Fronius Welding Frequently Asked Questions

Fronius is an Austrian firm which was founded in 1945 by Gunter Fronius a repair and maintenance man. The company began through an innovative idea of recharging car batteries, this meant they could be used for longer instead of replaced. Celebrating their 75th anniversary, Fronius is now a worldwide company but their heart is still in Austria where every machine is made. 

We are a part of the Fronius partner scheme which is a small group of approved partners which means you will always be supplied with genuine high quality Fronius machines, parts and accessories, at Tec Products we will always try to find a solution to any welding problem you have- need to get in touch? Call us on: 01845 202 989. 

These two powersources are similar and offer different solutions to MIG/MAG welding, the Transsteel is a multipurpose machine which is capable of MIG, TIG and MMA welding (with the correct accessories), the welding properties are significantly improved, and the machine is versatile and reliable and the TPS/I is an advanced and universal machine available in a range of power categories and has been redesigned especially for improved communication between machine and welder as well as perfected handling. 

Transsteel Series

The Transsteel multiprocess machines are ideal multi-purpose machines which can be used for assembly, repair, maintenance or industrial purposes. This series are compact and offer a 3 in 1 solution (offering MIG/MAG, MMA and TIG processes), these are portable machines with the smallest machine weighing only 15kg. These machines are quick to start up in just 3 steps. 

Genuine multi-process machines have to be able to perform all three welding processes to the same standard, the Transsteel series successfully do this which makes these machines ideal for Small/medium businesses, individuals or mobile operations. 

High power and wide range of application- four minutes of continuous welding at maximum output power.

Key features of the Transsteel series:

• Can weld using MIG/MAG, TIG and MMA processes, as well as pulse technology
• Easy to use interface
• Pulse, spot and stitch functionality, arc length correction are available as standard. 
• Intelligent design
• Lightweight and reliable solution 

TPS/I Series 

This series is an advanced and universal machine which is available in a range of power categories and has been recently redesigned. This redesign has allowed for improved communication between machine and welder as well as perfected handling.

The TPS/I has a plain text display which can be controlled easily using the graphic interface. Efficiency is key with the colour of display, perspective, brightness and overall robust design to ensure accurate parameter setting and allows the user to keep their gloves on throughout operation. The interface can be used in 32 different languages.

The TPS/I series features plug and weld technology- meaning no tools are required and the smart machine can recognize the component which has been attached automatically- this feature prevents any components which are incompatible from being used and prevents any disasters.

All Fronius machines have good data exchange systems through the SpeedNet connection which allows for 100Mbit/s data exchange. This ensures for accurate statuses of all machines. These welding machines are modular and allow for add on’s- this allows the individual to expand their welding capacity and configure to their exact requirements.

In the smaller power machines (TPS/I 270  C and TPS/I 320 C) the machines are compact and the wirefeeder is inbuilt to the housing- ideal for mobile operations.

In the higher power categories (TPS/I 320/400/500/600) the machines are modular and split so the wirefeeder is portable and can be taken to the area of application while the base machine is static- the hosepacks can reach up to 30 metres.

There are expandable software packages to increase your weldability available (the standard and pulse packages come as standard) but additional software featuring the LSC, PMC or CMT welding software packages are available. Fronius offer a 50 arc hour trial of the full welding packages.  

The TPS/I Steel edition is also available which only welds steel and is perfect for the steel industry. The steel market comes at a cost optimization due to just supplying the steel characteristics. It also includes the pulse functionality.

Key features of the TPS/I Series:

• Easy to use and understand interface
• Penetration and stableised arc length allow for high quality weld seams
• Flexibility through expansion of software packages
• Spatter free working is possible using Low spatter control functionality
• Hosepack range can have length of up to 30M
• Mobile wirefeeder
• Over 500 characteristics and weld processes the TPS/I range is ideal for every individual no matter their requirements.
• Can be used for robotic or automated welding applications
• Easy to switch material 

MIG Welding Functions

Pulse functionality

• Some machines in the Transsteel range offer a pulse functionality which can reduce the rework by up to 70% increasing welding time by 30%. The pulse functions allow a pulsed arc to be selected and allows for easy to control welding in the intermediate arc range.

Spot and stitch functionality

• Regular intervals using spot mode allows full flexibility over the time paused it is ideal for tacking pieces together. Stitched welding allows for rippled seam appearance and workpiece distortion is minimal due to low heat input.

Synchropulse

• Specifically for welding aluminium alloys when you want to produce a rippled seam effect. This is done by changing the welding power between the two operation points (this is only available on the TransSteel 3000C pulse and when in Synergic or pulse synergic mode).

Can I make corrections during welding?

• Yes, There are a range of corrections you can do during welding, these include- arc length correction, arc-force dynamic and pulse correction.

