FRONIUS TPS/i COMPACT User manual

Operating

Instructions

TPS 270i C

42,0426,0206,EN 019-19062023

EN Operating Instructions

Contents

Safety rules 8

Explanation of safety notices 8

General 8

Proper use 9

Environmental conditions 9

Obligations of the operator 9

Obligations of personnel 9

Mains connection 10

Residual current protective device 10

Protecting yourself and others 10

Noise emission values 11

Danger from toxic gases and vapours 11

Danger from ﬂying sparks 12

Risks from mains current and welding current 12

Meandering welding currents 13

EMC Device Classifications 13

EMC measures 14

EMF measures 14

Specific hazards 14

Requirement for the shielding gas 15

Danger from shielding gas cylinders 16

Danger from escaping shielding gas 16

Safety measures at the installation location and during transport 16

Safety measures in normal operation 17

Commissioning, maintenance and repair 18

Safety inspection 18

Disposal 18

Safety symbols 18

Data protection 19

General information 21

General 23

Device concept 23

Functional principle 23

Application areas 23

Warning notices on the device 24

Description of the warning notices on the device 26

System components 28

General 28

Overview 28

Options 28

Welding packages, welding characteristics and welding processes 31

Welding packages 33

General 33

Welding packages 33

Welding characteristics 34

Welding methods and processes 39

MIG/MAG pulse synergic welding 39

MIG/MAG standard synergic welding 39

PMC process 39

LSC process 39

SynchroPulse welding 40

CMT process 40

CMT Cycle Step welding process 40

SlagHammer 40

Stitch welding 40

Controls, connections and mechanical components 43

Control panel 45

General 45

Safety 45

Control panel 45

Displaying plain text for parameters 50

F1/F2 special function parameters, Favourites button 51

F1 and F2 special function parameters 51

The Favourites button 52

Connections, switches and mechanical components 55

Installation and commissioning 57

Minimum equipment needed for welding task 59

General 59

MIG/MAG gas-cooled welding 59

MIG/MAG water-cooled welding 59

Manual CMT welding 59

TIG DC welding 59

MMA welding 59

Before installation and commissioning 60

Safety 60

Proper use 60

Setup regulations 60

Mains connection 60

Generator-powered operation 61

Information on system components 61

Connecting the mains cable 62

Safety 62

General 62

Stipulated mains cables 62

Connecting the mains cable - general 63

Start-up 65

Safety 65

General 65

Connecting the gas cylinder 65

Establishing a ground earth connection 66

Connecting the welding torch 67

Inserting/replacing feed rollers 67

Inserting the wirespool 69

Inserting the basket-type spool 70

Feeding in the wire electrode 71

Setting the contact pressure 73

Adjusting the brake 73

Design of the brake 74

Performing R/L alignment 74

Welding 75

MIG/MAG modes 77

General 77

Symbols and their explanations 77

2-step mode 78

4-step mode 78

Special 4-step mode 79

Special 2-step mode 79

Spot welding 80

MIG/MAG and CMT welding 81

Safety 81

MIG/MAG and CMT welding – overview 81

Switching on the power source 81

Setting the welding process and operating mode 81

Retrieving the currently set filler metal 82

Selecting the filler metal 82

Setting the welding parameters 84

Set the shielding gas ﬂow rate 85

MIG/MAG or CMT welding 85

Spot and stitch welding 86

Spot welding 86

Stitch welding 87

MIG/MAG and CMT welding parameters 89

Welding parameters for MIG/MAG pulse synergic welding and PMC welding 89

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

welding

Welding parameters for MIG/MAG standard manual welding 93

Explanation of footnotes 93

EasyJob mode 95

General 95

EasyJob mode 95

TIG welding 96

Safety 96

Preparations 96

TIG welding 96

Igniting the arc 98

Finishing welding 98

MMA welding 99

Safety 99

Preparations 99

MMA welding 99

Welding parameters for manual metal arc welding 101

Setup settings 103

Setup menu - overview 105

Entering/exiting the Setup menu 105

Setup menu - overview 106

Process parameters 108

Process parameters for start of welding/end of welding 108

Process parameters for Gas-Setup 110

Process parameters for process control 110

Penetration stabilizer 110

Arc length stabilizer 112

Combination of penetration stabilizer and arc length stabilizer 114

Process parameters for spot welding 115

Process parameters for stitch welding 115

Process parameters for monitoring and components 115

Process parameters for electrode setup 117

Process parameters for TIG setup 119

Process parameters for SynchroPulse 121

Process parameters for Process Mix 123

R/L alignment 125

Settings 127

General 127

Overview 127

Setting the units 127

Setting the standards 128

Setting hold mode 128

Setting the display brightness 128

Displaying replaced characteristics 129

Setting F1 and F2 special function parameters via the Setup menu 129

Setting the Favourites button via the Setup menu 129

Retrieving system data 130

Setting the interior lighting 131

Restoring the factory settings 131

Resetting the password for the power source website 131

Retrieving device information 132

Setting the special display for JobMaster 132

Setting the mode for spot welding 132

Setting the language 133

Keylock 134

SmartManager - The power source website 135

SmartManager - The power source website 137

General 137

Calling up the power source website 137

Changing password / logging off 137

Settings 138

Language selection 138

Fronius 138

Current system data 139

Job-Data 141

Job data 141

Backup & Restore 142

General remarks 142

Backup & Restore 142

Automatic backup 143

Overview 144

Expanding / reducing all groups 144

Export component overview as ... 144

Update 145

Searching for an update file (performing the update) 145

Fronius WeldConnect 146

Function Packages 147

Function packages 147

Installing a function package 147

Synergic lines overview 148

Characteristics overview 148

Show filter 148

Screenshot 149

Troubleshooting and maintenance 151

The Error menu 153

Care, maintenance and disposal 154

General 154

Safety 154

At every start-up 154

If necessary 154

Every 2 months 154

Every 6 months 154

Updating firmware 155

Disposal 155

Troubleshooting 156

Technical data 161

Average consumption values during welding 163

Average wire electrode consumption during MIG/MAG welding 163

Average shielding gas consumption during MIG/MAG welding 163

Average shielding gas consumption during TIG welding 163

Technical data 164

Explanation of the term "duty cycle" 164

Special voltages 164

TPS 270i C 165

TPS 270i C /nc 166

TPS 270i C /MV/nc 167

TPS 270i C /S/nc 169

Overview with critical raw materials, year of production of the device 170

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.

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 en-

vironmental 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 sec-

tion 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!

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 in-

structions

-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 set-

ting.

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

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.)

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 sec-

tion "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.

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 pre-

vention

-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.

Mains connec-

tion

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 mat-

ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Residual current

protective

device

Local regulations and national guidelines may require a residual current protect-

ive device when connecting equipment to the public grid.

The type of residual current protective device recommended by the manufac-

turer for the equipment is indicated in the technical data.

Protecting your-

self 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 us-

ing 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 protect-

ive 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 in-

jury

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