Fronius TPS i Welding Machine

This safety function activates during MIG/MAG welding when the characteristic-dependent current limit is reached. If the welding power is too high, the arc may become smaller and extinguish. The welding machine automatically reduces wire speed and welding power to prevent arc extinguishment, and a corresponding message appears in the status bar.

Excessive welding spatter is occurring, which may be caused by contamination or magnetic charging of the shielding gas, wirefeeder, welding torch, or workpiece. These conditions can destabilize the arc and droplet transfer.

The wire feed speed is irregular because the braking force applied to the wire spool has been set too high, creating excessive resistance and hindering smooth wire delivery.

Irregular wire speed is observed due to a malfunction or damage in the inner liner of the welding torch. Kinks, dirt, or other defects in the liner can impede the smooth passage of the welding wire.

Irregular wire speed is occurring because the feed rollers have been adjusted with incorrect contact pressure on the wire electrode, causing either slippage or excessive deformation of the wire.

The wire feed speed is irregular because the wirefeeder rollers installed are not compatible or suitable for the specific type of wire electrode being used, leading to improper gripping or feeding.

There is an absence of protective gas shielding during welding, while all other welding machine functions appear normal. This indicates that the shielding gas cylinder is depleted.

Protective gas shielding is absent during welding, despite the rest of the machine functioning normally. This points to an issue with the gas hose, such as being improperly connected or damaged.

The welding process lacks a protective gas shield, even though all other functions are operating correctly. This suggests a malfunction of the gas pressure regulator, which controls gas flow.

The welding process is not receiving a protective gas shield, while all other functions of the machine are operating normally. This indicates a fault within the welding torch that is preventing gas delivery.

The welding machine's indicators are not lit, suggesting a short circuit on the 24V supply that powers the SpeedNet connection socket or an external sensor, preventing normal operation.

The welding machine's indicators remain unlit when the mains switch is engaged, pointing to a malfunction in the mains power supply components external to the device itself.

The welding machine's indicators are not illuminated when the device is powered on, indicating that the mains fuse protection has activated, likely due to an overcurrent condition.

The welding machine's indicators are not lit, despite the mains switch being in the 'on' position. This indicates an issue with the primary power connection to the device.

The welding machine is powered on and its indicators are lit, but it fails to produce welding current. This indicates a fault with the grounding (earthing) connection, possibly due to improper polarity.

The welding machine indicates overtemperature and fails to produce welding current, which is a symptom of insufficient cooling. This can occur if the airflow to the internal components is restricted.

The welding machine is displaying an overtemperature status and not generating welding current. This is caused by the internal thermostatic automatic circuit breaker tripping to protect the unit from excessive heat.

The welding machine is active and displaying an overtemperature condition but produces no welding current. This occurs when the device has been operated beyond its specified duty cycle, leading to internal heating.

The welding machine is operational with indicators lit, yet no welding current is generated. This points to a discontinuity or break in the power cable that runs within the welding torch itself.

Poor weld properties result from using an incorrect contact tip, a contact tip that is worn out, or one with a hole that is too narrow for the wire electrode. This affects wire feeding and current transfer.

Poor weld properties are observed due to an insufficient or completely absent supply of shielding gas. This compromises arc stability and weld protection from atmospheric contamination.

Poor weld properties are present because the welding torch is leaking, which allows shielding gas to escape, leading to inadequate protection of the weld pool from the atmosphere.

Poor weld properties occur when multiple welding machines are simultaneously used on a single component. This can be due to electrical interference from shared circuits or magnetic fields if components are too close.

The quality of the weld is poor, which can be directly linked to improperly configured welding or correction parameters. These settings influence the arc characteristics and material deposition.

Poor weld properties are observed, stemming from an inadequate or faulty grounding (earthing) connection to the workpiece. A poor ground can lead to an unstable arc and inconsistent weld quality.

Poor weld properties are observed because the chosen shielding gas is not chemically compatible or suitable for the specific wire alloy being used. This can lead to porosity, spatter, or other weld defects.

Poor weld properties occur because an unsuitable wire alloy or incorrect wire diameter has been selected and inserted for the welding application. This mismatch can significantly affect arc stability and material fusion.

In water-cooled welding systems, the torch becomes very hot due to an insufficient flow of coolant. This can be caused by low coolant levels, blockages, or contamination in the cooling system.

The welding torch becomes excessively hot because the distance between the contact tip and the workpiece (stickout) is too small. A short stickout can lead to increased heat transfer to the torch.

The welding torch becomes excessively hot during operation, indicating that its design or capacity is insufficient for the welding current and duration, or that the duty cycle is being exceeded.

When the welding machine is on and its indicators are lit, pressing the torch trigger produces no action. This issue is typically caused by the control plug not being connected to its receptacle.

With the mains switch on and indicators lit, the torch trigger fails to initiate welding. This suggests a malfunction within the welding torch itself or a fault in its dedicated control line.

When the welding machine is powered on and its indicators are lit, the torch trigger does not function. This problem is attributed to a defective or improperly connected interconnecting hosepack, particularly for welding machines without integrated wire drive.

Wirefeed problems are encountered, particularly when using long welding torch hosepacks, due to an improper physical arrangement. Kinks or sharp bends in the hosepack can obstruct wire movement.