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
Copyright 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 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
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EN

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
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
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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
90
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
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EN

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
Setting the language 133
Keylock 134
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
Current system data 139
Job-Data 141
Job data 141
Backup & Restore 142
General remarks 142
Backup & Restore 142
Automatic backup 143
Overview 144
Overview 144
Expanding / reducing all groups 144
Export component overview as ... 144
Update 145
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
Screenshot 149
Troubleshooting and maintenance 151
The Error menu 153
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
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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
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EN

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!
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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.
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EN

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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