager - the welding machine website
    2. Function Packages

    Function Packages

    The following data can be displayed under Function Packages:

    • Welding packages available on the welding machine
      (e.g. WP STANDARD, WP PULSE, WP LSC, etc.)
    • DB /i (databases)
    • Options available on the welding machine (OPT/i, etc.)
    • CFG /i (robot interface configurations)
    1. SmartManager - the welding machine website
    2. Function Packages

    Installing a function package

    1Organise and save a function package
    2Click on "Search function package file"
    3Select the desired function package file (*.xml)
    4Click on "Open"

    The selected function package file is displayed on the welding machine's SmartManager under "Install function package".
    5Click on "Install function package"

    Once the function package has been successfully installed, a confirmation to this effect is displayed.
    1. SmartManager - the welding machine website

    Synergic lines overview

    Characteristics overview

    In the Characteristics overview entry:

    • Available characteristics in the welding system can be displayed:
      Available characteristics button
    • Possible characteristics in the welding system can be displayed:
      Possible characteristics button
    • Characteristics for the welding system can be preselected:
      Characteristic preselection button
    • Saved characteristic preselections can be exported and imported:
      Export & import button

    You can search for, sort and filter the displayed characteristics at any time.

    The following information is displayed for the characteristics:

    • Status
    • Materials
    • Diameter
    • Gas
    • Property
    • Process
    • ID
    • Replaced by
    • SFI
    • SFI HotStart
    • Penetration stabilizer
    • Arc length stabilizer
    • CMT Cycle Step
    • Special
    • Requirements

    To sort the characteristics in ascending or descending order, click on the arrow next to the respective information.

    The column widths can be easily dragged and adjusted with the cursor.

    1. SmartManager - the welding machine website
    2. Synergic lines overview

    Characteristics overview

    In the Characteristics overview entry:

    • Available characteristics in the welding system can be displayed:
      Available characteristics button
    • Possible characteristics in the welding system can be displayed:
      Possible characteristics button
    • Characteristics for the welding system can be preselected:
      Characteristic preselection button
    • Saved characteristic preselections can be exported and imported:
      Export & import button

    You can search for, sort and filter the displayed characteristics at any time.

    The following information is displayed for the characteristics:

    • Status
    • Materials
    • Diameter
    • Gas
    • Property
    • Process
    • ID
    • Replaced by
    • SFI
    • SFI HotStart
    • Penetration stabilizer
    • Arc length stabilizer
    • CMT Cycle Step
    • Special
    • Requirements

    To sort the characteristics in ascending or descending order, click on the arrow next to the respective information.

    The column widths can be easily dragged and adjusted with the cursor.

    1. SmartManager - the welding machine website
    2. Synergic lines overview

    Show filter

    Clicking on the "Show filter" symbol displays the possible filter criteria. With the exception of "ID" and "Replaced by", the characteristics can be filtered by all information.

    First selection box = select all

    To hide the filter criteria, click on the "Hide filter" symbol.

    1. SmartManager - the welding machine website

    Screenshot

    Screenshot

    In the Screenshot entry, a digital image of the welding machine display can be created at any time, irrespective of the navigation or set values.

    1Click on "Create screenshot" to capture a screenshot of the display

    A screenshot of the currently displayed settings is created.

    Different functions are available for saving the screenshot depending on the browser used; the display may vary.

    1. SmartManager - the welding machine website
    2. Screenshot

    Screenshot

    In the Screenshot entry, a digital image of the welding machine display can be created at any time, irrespective of the navigation or set values.

    1Click on "Create screenshot" to capture a screenshot of the display

    A screenshot of the currently displayed settings is created.

    Different functions are available for saving the screenshot depending on the browser used; the display may vary.

    1. SmartManager - the welding machine website

    Interface

    Interface

    If a robot interface is available, the name of the interface will be displayed as an entry on the welding machine website.

    The following welding parameters can be displayed, edited, saved or deleted:

    • Characteristic assignment (current allocation of program numbers to characteristics)
    • Module configuration (network settings)

    Factory settings can be restored and the module can be restarted.

    1. SmartManager - the welding machine website
    2. Interface

    Interface

    If a robot interface is available, the name of the interface will be displayed as an entry on the welding machine website.

    The following welding parameters can be displayed, edited, saved or deleted:

    • Characteristic assignment (current allocation of program numbers to characteristics)
    • Module configuration (network settings)

    Factory settings can be restored and the module can be restarted.

    Troubleshooting and maintenance

    Troubleshooting

    General

    The welding machines are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the welding machine can be used again as normal.

    Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.

    1. Troubleshooting and maintenance

    Troubleshooting

    General

    The welding machines are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the welding machine can be used again as normal.

    Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.

    1. Troubleshooting and maintenance
    2. Troubleshooting

    General

    The welding machines are equipped with an intelligent safety system, meaning it has been possible to dispense with nearly all fuses. After a possible malfunction has been remedied, the welding machine can be used again as normal.

