what machine was it you used? Fronius machines normally don't need spool guns as they already have good wire feeding capabilities on alumm wires mate
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Hood
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Not if you want 8m or so reach from the WFU.
Yeah i mean i got mine sort of working now with a nice buzz but man these machines like their settings to be precise.. but once they in they weld so so niceMy two cents worth. I have a few Fronius machines. The TPS2700 I use for steel .8mm solid wire with 52 gas(argon, 5% co2 and 2%o2) and bascially use the default settings on the machine. Now where I have had a problem is with the wire. No matter what I did it didn't sound right, better on some setting and worse on others, but generally no good. I use and have used a magnetic earth clamp and no problems there and it even weld quite well when the clamp is smoking, which I know is not good. I changed the wire spool and all was good again. Only have had this happen once, and it was very unexpected. The wire supplier denied that their wire could ever be a problem, hence not bought wire from them anymore. I feel your pain. I at the moment I have much pain. My TPSi 320 two days ago whilst welding alli did something strange (arc length was increasing) eventually changed tip, neck liner, gun liner, cleaned out the water cooled neck water holes as were partially blocked, changed to air cooled gun, all to no result. Copied program to spare TPSi320 (since I have two) exactly the same ****. No problem I have the older TPS2700 with a brand new water cooled push pull gun fresh out of the box. Wire getting jammed at the back of the gun head and not going any further
. So I understand your pain
They can do more than 8m mate before you need a push pull torch. no idea how they pulled that off but hey.
henry Kadzielski
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Are you using pulse? for steel I am not. I have run steel on my 320i but that was years ago, so it is only used for alloy now. To try to resolve your 'issues' we most probably need a video, to actually see and hear what is going on.
I am assuming the problems that I was referring to is the arc length issue. Last thursday morning I was welding 5mm 5083 and all was going as expected. At about 10.00am something changed and the arc length go longer and the weld pool got bigger and you get those little black bits floating on top of the weld pool, also similar to 'lack of gas coverage'. I am using a water cooled Fronius torch and have built two boats and some play ground equipment with this machine and not touched a thing in the settings apart from the thickness setting depending on material thickness or position. I weld down hand, overhead and vertical up with the same setting. I keep the torch shroud quite close to the job, stickout is no more that about 12mm. What is actually happening is, when I start welding I can see the end of the wire protruding out of the shroud and can also see the arc length, you can see the weld pool, the cleaning being performed by the arc and the shape of the weld bead being put down. Now what happens is that the arc length gets longer and disappears inside the shroud where I cannot see it. I then started to move the shroud right into the 'V' of the fillet so the shroud was dragging on both side of the parent material. Even then the arc would seem to 'flare' and look like poor gas coverage. Once this was happening I never tried to pull the torch away from the job to see if it would come back down (the wire). Now this problem is happening on the 6mm synergic setting and to some extent on 5mm as well, but at 4.5mm or lower it operated as expected. I have tried to correct by shortening the arc length, but when I start there is too much wire. It seemed that there is a slowing down of the wire feed, so I pulled the consumables out, blow out cleaned out and swapped all I can, no effect. I have a 'spare' 320i so I thought I will copy the program to the 'spare' machine, same problem. Water cooled gun or air cooled gun no difference. I have since done a factory reset on my original machine and recalibrated the earth resistance. It seems to be operating, not quite as I remember but at least it's welding and I need it to keep going so that I can finish this current boat project. So after three days I don't know if it is me or the machine, and am I expecting something that is not going to happen. I really need someone to visit to tell me if I am stupid and I am seeing things!
Hood
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Aye, interconnect not an issue but feeding wire that length I can't see. There is the Kemppi WeldSnake that I have seen that will feed 8m but from what I have gathered it is not the most reliable unless conditions and consumables are perfect, also not even sure if it is that great when using pulse.
stuvy
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Sorry not a spool gun on that one
Was. A torch swap to save the liner swap every five mins
Even so it was really juddering after we swapped it
Also done by two different people and the same thing each time
stuvy
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We don’t pay the bills so it’s a brand new from its torch
Ever since we changed it the thing hasn’t been right
Might drive it to them as it’s only a few mins from work
Jan-DIY
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I got also a strange behavior on one tps2700. It was on pulsed steel. Amperage about 240.
I can’t weld under 15-20mm stickout.
But it takes about 5 sec or so to get into trouble.
This was a machine with special parameters (CrNi).
Never had any problems with my other TS TPS.
Calibration on resistance and conductance was done before. Also new Torches fixed not the problem.
I can’t weld under 15-20mm stickout.
But it takes about 5 sec or so to get into trouble.
This was a machine with special parameters (CrNi).
Never had any problems with my other TS TPS.
Calibration on resistance and conductance was done before. Also new Torches fixed not the problem.
What if you go with wire 9.0 , arc +3.0 and dynamic 0.0 ? Without mill scale , it should sound good .
Just to try a thing , try values showed in this video :
Result ?
