TransSteel 3500 / 5000 Syn Operating Instructions

1. Safety rules

1. Safety rules

• 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.

• be suitably qualified,
• have sufficient knowledge of welding and
• read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

• must be in a legible state,
• must not be damaged,
• must not be removed,
• must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!

1. Safety rules

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

The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

• carefully reading and following all the instructions given in the operating instructions
• studying and obeying all safety and danger notices carefully
• performing all stipulated inspection and maintenance work.

• Thawing out pipes
• Charging batteries
• Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

1. Safety rules

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

• 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)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

1. Safety rules

• are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device
• have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures
• are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

1. Safety rules

• to observe the basic instructions regarding safety at work and accident prevention
• to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

1. Safety rules

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

• Connection restrictions
• Criteria with regard to the maximum permissible mains impedance ^*)
• Criteria with regard to the minimum short-circuit power requirement ^*)

^*) at the interface with the public grid
see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

1. Safety rules

• flying sparks and hot pieces of metal
• Arc radiation, which can damage eyes and skin

• Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers

• Risk of electrocution from mains current and welding current

• Greater noise pollution

• Harmful welding fumes and gases

• Flame-resistant
• Insulating and dry
• Covers the whole body, is undamaged and in good condition
• Safety helmet
• Trousers with no turn-ups

• Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
• Wear regulation protective goggles with side protection behind the protective visor
• Wear stout footwear that provides insulation even in wet conditions
• Protect the hands with suitable gloves (electrically insulated and providing protection against heat)
• Wear ear protection to reduce the harmful effects of noise and to prevent injury

• Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)
• Provide suitable protective equipment
• Alternatively, erect suitable safety screens/curtains.

1. Safety rules

The fumes produced during welding contain harmful gases and vapours.

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

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

Keep your face away from welding fumes and gases.

• must not be breathed in
• must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

• Metals used for the workpiece
• Electrodes
• Coatings
• Cleaners, degreasers, etc.
• Welding process used

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

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

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

1. Safety rules

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

1. Safety rules

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

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

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or 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.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

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

• never be immersed in liquid for cooling
• Never touch the electrode when the power source is switched on.

Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

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

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

• Discharge all live components
• Ensure that all components in the device are de-energised.

If work on live parts is required, appoint a second person to switch off the main switch at the right moment.

1. Safety rules

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

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

1. Safety rules

• 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 mains.

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

1. Safety rules

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 operator is obliged to take appropriate action to rectify the situation.

• Safety devices
• Network, signal and data transfer lines
• IT and telecommunications devices
• Measuring and calibrating devices

1. Mains supply
   • If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)

2. Welding power-leads
   • must be kept as short as possible
   • must be laid close together (to avoid EMF problems)
   • must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece
   • If necessary, establish an earth connection using suitable capacitors.

5. Shield, if necessary
   • Shield other devices nearby
   • Shield the entire welding installation

1. Safety rules

• Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
• Individuals with pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
• For safety reasons, maintain as large a distance as possible between the welding power-leads and the head/torso of the welder
• Do not carry welding power-leads and hosepacks over the shoulders or wind them around any part of the body

1. Safety rules

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

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

• Ensure that all covers are closed and all side panels are fitted properly.
• Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

• Hook chains or ropes onto all suspension points provided on the load-carrying equipment.
• Chains and ropes must be at the smallest angle possible to the vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.

1. Safety rules

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

Use filters if necessary.

1. Safety rules

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

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

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any 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 attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

1. Safety rules

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

• Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
• Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
• Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
• Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.

1. Safety rules

• The maximum permissible tilt angle is 10°.

• Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

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

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

• Wirefeeder
• Wirespool
• Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

1. Safety rules

• injury or death to the operator or a third party
• damage to the device and other material assets belonging to the operator
• inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

1. Safety rules

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 rules

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

The manufacturer recommends that the power source be calibrated during the same 12-month period.

• after any changes are made
• after any additional parts are installed, or after any conversions
• after repair, care and maintenance has been carried out
• at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.

1. Safety rules

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally-friendly way, in accordance with the European Directive and national legislation. Used equipment must be returned to the distributor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material resources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.

Packaging materials
Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.

1. Safety rules

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: 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 rules

The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal settings.