    Possible malfunctions, warning notices or status codes are shown on the display as plain text dialogues.

    1. Troubleshooting and maintenance
    2. Troubleshooting

    Safety

    WARNING!

    Danger from electric current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all the devices and components involved and disconnect them from the grid.

    Secure all the devices and components involved to prevent unintentional restarting.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    CAUTION!

    Danger from inadequate ground conductor connections.

    This can result in injury and damage to property.

    The housing screws provide a suitable ground conductor connection for earthing the housing.

    The housing screws must never be replaced with different screws unless a reliable ground conductor connection is established.

    1. Troubleshooting and maintenance
    2. Troubleshooting

    MIG/MAG welding - current limit

    "Current limit" is a safety function for MIG/MAG welding, whereby

    • It is possible to operate the welding machine at the power limit
    • Process reliability is ensured

    If the welding power is too high, the arc gets smaller and smaller and may be extinguished. To stop the arc from being extinguished, the welding machine reduces the wire speed and therefore the welding power.
    A corresponding message appears in the status bar on the display.

    Corrective measures

    • Reduce one of the following welding power parameters:
      Wire speed
      Welding current
      Welding voltage
      Material thickness
    • Increase the distance between the contact tip and workpiece
    1. Troubleshooting and maintenance
    2. Troubleshooting

    Troubleshooting the welding machine

    Welding machine does not function
    Mains switch is on, but indicators are not lit up
    Cause:There is a break in the mains lead; the mains plug is not plugged in
    Remedy:Check the mains lead, ensure that the mains plug is plugged in
    Cause:Mains socket or mains plug faulty
    Remedy:Replace faulty parts
    Cause:Mains fuse protection
    Remedy:Change the mains fuse protection
    Cause:Short circuit on the 24 V supply of SpeedNet connection socket or external sensor
    Remedy:Unplug connected components
    No welding current
    Mains switch is on, overtemperature is displayed
    Cause:Overload; the duty cycle has been exceeded
    Remedy:Check duty cycle
    Cause:Thermostatic automatic circuit breaker has tripped
    Remedy:Wait until the welding machine automatically comes back on after the end of the cooling phase
    Cause:Limited supply of cooling air
    Remedy:Ensure accessibility to cooling air ducts
    Cause:Faulty fan in welding system
    Remedy:Contact After-Sales Service
    No welding current
    Welding machine mains switch is on and indicators are lit
    Cause:Grounding (earthing) connection is incorrect
    Remedy:Check the grounding (earthing) connection for correct polarity
    Cause:There is a break in the power cable in the welding torch
    Remedy:Replace welding torch
    Nothing happens when the torch trigger is pressed
    Mains switch is on, indicators are lit up
    Cause:The control plug is not plugged in
    Remedy:Plug in the control plug
    Cause:Welding torch or welding torch control line is faulty
    Remedy:Replace welding torch
    Cause:The interconnecting hosepack is defective or not connected properly
    (not for welding machines with integrated wire drive)
    Remedy:Check the interconnecting hosepack
    No protective gas shield
    All other functions are OK
    Cause:Gas cylinder is empty
    Remedy:Change the gas cylinder
    Cause:The gas pressure regulator is faulty
    Remedy:Replace the gas pressure regulator
    Cause:Gas hose is not fitted or is damaged
    Remedy:Fit or change the gas hose
    Cause:Welding torch is faulty
    Remedy:Change the welding torch
    Cause:Gas solenoid valve is faulty
    Remedy:Contact After-Sales Service
    Poor weld properties
    Cause:Incorrect welding and/or correction parameters
    Remedy:Check the settings
    Cause:Poor grounding (earthing) connection
    Remedy:Ensure good contact to workpiece
    Cause:Multiple welding machines are welding one component
    Remedy:Increase the distance between the hosepacks and the return lead cables;
    Do not use a common earth.
    Cause:Inadequate or no shielding gas
    Remedy:Check the pressure regulator, gas hose, gas solenoid valve, torch gas connection, etc.
    Cause:Welding torch is leaking
    Remedy:Change welding torch
    Cause:Wrong contact tip, or contact tip is worn out
    Remedy:Replace contact tip
    Cause:Wrong wire alloy or wrong wire diameter
    Remedy:Check the wire electrode that has been inserted
    Cause:Wrong wire alloy or wrong wire diameter
    Remedy:Check weldability of the base material
    Cause:The shielding gas is not suitable for this wire alloy
    Remedy:Use the correct shielding gas
    Excessive welding spatter
    Cause:Shielding gas, wirefeeder, welding torch or workpiece is contaminated or magnetically charged
    Remedy:Perform R/L alignment;
    adjust arc length;
    check whether shielding gas, wirefeed, welding torch position or workpiece is contaminated or magnetically charged
    Irregular wire speed
    Cause:Braking force has been set too high
    Remedy:Loosen the brake
    Cause:Hole in the contact tip is too narrow
    Remedy:Use a suitable contact tip
    Cause:Faulty inner liner in welding torch
    Remedy:Check the inner liner for kinks, dirt, etc. and replace if necessary
    Cause:The wirefeeder rollers are not suitable for the wire electrode being used
    Remedy:Use suitable feed rollers
    Cause:Feed rollers have the wrong contact pressure
    Remedy:Optimise the contact pressure
    Wirefeed problems
    when using applications with long welding torch hosepacks
    Cause:Incorrect arrangement of welding torch hosepack
    Remedy:Arrange the welding torch hosepack in as straight a line as possible, avoiding bends
    Welding torch becomes very hot
    Cause:Welding torch is inadequately dimensioned
    Remedy:Observe the duty cycle and loading limits
    Cause:Only on water-cooled systems: inadequate coolant flow
    Remedy:Check coolant level, coolant flow, for coolant contamination, etc. For further information refer to the cooling unit Operating Instructions
    1. Troubleshooting and maintenance

