• 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!

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

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 servicing work.

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 unexpected or incorrect results.

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: 0 °C to + 40 °C (32 °F to 104 °F)
• during transport and storage: 0 °C to + 40 °C (32 °F to 104 °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 up to 2000 m (6561 ft. 8.16 in.)

• 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.

• 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.

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

For your personal safety, take the following precautions:

Use suitable protective clothing

• protect their eyes with the specified protective goggles;
• wear stout footwear that provides insulation even in wet conditions;
• protect their hands by wearing suitable gloves (electrically insulated, heat-proof, protection from cut injuries);
• wear ear protection to reduce the harmful effects of noise and to prevent injury.

• warn them of all the dangers
• provide suitable protective equipment or
• erect suitable safety screens/curtains

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

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

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 pre-load.

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

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

The device must only be operated on a mains supply with a ground conductor and a socket with a ground conductor contact.

If the device is operated on a grid without a ground conductor and in a socket without a ground conductor contact, this will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide an adequate earth connection for the workpiece.

Switch off unused devices.

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.

• 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.

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)

1. 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

1. Equipotential bonding

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

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

• 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

• 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 wire speed measuring system poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

For this reason, always keep the wire speed measuring system away from the head and body and wear suitable protective goggles.

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.

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 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 accessories (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.

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.

• 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.

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.

• 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.

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 torque to 3 Nm.

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.

Regular calibration is required to guarantee the traceability to national or international standards of calibrations performed with this calibration system.
Fronius recommends a 12-month calibration interval. For more information, please contact your Fronius partner.

Do not dispose of this device with normal domestic waste! To comply with the European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives. Further details can be found in the appendix or the section headed "Technical data" in your documentation.

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.

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.

The device is only intended to be used for calibrating and testing welding systems and power sources.

Any use above and beyond this purpose is deemed improper. The manufacturer shall not be liable for any damage resulting from such use.

• carefully reading these Operating Instructions
• following all the instructions and safety rules in these Operating Instructions
• performing all stipulated inspection and maintenance work

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.

Further accessories (not pictured)

• Computer, laptop
• Calibration software
  The calibration software can be downloaded from:
  
  
  Fronius internal:
  

• Computer, laptop
• Calibration software
  The calibration software can be downloaded from:
  
  
  Fronius internal:
  

• Calibration system 2.0
• Interface calibration system
• Welding wire calibration system
• Accessories calibration system
• Trolley calibration system

For the calibration of WeldCube Connector U/I and WeldCube Connector Advanced:

• PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
• M12-X / RJ45 network cable, 5 m (42.0411.0232)
• Voltage measurement adapter
• Smart Device + WeldConnect app
• Power source (e.g. TransSteel 5000, TPS 500i + PowerConnector adapter - Dinse, iWave, etc.)

For the calibration of WeldCube Connector U/I/WFS WSM and WeldCube Connector Advanced + WSM:

• PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
• M12-X / RJ45 network cable, 5 m (42.0411.0232)
• Smart Device + WeldConnect app
• Available TransSteel system components
• 70/95 DIX KAB socket splitter (43,0003,0704)

For the calibration of WeldCube Connector U/I/WFS Euro and WeldCube Connector Advanced + Euro:

• PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
• M12-X / RJ45 network cable, 5 m (42.0411.0232)
• Smart Device + WeldConnect app
• Power source TPS 500i or TransSteel 5000
• Wirefeeder WF 25i / WF 30i or VR 5000, each with adapter-ZA FSC-S-G/Euro STD (44,0350,3565)
• Power sharing cable (only for TPSi)

Prerequisite:
The USB cable is not connected.

1Connect the PC to the calibration system via USB and switch on the calibration system (green LED lights up)

2Open the Device Manager

If no driver is yet installed, the device will appear as unknown

3Install the required driver software from the unzipped software package:
Right click on LAN9500

4Update driver software

5Find the driver software on the computer

6Open the path:
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\USBTOLAN\

7Depending on the operating system, select the subfolder (win / win_64) and follow the instructions

After successful installation, the driver can be found under the network adapters:

8If a driver is already installed,
ensure that it is the latest version and if necessary update it

Also use the connected USB port for future work with the calibration system.