1. Safety rules

Copyright of these operating instructions remains with the manufacturer.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

1. General information

TransSteel 3500 / 5000 Syn

The TransSteel (TSt) 3500 Syn and TSt 5000 Syn power sources are fully digitised, microprocessor-controlled inverter power sources.

The modular design and potential for system add-ons ensure a high degree of flexibility.
The devices are designed for the welding of steel and the following welding processes:

• MAG welding
• MMA welding

The device has a "Power limitation" safety feature. This means that the power source can be operated at the power limit without compromising process safety. For more information, see the "Welding mode" section.

1. General information
2. General

TransSteel 3500 / 5000 Syn

The TransSteel (TSt) 3500 Syn and TSt 5000 Syn power sources are fully digitised, microprocessor-controlled inverter power sources.

The modular design and potential for system add-ons ensure a high degree of flexibility.
The devices are designed for the welding of steel and the following welding processes:

• MAG welding
• MMA welding

The device has a "Power limitation" safety feature. This means that the power source can be operated at the power limit without compromising process safety. For more information, see the "Welding mode" section.

1. General information
2. General

The central control and regulation unit of the power source 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 command values are kept.

• a precise welding process,
• a high degree of reproducibility of all results,
• excellent weld properties.

1. General information
2. General

The devices are used in the commercial sector for manual and automated applications with classical steel and galvanised sheets:

• Machine and equipment construction
• Steelwork
• Plant and container construction
• Shipyards and the offshore industry
• Metal and gantry 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 damage.

Warning notices affixed to the power source

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

• Welders must be sufficiently qualified
• Suitable protective equipment must be used
• All persons not involved in the welding process must be kept at a safe distance

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

• These Operating Instructions
• All the Operating Instructions for the system components, especially the safety rules

1. General information

Power sources offer a selection of welding processes, procedures and welding characteristics that enable a wide range of materials to be processed in the most effective way.

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

Power sources offer a selection of welding processes, procedures and welding characteristics that enable a wide range of materials to be processed in the most effective way.

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

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

MIG/MAG standard synergic

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

Dip transfer arc
Droplet transfer takes place during a short circuit in the lower power range.

Intermediate arc
The droplet increases in size on 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

During arc air gouging, an arc is ignited between a carbon electrode and the workpiece, and the base material is melted and cleaned with compressed air.
The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

• Removing shrink holes, pores, or slag inclusions from workpieces
• Detaching sprue or finishing entire workpiece surfaces in casting operations
• Edge preparation for heavy plates
• Preparation and repair of weld seams
• Working out root passes 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 optimise procedures and to simplify machine handling and operation, as necessitated by the particular field of application in which the power source is to be used.

1. General information
2. System components

The power sources can be operated with various system components and options. This makes it possible to optimise procedures and to simplify machine handling and operation, as necessitated by the particular field of application in which the power source is to be used.

1. General information
2. System components

1. General information
2. System components

1. General information

The options listed below are available with all power source variants.

1. General information
2. Options

The options listed below are available with all power source variants.

1. General information
2. Options

The machine interface connects the power source to the machine control. The following signals can be transmitted across the machine interface:

• Signal input for a floating contact (sensor, relay, etc.) between pin X1:1 and pin X1:2
• The machine control signal input is processed by the power source in the same way as a welding torch signal input. Ensure that the correct mode is set (2-step or 4-step)
• Use gold-plated contacts for optimum signal transmission

• Floating contact between pin X1:3 and pin X1:4

1. General information
2. Options

External gas preheaters for gas pressure regulators can be connected to the gas preheater CO2 connection. Gas preheaters have a 36 V supply.

The power of the gas preheaters must not exceed 150 W.
The gas preheater supply is protected against overloads and short-circuits.

1. General information
2. Options

An optional keylock switch is available for the power source to prevent the settings from being inadvertently changed on the control panel. If the keylock switch is in the horizontal position,

• no settings can be set 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.

Keylock activated:
"CLO | SEd" appears on the display

Keylock deactivated:
"OP | En" appears on the display

1. General information
2. Options

A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. It is recommended for environments in which the risk of an electric shock or electrical accident is increased considerably during arc welding:

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

A low human body resistance is possible when there is:

• water in the area
• humidity
• heat, particularly ambient temperatures in excess of 32°C (89.6°F)

In wet, damp or hot locations, humidity or sweat can significantly reduce the skin resistance and the insulation resistance of protective equipment and clothing.