1. Arc length correction- shortening the arc reduces the welding voltage, increasing the length of the arc increases the welding voltage.
2. Arc force dynamic- to influence short circuiting dynamic at the instant of droplet transfer. A hard arc is a stable arc and a soft arc is a low-spatter arc.
3. Pulse correction- by correcting the pulse energy you can control the droplet detachment force (higher or slower)

TIG Welding Functions 

Pulsewelding

• This is used mostly for out of position welding or when welding very thin materials- the setting range is from 1Hz to 990Hz.

Tacking Function

• The weld pool oscillates through pulsed currents which means tacking components is easier and reduces the time required. This facilitates the process of tacking very thin materials as the temperatures are slightly lower during the low current phases. This benefits the user by a timesaving of up to 50%. It allows for fast tacking which doesn’t burn off the edges and reduces any colouration at the tacking points.

 Touch down ignition (also known as scratch start or lift arc ignition)

• This functionality improves user friendliness, it almost always works and is affordable- MIG/MAG or MMA machines can conduct TIG welding and the only part which needs replaced is the torch.
• Each time the welder ignites this wears the tungsten, touchdown ignition increases this wear- the material and tungsten electrode create a short circuit when they touch which heats the two- this means they evaporate- this can be called thermal ionization. The electrode tip can also be burnt off and if the electrode is lifted then a section can be left in the weld metal.

Are their disadvantages to Touch Down Ignition?

• Rework is usually required due to tungsten inclusions, so these must be ground away if high quality TIG seams are required.  Frequent ignitions are not possible as cooling the electrode takes time.

 HF (High frequency ignition)

• High Frequency ignition rules out inclusions, it makes weld seams better and easier to control. High frequency ignition and touchless ignition means low levels of wear to the tungsten. Touchless which means there is no short circuit created is only able to be used with high frequency ignition.

 Gas Pre/Post Flow time

• The transteel range automatically calculates the duration of the gas post flow time in comparison to the set welding current- this means an improvement of gas shield on the weld seam end and tungsten electrode.

MMA Welding

The TransSteel range is capable of MMA welding, this prevents the electrode sticking (stops the electrode from sticking). This anti-stick function switches off the process instantly preventing any burn out or serious weld seam faults.

HotStart function

• This function makes the electrode easier to ignite- increased current for the split second on start means an easier start.

Arc force dynamic

• For seam rippling on aluminum alloys. If the machine detects sticking then more current will be supplied to prevent sticking.

Fronius welding torches have additional configurable functions:

• Multilock- The patented interface allows fully configurable MIG/MAG torches (*standard up/down) The wide range of torch bodies. Flexible torch bodies exist and if in doubt for your requirements can be the best alternative.
• TIG Multi-connector- The Transsteel is a multi-process power source so a multi-connector allows for torches and other functionality to be connected.
• FSC (Fronius System Connector)- The FSC allows all media to be connected and allows for a variety of torches to be connected.

Additional features of the TPS/I

Standard- this software enables the user to use the dip transfer arc and the spray arc, these standard functions are easy to use and suitable across all unalloyed, low and high alloyed materials.

Pulse- this package is standard and allows pulsed arc welding, the low level of spatter allows for a range of working ( light gauge to thick gauge sheets).

LSC (low spatter control)- This additional functionality allows for high arc stability and reduced spatter, the penetration stabiliser allows for constant penetration in the spray arc no matter if the stick out changes.

PMC (Pulse multi control)- another additional feature pulse multi control allows for higher weld seam quality and quicker welding speeds. The penetration and arc length stabilization.

CMT (Cold metal transfer)- This is a specific type of droplet detachment which reduces the heat input- the reverse wire electrode movement allows for minimal spattering.

iWave

The iWave TIG welding system is a substantial, accurate and easy to use system. This flexible system allows for high quality welding with maximum control. The iWave welding system is new from Fronius, launched in January 2022 these machines are ideal for setting new standards and innovative welding systems. 

1) Targeted Heat Input- CycleTIG allows you to control the arc, this allows full control of the weld pool and heat input. The short welding times make it easy to keep a safe handle on the weld pool. This allows welding of very thin materials.

2) Intuitive Operation- Menu is made from a graphics based navigation and can have up to 32 languages, it is easy to use and the navigation is as you would expect. Up to a 7 inch touchscreen (190-230i have a 4.3 inch screen), with central push and turn button and graphic displayed visualizations. The touchscreen can be operated even while wearing gloves.

3) Reproduce Ignition-Ignition delays reduced by up to 71% (when you opt in to RPI Auto), intelligent ignition allows for fast and reliable ignition without having to adjust any parameters.

4) Ready for Industry 4.0- This machine can allow for a contactless data transfer and authentication- WLAN, Bluetooth, NFC and Wifi connectivity means that you can add or use any of the major connection standards.

Looking for a multi-process machine?

