TransSteel 4000 Pulse, TransSteel 5000 Pulse Operating instructions

1. Safety Instructions

1. Safety Instructions

• 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 equipment

• Be suitably qualified
• Have knowledge of welding
• Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

• Be kept in a legible state
• Not be damaged/marked
• Not be removed
• Not be covered, pasted, or painted over

For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!

1. Safety Instructions

The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.

• Completely reading and obeying all instructions in the Operating Instructions
• Completely reading and obeying all safety instructions and danger notices
• Carrying out all the specified inspection and servicing work

• Thawing pipes
• Charging batteries
• Starting motors

The device is designed for operation in industry and business. The manufacture shall not be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work results.

1. Safety Instructions

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

• 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)

• Up to 50% at 40°C (104°F)
• Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

1. Safety Instructions

• Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
• Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
• Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

1. Safety Instructions

• Follow the basic regulations for occupational safety and accident prevention
• Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can occur in one's absence.

1. Safety Instructions

Devices with a high output can influence the energy quality of the grid due to their current consumption.

• connection restrictions
• criteria regarding maximum permissible grid impedance ^*)
• criteria regarding the minimum required short-circuit power ^*)

^*) both at the interface with the public grid
See technical data

In this case, the operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

1. Safety Instructions

• Flying sparks and pieces of hot metal
• Arc radiation that poses a risk of injury to the eyes and skin

• Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers

• Electrical risks from grid current and welding current

• Increased noise exposure

• Harmful welding fumes and gases

• Flame resistant
• Insulating and dry
• Covering the entire body and in good condition with no damage
• Safety helmet
• Cuffless pants

• Protecting the face and eyes from UV radiation, heat and flying sparks with a face guard featuring a regulation-compliant filter
• Wearing regulation-compliant protective goggles with side protection behind the face guard
• Wearing rigid, wet-insulating footwear
• Protecting hands with appropriate gloves (featuring electrical insulation and thermal protection)
• Wearing ear protection to reduce noise exposure and protect against injury

• Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
• Provide suitable protective equipment or
• Construct suitable protective walls and curtains.

1. Safety Instructions

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.

Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.

Keep your head out of the welding fumes and gases.

• Do not breathe them in.
• Extract them from the work area using appropriate equipment.

Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³ per hour.

Use a welding helmet with air supply if there is insufficient ventilation.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.

• The metals used for the workpiece
• Electrodes
• Coatings
• Cleaning agents, degreasers, and the like
• The welding process used

Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.

Recommendations for exposure scenarios, risk management measures and identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Keep flammable vapors (such as solvent vapors) out of the arc radiation range.

When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.

1. Safety Instructions

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.

1. Safety Instructions

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers, as well as all pieces of metal that are in contact with the welding wire, are live.

Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating wirefeeder holder.

Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential.

All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the longitudinal axis and pretension.

Do not wrap cables or leads around your body or parts of the body.

• Never immerse it in liquids to cool it
• Never touch it when the welding system is switched on

The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.

Protection class I devices require a grid with a ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.

Switch off unused devices.

When working at elevated heights, wear a safety harness to prevent falls.

Before working on the device, switch off the device and remove the mains plug.

Secure the device to prevent the mains plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

• Discharge all electrically charged components
• Ensure that all components are disconnected from the power supply

If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.

1. Safety Instructions

• Fire
• Overheating of parts connected to the workpiece
• Irreparable damage to ground conductors
• Damage to the device and other electrical equipment

Ensure that the workpiece clamp is securely connected to the workpiece.

Secure the workpiece clamp as close to the spot to be welded as possible.

Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.

Observe the following when using power distribution boards, twin-head mounts, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.

In automated MIG/MAG applications, only guide the wire electrode from the welding wire drum, large spool, or wirespool to the wirefeeder with insulation.

1. Safety Instructions

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage grid.

EMC device classification as per the rating plate or technical data.

1. Safety Instructions

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.

• Safety devices
• Grid power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating

1. Grid power supply
   • If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
   • Keep them as short as possible
   • Route them close together (also to avoid EMF problems)
   • Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.
5. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield the entire welding installation

1. Safety Instructions

• Effects on the health of persons close by, e.g., those with pacemakers and hearing aids
• Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
• Keep distances between welding power-leads and the head/torso of the welder as great as possible for safety reasons
• Do not carry welding power-leads and hosepacks over your shoulder or wrap them around your body or body parts

1. Safety Instructions

• Fans
• Gears
• Rollers
• Shafts
• Wirespools and welding wires

Do not reach into rotating gears of the wire drive or into rotating drive parts.

Covers and side panels must only be opened/removed during maintenance and repair work.

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

The welding wire protruding from the welding torch poses a high risk of injury (cuts to the hand, facial and eye injuries, etc.).
Therefore, always hold the welding torch away from the body (devices with wirefeeder) and use suitable protective goggles.

Do not touch the workpiece during or after welding—risk of burns.

Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.

Leave the welding torch and other parts with a high operating temperature to cool before working on them.

Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.

Welding machines for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the welding machine may not be located in such areas.

Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.

When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufacturer's website.

Only use suitable load-carrying equipment from the manufacturer to transport devices by crane.

• Attach chains or ropes to all designated attachments of the suitable load-carrying equipment.
• Chains or ropes must be the smallest angle possible from vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).

Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

If the device is equipped with a carrier strap or handle, then this is used exclusively for transport by hand. The carrier strap is not suitable for transport by crane, counterbalanced lift truck, or other mechanical lifting tools.

All lifting equipment (straps, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.

There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before installation.

1. Safety Instructions

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety Instructions

Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders are an integral part of the welding equipment, so they must be handled very carefully.

Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.

Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.

Keep shielding gas cylinders away from welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion: Never weld on a compressed shielding gas cylinder.

Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition.

If a valve on a shielding gas cylinder is open, turn your face away from the outlet.

When no welding is taking place, close the valve of the shielding gas cylinder.

Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.

Follow the manufacturer's instructions and applicable national and international provisions for shielding gas cylinders and accessories.

1. Safety Instructions

Risk of asphyxiation due to uncontrolled shielding gas leak

Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.

• Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
• Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
• When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
• Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

Only set up and operate the device in accordance with the protection class shown on the rating plate.

When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Do not lift or transport any active devices. Switch off and disconnect devices from the grid before transport or lifting.