TPS 320i with standard pulse.. might get PMC package at a later date
bud first the value of 9 is not the wire feed speed. im trying to weld 2.5mm with a stable pulse at 150 ish amps.. hes running 270a and the dynamic is -9 which is pretty excessive and its why his arc length is that high at that setting.. im trying to get mine to around 1.5 as the amps im using is not that high so i should not need a high arc length like that bud. I can get a good pulse buzz when im trying to weld 8mm steel or upwards etc as you do need high arc length to do it.. its the low settings is whats concerning.. thanks for the help though
I mean dont get me wrong.. it works fine when you welding thick stuff like 8mm or upwards.. but its the low settings that are tricky to get right as there is so little room for error.. I do have the rep visiting soon so it will be sorted. But overall i am really happy with this machine. blows away anything in the market to be honest
Yep I meant to have a try on high values just to understand if it works correctly , in case of electrical bugs you would have problems too .
Welding 2,5 mm ( what material shape are you using ? Tubes ? Sheets ? ) in pulsed could be a bit annoying expecially if you have gaps or strange joints where the arc can dig away the material , but it's not impossible .
Yes I've tried wire 1,0 and it seems you have to spend more time finding the correct set up with values , but that's not about Fronius only , I got the same problem with our pulsed Selco ( with that machine it's absolutely impossible to use 1,0 wire , it just explodes when touching the material ) . With 1,2 it is way better believe me , a couple of weeks ago I've welded in pulsed some steel tanks ( thickness 3 mm ) to U beams ( thickness 8 mm ) , just cleaned the mill scale where needed , unfortunately I do not remember values I used ( I have to take note of them I guess ) but it didn't take me too much , and weldings came out absolutely perfect , I think it was wire 4,5 , arc - 2.0 , dynamic + 2.0 or + 3.0 , I don't remember exactly , but for sure I got a negstive arc and a positive dynamic .
Sometimes I get crackling while I'm welding in vertical position , going down from the top , so I do need to change values to have it dialed in .
Yes Fronius is the top , I've tested different machines before buying it ( Ewm Titan , Lorch , Cebora , Selco .. ) , but the austrian lady was the only one that convinced us at 100% . It's just about to take time to deeply understand settings I guess .
you reckon i can weld 2mm on 1.2 wire? I do have the means to switch to 1.2 but you think its easier to get a pulse going you say? what settings would you say to use for 2mm sheet?
I do weld from 2-3 mm up to 50 mm thickness with a 1,2 . I don't know why but pulsed machines needs more specific set up to get them dialed in with wire 1,0 .
2 mm sheet welding is annoying in any case , unless you use bodyworks machines that are made for tiny sheet only , BUT I got so impressed when I've seen an american guy on youtube who purchased a Fronius 500 amps pulsed ( like mine ) just to do car bodyworks ! Just search for Fronius Transsteel 500 pulsed on youtube , you will recognize him because he was working on some kind of hot rod .
We cannot compare at 100% your machine with mine - values , synergic curves and set up are different , also the inverter is s bit different .
Anyway , sunday I will have a try on 2 mm sheet with my new torch , I will upload some pictures and values .
Bests
2 mm sheet welding is annoying in any case , unless you use bodyworks machines that are made for tiny sheet only , BUT I got so impressed when I've seen an american guy on youtube who purchased a Fronius 500 amps pulsed ( like mine ) just to do car bodyworks ! Just search for Fronius Transsteel 500 pulsed on youtube , you will recognize him because he was working on some kind of hot rod .
We cannot compare at 100% your machine with mine - values , synergic curves and set up are different , also the inverter is s bit different .
Anyway , sunday I will have a try on 2 mm sheet with my new torch , I will upload some pictures and values .
Bests
Dude have a look here , got no so much time to do tests ( impossible to weld 2,0 mm at 150 amps unless you speed up like hell ) , cleaned mill scale , tried with wire diameter 1,2 .
SAMPLE A ( looked better to me )
wire feed 3,5
arc +3.0
dynamic +3.5
amps 104
volts 20.1
SAMPLE B
wire 3,5
arc +2.0
dynamic -1.0
amps 104
volts 21.2
If you keep hearing crackling and you have spatters , you need to stay in positive dynamic and positive arc ( at least 0 ) , that's the only way . To reduce even more spatters , you have to go with copper free wire , which is damn expensive at the moment .
Attention , arc and dynamic scales between TST and TPS are completely different .
Here you have photos
SAMPLE A ( looked better to me )
wire feed 3,5
arc +3.0
dynamic +3.5
amps 104
volts 20.1
SAMPLE B
wire 3,5
arc +2.0
dynamic -1.0
amps 104
volts 21.2
If you keep hearing crackling and you have spatters , you need to stay in positive dynamic and positive arc ( at least 0 ) , that's the only way . To reduce even more spatters , you have to go with copper free wire , which is damn expensive at the moment .
Attention , arc and dynamic scales between TST and TPS are completely different .
Here you have photos
wow its a difference changing to 1.2 wire. A lot easier to get a stable buzz. my current settings for 2.5mm steel work is 1.9 arc length -2 dynamic so it is a lot better and is pretty much crackle free. The only thing is though is when I'm trying out duel pulse at this setting.. i end up getting 220a hold. rather than the selected 134a on the display. any idea?
I told you 1,2 is a different animal , I have to do more tests with 1,0 wire just to understand why the hell it's so difficult to find the proper set up , expecially on thin materials .
What's the problem with double pulse ? Your explanation wasn't clear to me .
I don't recommend it on steel at normal positions , it's good only for ss and alu , just go with normal pulse and waving , way better and faster .
What's the problem with double pulse ? Your explanation wasn't clear to me .
I don't recommend it on steel at normal positions , it's good only for ss and alu , just go with normal pulse and waving , way better and faster .
