TPS 270i C 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

Local regulations and national guidelines may require a residual current protective device when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufacturer for the equipment is indicated in the technical data.

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 device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

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 wire spool, 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 be touched when the welding system is switched on.

Double the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. 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, have a second person 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
• Wire spools 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 facing 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.

Welding machines for work in areas with increased electrical risk (e.g. near boilers) must carry the 'Safety' sign. However, the welding machine 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 suitable load-carrying equipment.
• Chains or 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).

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

If the device 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 and disconnect devices from the grid 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 be performed at least once every 12 months.

The manufacturer recommends that the welding system 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 are 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 with any documents you may require, on request.

1. Safety rules

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

• Collect separately
• Observe locally valid regulations
• Compress the cardboard box to reduce volume

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

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

1. Safety rules

Copyright of these operating instructions remains with the manufacturer.

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

1. General information

The TPS 270i C MIG/MAG power source is a completely digitised, microprocessor-controlled inverter power source with integrated 4-roller wire drive.

The modular design and potential for system add-ons ensure a high degree of flexibility.
Its compact design makes the TPS 270i C particularly suitable for mobile applications.

The power source can be adapted to any specific situation.

1. General information
2. General

The TPS 270i C MIG/MAG power source is a completely digitised, microprocessor-controlled inverter power source with integrated 4-roller wire drive.

The modular design and potential for system add-ons ensure a high degree of flexibility.
Its compact design makes the TPS 270i C particularly suitable for mobile applications.

The power source can be adapted to any specific situation.

1. General information
2. General

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

• a precise welding process
• exact reproducibility of all results
• excellent weld properties.

1. General information
2. General

The devices are used in trade and industry for manual applications with classical steel, galvanised sheets, chrome/nickel and aluminium.

The integrated 4-roller wire drive, high performance and low weight of the power source makes it the ideal choice for portable applications on building sites or in repair workshops.

1. General information
2. General

Warning notices and safety symbols are affixed to power sources with the CSA test mark for use in North America (USA and Canada). 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.

Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:

• Anyone performing automated welding must be sufficiently qualified
• Suitable protective equipment must be used
• All persons not involved must be kept at a safe distance from the wirefeeder and the welding process
  

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
  

Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

Keep hands, hair, clothing and tools away from moving parts. For example:

• Cogs
• Feed rollers
• 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.

1. General information
2. General

For certain device versions, warning notices are affixed to the device.

The arrangement of the symbols may vary.

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

also:

• Welding torch
• Grounding cable and electrode cable
• Dust filter
• Additional current sockets

1. General information
2. System components

OPT/i TPS C polarity reverser

OPT/i TPS C SpeedNet Connector
Optional second SpeedNet connection socket

Installed on the rear of the power source.

OPT/i external sensor connector

OPT/i TPS 270i C PushPull

OPT/i TPS C TIG TMC

OPT/i TPS 270i C Ethernet

OPT/i Synergic Lines
Option for enabling all special characteristics available on TPSi power sources;
this also automatically enables special characteristics created in future.

OPT/i GUN Trigger
Option for special functions in conjunction with the torch trigger

OPT/i OPC-UA
Standardised data interface protocol

OPT/i MQTT
Standardised data interface protocol

Various welding packages, welding characteristics and welding processes are available with TPSi power sources that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes

Various welding packages, welding characteristics and welding processes are available with TPSi power sources that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes
2. Welding packages

Various welding packages, welding characteristics and welding processes are available with TPSi power sources that enable a wide range of materials to be effectively welded.