    Care, maintenance and disposal

    General

    Under normal operating conditions, the welding machine requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years.

    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    General

    Under normal operating conditions, the welding machine requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years.

    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    Safety

    WARNING!

    Danger from electrical current.

    This can result in serious personal injury and damage to property.

    Before starting work, switch off all devices and components involved, and disconnect them from the grid.

    Secure all devices and components involved so they cannot be switched back on.

    After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    At every start-up

    • Check mains plug, mains cable, welding torch, interconnecting hosepack and grounding (earthing) connection for damage
    • Check whether the all-round clearance of 0.5 m (1 ft. 8 in.) is kept to ensure that the cooling air can easily flow and escape.

    NOTE!

    Air inlets and outlets must never be covered, not even partially.

    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    Every 2 months

    • If present: clean air filter
    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    Every 6 months

    CAUTION!

    Danger due to the effect of compressed air.

    This can result in damage to property.

    Do not clean electronic components with compressed air from a short distance.

    • Open the device
    • Blow out the inside of the device with dry and reduced compressed air
    • Also clean the cooling air ducts if there is a large accumulation of dust
    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    Updating firmware

    IMPORTANT! To update the firmware you need a PC or laptop that is connected to the welding machine via an Ethernet network.

    1Get latest firmware (e.g. from the DownloadCenter)
    File format: official_tpsi_x.x.x-xxxx.ffw
    2Establish Ethernet connection between PC/laptop and welding machine
    3Open the welding machine's SmartManager (see page (→))
    4Transfer the firmware to the welding machine (see page (→))
    1. Troubleshooting and maintenance
    2. Care, maintenance and disposal

    Disposal

    Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Correct disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

    Packaging materials
    • Collect separately
    • Observe locally valid regulations
    • Compress the cardboard box to reduce volume

    Appendix

    Average consumption values during welding

    Average wire electrode consumption during MIG/MAG welding

    Average wire electrode consumption at a wire speed of 5 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    1.8 kg/h

    2.7 kg/h

    4.7 kg/h

    Aluminium wire electrode

    0.6 kg/h

    0.9 kg/h

    1.6 kg/h

    CrNi wire electrode

    1.9 kg/h

    2.8 kg/h

    4.8 kg/h

    Average wire electrode consumption at a wire speed of 10 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    3.7 kg/h

    5.3 kg/h

    9.5 kg/h

    Aluminium wire electrode

    1.3 kg/h

    1.8 kg/h

    3.2 kg/h

    CrNi wire electrode

    3.8 kg/h

    5.4 kg/h

    9.6 kg/h

    1. Appendix

    Average consumption values during welding

    Average wire electrode consumption during MIG/MAG welding

    Average wire electrode consumption at a wire speed of 5 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    1.8 kg/h

    2.7 kg/h

    4.7 kg/h

    Aluminium wire electrode

    0.6 kg/h

    0.9 kg/h

    1.6 kg/h

    CrNi wire electrode

    1.9 kg/h

    2.8 kg/h

    4.8 kg/h

    Average wire electrode consumption at a wire speed of 10 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    3.7 kg/h

    5.3 kg/h

    9.5 kg/h

    Aluminium wire electrode

    1.3 kg/h

    1.8 kg/h

    3.2 kg/h

    CrNi wire electrode

    3.8 kg/h

    5.4 kg/h

    9.6 kg/h

    1. Appendix
    2. Average consumption values during welding

    Average wire electrode consumption during MIG/MAG welding

    Average wire electrode consumption at a wire speed of 5 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    1.8 kg/h