Such environments can include:

• Temporary dams for draining certain areas of a site during construction work (cofferdams)
• Trenches
• Mines
• Rain
• Areas partly submerged by water
• Spraywater areas

The VRD option reduces the voltage between the electrode and the workpiece. In safe conditions, the indicator for the currently selected welding process is permanently lit. A safe condition is defined as follows:

• The output voltage in an open circuit is limited to 35 V.

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

1. General information
2. Options

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

• VRD is active
• Open circuit voltage is limited to 35 V
• Unintentional contact with the output voltage does not put the welder at risk

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

• VRD is inactive
• Output voltage not restricted in order to ensure sufficient welding power
• Example: Welding starts

In MMA welding mode:
Within 0.3 seconds of end of welding:

• VRD is active again
• The output voltage is limited to 35 V once more

The functions on the control panel are all arranged in a logical way. The various welding parameters can easily be selected using buttons and can just as easily be

• altered using buttons or the adjusting dial
• displayed on the digital display during welding

The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to be set manually.

1. Control elements and connections

The functions on the control panel are all arranged in a logical way. The various welding parameters can easily be selected using buttons and can just as easily be

• altered using buttons or the adjusting dial
• displayed on the digital display during welding

The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to be set manually.

1. Control elements and connections
2. Synergic control panel

The functions on the control panel are all arranged in a logical way. The various welding parameters can easily be selected using buttons and can just as easily be

• altered using buttons or the adjusting dial
• displayed on the digital display during welding

The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to be set manually.

1. Control elements and connections
2. Synergic control panel

1. Control elements and connections
2. Synergic control panel

(1) "Parameter selection" button (right) a) for selecting the following welding parameters
			Arc length correction for correcting the arc length
			Welding voltage in V *) Before the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.
			Arc-force dynamic for influencing the short-circuiting dynamic at the moment of droplet transfer - ... harder, more stable arc 0 ... neutral arc + ... soft, low-spatter arc
	b) for changing parameters in the Setup menu
(2) "Parameter selection" button (left) a) for selecting the following welding 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 the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.
			Wire speed *) Wire speed in m/min or ipm.
	b) for changing parameters in the Setup menu
(3) Adjusting dial (right) for changing the arc length correction, welding voltage and arc-force dynamic parameters for changing welding parameters in the Setup menu
(4) Adjusting dial (left) for changing the sheet thickness, welding current and wire speed parameters for selecting welding parameters in the Setup menu
(5) "Save" buttons (Easy Job) zum Speichern von bis zu 5 Arbeitspunkten
(6) "Process" button **) for saving up to 5 operating points
			MANUAL - MIG/MAG standard manual welding
			SYNERGIC - MIG/MAG standard synergic welding
			STICK - Manual metal arc (MMA) welding
(7) "Mode" button for selecting the operating mode
			2 T - 2-step mode
			4 T - 2-step mode
			S 4 T - Special 4-step mode
(8) "Shielding gas" button for selecting the shielding gas to be used. The SP parameter is reserved for additional shielding gases. When a shielding gas is selected, the LED behind the relevant shielding gas lights up.
(9) "Wire diameter" button for selecting the wire diameter to be used. The SP parameter is reserved for additional wire diameters. When a wire diameter is selected, the LED behind the relevant wire diameter lights up.
(10) "Material" button for selecting the filler metal to be used. The SP parameter is reserved for additional filler metals When a material is selected, the LED behind the relevant 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 necessary gas flow rate on the pressure regulator. Press the button once: shielding gas flows out Press 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 welding indicator lights up if a value has been entered for the spot / stitch welding time Setup parameter (SPt) (spot or stitch welding operating mode is enabled)
(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 range.
(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) Real Energy Input for displaying the energy applied during the welding operation. The Real Energy Input display 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 yield. The final value at the end of welding remains stored until welding starts again or the power source is switched back on - the HOLD indicator lights up.

1. Control elements and connections
2. Synergic 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") is displayed, e.g. "1.00 | 4.21"

Selecting parameters

2

Use the "Mode" and "Process" buttons or the left-hand adjusting 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
654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins	Indicates the actual arc time since using for the first time Note: The arc time indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.
Example: iFd | 0.0	Motor current for wire drive in A The value changes as soon as the motor is running.
2nd	Second menu level for service technicians

1. Control elements and connections
2. Synergic 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

• No settings can be made 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

To activate/deactivate 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 be activated and deactivated using the keylock switch option.