• Wirefeeder
• Wire spool
• shielding gas cylinder

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained service technicians before commissioning the device.

1. Safety Instructions

• 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

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one can be put in danger.

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

Always secure the shielding gas cylinder well and remove before transporting by crane.

Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)

Only use appropriate original coolant from the manufacturer.

Do not mix original coolant from the manufacturer with other coolants.

Only connect system components from the manufacturer to the cooling unit circuit.

If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.

Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.

Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.

When the system is cool, always check the coolant level before starting welding.

1. Safety Instructions

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

1. Safety Instructions

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

The manufacturer recommends calibrating welding systems within the same 12-month interval.

• After changes
• After alterations
• After repair, service, and maintenance
• At least every twelve months

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.

1. Safety Instructions

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or through a local authorized collection and disposal system. Proper disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

• Collect separately
• Observe local regulations
• Crush cardboard boxes

1. Safety Instructions

Devices with the CE label satisfy the essential requirements of the low-voltage and electromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).

Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety Instructions

• backing up any changes made to the factory settings
• saving and storing personal settings

1. Safety Instructions

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information on any discrepancies in the operating instructions.

TransSteel 4000 / 5000 Pulse

The TransSteel (TSt) 4000 Pulse and TransSteel 5000 Pulse power sources are fully digitized, microprocessor-controlled inverter power sources.

A modular design and ability to easily extend the system ensure high flexibility.
The devices are designed for the following welding processes:

• MIG/MAG pulse welding
• MIG/MAG standard synergic welding
• Manual metal arc welding

The devices have a "Power limitation" safety feature. This means that the power sources can be operated at the power limit without compromising process safety. For details, refer to the "Welding operations" chapter.

1. General information

TransSteel 4000 / 5000 Pulse

The TransSteel (TSt) 4000 Pulse and TransSteel 5000 Pulse power sources are fully digitized, microprocessor-controlled inverter power sources.

A modular design and ability to easily extend the system ensure high flexibility.
The devices are designed for the following welding processes:

• MIG/MAG pulse welding
• MIG/MAG standard synergic welding
• Manual metal arc welding

The devices have a "Power limitation" safety feature. This means that the power sources can be operated at the power limit without compromising process safety. For details, refer to the "Welding operations" chapter.

1. General information
2. General

TransSteel 4000 / 5000 Pulse

The TransSteel (TSt) 4000 Pulse and TransSteel 5000 Pulse power sources are fully digitized, microprocessor-controlled inverter power sources.

A modular design and ability to easily extend the system ensure high flexibility.
The devices are designed for the following welding processes:

• MIG/MAG pulse welding
• MIG/MAG standard synergic welding
• Manual metal arc welding

The devices have a "Power limitation" safety feature. This means that the power sources can be operated at the power limit without compromising process safety. For details, refer to the "Welding operations" chapter.

1. General information
2. General

The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and signal processor control the entire welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired target state is maintained.

• A precise welding process
• A high degree of reproducibility on all results
• Excellent weld properties.

1. General information
2. General

The devices are used in trade and industry for manual and automated applications with classical steel and galvanized sheet metal:

• Mechanical and equipment engineering
• Steel construction
• Plant and container construction
• Shipyards and the offshore sector
• Metal and portal construction
• Rail vehicle construction
• Metalworking trades

1. General information
2. General

Warning notices and safety symbols are affixed to the power source. These warning notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and property damage.

Warning notices on the power source

Welding is dangerous. The following basic requirements must be met:

• Adequate welding qualifications
• Appropriate protective equipment
• Exclusion of unauthorized persons

Do not use the functions described here until you have fully read and understood the following documents:

• These Operating Instructions
• All system component Operating Instructions, especially the safety rules

1. General information

In order to process a wide range of materials effectively, various welding processes, procedures, and welding characteristics are available on the power source.

1. General information
2. Welding processes, procedures, and welding characteristics for MIG/MAG welding

In order to process a wide range of materials effectively, various welding processes, procedures, and welding characteristics are available on the power source.

1. General information
2. Welding processes, procedures, and welding characteristics for MIG/MAG welding

MIG/MAG standard synergic

MIG/MAG standard synergic welding is a MIG/MAG welding process covering the entire power range of the power source with the following arc types:

Dip transfer arc
Droplet transfer occurs in the lower power range during the short circuit.

Intermediate arc
The droplet increases in size at the end of the wire electrode and is transferred in the mid power range during the short circuit.

Spray arc
A short circuit-free transfer of material in the high power range.

1. General information
2. Welding processes, procedures, and welding characteristics for MIG/MAG welding

MIG/MAG pulsed synergic

MIG/MAG pulsed synergic welding is a pulsed arc process with a controlled material transfer.
In the base current phase, the energy input is reduced to such an extent that the arc barely burns steadily and the surface of the workpiece is preheated. In the pulsing current phase, an accurately timed current pulse guarantees a precise detachment of the weld material droplet.
This principle guarantees low-spatter welding and precise operation throughout the entire power range.

1. General information
2. Welding processes, procedures, and welding characteristics for MIG/MAG welding

SynchroPulse is available for the standard synergic and pulsed synergic processes.
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat input.

1. General information
2. Welding processes, procedures, and welding characteristics for MIG/MAG welding

In arc air gouging, an arc is ignited between a carbon electrode and the workpiece; the parent material is melted and blown out with compressed air.
The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

• Removal of shrink holes, pores, or slag inclusions from workpieces
• Detaching sprues or the processing of entire workpiece surfaces in foundries
• Edge preparation for heavy plates
• Preparation and repair of weld seams
• Finishing of roots or defects
• Production of air gaps

1. General information

The power sources can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the power source.

1. General information
2. System components

The power sources can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the power source.

1. General information
2. System components

1. General information
2. System components

1. General information

The Voltage Reduction Device (VRD) is an optional safety device for voltage reduction. It is recommended for environments where arc welding significantly increases the risk of electric shock or electrical accident:

• Due to low body resistance of the welder
• If the welder is exposed to a significant risk of touching the workpiece or other parts of the welding circuit

A low body resistance is likely in the event of:

• Water in the environment
• Humidity
• Heat, especially at ambient temperatures above 32 °C (89.6 °F)

In wet, damp, or hot places, moisture or sweat can significantly reduce skin resistance, as well as the insulation resistance of protective equipment and clothing.