    2.7 kg/h

    4.7 kg/h

    Aluminium wire electrode

    0.6 kg/h

    0.9 kg/h

    1.6 kg/h

    CrNi wire electrode

    1.9 kg/h

    2.8 kg/h

    4.8 kg/h

    Average wire electrode consumption at a wire speed of 10 m/min

     

    1.0 mm wire electrode diameter

    1.2 mm wire electrode diameter

    1.6 mm wire electrode diameter

    Steel wire electrode

    3.7 kg/h

    5.3 kg/h

    9.5 kg/h

    Aluminium wire electrode

    1.3 kg/h

    1.8 kg/h

    3.2 kg/h

    CrNi wire electrode

    3.8 kg/h

    5.4 kg/h

    9.6 kg/h

    1. Appendix
    2. Average consumption values during welding

    Average shielding gas consumption during MIG/MAG welding

    Wire electrode diameter

    1.0 mm

    1.2 mm

    1.6 mm

    2.0 mm

    2 x 1.2 mm (TWIN)

    Average consumption

    10 l/min

    12 l/min

    16 l/min

    20 l/min

    24 l/min

    1. Appendix
    2. Average consumption values during welding

    Average shielding gas consumption during TIG welding

    Gas nozzle size

    4

    5

    6

    7

    8

    10

    Average consumption

    6 l/min

    8 l/min

    10 l/min

    12 l/min

    12 l/min

    15 l/min

    1. Appendix

    Technical data

    Explanation of the term "duty cycle"

    Duty cycle (ED) is the proportion of time in a 10-minute cycle at which the device may be operated at its rated output without overheating.

    NOTE!

    The ED values specified on the rating plate are based on an ambient temperature of 40 °C.

    If the ambient temperature is higher, either the ED or output must be reduced accordingly.

    Example: Welding at 150 A at 60% ED

    • Welding phase = 60% of 10 minutes = 6 minutes
    • Cooling phase = remaining time = 4 minutes
    • After the cooling phase, the cycle begins again.

    If the device is to be continuously operated without stopping:

    1Look in the technical data for a ED value of 100% for the current ambient temperature.
    2Reduce the output or amperage in line with this value so that the device can remain in use without observing a cooling phase.
    1. Appendix
    2. Technical data

    Explanation of the term "duty cycle"

    Duty cycle (ED) is the proportion of time in a 10-minute cycle at which the device may be operated at its rated output without overheating.

    NOTE!

    The ED values specified on the rating plate are based on an ambient temperature of 40 °C.

    If the ambient temperature is higher, either the ED or output must be reduced accordingly.

    Example: Welding at 150 A at 60% ED

    • Welding phase = 60% of 10 minutes = 6 minutes
    • Cooling phase = remaining time = 4 minutes
    • After the cooling phase, the cycle begins again.

    If the device is to be continuously operated without stopping:

    1Look in the technical data for a ED value of 100% for the current ambient temperature.
    2Reduce the output or amperage in line with this value so that the device can remain in use without observing a cooling phase.
    1. Appendix
    2. Technical data

    Special voltages

    For devices designed for special voltages, the technical data on the rating plate applies.

    For all machines with a permitted mains voltage of up to 460 V: The standard mains plug allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly.

    1. Appendix
    2. Technical data

    Overview with critical raw materials, year of production of the device

    Overview with critical raw materials:
    An overview of which critical raw materials are contained in this device can be found at the following Internet address.
    www.fronius.com/en/about-fronius/sustainability.

    To calculate the year of production of the device:
    • Each device is provided with a serial number
    • The serial number consists of 8 digits - for example 28020099
    • The first two digits give the number from which the year of production of the device can be calculated
    • This figure minus 11 gives the year of production
      • For example: Serial number = 28020065, calculation of the year of production = 28 - 11 = 17, year of production = 2017
    1. Appendix
    2. Technical data

    TPS 320i

    Mains voltage (U1)

    3 x 400 V

    Max. effective primary current (I1eff)

    12.3 A

    Max. primary current (I1max)

    19.4 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    +/- 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    95 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-320 A

    TIG

    3-320 A

    MMA

    10-320 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 320 A
    60% / 260 A

     

    100% / 240 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-30.0 V

    TIG

    10.1-22.8 V

    MMA

    20.4-32.8 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    73 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    35.0 kg / 77.2 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    34.2 W

    Welding machine efficiency
    at 320 A / 32.8 V

    87%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 320i /nc

    Mains voltage (U1)

    3 x 380 / 400 / 460 V

    Max. effective primary current (I1eff)

     

    3 x 380 V

    12.7 A

    3 x 400 V

    12.3 A

    3 x 460 V

    11.4 A

    Max. primary current (I1max)

     

    3 x 380 V

    20.1 A

    3 x 400 V

    19.4 A

    3 x 460 V

    18.0 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    -10 / +15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    95 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-320 A

    TIG

    3-320 A

    MMA

    10-320 A

    Welding current at
    10 min / 40 °C (104 °F)
    U1 = 380-460 V

    40% / 320 A
    60% / 260 A
    100% / 240 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-30.0 V