1. Welding packages, welding characteristics and welding processes
2. Welding packages

The following welding packages are available for TPSi power sources:

Standard Welding Package
4,066,012
(enables MIG/MAG standard synergic welding)

Pulse Welding Package
4,066,013
(enables MIG/MAG pulse synergic welding)

LSC Welding Package *
4,066,014
(enables the LSC process)

PMC Welding Package **
4,066,015
(enables the PMC process)

CMT Welding Package ***
4,066,016
(enables the CMT process)

ConstantWire Welding Package
4,066,019
(enables constant current or constant voltage operation during brazing)

IMPORTANT! A TPSi power source without welding packages only offers the following welding processes:

• MIG/MAG standard manual welding
• TIG welding
• MMA welding

1. Welding packages, welding characteristics and welding processes

Depending on the welding process and shielding gas mix, various process-optimised welding characteristics are available when selecting the filler metal.

Examples of welding characteristics:

• MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow *
• MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
• MIG/MAG 3044 Puls AlMg5 1.2 mm I1 - universal *
• MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the special properties and use of the welding characteristic.
The description of the characteristics is set out as follows:

Marking
Welding process
Properties

additive
CMT

Characteristics with reduced heat input and greater stability at a higher deposition rate for welding bead onto bead in adaptive structures

arc blow
PMC

Characteristic to avoid arc breaks due to arc blow.

arcing
Standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

base
standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

braze
CMT, LSC, PMC

Characteristic for brazing processes (reliable wetting and good flow of braze material)

braze+
CMT

Characteristic for brazing processes with the special Braze+ gas nozzle and high brazing speed (gas nozzle with narrow opening and high flow rate)

CC/CV
CC/CV

Characteristic with constant current or constant voltage curve for power supply operation of the power source, a wirefeeder is not required.

cladding
CMT, LSC, PMC

Characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting

constant current
PMC

Constant current characteristic
for applications where no arc length control is required (stick out changes are not compensated)

CW additive
PMC, ConstantWire

Characteristic with constant wire speed progression for the additive production process
With this characteristic, no arc is ignited, the welding wire is only fed as filler metal.

dynamic
CMT, PMC, Puls, Standard

Characteristic for deep penetration and reliable root fusion at high welding speeds

dynamic +
PMC

Characteristic with short arc length for high welding speeds with arc length control independent of the material surface.

edge
CMT

Characteristic for welding corner seams with targeted energy input and high welding speed

flanged edge
CMT

Characteristic for welding flange welds with targeted energy input and high welding speed

galvanized
CMT, LSC, PMC, Puls, Standard

Characteristics for galvanised sheet surfaces (low risk of zinc pores and reduced penetration)

galvannealed
PMC

Characteristics for iron-zinc coated material surfaces

gap bridging
CMT, PMC

Characteristic for the best gap-bridging ability due to very low heat input

hotspot
CMT

Characteristic with hot start sequence, specifically for plug welds and MIG/MAG spot weld joints

mix ^{2) / 3)}
PMC

Also required:
Pulse and PMC Welding Packages

Characteristic for the production of a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed and dip transfer arc.

marking
Characteristics for marking conductive surfaces

Characteristic for marking electrically conductive surfaces.
Marking is performed by low power spark erosion and a reversing wire movement.

mix ^{2) / 3)}
CMT

Also required:
CMT drive unit WF 60i Robacta Drive CMT
Pulse, Standard and CMT Welding Packages

Characteristic for the production of a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed arc or CMT.

mix drive ²⁾
PMC

Also required:
PushPull drive unit WF 25i Robacta Drive or WF 60i Robacta Drive CMT
Pulse and PMC Welding Packages

Characteristic for the production of a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement

multi arc
PMC

Characteristic for components being welded by several arcs each influencing the other. Ideal for increased welding circuit inductance or mutual welding circuit coupling.

open root
LSC, CMT

Characteristic with powerful arc, especially suitable for root passes with air gap

PCS ³⁾
PMC

The characteristic changes directly from a pulsed arc to a concentrated spray arc above a certain power. The advantages of pulsed and spray arcs are combined in a single characteristic.