1Open the path:
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\OMNIKEY\

2 Depending on the operating system, select the subfolder, install the file located there and follow the instructions

Win7 / Win8:
Successful installation will be displayed in the Device Manager as follows:

If under Properties / General / Storage location NO port is specified for a SmartCard reader, it must be deactivated:

1Connect the power source with LocalNet to the calibration system via USB and switch on both components

2Open the Device Manager

If no driver is yet installed, the device will appear as unknown (USB Serial Port, USB-RS232 cable, etc.)

3Install the required driver software from the unzipped software package:
Right click on USB Serial Port

4Update driver software

5Find the driver software on the computer

6Open the path:
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\FTDI\

7Confirm and follow the instructions

After successful installation of the driver, the COM Port can be found under Ports:

8Restart the PC
(only if prompted to do so at the end of installation)

9If a driver is already installed,
ensure that it is the latest version and if necessary update it

If the device still appears as unknown after installation, repeat the process.

Requirements:

• Windows 7 or higher
• Local admin rights
• Screen resolution higher than 1024 * 768
• .net Framework 4.7.2
  
  If this .net Framework version is not yet installed on the computer, a message is displayed to this effect.
  The appropriate .net Framework version can be downloaded and installed from the following link:
  https://dotnet.microsoft.com/download/dotnet-framework-runtime/net472

IMPORTANT! Prerequisites for USB calibration:

• DHCP server, which starts automatically when the program starts.
• .net Framework, at least version 4.7.2

Action if the IP address 192.168.125.1 is not displayed on the power source:

• Check if the DHCP server is running (icon!)
  If the DHCP server is not running, restart the software.
• Disconnect the USB briefly from the power source and reconnect it again
• Only connect the USB Ethernet adapter to the calibration system, not to the computer/laptop

1Click on the TwinCat symbol in the lower bar of your PC and select "Edit routes"

2Add a new route by going to "Add" and then "Broadcast Search"

The calibration system is then normally displayed.

3Implement the following settings:

4Deactivate "Encrypt password (Twincat 3 only)"

If connection is successful, an X is displayed in the overview.

5Close the window by clicking "Close"

Possible errors/points to check if the route cannot be set as described above include:

1. Check network settings:
   The calibration station must be accessible in the Windows command prompt (CMD) at the IP address 192.168.120.50 with the ping command.
2. Various security programmes (e.g. F-Secure, etc.) may block the network connection.
   If necessary, allow network traffic
3. Reset the calibration station and ensure that the green LED is on
4. Remove the USB cable for a short time, then reconnect it and try again
5. Restart the PC

After the calibration software has been installed, the language can be set for the user interface:

The system switches to the chosen language when the program is restarted.

After the calibration software has been installed, the language can be set for the user interface:

The system switches to the chosen language when the program is restarted.

1Connect the connection cable to the welding wire calibration system

IMPORTANT! A maximum of 3 connection cables (max. 15 m) can be used to connect the welding wire calibration system and the calibration system!

2Connect the connection cable to the calibration system

3Disconnect the (+) power cable of the calibration system from the welding system

4Connect the MIG/MAG welding torch to the welding system

5Remove the gas nozzle from the welding torch

6Thread the wire
The welding wire should protrude approx. 200 mm from the contact tip.

7Thread the welding wire into the intake part of the sensor

8Secure the welding torch in the welding wire calibration system at the contact tip

9Make sure that the torch hosepack is arranged as straight as possible

The system is now ready for welding wire calibration.

If, in this case, it is not possible to attach it properly, the following longer contact tips may be used on the robot welding torch:

• 42,0001,0056
  contact tip 1.6/M6/ø8x33 mm
• 42,0001,3485
  contact tip 1.6/M8/ø8x35 mm/CB4.8
• 42,0001,5413
  contact tip 3.2/M10/ø10x40 mm

IMPORTANT! The interface calibration system is required for calibrating a gas supply.

1Connect the gas hose:

to the gas pressure regulator

and

to the Gas IN connection on the calibration system interface

max. inlet pressure: 5 bar

2Connect the gas hose:

to the wirefeeder or the power source

and

to the Gas OUT connection on the interface calibration system

3Connect the gas connection on the calibration system with the data connection on the calibration system interface

4Connect the power source with the calibration system

With single-phase machines, the mains voltage must be measured manually using a FLUKE measuring device.