    TIG

    10.1-22.8 V

    MMA

    20.4-32.8 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    84 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    33.7 kg / 74.3 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    34.2 W

    Welding machine efficiency
    at 320 A / 32.8 V

    87%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 320i /600V/nc

    Mains voltage (U1)

    3 x 575 V

    Max. effective primary current (I1eff)

    10.6 A

    Max. primary current (I1max)

    16.7 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    +/- 10%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-320 A

    TIG

    3-320 A

    MMA

    10-320 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 320 A
    60% / 260 A

     

    100% / 240 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-30.0 V

    TIG

    10.1-22.8 V

    MMA

    20.4-32.8 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    67 V

    Protection class

    IP 23

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    32.7 kg / 72.1 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    1. Appendix
    2. Technical data

    TPS 320i /MV/nc

    Mains voltage (U1)

    3 x 200 / 230 / 380 / 400 / 460 V

    Max. effective primary current (I1eff)

     

    3 x 200 V

    22.0 A

    3 x 230 V

    19.0 A

    3 x 380 V

    12.0 A

    3 x 400 V

    11.6 A

    3 x 460 V

    10.7 A

    Max. primary current (I1max)

     

    3 x 200 V

    34.7 A

    3 x 230 V

    30.1 A

    3 x 380 V

    19.0 A

    3 x 400 V

    18.3 A

    3 x 460 V

    16.8 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    -10 / +15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    54 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-320 A

    TIG

    3-320 A

    MMA

    10-320 A

    Welding current at
    10 min/40 °C (104 °F)

     

    U1 = 200-230 V

    40% / 320 A

     

    60% / 260 A

     

    100% / 240 A

    U1 = 380-460 V

    40% / 320 A

     

    60% / 260 A

     

    100% / 240 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-30.0 V

    TIG

    10.1-22.8 V

    MMA

    20.4-32.8 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    68 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    42.8 kg / 94.4 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    49.7 W

    Welding machine efficiency at 320 A / 32.8 V

    86%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 400i

    Mains voltage (U1)

    3 x 400 V

    Max. effective primary current (I1eff)

    15.9 A

    Max. primary current (I1max)

    25.1 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    +/- 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    92 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-400 A

    TIG

    3-400 A

    MMA

    10-400 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 400 A
    60% / 360 A

     

    100% / 320 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-34.0 V

    TIG

    10.1-26.0 V

    MMA

    20.4-36.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    73 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    36.5 kg / 80.5 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    33.7 W

    Welding machine efficiency
    at 400 A / 36 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 400i /nc

    Mains voltage (U1)

    3 x 380 / 400 / 460 V

    Max. effective primary current (I1eff)

     

    3 x 380 V

    16.5 A

    3 x 400 V

    15.9 A

    3 x 460 V

    14.6 A

    Max. primary current (I1max)

     

    3 x 380 V

    26.1 A

    3 x 400 V

    25.1 A

    3 x 460 V

    23.5 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    -10 / +15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    92 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-400 A

    TIG

    3-400 A

    MMA

    10-400 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 400 A
    60% / 360 A

    U1 = 380-460 V

    100% / 320 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-34.0 V

    TIG

    10.1-26.0 V

    MMA

    20.4-36.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    83 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    35.2 kg / 77.6 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    33.7 W

    Welding machine efficiency
    at 400 A / 36 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 400i /600V/nc

    Mains voltage (U1)

    3 x 575 V

    Max. effective primary current (I1eff)

    14.3 A

    Max. primary current (I1max)

    22.6 A

    Mains fuse

    35 A slow-blow

    Mains voltage tolerance

    +/- 10%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3 - 400 A

    TIG

    3 - 400 A

    MMA

    10 - 400 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 400 A
    60% / 360 A

     

    100% / 320 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2 - 34.0 V

    TIG

    10.1 -26.0 V

    MMA

    20.4 - 36.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    68 V

    Protection class

    IP 23

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    34.6 kg / 76.3 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    1. Appendix
    2. Technical data

    TPS 400i /MV/nc

    Mains voltage (U1)

    3 x 200 V / 230 V / 380 V / 400 V / 460 V

    Max. effective primary current (I1eff)

    3 x 200 V

    30.5 A

    3 x 230 V

    26.4 A

    3 x 380 V

    16.2 A

    3 x 400 V

    15.5 A

    3 x 460 V

    14.0 A

    Max. primary current (I1max)

    3 x 200 V

    48.2 A

    3 x 230 V

    41.6 A

    3 x 380 V

    25.5 A

    3 x 400 V

    24.4 A

    3 x 460 V

    22.1 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    -10 / +15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    74 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-400 A

    TIG

    3-400 A

    MMA

    10-400 A

    Welding current at
    10 min/40 °C (104 °F)