Such environments may include:

• Temporary dam structures for draining certain areas of a construction site during the construction period (cofferdams)
• Ditches
• Mines
• Rain
• Areas partially covered by water
• Spray water zones

The VRD option reduces the voltage between the electrode and the workpiece. In the safe state, the indicator for the currently selected welding process lights up continuously. The safe state is defined as follows:

• In an open circuit, the output voltage is limited to a maximum of 35 V.

As long as the welding operation is active (welding circuit resistance < 200 ohms), the indicator of the currently selected welding process flashes and the output voltage can exceed 35 V.

1. General information
2. VRD: Safety function

The Voltage Reduction Device (VRD) is an optional safety device for voltage reduction. It is recommended for environments where arc welding significantly increases the risk of electric shock or electrical accident:

• Due to low body resistance of the welder
• If the welder is exposed to a significant risk of touching the workpiece or other parts of the welding circuit

A low body resistance is likely in the event of:

• Water in the environment
• Humidity
• Heat, especially at ambient temperatures above 32 °C (89.6 °F)

In wet, damp, or hot places, moisture or sweat can significantly reduce skin resistance, as well as the insulation resistance of protective equipment and clothing.

Such environments may include:

• Temporary dam structures for draining certain areas of a construction site during the construction period (cofferdams)
• Ditches
• Mines
• Rain
• Areas partially covered by water
• Spray water zones

The VRD option reduces the voltage between the electrode and the workpiece. In the safe state, the indicator for the currently selected welding process lights up continuously. The safe state is defined as follows:

• In an open circuit, the output voltage is limited to a maximum of 35 V.

As long as the welding operation is active (welding circuit resistance < 200 ohms), the indicator of the currently selected welding process flashes and the output voltage can exceed 35 V.

1. General information
2. VRD: Safety function

The welding circuit resistance is greater than the minimum body resistance (greater than or equal to 200 ohms):

• VRD is active
• Open circuit voltage is limited to 35 V
• Unintentional contact with the output voltage does not pose any danger

The welding circuit resistance is less than the minimum body resistance (less than 200 ohms):

• VRD is inactive
• No limitation of the output voltage to ensure adequate welding power
• Example: welding start

Applies to MMA welding mode:
Within 0.3 seconds of the end of welding:

• VRD is active again
• Restriction of the output voltage to 35 V is ensured again

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• Selected by means of buttons
• Changed using buttons or the selection dial
• Shown on the digital display during welding.

Due to the synergic function, all other parameters are also adjusted if a single parameter is changed.

1. Operating controls and connections

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• Selected by means of buttons
• Changed using buttons or the selection dial
• Shown on the digital display during welding.

Due to the synergic function, all other parameters are also adjusted if a single parameter is changed.

1. Operating controls and connections
2. Control Panel

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• Selected by means of buttons
• Changed using buttons or the selection dial
• Shown on the digital display during welding.

Due to the synergic function, all other parameters are also adjusted if a single parameter is changed.

1. Operating controls and connections
2. Control Panel

1. Operating controls and connections
2. Control Panel

No.	Function
(1)	"Parameter selection" button (right) a) for selecting the following parameters Arc length correction For correcting the arc length Welding voltage in V *) Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding. Pulse / arc-force dynamic correction For continuously correcting the droplet detachment force in MIG/MAG pulsed synergic welding - ... reduced droplet detachment force 0 ... neutral droplet detachment force + ... increased droplet detachment force For influencing the short-circuiting dynamic at the instant of droplet transfer in MIG/MAG standard synergic welding, MIG/MAG standard manual welding, and manual metal arc welding - ... harder and more stable arc 0 ... neutral arc + ... soft and low-spatter arc b) for changing parameters in the Setup menu
(2)	"Parameter selection" button (left) a) for selecting the following parameters Sheet thickness Sheet thickness in mm or in. If the welding current to be selected is not known, it is sufficient to enter the sheet thickness. The required welding current and any other parameters marked with *) will then be adjusted automatically. Welding current *) Welding current in A Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding. Wire speed *) Wire speed in m/min or ipm. b) for changing parameters in the Setup menu
(3)	Selection dial (right) For changing the arc length correction, welding voltage, and arc-force dynamic parameters For changing parameters in the Setup menu
(4)	Selection dial (left) For changing the sheet thickness, welding current, and wire speed parameters For selecting parameters in the Setup menu
(5)	EasyJob save buttons For saving up to 5 operating points
(6)	"Process" button **) For selecting the welding process MIG/MAG standard manual welding MIG/MAG standard synergic welding MIG/MAG pulsed synergic welding Manual metal arc welding
(7)	"Mode" button For selecting the operating mode 2-step mode 4-step mode Special 4-step mode Spot welding/stitch welding
(8)	"Shielding gas" button For selecting the shielding gas used. The SP parameter is reserved for additional shielding gases. When the shielding gas is selected, the LED behind the corresponding shielding gas lights up.
(9)	"Wire diameter" button For selecting the wire diameter used. The SP parameter is reserved for additional wire diameters. When the wire diameter is selected, the LED behind the corresponding wire diameter lights up.
(10)	"Material" button For selecting the filler metal used. The SP parameter is reserved for additional materials. When the material type is selected, the LED behind the corresponding filler metal lights up.
(11)	"Wire threading" button Press and hold the button: Gasless wire threading into the torch hosepack While the button is being held, the wire drive operates at feeder inching speed.
(12)	Gas-test button For setting the required gas volume on the gas pressure regulator. Tap the button once: shielding gas flows out Tap the button again: shielding gas flow stops If the Gas-test button is not tapped again, the shielding gas flow will stop after 30 s.
(13)	SF - spot/stitch/SynchroPulse welding indicator Lights up if a value is set for the spot welding/stitch welding time (SPt) setup parameter when spot welding or stitch welding mode is activated Lights up if a value is set for the Frequency (F) setup parameter when the MIG/MAG synergic welding process is activated.
(14)	Intermediate arc indicator A spatter-prone "intermediate arc" occurs between the dip transfer arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area.
(15)	HOLD indicator At the end of each welding operation, the actual values for welding current and welding voltage are stored - the "HOLD" indicator lights up.
(16)	Pulse indicator Lights up when the MIG/MAG pulsed synergic welding process is selected
(17)	Real Energy Input For displaying the energy applied during the welding operation. The Real Energy Input indicator must be activated in level 2 of the Setup menu – EnE parameter. The value continuously rises during welding in line with the permanently increasing energy input. The final value is stored after the end of welding until welding starts again or the power source is switched back on - the HOLD indicator lights up.