1. Control elements and connections

1. Control elements and connections
2. Connections, switches and mechanical components

Depending on which welding process you intend to use, a certain minimum equipment level will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task are then described.

1. Installation and commissioning

Depending on which welding process you intend to use, a certain minimum equipment level will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task are then described.

1. Installation and commissioning
2. Minimum equipment needed for welding task

Depending on which welding process you intend to use, a certain minimum equipment level will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task are then described.

1. Installation and commissioning
2. Minimum equipment needed for welding task

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

1. Installation and commissioning
2. Minimum equipment needed for welding task

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

1. Installation and commissioning
2. Minimum equipment needed for welding task

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

1. Installation and commissioning

1. Installation and commissioning
2. Before installation and commissioning

1. Installation and commissioning
2. Before installation and commissioning

The power source may only be used for MIG/MAG and MMA welding.
Any other form of usage is deemed "not in accordance with the intended purpose".
The manufacturer shall not be held liable for any damages arising from such usage.

• following all the information in the operating instructions
• carrying out all the specified inspection and servicing work

1. Installation and commissioning
2. Before installation and commissioning

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

The device can be set up and operated outdoors in accordance with degree of protection IP 23.
Avoid direct wetting (e.g. from rain).

The venting duct is a very important safety device. When choosing the installation location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Electroconductive metallic dust (e.g. from grinding work) must not be allowed to get sucked into the device.

1. Installation and commissioning
2. Before installation and commissioning

The devices are designed for the mains voltage specified on the rating plate. If your version of the appliance does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. For details of fuse protection of the mains lead, please see the technical data.

1. Installation and commissioning

1. Installation and commissioning
2. Connecting the mains cable

1. Installation and commissioning
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 commissioning
2. Connecting the mains cable

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

AWG ... American Wire Gauge

1. Installation and commissioning
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.

An illustration of the mains cable connection can be found in the following 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 commissioning
2. Connecting the mains cable

1

2

3

4

5

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

1. Installation and commissioning
2. Connecting the mains cable

1

2

3

4

5

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

1. Installation and commissioning

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 as follows:

3-phase devices: S_1max = I_1max x U₁ x √3

Single-phase devices: S_1max = I_1max x U₁

See device rating plate or technical data for I_1max and U₁ values

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 may be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must always be higher than the maximum apparent power S_1max of the power source.

When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the single-phase power of the generator from the generator manufacturer.

1. Installation and commissioning
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 as follows:

3-phase devices: S_1max = I_1max x U₁ x √3

Single-phase devices: S_1max = I_1max x U₁

See device rating plate or technical data for I_1max and U₁ values

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 may be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must always be higher than the maximum apparent power S_1max of the power source.

When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the single-phase power of the generator from the generator manufacturer.

1. Installation and commissioning

Commissioning a power source is described by reference to a manual water-cooled MIG/MAG application.

1. Installation and commissioning
2. Start-up

Commissioning a power source is described by reference to a manual water-cooled MIG/MAG application.

1. Installation and commissioning
2. Start-up

The steps and activities described below include references to various system components, including:

• trolley
• upright console
• cooling units
• wire-feed units
• interconnecting hosepacks
• welding torches, etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.

1. Installation and commissioning
2. Start-up

The diagram below is intended to show you how to fit the individual system components.

1. Installation and commissioning
2. Start-up

1

1. Installation and commissioning
2. Start-up

1

Fitting the strain-relief device to the trolley

2

Fitting the strain-relief device to the wirefeeder

IMPORTANT! To prevent wear and tear, leave some slack when connecting the cables. A strain-relief device is not provided for 1.2 m (3 ft 11.24 in.) interconnecting hosepacks.

1. Installation and commissioning
2. Start-up

IMPORTANT! There is no cooling unit present in the case of gas-cooled systems. There is no need to attach the water connections in the case of gas-cooled systems.