     

    U1 = 200-230 V

    40% / 400 A
    60% / 360 A
    100% / 320 A

    U1 = 380-460 V

    40% / 400 A
    60% / 360 A
    100% / 320 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-34.0 V

    TIG

    10.1-26.0 V

    MMA

    20.4-36.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    67 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    47.1 kg / 103.8 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    49.3 W

    Welding machine efficiency
    at 400 A / 36 V

    87%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 500i

    Mains voltage (U1)

    3 x 400 V

    Max. effective primary current (I1eff)

    23.7 A

    Max. primary current (I1max)

    37.5 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    +/- 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    49 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-500 A

    TIG

    3-500 A

    MMA

    10-500 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 500 A
    60% / 430 A
    100% / 360 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-39.0 V

    TIG

    10.1-30.0 V

    MMA

    20.4-40.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    71 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    38 kg
    838 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    34.1 W

    Welding machine efficiency
    at 500 A / 40 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 500i /nc

    Mains voltage (U1)

    3 x 380 V / 400 V / 460 V

    Max. effective primary current (I1eff)
    3 x 380 V
    3 x 400 V
    3 x 460 V


    24.5 A
    23.7 A
    21.9 A

    Max. primary current (I1max)
    3 x 380 V
    3 x 400 V
    3 x 460 V


    38.8 A
    37.5 A
    34.7 A

    Mains fuse protection

    35 A slow-blow

    Mains voltage tolerance

    - 10 / + 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    49 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-500 A

    TIG

    3-500 A

    MMA

    10-500 A

    Welding current at
    10 min/40 °C (104 °F)

     

    U1 = 380-460 V

    40% / 500 A
    60% / 430 A
    100% / 360 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-39.0 V

    TIG

    10.1-30.0 V

    MMA

    20.4-40.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    82 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    36.7 kg
    809 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    34.1 W

    Welding machine efficiency
    at 500 A / 40 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 500i /600V/nc

    Mains voltage (U1)

    3 x 575 V

    Max. effective primary current (I1eff)

    19.7 A

    Max. primary current (I1max)

    31.2 A

    Mains fuse

    35 A slow-blow

    Mains voltage tolerance

    +/- 10%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3 - 500 A

    TIG

    3 - 500 A

    MMA

    10 - 500 A

    Welding current at
    10 min/40 °C (104 °F)

    40% / 500 A
    60% / 430 A
    100% / 360 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2 - 39.0 V

    TIG

    10.1 - 30.0 V

    MMA

    20.4 - 40.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    71 V

    Protection class

    IP 23

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    34.9 kg / 76.9 lb.

    Max. noise emission (LWA)

    74 dB (A)

    1. Appendix
    2. Technical data

    TPS 500i /MV/nc

    Mains voltage (U1)

    3 x 200 V / 230 V
    3 x 380 V / 400 V / 460 V

    Max. effective primary current (I1eff)

     

    3 x 200 V

    43.5 A

    3 x 230 V

    37.4 A

    3 x 380 V

    22.7 A

    3 x 400 V

    21.6 A

    3 x 460 V

    19.2 A

    Max. primary current (I1max)

    3 x 200 V

    68.8 A

    3 x 230 V

    59.2 A

    3 x 380 V

    35.9 A

    3 x 400 V

    34.1 A

    3 x 460 V

    30.3 A

    Mains fuse protection

    3 x 200 / 230 V

    63 A slow-blow

    3 x 380 / 400 / 460 V

    35 A slow-blow

    Mains voltage tolerance

    -10 / +15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    38 mOhm

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-500 A

    TIG

    3-500 A

    MMA

    10-500 A

    Welding current at
    10 min/40 °C (104 °F)

     

    U1 = 200-230 V

    40% / 500 A
    60% / 430 A
    100% / 360 A

    U1 = 380-460 V

    40% / 500 A
    60% / 430 A
    100% / 360 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-39.0 V

    TIG

    10.1-30.0 V

    MMA

    20.4-40.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    68 V

    Protection class

    IP 23

    EMC emission class

    A 2)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    47.1 kg / 103.8 lb.

    Max. noise emission (LWA)

    < 80 dB (A)

    Idle state power consumption at 400 V

    46.5 W

    Welding machine efficiency
    at 500 A / 40 V

    88%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 600i

    Mains voltage (U1)

    3 x 400 V

    Max. effective primary current (I1eff)

    44.4 A

    Max. primary current (I1max)

    57.3 A

    Mains fuse protection

    63 A slow-blow

    Mains voltage tolerance

    +/- 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    possible connection restrictions 2)

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-600 A

    TIG

    3-600 A

    MMA

    10-600 A

    Welding current at
    10 min/40 °C (104 °F)

    60% / 600 A
    100% / 500 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-44.0 V

    TIG

    10.1-34.0 V

    MMA

    20.4-44.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    74 V

    Protection class

    IP 23

    EMC emission class

    A 3)

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    50 kg / 100.2 lb.