PCS mix
PMC

The characteristic changes cyclically between a pulsed or spray arc to a dip transfer arc, depending on the power range. It is especially suitable for vertical-up welds due to the alternating hot and then cold, supporting process phase.

pin
CMT

Characteristic for welding brads to an electrically conductive surface
The retraction movement of the wire electrode and the set current curve progression define the appearance of the pin.

pin picture
CMT

Characteristic for welding brads with a spherical end onto an electrically conductive surface, especially for creating pin pictures.

pin print
CMT

Characteristic for writing texts, patterns or markings on electrically conductive component surfaces
Writing takes place by positioning individual dots the size of a welding droplets.

pin spike
CMT

Characteristic for welding brads with pointed ends onto an electrically conductive surface.

pipe
PMC, Pulse, Standard

Characteristics for pipe applications and positional welding on narrow gap applications

pipe cladding
PMC, CMT

Characteristics for overlay welding of outer pipe claddings with little penetration, low dilution and wide weld seam flow

retro
CMT, Puls, PMC, Standard

The characteristic has the same weld properties as the predecessor TransPuls Synergic (TPS) series.

ripple drive ²⁾
PMC

Also required:
CMT drive unit, WF 60i Robacta Drive CMT

Characteristic for the production of a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement.
The weld rippling characteristics are similar to that of TIG welds.

root
CMT, LSC, Standard

Characteristics for root passes with powerful arc

seam track
PMC, Pulse

Characteristic with amplified current control, especially suitable for the use of a seam tracking system with external current measurement.

TIME
PMC

Characteristic curve for welding with very long stick out and T.I.M.E. shielding gases to increase the deposition rate.
(T.I.M.E. = Transferred Ionized Molten Energy)

universal
CMT, PMC, Puls, Standard

The characteristic is ideal for all standard welding tasks.

weld+
CMT

Characteristics for welding with short stick out and Braze+ gas nozzle (gas nozzle with small opening and high flow velocity)

1. Welding packages, welding characteristics and welding processes
2. Welding characteristics

Depending on the welding process and shielding gas mix, various process-optimised welding characteristics are available when selecting the filler metal.

Examples of welding characteristics:

• MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow *
• MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *
• MIG/MAG 3044 Puls AlMg5 1.2 mm I1 - universal *
• MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the special properties and use of the welding characteristic.
The description of the characteristics is set out as follows:

Marking
Welding process
Properties

additive
CMT

Characteristics with reduced heat input and greater stability at a higher deposition rate for welding bead onto bead in adaptive structures

arc blow
PMC

Characteristic to avoid arc breaks due to arc blow.

arcing
Standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

base
standard

Characteristics for a special type of hardfacing on a wet or dry surface
(e.g. grinding rollers in the sugar and ethanol industries)

braze
CMT, LSC, PMC

Characteristic for brazing processes (reliable wetting and good flow of braze material)

braze+
CMT

Characteristic for brazing processes with the special Braze+ gas nozzle and high brazing speed (gas nozzle with narrow opening and high flow rate)

CC/CV
CC/CV

Characteristic with constant current or constant voltage curve for power supply operation of the power source, a wirefeeder is not required.

cladding
CMT, LSC, PMC

Characteristics for overlay welding with low penetration, low dilution and wide weld seam flow for improved wetting

constant current
PMC

Constant current characteristic
for applications where no arc length control is required (stick out changes are not compensated)

CW additive
PMC, ConstantWire

Characteristic with constant wire speed progression for the additive production process
With this characteristic, no arc is ignited, the welding wire is only fed as filler metal.

dynamic
CMT, PMC, Puls, Standard

Characteristic for deep penetration and reliable root fusion at high welding speeds

dynamic +
PMC

Characteristic with short arc length for high welding speeds with arc length control independent of the material surface.