With single-phase machines, the mains voltage must be measured manually using a FLUKE measuring device.

With single-phase machines, the mains voltage must be measured manually using a FLUKE measuring device.

If the values specified by the calibration software are not achieved, the set value or load resistance may need to be modified.

Examples:

AccuPocket 150 / 400 Tig
Current calibration (M1: Set value [A] = 60 A / RLoad [mOhm] = 240 mOhm)

TransTig 2200 Job
Current calibration (M5: RLoad [mOhm] = 96 mOhm)

VarioSynergic 3400
Read the measured value for the respective level in the calibration program and enter it in the "set value" box.

IMPORTANT! Before starting the calibration process:

• The power source must be connected to the calibration system.
• Calibration of a wirefeeder takes place after calibration of the power source.
• The power source to be calibrated must be switched on at least 5 minutes before the calibration process starts.

The calibration process is started from the calibration software on the computer / laptop.

IMPORTANT! Before starting the calibration process:

• The power source must be connected to the calibration system.
• Calibration of a wirefeeder takes place after calibration of the power source.
• The power source to be calibrated must be switched on at least 5 minutes before the calibration process starts.

The calibration process is started from the calibration software on the computer / laptop.

Welding systems with external wirefeeder

• TS 4000 / 5000
• TPS 3200 / 4000 / 5000
• TIME 5000 Digital
• CMT 4000 Advanced
• TSt 3500/5000
• TSt 3500 / 5000 Rob
• TSt 3500 / 5000 Syn
• TSt 4000 / 5000 Pulse

Welding systems with integrated wire drive

• TPS 2700
• TSt 2200c (cable harness 43,0004,4850 also required)
• TSt 2500c / 2700c / 3000 c Pulse / 3500c

TIG welding systems

• TT 800 / 2200 / 2500 / 3000 / 4000 / 5000
• TT 800 / 2200 / 2500 / 3000 / 4000 / 5000 Job
• TT 2200 / 2500 / 3000 / 4000 / 5000 Comfort
• MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000
• MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000 Job
• MW 2200 / 2500 / 3000 / 4000 / 5000 Comfort

Manual metal arc welding systems

• TP 4000 / 5000 CEL

The power sources listed above have a LocalNet port and are calibrated using the following calibration process.

Welding systems with external wirefeeder

• TS 4000 / 5000
• TPS 3200 / 4000 / 5000
• TIME 5000 Digital
• CMT 4000 Advanced
• TSt 3500/5000
• TSt 3500 / 5000 Rob
• TSt 3500 / 5000 Syn
• TSt 4000 / 5000 Pulse

Welding systems with integrated wire drive

• TPS 2700
• TSt 2200c (cable harness 43,0004,4850 also required)
• TSt 2500c / 2700c / 3000 c Pulse / 3500c

TIG welding systems

• TT 800 / 2200 / 2500 / 3000 / 4000 / 5000
• TT 800 / 2200 / 2500 / 3000 / 4000 / 5000 Job
• TT 2200 / 2500 / 3000 / 4000 / 5000 Comfort
• MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000
• MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000 Job
• MW 2200 / 2500 / 3000 / 4000 / 5000 Comfort

Manual metal arc welding systems

• TP 4000 / 5000 CEL

The power sources listed above have a LocalNet port and are calibrated using the following calibration process.

Example layout with TPS 5000: CALSYS = Calibration system, CON = Interconnecting hosepack

Connecting the power source and calibration system

1Plug the mains cable into the calibration system

2Switch on the mains switch

3Connect the (+) power cable to the calibration system and the power source

4Connect the sense lead (red) to the calibration system

5Connect the (-) power cable to the calibration system and the power source

6Connect the sense lead (blue) to the calibration system

7Connect the LocalNet/USB converter to the calibration system and to a free LocalNet port on the welding system If there is no LocalNet port available, use the LocalNet passive distributor (4,100,261) e.g. for TSt 5000

8Switch on the power source

9Start calibration

For TransSteel TSt 2200c only:

A cable harness (item number 43,0004,4850) is also required when calibrating a TSt 2200c power source.
The calibration process is performed with an open power source housing.