1

2

1. Installation and commissioning
2. Start-up

1Place the gas cylinder on the base of the trolley

2Secure the gas cylinder by fixing the cylinder strap around the upper part of the cylinder (but not around the neck) to prevent it from toppling over

3Take the protective cap off the gas cylinder

4Briefly open the gas cylinder valve to remove any dust or dirt

5Inspect the seal on the gas pressure regulator

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

7Connect the shielding gas hose of the interconnecting hosepack to the pressure regulator using the gas hose

1. Installation and commissioning
2. Start-up

1

1. Installation and commissioning
2. Start-up

1

* when the optional water connection and the water-cooled welding torch are fitted

1. Installation and commissioning
2. Start-up

1

2

3

4

1. Installation and commissioning
2. Start-up

1

1. Installation and commissioning
2. Start-up

1

2

1. Installation and commissioning
2. Start-up

1

2

IMPORTANT! To facilitate the exact positioning of the wire electrode, the following sequences are possible when the wire threading button is pressed and held down.

• Hold the button for up to one second ... the wire speed stays at 1 m/min or 39.37 ipm for the first second.
• Hold the button for up to 2.5 seconds ... after one second has elapsed, the wire speed increases at a uniform rate over the next 1.5 seconds.
• Hold the button for more than 2.5 seconds ... after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the Fdi welding parameter.

If the "Wire threading" button is released and pressed again before one second has elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire speed of 1 m/min or 39.37 ipm where necessary.

If there is no "Wire threading" button, the torch trigger can be used in the same way. Before using the torch trigger for wire threading, proceed as follows:

IMPORTANT! If the torch trigger is pressed instead of the "Wire threading" button, the welding wire runs at the feeder creep speed (depending on the welding program) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.

The welding system detects that the welding process should not start, but that the wire is to be fed in. At the same time, the gas solenoid valve closes, and the welding voltage on the wire electrode is switched off.

If the torch trigger is held down, wirefeeding restarts immediately without shielding gas and welding voltage, and the process continues as described above.

3

4

1. Installation and commissioning
2. Start-up

1

Contact pressure preferred values for U-groove rollers:

Steel: 4 - 5

CrNi: 4 - 5

Tubular cored electrodes: 2 - 3

1. Installation and commissioning
2. Start-up

1

2

3

1. Installation and commissioning
2. Start-up

WARNING!

Danger from incorrect installation.

This can result in severe personal injury and damage to property.

Do not dismantle the brake.

Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only.

The brake is only available as a complete unit.
This illustration of the brake is for information purposes only.

"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.

For the selected "MIG/MAG standard synergic welding" process, 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.

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

1. 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.

For the selected "MIG/MAG standard synergic welding" process, 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.

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

1. 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.

For the selected "MIG/MAG standard synergic welding" process, 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.

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

1. 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. Welding
2. MIG/MAG 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. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG modes

• Tacking work
• Short weld seams
• Automated and robot welding

1. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG 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 for the duration of the SPt spot welding time - GPo gas post-flow.

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

1. Welding
2. MIG/MAG 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 base material.

1. Welding
2. MIG/MAG 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 base material.

1. Welding

1. Welding
2. MIG/MAG welding

1. Welding
2. MIG/MAG welding

IMPORTANT! Follow the safety rules and note operating conditions in the cooling unit Operating Instructions.

1. Welding
2. MIG/MAG welding

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

1. 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
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 (TR 2000 or TR 3000 remote control) 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 adjusting dial to set the relevant welding parameters.
	The welding parameter values are shown in the digital display located above them. 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.
8Open the gas cylinder valve
9Setting the shielding gas flow rate:
	Tap the "Gas-test" button
	Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the required gas flow rate
	Tap the "Gas-test" button again

1. Welding
2. MIG/MAG standard 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
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 (TR 2000 or TR 3000 remote control) 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 adjusting dial to set the relevant welding parameters.
	The welding parameter values are shown in the digital display located above them. 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.
8Open the gas cylinder valve
9Setting the shielding gas flow rate:
	Tap the "Gas-test" button
	Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the required gas flow rate
	Tap the "Gas-test" button again

1. Welding
2. MIG/MAG standard synergic welding

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

 Arc length correction:

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

1. 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. 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. Welding
2. MIG/MAG standard manual welding

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

	Wire feed speed
		1 m/min (39.37 ipm) - maximum wire feed speed, e.g. 25 m/min (984.25 ipm)
	Welding voltage
		TSt 3500: 15.5 - 31.5 V TSt 5000: 14.5 - 39 V
	Dynamic
		for influencing the short-circuiting dynamic at the moment of particle transfer
	Welding current
		only for displaying the actual value

1. 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 (TR 2000 or TR 3000 remote control) on the control panel of the wirefeeder.
3Press the "Parameter selection" button to select the wire speed parameter
4Use the adjusting dial to set the desired value for the wire speed
5Press the "Parameter selection" button to select the welding voltage parameter
6Use the adjusting dial to set the desired value for the welding voltage
	The welding parameter values are shown in the digital display located above them.
	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.
7Open the gas cylinder valve
8Setting the shielding gas flow rate:
	Tap the "Gas-test" button
	Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the required gas flow rate
	Tap the "Gas-test" button again

1. 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.