    Max. shielding gas pressure

    7.0 bar / 101.5 psi

    Coolant

    Original Fronius

    Max. noise emission (LWA)

    83 dB (A)

    Idle state power consumption at 400 V

    50 W

    Welding machine efficiency at 600 A / 44 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    Before connecting the device to the public grid, consult with the grid operator!
    3)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 600i /nc

    Mains voltage (U1)

    3 x 380 V / 400 V / 460 V

    Max. effective primary current (I1eff)

    3 x 380 V

    46.6 A

    3 x 400 V

    44.4 A

    3 x 460 V

    39.2 A

    Max. primary current (I1max)

    3 x 380 V

    60.1 A

    3 x 400 V

    57.3 A

    3 x 460 V

    50.6 A

    Mains fuse protection

    63 A slow-blow

    Mains voltage tolerance

    - 10 / + 15%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Max. permitted mains impedance Zmax at PCC1)

    possible connection restrictions 2)

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3-600 A

    TIG

    3-600 A

    MMA

    10-600 A

    Welding current at
    10 min/40 °C (104 °F)

    60% / 600 A
    100% / 500 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2-44.0 V

    TIG

    10.1-34.0 V

    MMA

    20.4-40.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    85 V

    Protection class

    IP 23

    EMC emission class

    A 3)

    Safety symbols

    S, CE, CSA

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    47.0 kg / 103.6 lb.

    Max. shielding gas pressure

    7.0 bar / 101.49 psi

    Coolant

    Original Fronius

    Max. noise emission (LWA)

    83 dB (A)

    Idle state power consumption at 400 V

    50 W

    Welding machine efficiency
    at 600 A / 44 V

    89%

    1)
    Interface to a 230/400 V and 50 Hz public grid
    2)
    Before connecting the device to the public grid, consult with the grid operator!
    3)
    An emission class A device is not designed for use in residential areas supplied with power from a public low-voltage grid.
    The electromagnetic compatibility can be influenced by conducted or radiated radio frequencies.
    1. Appendix
    2. Technical data

    TPS 600i /600V/nc

    Mains voltage (U1)

    3 x 575 V

    Max. effective primary current (I1eff)

    37.6 A

    Max. primary current (I1max)

    48.5 A

    Mains fuse

    63 A slow-blow

    Mains voltage tolerance

    +/- 10%

    Grid frequency

    50/60 Hz

    Cos phi (1)

    0.99

    Recommended residual current circuit breaker

    Type B

    Welding current range (I2)

     

    MIG/MAG

    3 - 600 A

    TIG

    3 - 600 A

    MMA

    10 - 600 A

    Welding current at
    10 min/40 °C (104 °F)

    60% / 600 A
    100% / 500 A

    Output voltage range according to standard characteristic (U2)

    MIG/MAG

    14.2 - 44.0 V

    TIG

    10.1 - 34.0 V

    MMA

    20.4 - 44.0 V

    Open circuit voltage
    (U0 peak/U0 r.m.s)

    73 V

    Protection class

    IP 23

    Dimensions L x W x H

    706 x 300 x 510 mm
    27.8 x 11.8 x 20.1 in.

    Weight

    42.0 kg / 92.6 lb.

    Max. shielding gas pressure

    7 bar / 101.49 psi

    Coolant

    Original Fronius

    Max. noise emission (LWA)

    83 dB (A)

    1. Appendix
    2. Technical data

    China Energy Label

    TPS 320i /nc

    TPS 320i C /4R/FSC/G/nc

    TPS 400i /nc

    TPS 400i /MV/nc

     

     

    TPS 500i /nc

    TPS 600i /nc

     

     

    1. Appendix
    2. Technical data

    Radio parameters

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

    The following table contains the frequency ranges and maximum HF transmission power used by Fronius wireless products sold in the EU in accordance with Article 10.8 (a) and 10.8 (b) of the RED.

    Frequency range
    Channels used
    Power

    Modulation

    2412 - 2462 MHz
    Channel: 1 - 11 b ,g, n HT20
    Channel: 3 - 9 HT40
    < 16 dBm

    802.11b: DSSS
    (1Mbps DBPSK, 2Mbps DQPSK, 5.5/11Mbps CCK)

    802.11g: OFDM
    (6/9Mbps BPSK, 12/18Mbps QPSK, 24/36Mbps 16-QAM, 48/54Mbps 64-QAM)

    802.11n: OFDM
    (6.5Mbps BPSK, 13/19 Mbps QPSK, 26/39 Mbps16-QAM,52/58.5/65Mbps 64-QAM)