7Connect the LocalNet/USB converter to the calibration system

8Remove the right side panel from the power source

9Connect the cable harness 43,0004,4850 to the 6-pin connector on the PC board LSTMAG20 as shown in the illustration

10Connect the cable harness and LocalNet/USB converter

Preliminary settings / device selection:Under Settings, select the connection to the power source:
o LocalNet

Set calibration class:
o Precision
o Standard

For details on calibration class, see page (→).

MIG/MAG welding systems with external wirefeeder

• TPS 320i / 400i / 500i / 600i
• TPS 400i LSC ADV

MIG/MAG welding systems with integrated wire drive

• TPS 270i C
• TPS 320i C

TIG welding systems

• iWave 300i - 500 DC
• iWave 300i - 500i AC/DC

The power sources listed above have a SpeedNet port and are calibrated using the following calibration process.

MIG/MAG welding systems with external wirefeeder

• TPS 320i / 400i / 500i / 600i
• TPS 400i LSC ADV

MIG/MAG welding systems with integrated wire drive

• TPS 270i C
• TPS 320i C

TIG welding systems

• iWave 300i - 500 DC
• iWave 300i - 500i AC/DC

The power sources listed above have a SpeedNet port and are calibrated using the following calibration process.

Example layout with TPS 500i: CALSYS = Calibration System

Connecting the power source and calibration system

Preliminary settings / device selection:
Under Settings, select the connection to the power source:
o SpeedNet

Define the calibration class:
o Precision

Software version 1.0.28 and higher:

TIG welding systems

• iWave 230i DC
• iWave 190i / 230i AC/DC

MIG/MAG welding systems with external wirefeeder

• TPS 320i / 400i / 500i / 600i
• TPS 400i LSC ADV

MIG/MAG welding systems with integrated wire drive

• TPS 270i C
• TPS 320i C

The TPS /i power sources can be calibrated via both the SpeedNet port and the USB port.

The power sources listed above have a USB port and are calibrated using the following calibration process.

Software version 1.0.28 and higher:

TIG welding systems

• iWave 230i DC
• iWave 190i / 230i AC/DC

MIG/MAG welding systems with external wirefeeder

• TPS 320i / 400i / 500i / 600i
• TPS 400i LSC ADV

MIG/MAG welding systems with integrated wire drive

• TPS 270i C
• TPS 320i C

The TPS /i power sources can be calibrated via both the SpeedNet port and the USB port.

The power sources listed above have a USB port and are calibrated using the following calibration process.

Example layout with iWave 230i: CALSYS = Calibration System

Connecting the power source and calibration system

Also required:

• 2 USB Ethernet adapters (from the scope of delivery of the calibration system)
  
  If the OPT/i Ethernet option is available at the power source, only one USB Ethernet adapter is required.
  
• 1 Ethernet cable with RJ45 plug connectors

IMPORTANT! Before starting the calibration process, check / set the network settings for USB calibration (see page (→)).

Preliminary settings / device selection:
Under Settings, select the connection to the power source:
o SpeedNet

[ ] Activate USB

When the connection has been successfully established, a message to this effect is displayed.

What to do if connection is unsuccessful:

• Check if the DHCP server is running (icon in the task bar!)
  If the DHCP server is not running, restart the software and check the network settings.
• Disconnect the USB briefly from the power source and reconnect it again

Define the calibration class:
o Precision

MIG/MAG welding systems with external wirefeeder

• VarioSynergic 3400 / 4000 / 5000

MIG/MAG welding systems with integrated wire drive

• VarioStar 1500 / 2500 / 3100
• VarioSynergic 3400 / 4000 / 5000

TIG welding systems

• MagicWave 2600 / 2600 CEL / 3000
• TransTig 2600 / 2600 CEL / 3000
• TransTig 1750 Puls
• TransTig 170 / 210

Manual metal arc welding systems

• TransPocket 125 VRD / 150 / 180
• TransPocket 1100 / 1200 / 1400 / 1500 / 2000
• TransPocket 2500 / 3500 - RC, TIG, Comfort
• AccuPocket 150

The Fronius power sources listed above do not have a SpeedNet or LocalNet port and are calibrated using the following calibration process.