1. Welding

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

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

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

1. Welding
2. Spot and stitch welding

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

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

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

1. Welding
2. Spot and stitch welding

Activating spot welding mode:

• For the SPt Setup parameter (spot / stitch welding time), enter a value > OFF

As soon as a value is entered for the SPt Setup parameter, spot welding mode is activated. The spot / stitch welding indicator (SF) lights up on the control panel.

Preparations:

1Set the spot / stitch welding time (SPt) in the Setup menu

2Select the filler metal, wire diameter and shielding gas being used with the relevant buttons

3Select the desired welding process:   MIG/MAG standard manual welding   MIG/MAG standard synergic welding

4Select the desired MIG/MAG mode:   2-step mode

(For spot welding mode, only 2-step mode is available)

5Depending on the selected welding process, select the desired welding parameters using the relevant adjusting dial

6Open the gas cylinder valve

7Set the shielding gas flow rate

Procedure for producing a welding spot:

1. Welding
2. Spot and stitch welding

Activating stitch welding mode:

• For the SPt Setup parameter (spot / stitch welding time), enter a value > OFF
• For the SPt Setup parameter (spot pause time), enter a value > OFF

As soon as a value is entered for the SPt Setup parameter, the spot / stitch welding indicator (SF) lights up.

Preparations:

1Set the spot / stitch welding time (SPt) in the Setup menu

2Set the spot pause time (SPb) in the Setup menu

3Select the filler metal, wire diameter and shielding gas being used with the relevant buttons

4Select the desired welding process:   MIG/MAG standard manual welding   MIG/MAG standard synergic welding

5Select the desired MIG/MAG mode for stitch welding mode:   2-step mode   4-step mode

6Depending on the selected welding process, select the desired welding parameters using the relevant adjusting dial

7Open the gas cylinder valve

8Set the shielding gas flow rate

Procedure for stitch welding:

1. Welding

The "Save" buttons allow up to 5 EasyJob operating points to be saved. Every operating point matches the settings on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

1. Welding
2. EasyJob mode

The "Save" buttons allow up to 5 EasyJob operating points to be saved. Every operating point matches the settings on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

1. 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 indicator displays "Pro" After a short time, the left indicator switches to the original value
2Release the "Save" button

1. 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. Welding
2. EasyJob mode

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

1. Welding
2. EasyJob mode

One of the "Save" buttons on the control panel must be pressed in order 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:

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

1. Welding

1. Welding
2. MMA welding

1. Welding
2. MMA welding

1. Welding
2. MMA welding

1Move the mains switch to the "I" position: all the indicators on the control panel will briefly light up

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, any cooling unit present is automatically deactivated. It is not possible to switch it on.

NOTE!

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

3Press the "Parameter selection" button to select the amperage parameter.

4Use the adjusting dial to set the desired amperage.The amperage value is displayed in the left-hand digital display.
All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed. This applies even if the power source was switched off and on again in the interim.

5Start welding

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. Welding
2. MMA welding

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

Influence of the short-circuiting dynamic at the instant of droplet transfer:

1. Welding
2. MMA welding

To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart function.

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of the base material during the start-up phase, meaning fewer cold-shut defects
• Largely prevents slag inclusions

For details on setting the available welding parameters, please refer to "Setup parameters", "Setup menu - level 2".

Legend

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. Welding
2. MMA welding

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to stick. 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. After the rod electrode has been detached from the workpiece, the welding process can be continued without any problems.

The anti-stick function (Ast) can be activated and deactivated in the Setup menu with the Setup parameters for manual metal arc welding.

1. Welding

1. Welding
2. Arc Air Gauging (TSt 5000 Syn)

1. Welding
2. Arc Air Gauging (TSt 5000 Syn)

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

1. Welding
2. Arc Air Gauging (TSt 5000 Syn)

1Move the mains switch to the "I" position: all the indicators on the control panel will briefly light up

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, any cooling unit present is automatically deactivated. It is not possible to switch it on.