    13.56 MHz
    -14.6 dBµA/m at 10 m

    Functions:
    R/W, card emulation and P2P

    Protocol standards:
    ISO 14443A/B, ISO15693, ISO18092,
    NFCIP-2,

    Data rate:
    848 kbps

    Reader/Writer, Card Emulation, Peer to Peer Modes

    2402 - 2482 MHz
    0 - 39
    < 4 dBm

    GFSK

    1. Appendix
    2. Technical data

    Catalogue C

    Template for No. 52 regulation warning sentences

    Micropower equipment shall indicate the following contents in its product operation instructions (including those with electronic display) in Chinese:

    (1)
    The specific provisions and use scenarios which compliance with "Catalogue and Technical Requirements of Micropower Short-Range Radio Transmission Equipment"; the type and performance of the antenna used, the control, adjustment and switching methods;
    Specific provisions:
    Class C equipment:
    1. Frequency: 13553-13567KHz
    2. Magnetic field intensity at 10m: no more than 42dB ?A /m
      (quasi-peak detection)
    3. Frequency tolerance: 100×10-6.
    4. Special frequency band radiation emission: for 13553-13567KHz frequency band equipment, the magnetic field intensity at 10 meters at both ends of the frequency band offset 140KHz frequency range is no more than 9dB microA /m (quasi-peak detection).

      Usage scenario: Lock and unlock
      Antenna type: frame antenna
      Antenna performance: 1
      Control, adjustment and switch product use method: only one version available
    (2)
    It is not allowed to change the use scene or use conditions, expand the range of transmission frequency, or increase the transmission power (including the amount) without authorization Install a radio frequency power amplifier outside), and do not change the transmitting antenna without authorization;
    (3)
    It shall not cause harmful interference to other lawful radio stations, nor shall it claim protection from such harmful interference;
    (4)
    It shall be subjected to interference by equipment for industrial, scientific and medical (ISM) applications radiating radio frequency energy or otherwise legally Radio (station) interference;
    (5)
    If harmful interference is caused to other legitimate radio stations, the radio station shall stop using them immediately and take measures Eliminate interference before continuing to use;
    (6)
    Radio observatories and meteorological radars set up in the aircraft or in accordance with laws and regulations, relevant State regulations and standards
    Electromagnetism of military and civilian radio stations (stations) and airports, such as stations, satellite earth stations (including measurement and control, ranging, receiving and navigation stations) The use of micro-power equipment within the environmental protection area shall comply with the provisions of the competent authorities for electromagnetic environmental protection and related industries;
    (7)
    It is forbidden to use all kinds of model remote controls in an area with a radius of 5000 meters and the center of the airport runway as the center of the circle;
    (8)
    environmental conditions of the temperature and voltage when the micro-power equipment is in use.
    Temperature when the product is used: -40/+85
    Voltage when the product is in use: +24V DC
    1. Appendix

    Hazardous Substances

    Part Name

    Hazardous Substances

    Lead
    (Pb)

    Mercury
    (Hg)

    Cadmium
    (Cd)

    hexavalent
    chromium
    (Cr (VI))

    polybrominated
    biphenyls
    (PBB)

    polybrominated
    diphenyl ethers
    (PBDE)

    metal parts - copper alloys

    X

    O

    O

    O

    O

    O

    PCB assembly

    X

    O

    O

    O

    O

    O

    cables and cable assemblies

    O

    O

    O

    O

    O

    O

    plastic and polymeric parts

    O

    O

    O

    O

    O

    O

    device housing

    O

    O

    O

    O

    O

    O

     

     

     

     

     

     

     

    This table is prepared in accordance with the provisions of SJ/T 11364.

     

     

     

     

     

     

     

    O
    Indicates that the hazardous substance contained in all of the homogeneous materials for this part is below the limit requirement of GB/T 26572.
    X
    Indicates that the hazardous substance contained in at least one of the homogeneous materials used for this part is above the limit requirement of GB/T 26572.

    Part Name

    Hazardous Substances

    Lead
    (Pb)

    Mercury
    (Hg)

    Cadmium
    (Cd)

    hexavalent
    chromium
    (Cr (VI))

    polybrominated
    biphenyls
    (PBB)

    polybrominated
    diphenyl ethers
    (PBDE)

    metal parts - copper alloys

    X

    O

    O

    O

    O

    O

    PCB assembly

    X

    O

    O

    O

    O

    O

    cables and cable assemblies

    O

    O

    O

    O

    O

    O

    plastic and polymeric parts

    O

    O

    O

    O

    O

    O

    device housing

    O

    O

    O

    O

    O

    O

     

     

     

     

     

     

     

    This table is prepared in accordance with the provisions of SJ/T 11364.

     

     

     

     

     

     

     

    O
    Indicates that the hazardous substance contained in all of the homogeneous materials for this part is below the limit requirement of GB/T 26572.
    X
    Indicates that the hazardous substance contained in at least one of the homogeneous materials used for this part is above the limit requirement of GB/T 26572.