MIG/MAG welding systems with external wirefeeder

• VarioSynergic 3400 / 4000 / 5000

MIG/MAG welding systems with integrated wire drive

• VarioStar 1500 / 2500 / 3100
• VarioSynergic 3400 / 4000 / 5000

TIG welding systems

• MagicWave 2600 / 2600 CEL / 3000
• TransTig 2600 / 2600 CEL / 3000
• TransTig 1750 Puls
• TransTig 170 / 210

Manual metal arc welding systems

• TransPocket 125 VRD / 150 / 180
• TransPocket 1100 / 1200 / 1400 / 1500 / 2000
• TransPocket 2500 / 3500 - RC, TIG, Comfort
• AccuPocket 150

The Fronius power sources listed above do not have a SpeedNet or LocalNet port and are calibrated using the following calibration process.

Example layout with VarioSynergic 3400: CALSYS = Calibration System

Connecting the power source and calibration system

If there is a Tuchel connection on the power source:

Calibrating the wire:

Set the manual metal arc welding operating mode on the power source and start the calibration program.

Preliminary settings / device selection:
Under settings, select:
o Fronius devices

Select the respective TransPocket variant

IMPORTANT! The mains voltage displayed is incorrect!
With single-phase machines, the mains voltage must be measured manually using a FLUKE measuring device, and entered!

[ ] Enable In Use and enter the measuring device used under External measuring equipment

Set calibration class:
o Precision
o Standard

For details on calibration class, see page (→).

• Set the specified measured value M1 on the power source and start the measuring process
• Enter the value displayed on the power source in the Display [A] box and click [Next >]
• Repeat the steps for the measured values M2 - M5 - M1
  (10 measurements)

Connect the Tuchel adapter cable to the power source and to the calibration system

Set the welding current on the power source:

• Set the manual metal arc welding operating mode
• Set the parameter Hti = 0 in the MMA welding setup menu

Start the calibration program

Preliminary settings / device selection
Under settings, select:
o Fronius devices

Select TransTig 1750 Puls

Click [External start with calibration system]

Enter the serial number of the TT 1750 Puls in the box

IMPORTANT! The mains voltage displayed is incorrect!
With single-phase machines, the mains voltage must be measured manually using a FLUKE measuring device, and entered!

[ ] Enable In Use and enter the measuring device used under External measuring equipment

Define the calibration class:
o Precision

• Set the specified measured value M1 on the power source and start the measuring process
• Enter the value displayed on the power source in the Display [A] box and click [Next >]
• Repeat the steps for the measured values M2 - M5 - M1 (10 measurements)

Open the clamping lever on the wirefeeder

Thread the welding wire back again and attach to the wire spool

Connect the Tuchel adapter cable to the power source and to the calibration system

Start the calibration program

Preliminary settings / device selection:
Under settings, select:
o Fronius devices

Select VarioSynergic 3400

[Display available] and [External start with calibration system] have been pre-selected

Enter the serial number of the VarioSynergic in the field

For the wirefeeder, enter five wire speed measured values M1 - M5 [m/min]:

• The measured value M5 corresponds to the maximum wire speed value (= 18 m/min with VS 3400).
• Enter the remaining measured values by pressing the tab key

Specify the following settings on the power source:

Move the welding program selector switch to the MANUAL position

For the U_S measurement, set the coarse stage switch to B and the fine stage switch to 7

Set the toggle switch to A (current)

Set the selector switch on the interior of the device to 2-step mode.

Starting the measuring process

Define the calibration class:
o Precision
o Standard

• Set the stage switch on the power source as specified in the calibration program for measuring point M1 (e.g. stage A1)
• Start the calibration process
• Read the measured value for the respective level in the calibration program and enter it in the Set value [A] box
• Start the calibration process
• Enter the value displayed on the power source in the Display [A] box and click [Next >]
• Repeat steps for measuring points M2 - M5
  
  For the subsequent measurement of M5 to M1, the set values entered are saved by the calibration program.
  
• Repeat the steps for the welding voltage
  
  After completing the current and voltage calibration, the message [Start calibration wirefeeder 1!] is displayed.
  

To calibrate the welding wire on the power source, specify the following settings:

Set the toggle switch to wirefeeder.
Set the wirefeeder controller on the interior of the device under MANUAL to 100 %.
Set the wire diameter for the welding wire used.

Depending on the measurement, set the wire speed controller to the relevant measured value according to the table.