1. Operating controls and connections
2. Control Panel

Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.

Opening the display

1

The first parameter "Firmware version" will be displayed, e.g., "1.00 | 4.21"

Selecting parameters

2

Use the "Mode" and "Process" buttons or the left-hand selection dial to select the required setup parameter

Available parameters

	Explanation
Example: 1.00 | 4.21	Firmware version
Example: 2 | 491	Welding program configuration
Example: r 2 | 290	Number of the currently selected welding program
Example: 654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins	Indicates the actual arc time since first use Note: The arc time indicator is not suitable as a basis for calculating hiring fees or for warranty purposes, etc.
Example: iFd | 0.0	Motor current for wire drive in A The value changes as soon as the motor is running.
2nd	2nd menu level for service technicians

1. Operating controls and connections
2. Control Panel

A keylock can be selected to prevent the settings from being inadvertently changed on the control panel. As long as the keylock is active:

• Settings cannot be adjusted on the control panel
• Only parameter settings can be retrieved
• Any assigned "Save" button can be retrieved provided that an assigned "Save" button was selected when the keylock was enabled

Activating/deactivating the keylock:

1

Keylock activated:
The message "CLO | SEd" appears on the displays.

Keylock deactivated:
The message "OP | En" appears on the displays.

The keylock can also be activated and deactivated using the keylock switch option.

1. Operating controls and connections

1. Operating controls and connections
2. Connections, Switches, and Mechanical Components

Depending on the welding process, a minimum level of equipment is required to work with the power source.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Installation and Startup

Depending on the welding process, a minimum level of equipment is required to work with the power source.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Installation and Startup
2. Minimum equipment for welding operations

Depending on the welding process, a minimum level of equipment is required to work with the power source.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Installation and Startup
2. Minimum equipment for welding operations

• Power source
• Grounding cable
• Gas-cooled MIG/MAG welding torch
• Gas connection (shielding gas supply)
• Wirefeeder (VR 5000 Remote)
• Gas-cooled interconnecting hosepack
• Wire electrode

1. Installation and Startup
2. Minimum equipment for welding operations

• Power source
• Cooling unit
• Grounding cable
• Water-cooled MIG/MAG welding torch
• Gas connection (shielding gas supply)
• Wirefeeder (VR 5000 Remote)
• Water cooling option (for VR 5000 Remote)
• Water-cooled interconnecting hosepack
• Wire electrode

1. Installation and Startup
2. Minimum equipment for welding operations

• Power source
• Grounding cable
• Electrode holder
• Rod electrodes

1. Installation and Startup
2. Minimum equipment for welding operations

• TransSteel 4000 / 5000 Pulse, TransSteel 5000 Syn power source
• Grounding cable 120 mm²
• KRIS 13 arc air gouging torch
• Compressed air supply

1. Installation and Startup

1. Installation and Startup
2. Before installation and initial operation

1. Installation and Startup
2. Before installation and initial operation

The power source is intended exclusively for MIG/MAG, MMA, and TIG welding.
Utilization for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such use.

• Following all the instructions in these Operating Instructions
• Carrying out all the specified inspection and maintenance work

1. Installation and Startup
2. Before installation and initial operation

• Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

The device can be set up and operated outdoors in accordance with degree of protection IP 23.
Direct moisture (e.g., from rain) must be avoided.

The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked into the device.

1. Installation and Startup
2. Before installation and initial operation

The devices are designed for the grid voltage stated on the rating plate. If the mains cable or mains plug has not been attached to your version of the appliance, these must be installed according to national standards. Fuse protection for the grid lead can be found in the technical data.

1. Installation and Startup

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.
A strain-relief device for the following cable cross-sections is fitted to the power source:

Strain-relief devices for other cable cross-sections must be designed accordingly.

1. Installation and Startup
2. Connecting the Mains Cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.
A strain-relief device for the following cable cross-sections is fitted to the power source:

Strain-relief devices for other cable cross-sections must be designed accordingly.

1. Installation and Startup
2. Connecting the Mains Cable

The item numbers of the different cables can be found in the Spare Parts List for the devices.

AWG ... American Wire Gauge

1. Installation and Startup
2. Connecting the Mains Cable

1. Installation and Startup
2. Connecting the Mains Cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.

The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

A graphic representation of the mains cable connection is provided in the sections "Fitting the strain-relief device" or "Fitting the strain-relief device for Canada / US." To connect the mains cable, proceed as follows:

1. Installation and Startup
2. Connecting the Mains Cable

1

2

3

4

5

IMPORTANT! Tie the phase conductors near the block terminal using cable ties.

1. Installation and Startup
2. Connecting the Mains Cable

1

2

3

4

5

IMPORTANT! Tie the phase conductors near the block terminal using cable ties.

1. Installation and Startup

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated for 3-phase devices as follows:

S_1max = I_1max x U₁ x √3

I_1max and U₁ according to the device rating plate and technical data

The generator apparent power S_GEN needed is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the power source!

1. Installation and Startup
2. Generator-Powered Operation

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated for 3-phase devices as follows:

S_1max = I_1max x U₁ x √3

I_1max and U₁ according to the device rating plate and technical data

The generator apparent power S_GEN needed is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the power source!

1. Installation and Startup

1. Installation and Startup
2. Commissioning

1. Installation and Startup
2. Commissioning

Commissioning is described with reference to a manual, water-cooled MIG/MAG application.

1. Installation and Startup
2. Commissioning

The steps and activities described below include references to various system components, such as

• Trolley
• Upright bracket
• Cooling units
• Wirefeeders
• Interconnecting hosepacks
• Welding torches, etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate Operating Instructions for the system components.

1. Installation and Startup
2. Commissioning

The following diagram is intended to provide you with an overview of how the individual system components are put together.

1. Installation and Startup
2. Commissioning

1

1. Installation and Startup
2. Commissioning

1

Fit the strain-relief device on the trolley

2

Fit the strain-relief device on the wirefeeder

IMPORTANT! In order to prevent wear, the cables should form a "loop inwards" when fitted. For interconnecting hosepacks with a length of 1.2 m (3 ft. 11.24 in.), no strain-relief device is provided.