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

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

The arc air gouging parameters are the same as 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 weld can be documented and saved as a CSV file on a USB flash 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 flash 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 weld can be documented and saved as a CSV file on a USB flash 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 flash 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 weld can be documented and saved as a CSV file on a USB flash 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 flash 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 is also documented:

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

The welding data is documented as average values in the main process phase and per weld.

1. Easy Documentation
2. General

• if the USB flash drive is disconnected and reconnected while the power source is on
• If the date and time are changed
• From 1000 welds
• During a firmware update
• if the USB flash drive is disconnected and reconnected to another power source
  (= change of serial number).

1. Easy Documentation
2. General

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

1. Easy Documentation

The date and time are set 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 adjusting 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 adjusting dial

5

To set the date and time:

• Left-hand adjusting dial:
  Select parameter
• Right-hand adjusting 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 date and time are set 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 adjusting 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 adjusting dial

5

To set the date and time:

• Left-hand adjusting dial:
  Select parameter
• Right-hand adjusting 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 following appears on the power source display:

Easy Documentation is deactivated.

2Confirm the display by pressing the arrow key

The Setup menu provides simple access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the parameters to suit the various job settings.

1. Setup settings

The Setup menu provides simple access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the parameters to suit the various job settings.

1. Setup settings
2. Setup menu

The Setup menu provides simple access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the parameters to suit the various job settings.

1. Setup settings
2. Setup menu

Access to the setup menu is described based on the MIG/MAG standard synergic welding process.
Access is the same for the other welding processes.

Accessing the Setup menu

1

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

2

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

Changing welding parameters

1

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

Alter the setup parameter value using the right-hand adjusting dial

Exiting the Setup menu

1

1. Setup settings
2. Setup menu

"Min." and "max." are used for setting ranges that differ according to power source, welding program, etc.

1. Setup settings
2. Setup menu

"Min." and "max." are used for setting ranges that differ according to power source, welding program, etc.

1. Setup settings
2. Setup menu

IMPORTANT! If you reset the power source using the FAC factory setup parameter, the hot-current time (Hti) and HotStart current (HCU) setup parameters are also reset.

1. Setup settings

To access the Level 2 Setup menu:

1

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

2

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

3

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

4

The control panel is now in the second level of the setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.

Changing welding parameters

1

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

Alter the setup parameter value using the right-hand adjusting 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 - Level 2

To access the Level 2 Setup menu:

1

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

2

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

3

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

4

The control panel is now in the second level of the setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.

Changing welding parameters

1

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

Alter the setup parameter value using the right-hand adjusting 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 - Level 2

1. Setup settings
2. Setup menu - Level 2

1. Setup settings

Measuring the welding circuit resistance makes it possible to have a consistent 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 welding circuit resistance r

Measuring the welding circuit resistance makes it possible to have a consistent 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 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

Laying of the hosepacks has a significant effect on 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. Retrieving the welding circuit inductivity L

Laying of the hosepacks has a significant effect on 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. Retrieving 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 calibrated at the same time as the welding circuit resistance is measured. Detailed information can be found in the "Measuring welding circuit resistance" section.

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

L ... Welding circuit inductivity (in microhenry)

1. Setup settings
2. Retrieving the welding circuit inductivity L

The devices are equipped with an intelligent safety system. This means that to a large extent it has been possible to dispense with 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. This means that to a large extent it has been possible to dispense with 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. This means that to a large extent it has been possible to dispense with 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

Make a note of the serial number and configuration of the device and contact our After-Sales Service team with a detailed description of the error, if

• errors occur that are not listed below
• the troubleshooting measures listed are unsuccessful

1. Troubleshooting and maintenance
2. Troubleshooting

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

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, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.

1. Troubleshooting and maintenance
2. Care, maintenance and disposal

Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.

1. Troubleshooting and maintenance
2. Care, maintenance and disposal

1. Troubleshooting and maintenance
2. Care, maintenance and disposal

• Check mains plug, mains cable, welding torch, interconnecting hosepack and ground earth connection for damage
• Check that the device has an all-round clearance of 0.5 m (1 ft. 8 in.) to ensure that cooling air can flow in and out freely

1. Troubleshooting and maintenance
2. Care, maintenance and disposal