• Disconnect the +/- current cables from the calibration station on the power source
• Connect the welding torch and Tuchel plug to the power source
• Remove the gas nozzle
• Thread the wire
• Close the clamping lever on the wirefeeder
• Thread the wire until it protrudes approx. 200 mm from the contact tip
• Thread the welding wire into the intake part of the sensor
• Use clamps to secure the welding torch in the welding wire calibration system at the contact tip
• Click on [Start calibration wirefeeder 1!]
• Set the respective measured value on the power source wire speed controller. (e.g.: M1 = 1 m)

• Press and hold the torch trigger to start the wirefeeder
• After about 3 seconds of wirefeeder running time, click on "Start measuring process" in the calibration program and release the torch trigger
• Enter the value displayed on the power source under "Display" and click on [Next >]
• Repeat the steps for the measurements from M2 to M5 and M1
  

Requirement:

• TransTig 170 / 210 firmware version: at least 4.1.7 or higher
• Start with external ignition aid (EHF) activated:
  TIG setup menu - Level 2 / IGn / EHF
  
  After calibration, deactivate EHF again or reset it to the original value.
  
• Break voltage UCo set to a value > 30 V:
  TIG setup menu - Level 2 / UCo > 30 V (factory setting = 35 V)

Notes on voltage calibration:

• The maximum voltage during calibration is 30 V.
• The same resistance of 480 mOhm is used for all measuring points.
• The calibration software automatically specifies the measuring points to be measured.
• The voltage is regulated by the current;
  the predefined current values are standard values and may have to be adjusted to achieve the specified voltages.

Recommended points for calibration:

Start the calibration program

Preliminary settings / device selection:
Under settings, select:
o Fronius devices

Select TransTig 170 / 210

Click [External start with calibration system]

Enter the serial number of the TT 170 / 210 in the box

Measure the mains voltage

Enter the mains voltage measured

Measure the open circuit voltage,
key in,
click [Start measurement]

[ ] Enable In Use and enter the measuring device used under External measuring equipment

Define the calibration class:
o Standard

• Set the specified measured value M1 on the power source
• Click [ Start measuring process ]
• Enter the value displayed on the power source in the Display [A] box
• Click [Next >]

The WeldCube Connector is always calibrated in connection with a welding system.

The following variants of the WeldCube Connector can be calibrated:

WeldCube Connector with current/voltage measurement:

• WeldCube Connector U/I
• WeldCube Connector Advanced

WeldCube Connector with current/voltage measurement and wire speed measurement (Euro):

• WeldCube Connector U/I/WFS Euro
• WeldCube Connector Advanced + OPT/WCC Wire Sensor EUR

WeldCube Connector with current/voltage measurement and wire speed measurement (TSt c, VR 5000):

• WeldCube Connector U/I/WFS WSM
• WeldCube Connector Advanced + OPT/WCC Wire Sensor WSM

Wire sensor installed in VR 5000 or in TSt c.

The WeldCube Connector is always calibrated in connection with a welding system.

The following variants of the WeldCube Connector can be calibrated:

WeldCube Connector with current/voltage measurement:

• WeldCube Connector U/I
• WeldCube Connector Advanced

WeldCube Connector with current/voltage measurement and wire speed measurement (Euro):

• WeldCube Connector U/I/WFS Euro
• WeldCube Connector Advanced + OPT/WCC Wire Sensor EUR

WeldCube Connector with current/voltage measurement and wire speed measurement (TSt c, VR 5000):

• WeldCube Connector U/I/WFS WSM
• WeldCube Connector Advanced + OPT/WCC Wire Sensor WSM

Wire sensor installed in VR 5000 or in TSt c.

Example layout with TPS 500i: WCC = WeldCube Connector, PoE = Power over Ethernet, CALSYS = Calibration system

Connecting the welding system, WeldCube Connector U/I and calibration system

Welding system polarity reversed

Preliminary settings / device selection:
Under Settings, select the connection to the power source:
o SpeedNet
o ...

Establishing a connection to the WeldCube Connector
(for details see WeldCube Connector operating instructions 42,0426,0363,xx)

• Start WeldConnect app and open menu
• Determine the welding circuit resistance of the welding system incl. WeldCube Connector
• Select WeldCube Connector Setup
• Take smartphone to the WeldCube Connector
• Follow the instructions in the installation wizard (Setup 1 - 7)
  
  Following the 7 setup steps, the WeldCube Connector will be ready to connect to the calibration software.