1. Installation and Startup
2. Commissioning

IMPORTANT! Gas-cooled systems are not fitted with a cooling unit. The water connections therefore do not need to be connected for gas-cooled systems.

1

2

1. Installation and Startup
2. Commissioning

IMPORTANT! The duty cycle values (D.C.) of the interconnecting hosepack can only be achieved if it is correctly routed.

Correct routing of the interconnecting hosepack

1. Installation and Startup
2. Commissioning

1Place the gas cylinder on the base of the trolley

2Secure the gas cylinder against falling using the cylinder strap in the upper area of the gas cylinder (but not on the neck of the cylinder)

3Remove the protective cap of the gas cylinder

4Briefly open the gas cylinder valve to remove any dirt

5Inspect the seal on the gas pressure regulator

6Screw the pressure regulator onto the gas cylinder and tighten it

7Connect the protective gas shield hose of the interconnecting hosepack to the pressure regulator using a gas hose

1. Installation and Startup
2. Commissioning

1

1. Installation and Startup
2. Commissioning

1

* with integrated water connection option and water-cooled welding torch

1. Installation and Startup
2. Commissioning

1. Installation and Startup
2. Commissioning

After switching on the power source for the first time, the date and time must be set. For this purpose, the power source changes to the second level of the service menu; the yEA parameter is selected.

To set the date and time see page (→), step 5

"Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety.

Wire speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. In order to prevent this, the welding power is lowered.

If the "MIG/MAG standard synergic welding" or "MIG/MAG pulsed synergic welding" process is selected, the symbol for the "Wire speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire speed is displayed.

1. MIG/MAG welding

"Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety.

Wire speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. In order to prevent this, the welding power is lowered.

If the "MIG/MAG standard synergic welding" or "MIG/MAG pulsed synergic welding" process is selected, the symbol for the "Wire speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire speed is displayed.

1. MIG/MAG welding
2. Power Limitation

"Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety.

Wire speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. In order to prevent this, the welding power is lowered.

If the "MIG/MAG standard synergic welding" or "MIG/MAG pulsed synergic welding" process is selected, the symbol for the "Wire speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire speed is displayed.

1. MIG/MAG welding

For details of the meaning, settings, setting range and units of the available welding parameters (e.g., gas pre-flow time), please refer to the "Setup parameters" chapter.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

For details of the meaning, settings, setting range and units of the available welding parameters (e.g., gas pre-flow time), please refer to the "Setup parameters" chapter.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

Press the torch trigger | Hold the torch trigger | Release the torch trigger

1. MIG/MAG welding
2. MIG/MAG Operating Modes

• Tacking work
• Short weld seams
• Automatic and robot operation

1. MIG/MAG welding
2. MIG/MAG Operating Modes

"4-step mode" is suitable for longer weld seams.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

"Special 2-step mode" is ideal for welding in higher power ranges. In special 2-step mode, the arc starts at a lower power, which makes it easier to stabilize.

To activate special 2-step mode:

1. MIG/MAG welding
2. MIG/MAG Operating Modes

Special 4-step mode allows the starting and final current to be configured in addition to the advantages of 4-step mode.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

The "Spot welding" mode is suitable for welded joints on overlapped sheets.

Start by pressing and releasing the torch trigger - GPr gas pre-flow time - welding current phase over the SPt spot welding time duration - GPo gas post-flow time.

If the torch trigger is pressed again before the end of the spot welding time (< SPt), the process is canceled immediately.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

2-step stitch welding

The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the parent material.

1. MIG/MAG welding
2. MIG/MAG Operating Modes

4-step stitch welding

The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the parent material.

1. MIG/MAG welding

1. MIG/MAG welding
2. MIG/MAG welding

1. MIG/MAG welding
2. MIG/MAG welding

IMPORTANT! Observe the safety rules and operating conditions in the Operating Instructions for the cooling unit.

1. MIG/MAG welding
2. MIG/MAG welding

• MIG/MAG synergic welding
• MIG/MAG standard manual welding
• Spot welding and stitch welding

1. MIG/MAG welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press the "Shielding gas" button to select the shielding gas to be used.
The assignment of the SP position is in the welding program tables in the appendix.

4Press the "Process" button to select the desired welding process:

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

5Press the "Mode" button to select the desired MIG/MAG mode:

2-step mode

4-step mode

Special 4-step mode

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source.

6Use the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power:

Sheet thickness

Welding current

Wire speed

Welding voltage

7Use the appropriate selection dial to set the welding parameter.
The value of the parameter is displayed on the digital display located above.

The sheet thickness, welding current, wire speed, and welding voltage parameters are directly linked. It is sufficient to change one of the parameters, as the remaining parameters are immediately adjusted accordingly

All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter.

1. MIG/MAG welding
2. MIG/MAG synergic welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press the "Shielding gas" button to select the shielding gas to be used.
The assignment of the SP position is in the welding program tables in the appendix.

4Press the "Process" button to select the desired welding process:

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

5Press the "Mode" button to select the desired MIG/MAG mode:

2-step mode

4-step mode

Special 4-step mode

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source.

6Use the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power:

Sheet thickness

Welding current

Wire speed

Welding voltage

7Use the appropriate selection dial to set the welding parameter.
The value of the parameter is displayed on the digital display located above.

The sheet thickness, welding current, wire speed, and welding voltage parameters are directly linked. It is sufficient to change one of the parameters, as the remaining parameters are immediately adjusted accordingly

All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter.

1. MIG/MAG welding
2. MIG/MAG synergic welding

The arc length correction and arc-force dynamic parameters can be used to optimize the welding result.

 Arc length correction:

Pulse / arc-force dynamic correction
For continuous correction of the droplet detachment force in MIG/MAG pulsed synergic welding

For influencing the short-circuiting dynamic at the instant of droplet transfer during MIG/MAG standard synergic welding

1. MIG/MAG welding
2. MIG/MAG synergic welding

SynchroPulse is recommended for welded joints with aluminum alloys whose weld seams should have a rippled appearance. This effect is achieved using a welding power that changes between two operating points.