The iWave Multi-Process PRO is the ideal multi-process welding machome which offers all TIG welding processes. This machine allows for TIG, MIG/MAG and MMA welding. This machine is future proofed to work with industry 4.0.

3 steps to unleash your full potential:

1. Place an order for the Multi-process PRO hardware option
2. Expand your collection by purchasing MIG/MAG hardware options such as a wirefeeder, welding torch(es) and any other additionals you may require.
3. Select your software options.

 iWave options:

TransTig Welding Machines

The Transtig range is a completely digital TIG DC powersource, at Tec Products we offer a range of Transtig machines which vary in mobility- modular, mobile and portable machines and stationary highly powered machine. All machines are robust and designed for long usage life.

What functionality does the Transtig have?

TAC

One spot tacking using the pulsed arc to connect the two weld pools which jump together to make one single weld pool, this function is also useful for welding light gauge sheets without filler materials.

HF ignition

Touchless and gentle high-frequency ignition is the easiest option to ignite the arc.

Touchdown Ignition

This function should be used to prevent electromagnetic interference which can occur during High Frequency ignition.

Transpocket TIG

These models are available in the 150 to 350Amp categories, they have TIG Comfort Stop which aims to make the process easier for the user- these prevent arc breaks at the end of welding. The pulsed arc functionality allows for good control of the weld pool when out of position welding and when gap filling- the Transpocket TIG welding machine also has a gas- test functionality. These lightweight machines are portable and have inbuilt carry handle and strap.

The new generation of Transpocket machine allow for total flexibility and has integrated Power Factor correction which allows long mains leads to be used. This display features 7 segment display and allows for parameters to be easily set through the dial and interface which is on a set back display to protect from damage.

The Transpocket TIG welder has the same functionality as the Accupocket TIG welding machines- softstart, hot start, TAC and TIG comfort stop.

Accupocket TIG

The Accupocket TIG welders are ultra portable, these are battery operated devices which are capable of highly powerful welds without the need to be connected to mains electricity. The Accupocket TIG offers the TIG pulse function to ensure reduced heat input, improved gap building ability and better weld seam appearance. This device guarantees the best gas shield in the start and stop phase. With inbuilt handle the Accupocket is the ideal welder for on site work.

Functions of the Accupocket?

Hot start

Ignition is easier as the current at the beginning of the weld is increased for a fraction of a second during ignition. This is especially designed for welding with rutile and Cel Electrodes.

Soft start

This allows for the stable arc at the start of welding and was designed for electrodes that are welded with a low welding current (basic electrodes).

TAC

Tacking using just one spot allows for the pulsed arc to join two weld pools- this is ideal for welding light gauge sheets without filler.

TIG Comfort Stop

Once the weld is complete the current is switched off automatically when a specific change is made to the arc length. This prevents any elongation of the arc when not required- this has the result of a better weld result at the end crater.

The Magic Cleaner is the ideal machine for rework of TIG welds and surfaces, this is an innovative system to treat TIG welding seams and stainless steel surfaces. This machine is different to other mechanical or chemical cleaning processes as the material surface is not damaged, there is no need for exposure time or any additional passivation processes. This stainless steel cleaning machine is lightweight at only 4.5kg it is ideal for workshop use or on construction sites. 

What can you do with this machine?

• Cleaning 
• Polishing
• Labelling 

These three functions together provide the most innovative system for electrochemical cleaning, removal of post weld temper colouration and able to restore the protective passive layer. The polishing process allows a consistent finish as well as the printing feature which allows you to permanently inscribe on stainless steel surfaces. There are a wide variety of tools and brushes available for clenaing- welded pipes, undercuts, sharp edges or complex shapes. For polishing there is a range of pads and electrodes to choose from to clean and polish linear weld seams, corner welds, T joints and butt welds. For cleaning, polishing and printing a range of electrolytes and neutralises are available. 

Benefits of the Magic Cleaner

• Cleaning and passivation in one step- allows passivation and cleaning of TIG welds in one go.
• Efficient electrolyte consumption- can be attached via the cleaning torch or into the 1.8 litre tank the usage is sustainable. 
• 3 step preparation- set up is easy and efficient, the front panel is used to change any parameters. 
• Innovative Inverter Technology- efficient and reduced power consumption meaning the machine is cheap to run but also lightweight. 

Options

At Tec Products we offer a range of MMA welders, we stock a range of multi-process welders, in particular the Transsteel range are capable of MMA welding as well as the Transpocket and the Accupocket machines also offer MMA welding. The Transpocket range are ideal portable welding machines which have power factor control which means that long mains leads (up to 100m) can be used. These small and lightweight welders are flexible and innovative so ideal for on site or workshop fabrication or repair work. The Accupocket is the perfect off grid solution for welding in hard to reach areas- this innovative machine is robust and has integrated carry handle for ultimate portability. 

If you need more information or need to ask us something we haven't answered above then please get in touch on: 01845 202 989