Click [Establish connection] in the calibration software

Deselect wire speed:
Click on the selection box

Enter the DHCP IP address of the WeldCube Connector

The network settings message is displayed.

Briefly disconnect and reconnect the Ethernet cable between the WeldCube Connector and PoE (OUT)

Set calibration class:
o Precision
o Standard

For details on calibration class, see page (→).

Start the automatic calibration process

When calibration is complete, a message to reverse the polarity of the WeldCube Connector is displayed.

IMPORTANT!
Reverse the polarity of the welding system according to figure B on page (→)

Confirm the message to reverse the polarity of the WeldCube Connector with OK.

The calibration process continues.

Example layout with TPS 500i: WCC = WeldCube Connector, PoE = Power over Ethernet, CALSYS = Calibration system, CON = Interconnecting hosepack

Connecting the welding system, WeldCube Connector U/I/WFS Euro and calibration system

Wire calibration

Preliminary settings / device selection:
Under Settings, select the connection to the power source:
o SpeedNet
o ...

Establishing a connection to the WeldCube Connector
(for details see WeldCube Connector operating instructions 42,0426,0363,xx)

• Start WeldConnect app and open menu
• Determine the welding circuit resistance of the welding system incl. WeldCube Connector
• Select WeldCube Connector Setup
• Take smartphone to the WeldCube Connector
• Follow the instructions in the installation wizard (Setup 1 - 7)
  
  Following the 7 setup steps, the WeldCube Connector will be ready to connect to the calibration software.

Click [Establish connection] in the calibration software

Enter the DHCP IP address of the WeldCube Connector

The network settings message is displayed.

Briefly disconnect and reconnect the Ethernet cable between the WeldCube Connector and PoE (OUT)

Define the calibration class:
o Precision
o Standard

For details on the calibration class, see page (→).

Start the automatic calibration process

IMPORTANT! If the calibration process is interrupted before the welding wire has been calibrated, a corresponding notification is displayed.

Convert welding system for wire calibration according to figure B from page (→)

Start wire calibration

When wire calibration is complete, a message to reverse the polarity of the WeldCube Connector is displayed.

IMPORTANT! Reverse the polarity of the welding system according to figure C from page (→)

Confirm the message to change the polarity of the WeldCube Connector with OK. The calibration process continues.

Otherwise, the WeldCube Connector U/I/WFS calibration process is the same as the calibration process for the WeldCube Connector U/IWFS Euro.

The calibration of gas supplies is only possible if one of the following devices or gas controls is present in the welding system:

LocalNet

• PlasmaModule 10 - 4,075,146
• External gas control 0.2-10.0 l/mi - 4,045,995
• I-kit digital gas sensor Gas 10 - 4,100,538 *
• External gas control 5-30 l/mi - 4,045,997
  

SpeedNet

• OPT/i gas control - 4,100,969
• OPT/i WF gas flow sensor - 4,101,150
• OPT/i gas control Compact - 4,101,422
• OPT/i TIG gas control - 4,101,259
• OPT/i WF TWIN gas control - 4,101,158

The calibration of gas supplies is only possible if one of the following devices or gas controls is present in the welding system:

LocalNet

• PlasmaModule 10 - 4,075,146
• External gas control 0.2-10.0 l/mi - 4,045,995
• I-kit digital gas sensor Gas 10 - 4,100,538 *
• External gas control 5-30 l/mi - 4,045,997
  

SpeedNet

• OPT/i gas control - 4,100,969
• OPT/i WF gas flow sensor - 4,101,150
• OPT/i gas control Compact - 4,101,422
• OPT/i TIG gas control - 4,101,259
• OPT/i WF TWIN gas control - 4,101,158

Example layout with TPS 500i: CALSYS = Calibration system, CON = Interconnecting hosepack, GAS = Gas hose

Connect gas supply with interface calibration system, calibration system and power source

Calibration of a gas supply is usually done as the last step of complete welding system calibration:

1. Calibrate power source (welding current, welding voltage)
2. Calibrate wirefeeder (wire speed)
3. Calibration of the gas supply

To calibrate a gas supply, the checkbox for gas flow must be activated in the calibration software for the wirefeeder.

Enter shielding gas composition

Start calibration

The "Gas calibration system" installation set is installed in the interface calibration system at the factory when ordered.