The two operating points result from a positive and negative change in the welding power to a dFd (delta wire feed) value that can be adjusted in the Setup menu (delta wire feed: 0.0 - 3.0 m/min or 0.0 - 118.1 ipm).

• Frequency F of the operating point change (set in the Setup menu)
• Arc length correction for the lower operating point (set via the arc length correction parameter on the control panel)
• Arc length correction for the higher operating point (set in the Setup menu, parameter Al.2)

To enable SynchroPulse, you must change at least the value of the F (Frequency) parameter from OFF to a variable in the range of 0.5 to 5 Hz in the process Setup menu.

How SynchroPulse works when used in "Special 4-step" mode

I-S = starting-current phase, SL = Slope, I-E = crater-fill phase, v = wire speed

SynchroPulse mode of operation

1. MIG/MAG welding

The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

1. MIG/MAG welding
2. MIG/MAG Standard Manual Welding

The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

1. MIG/MAG welding
2. MIG/MAG Standard Manual Welding

The following parameters are available for MIG/MAG manual welding:

Wire speed
1 m/min (39.37 ipm.) - maximum wire speed, e.g., 25 m/min (984.25 ipm.)

Welding voltageTransSteel 4000 Pulse: 15.5 - 31.5 V
TransSteel 5000 Pulse: 14.5 - 39 V

Arc-force dynamic:
For influencing the short-circuiting dynamic at the instant of droplet transfer

Welding current
Only the actual value is displayed

1. MIG/MAG welding
2. MIG/MAG Standard Manual Welding

1Press the "Process" button to select the desired welding process:

MIG/MAG standard manual welding

2Press the "Mode" button to select the desired MIG/MAG mode:

2-step mode

4-step mode

In MIG/MAG standard manual welding, special 4-step mode corresponds to conventional 4-step mode.

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source.

The welding parameter values are shown in the digital display located above.

All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter.

To display the actual welding current during welding:

• Press the "Parameter selection" button to select the welding current parameter
• The actual welding current is shown on the digital display during welding.

1. MIG/MAG welding
2. MIG/MAG Standard Manual Welding

To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.

1Press the "Parameter selection" button to select the arc-force dynamic parameter

2Use the selection dial to set the desired arc-force dynamic valueThe welding parameter value is shown in the digital display located above it.

1. MIG/MAG welding

The spot welding and stitch welding modes are MIG/MAG welding processes. The spot welding and stitch welding modes are activated on the control panel.

Spot welding is used on welded joints on overlapping sheets that are only accessible on one side.

Stitch welding is used for light-gage sheets.
As the wire electrode is not fed continuously, the weld pool can cool down during the intervals. Local overheating leading to the parent material being melted through is largely avoided.

1. MIG/MAG welding
2. Spot welding and stitch welding

The spot welding and stitch welding modes are MIG/MAG welding processes. The spot welding and stitch welding modes are activated on the control panel.

Spot welding is used on welded joints on overlapping sheets that are only accessible on one side.

Stitch welding is used for light-gage sheets.
As the wire electrode is not fed continuously, the weld pool can cool down during the intervals. Local overheating leading to the parent material being melted through is largely avoided.

1. MIG/MAG welding
2. Spot welding and stitch welding

1In the Setup menu, set the spot welding time / stitch welding time SPt

IMPORTANT! Stitch pause time SPb = OFF must be set for spot welding!

2Only for synergic welding:
Use the corresponding buttons to select the filler metal used, the wire diameter, and the shielding gas

3Select the desired welding process:

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

4Select spot welding/stitch welding mode:

Spot welding/stitch welding
The spot/stitch/SynchroPulse (SF) indicator lights up on the control panel.

5Depending on the welding process selected, select the desired welding parameters and adjust them using the appropriate selection dial

6Open the gas cylinder valve

7Adjust quantity of shielding gas

Procedure for establishing a welding spot:

1. MIG/MAG welding
2. Spot welding and stitch welding

1In the Setup menu, set the stitch pause time SPb

Stitch welding is enabled.
The Int (Interval) parameter is displayed in the Setup menu.

2In the Setup menu for the Int parameter, set the operating mode for stitch welding (2T / 4T)

3In the Setup menu, set the spot welding/stitch welding time SPt

4Only for synergic welding:
Use the corresponding buttons to select the filler metal used, the wire diameter, and the shielding gas

5Select the desired welding process:

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

6Select spot welding/stitch welding mode:

Spot welding/stitch welding
The spot/stitch/SynchroPulse (SF) indicator lights up on the control panel.

7Depending on the welding process selected, select the desired welding parameters and adjust them using the appropriate selection dial

8Open the gas cylinder valve

9Adjust quantity of shielding gas

Procedure for stitch welding:

1. MIG/MAG welding

The "Save" buttons allow up to five EasyJob operating points to be saved. Each operating point corresponds to the settings made on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

1. MIG/MAG welding
2. EasyJob mode

The "Save" buttons allow up to five EasyJob operating points to be saved. Each operating point corresponds to the settings made on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

1. MIG/MAG welding
2. EasyJob mode

1Press and hold one of the "Save" buttons to save the current settings on the control panel, e.g. The left display reads "Pro" After a short time, the left display switches to the original value
2Release the "Save" button

1. MIG/MAG welding
2. EasyJob mode

1To retrieve saved settings, press the corresponding "Save" button briefly, e.g. The control panel will show the saved settings

1. MIG/MAG welding
2. EasyJob mode

1Press and hold the relevant "Save" button to delete the memory content of that "Save" button, e.g. The left display reads "Pro". After a short time, the left display switches to the original value
2Keep the "Save" button held down The left display reads "CLr". After a while, both displays show "---"
3Release the "Save" button

1. MIG/MAG welding
2. EasyJob mode

Press one of the "Save" buttons on the control panel to retrieve the saved settings using the Up/Down welding torch.

1Press one of the "Save" buttons on the control panel, e.g.:

The control panel will show the saved settings.

The "Save" buttons can now be selected using the buttons on the Up/Down welding torch. Vacant "Save" buttons are skipped.

In addition to the "Save" button number lighting up, a number is displayed directly on the Up/Down welding torch:

Display on the Up/Down welding torch	EasyJob operating point on the control panel

1. MMA welding, arc air gouging

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

1Set the power switch to position - I -: all indicators on the control panel briefly illuminate

2Press the "Process" button to select the MMA welding process:

The welding voltage is applied to the welding socket with a three second time lag.If the MMA welding process is selected, a cooling unit, if present, is automatically deactivated. It is not possible to turn it on.

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source.

To display the actual welding current during welding:

• Press the "Parameter selection" button to select the welding current parameter
• The actual welding current is shown on the digital display during welding.

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.

To influence the short-circuiting dynamic at the instant of droplet transfer:

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

To obtain the best possible welding result, the HotStart function will sometimes need to be adjusted.

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of the parent material during the start-up phase, meaning fewer cold-shut defects
• Slag inclusions largely avoided

The setting of the available parameters is described in the section "Setup settings", "Setup menu - level 2".

Key

Hti	Hot-current time, 0 - 2 s, Factory setting 0.5 s
HCU	HotStart current, 100 - 200%, Factory setting 150%
IH	Main current = set welding current

Function
During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (I_H).

1. MMA welding, arc air gouging
2. Manual Metal Arc Welding

As the arc becomes shorter, the welding voltage may also fall so that the rod electrode is more likely to stick to the workpiece. This may also cause the rod electrode to burn out.

Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. The welding process can be resumed without problems once the rod electrode has been detached from the workpiece.

The anti-stick (Ast) function can be activated and deactivated in the Setup menu for the setup parameters for MMA welding.

1. MMA welding, arc air gouging

1. MMA welding, arc air gouging
2. Arc Air Gauging

1. MMA welding, arc air gouging
2. Arc Air Gauging

IMPORTANT! A grounding cable with a cable cross-section of 120 mm² is required for arc air gouging.

1. MMA welding, arc air gouging
2. Arc Air Gauging

1Set the power switch to position - I -: all indicators on the control panel briefly illuminate

2Press the "Process" button to select the MMA welding process:

The welding voltage is applied to the welding socket with a three second time lag.If the MMA welding process is selected, a cooling unit, if present, is automatically deactivated. It is not possible to turn it on.

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source.

The angle of contact of the carbon electrode and gouging speed determine the depth of an air gap.

The parameters for arc air gouging correspond to the welding parameters for MMA welding, see page (→).

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a CSV file on a USB thumb drive.
A Fronius signature is stored with the welding data, which can be used to check and guarantee the authenticity of the data.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a CSV file on a USB thumb drive.
A Fronius signature is stored with the welding data, which can be used to check and guarantee the authenticity of the data.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation
2. General

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a CSV file on a USB thumb drive.
A Fronius signature is stored with the welding data, which can be used to check and guarantee the authenticity of the data.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation
2. General

The following data are documented:

Device type
File name
Part number
Serial number
Firmware version of power source
Firmware of PC board DOCMAG (Easy Documentation)
Document version
https://www.easydocu.weldcube.com (A PFDF report of selected welding data can be created under this link)

The welding data are documented as average values in the main process phase and for each welding operation.

1. Easy Documentation
2. General

• When the USB thumb drive is disconnected and reconnected with the power source switched on
• When the date and time are changed
• From 1000 welding operations
• During a firmware update
• When the USB thumb drive is disconnected and reconnected to another power source
  (= change of serial number).

1. Easy Documentation
2. General

By scanning this link... A PDF report of the selected welding data can be created The authenticity of the welding data can be checked and guaranteed via the Fronius signature read out with the welding data. https://easydocu.weldcube.com

1. Easy Documentation

Plug in the USB thumb drive

The power source display shows:

Easy Documentation is activated.

doc | on is also displayed when the power source is switched off and on again with the USB thumb drive connected.

Easy Documentation remains activated.

2Acknowledge the display by pressing the arrow key

3Set the date and time

1. Easy Documentation
2. Activating / deactivating Easy Documentation

Plug in the USB thumb drive

The power source display shows:

Easy Documentation is activated.

doc | on is also displayed when the power source is switched off and on again with the USB thumb drive connected.

Easy Documentation remains activated.

2Acknowledge the display by pressing the arrow key

3Set the date and time

1. Easy Documentation
2. Activating / deactivating Easy Documentation

Setting the date and time is carried out in the 2nd level of the service menu.

1

The first parameter in the service menu is displayed.

2

Select the "2nd" setup parameter using the left-hand selection dial

3

The first parameter in the 2nd level of the service menu is displayed.

4

Select the "yEA" (= year) setup parameter using the left-hand selection dial

5

To set the date and time:

• Left-hand selection dial:
  select parameter
• Right-hand selection dial:
  change values
  

Setting ranges:

yEA	Year (20yy; 0 - 99)
Mon	Month (mm; 1 -1 12)
dAY	Day (dd; 1 - 31)
Hou	Hour (hh; 0 - 24)
Min	Minute (mm; 0 - 59)

1. Easy Documentation
2. Activating / deactivating Easy Documentation

The power source display shows:

Easy Documentation is deactivated.

2Acknowledge the display by pressing the arrow key

The Setup menu offers easy access to expert knowledge related to the power source, as well as additional functions. The Setup menu makes it possible to easily adjust the parameters for various tasks.

1. Setup Settings

The Setup menu offers easy access to expert knowledge related to the power source, as well as additional functions. The Setup menu makes it possible to easily adjust the parameters for various tasks.

1. Setup Settings
2. Setup Menu

The Setup menu offers easy access to expert knowledge related to the power source, as well as additional functions. The Setup menu makes it possible to easily adjust the parameters for various tasks.

1. Setup Settings
2. Setup Menu

Accessing the Setup menu is described with reference to the MIG/MAG standard synergic welding process.
Access is the same for the other welding processes.

Accessing the Setup menu

1

Press the "Process" button to select the "MIG/MAG standard synergic welding" process

2

The control panel is now located in the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

Adjusting parameters

1

Select the desired setup parameter using the left-hand selection dial

Change the setup parameter value using the right-hand selection dial

Exiting the Setup menu

1

1. Setup Settings
2. Setup Menu

The specifications "min." and "max." are used for setting ranges that vary according to the power source, welding program, etc.

1. Setup Settings
2. Setup Menu

The specifications "min." and "max." are used for setting ranges that vary according to the power source, welding program, etc.

1. Setup Settings
2. Setup Menu

IMPORTANT! When resetting the power source using the Factory FAC setup parameter, the hot current time (Hti) and HotStart current (HCU) setup parameters are also reset.

1. Setup Settings

The following restrictions occur in relation to the Setup menu 2nd level:

Setup menu 2nd level cannot be selected:

• during welding
• if the "Gas test" function is active
• if the "Wire threading" function is active
• if the "Wire withdrawal" function is active
• if the "Gas purging" function is active

If level 2 of the Setup menu is selected, the following functions are not available, even in robot mode:

• Welding start-up - the "Power source ready" signal will not be emitted for robot mode
• Gas test
• Wire inching
• Wire withdrawal
• Gas purging

1. Setup Settings
2. Setup Menu 2nd Level

The following restrictions occur in relation to the Setup menu 2nd level:

Setup menu 2nd level cannot be selected:

• during welding
• if the "Gas test" function is active
• if the "Wire threading" function is active
• if the "Wire withdrawal" function is active
• if the "Gas purging" function is active

If level 2 of the Setup menu is selected, the following functions are not available, even in robot mode:

• Welding start-up - the "Power source ready" signal will not be emitted for robot mode
• Gas test
• Wire inching
• Wire withdrawal
• Gas purging

1. Setup Settings
2. Setup Menu 2nd Level

Accessing the 2nd level of the Setup menu:

1

Press the "Process" button to select the "MIG/MAG standard synergic welding" process

2

The control panel is now located in the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

3

Select the "2nd" setup parameter using the left-hand selection dial

4

The control panel is now located in the 2nd level of the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

Adjusting parameters

1

Select the desired setup parameter using the left-hand selection dial

Change the setup parameter value using the right-hand selection dial

Exiting the Setup menu

1

A parameter is displayed in the first level of the Setup menu.

2

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings

Measuring the welding circuit resistance makes it possible to have a constant welding result at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. The use of arc length correction is no longer required.

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

If the welding circuit resistance has been measured correctly, the set welding voltage will correspond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.

• If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
• Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads

1. Setup Settings
2. Measuring the Welding Circuit Resistance r

Measuring the welding circuit resistance makes it possible to have a constant welding result at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. The use of arc length correction is no longer required.

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

If the welding circuit resistance has been measured correctly, the set welding voltage will correspond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.

• If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
• Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads

1. Setup Settings
2. Measuring the Welding Circuit Resistance r

The measurement is finished when the welding circuit resistance is shown on the display in mOhm (for example 11.4).

1. Setup Settings
2. Measuring the Welding Circuit Resistance r

5Place the electrode flush against the workpiece surface

6Press the "Parameter selection" button (right)

The welding circuit resistance is calculated. During the measurement the display shows "run".

The measurement is finished when the welding circuit resistance is shown on the display in mOhm (for example 11.4).

1. Setup Settings

The way that the hosepack is arranged has a very significant effect on the welding circuit inductivity and therefore affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result.

1. Setup Settings
2. Displaying the welding circuit Inductivity L

The way that the hosepack is arranged has a very significant effect on the welding circuit inductivity and therefore affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result.

1. Setup Settings
2. Displaying the welding circuit Inductivity L

The setup parameter "L" is used to display the most recently calculated welding circuit inductivity. The welding circuit inductivity is adjusted when the welding circuit resistance is measured. Detailed information in this regard can be found under the "Welding circuit resistance" chapter.

The most recently calculated welding circuit inductivity L is shown on the right-hand digital display.

L ... Welding circuit inductivity (in microhenrys)

1. Setup Settings
2. Displaying the welding circuit Inductivity L

The devices are equipped with an intelligent safety system, which largely negates the need for melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again.

1. Troubleshooting and Maintenance

The devices are equipped with an intelligent safety system, which largely negates the need for melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again.

1. Troubleshooting and Maintenance
2. Troubleshooting

The devices are equipped with an intelligent safety system, which largely negates the need for melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again.

1. Troubleshooting and Maintenance
2. Troubleshooting

1. Troubleshooting and Maintenance
2. Troubleshooting

If an error message that is not described here appears on the displays, first try to resolve the problem as follows:

If the error occurs again despite several attempts to eliminate it, or if the troubleshooting measures listed here are unsuccessful.

1. Troubleshooting and Maintenance
2. Troubleshooting

1. Troubleshooting and Maintenance

Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, several points must be observed in order for the welding system to remain operational for years to come.

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, several points must be observed in order for the welding system to remain operational for years to come.

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

• Check mains plug and mains cable, as well as the welding torch, interconnecting hosepack, and ground earth connection for damage
• Check if the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that cooling air can circulate unimpeded

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

1. Troubleshooting and Maintenance
2. Service, maintenance and disposal

Disposal must only be carried out in accordance with the section of the same name in the "Safety rules" chapter.

1. Appendix

1. Appendix
2. Average consumption values during welding

1. Appendix
2. Average consumption values during welding

1. Appendix
2. Average consumption values during welding

1. Appendix

Overview with critical raw materials:
An overview of which critical raw materials are contained in this device can be found at the following Internet address.
www.fronius.com/en/about-fronius/sustainability.

• Each device is provided with a serial number
• The serial number consists of 8 digits - for example 28020099
• The first two digits give the number from which the year of production of the device can be calculated
• This figure minus 11 gives the year of production
  • For example: Serial number = 28020065, calculation of the year of production = 28 - 11 = 17, year of production = 2017

1. Appendix
2. Technical data

Overview with critical raw materials:
An overview of which critical raw materials are contained in this device can be found at the following Internet address.
www.fronius.com/en/about-fronius/sustainability.

• Each device is provided with a serial number
• The serial number consists of 8 digits - for example 28020099
• The first two digits give the number from which the year of production of the device can be calculated
• This figure minus 11 gives the year of production
  • For example: Serial number = 28020065, calculation of the year of production = 28 - 11 = 17, year of production = 2017

1. Appendix
2. Technical data

For devices designed for special voltages, the technical data on the rating plate applies.

The following applies for all devices with a permitted grid voltage of up to 460 V: The standard mains plug allows the user to operate with a grid voltage of up to 400 V. For grid voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly.

1. Appendix
2. Technical data

The duty cycle (ED) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.

Example: Welding with 150 A at 60% ED

• Welding phase = 60% of 10 mins = 6 mins
• Cool-down phase = rest time = 4 mins
• Following the cool-down phase, the cycle begins again.

To use the device without interruptions:

1. Appendix
2. Technical data