edge
CMT

Characteristic for welding corner seams with targeted energy input and high welding speed

flanged edge
CMT

Characteristic for welding flange welds with targeted energy input and high welding speed

galvanized
CMT, LSC, PMC, Puls, Standard

Characteristics for galvanised sheet surfaces (low risk of zinc pores and reduced penetration)

galvannealed
PMC

Characteristics for iron-zinc coated material surfaces

gap bridging
CMT, PMC

Characteristic for the best gap-bridging ability due to very low heat input

hotspot
CMT

Characteristic with hot start sequence, specifically for plug welds and MIG/MAG spot weld joints

mix ^{2) / 3)}
PMC

Also required:
Pulse and PMC Welding Packages

Characteristic for the production of a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed and dip transfer arc.

marking
Characteristics for marking conductive surfaces

Characteristic for marking electrically conductive surfaces.
Marking is performed by low power spark erosion and a reversing wire movement.

mix ^{2) / 3)}
CMT

Also required:
CMT drive unit WF 60i Robacta Drive CMT
Pulse, Standard and CMT Welding Packages

Characteristic for the production of a rippled weld.
The heat input into the component is specifically controlled by the cyclical process change between pulsed arc or CMT.

mix drive ²⁾
PMC

Also required:
PushPull drive unit WF 25i Robacta Drive or WF 60i Robacta Drive CMT
Pulse and PMC Welding Packages

Characteristic for the production of a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement

multi arc
PMC

Characteristic for components being welded by several arcs each influencing the other. Ideal for increased welding circuit inductance or mutual welding circuit coupling.

open root
LSC, CMT

Characteristic with powerful arc, especially suitable for root passes with air gap

PCS ³⁾
PMC

The characteristic changes directly from a pulsed arc to a concentrated spray arc above a certain power. The advantages of pulsed and spray arcs are combined in a single characteristic.

PCS mix
PMC

The characteristic changes cyclically between a pulsed or spray arc to a dip transfer arc, depending on the power range. It is especially suitable for vertical-up welds due to the alternating hot and then cold, supporting process phase.

pin
CMT

Characteristic for welding brads to an electrically conductive surface
The retraction movement of the wire electrode and the set current curve progression define the appearance of the pin.

pin picture
CMT

Characteristic for welding brads with a spherical end onto an electrically conductive surface, especially for creating pin pictures.

pin print
CMT

Characteristic for writing texts, patterns or markings on electrically conductive component surfaces
Writing takes place by positioning individual dots the size of a welding droplets.

pin spike
CMT

Characteristic for welding brads with pointed ends onto an electrically conductive surface.

pipe
PMC, Pulse, Standard

Characteristics for pipe applications and positional welding on narrow gap applications

pipe cladding
PMC, CMT

Characteristics for overlay welding of outer pipe claddings with little penetration, low dilution and wide weld seam flow

retro
CMT, Puls, PMC, Standard

The characteristic has the same weld properties as the predecessor TransPuls Synergic (TPS) series.

ripple drive ²⁾
PMC

Also required:
CMT drive unit, WF 60i Robacta Drive CMT

Characteristic for the production of a rippled weld by means of a cyclical process interruption of the pulsed arc and an additional wire movement.
The weld rippling characteristics are similar to that of TIG welds.

root
CMT, LSC, Standard

Characteristics for root passes with powerful arc

seam track
PMC, Pulse

Characteristic with amplified current control, especially suitable for the use of a seam tracking system with external current measurement.

TIME
PMC

Characteristic curve for welding with very long stick out and T.I.M.E. shielding gases to increase the deposition rate.
(T.I.M.E. = Transferred Ionized Molten Energy)

universal
CMT, PMC, Puls, Standard

The characteristic is ideal for all standard welding tasks.

weld+
CMT

Characteristics for welding with short stick out and Braze+ gas nozzle (gas nozzle with small opening and high flow velocity)

1. Welding packages, welding characteristics and welding processes

MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material transfer.
In the base current phase, the energy supply is reduced to such an extent that the arc is only just stable and the surface of the workpiece is preheated. In the pulsing current phase, a precisely dosed current pulse ensures the targeted detachment of a droplet of welding material.
This principle guarantees low-spatter welding and precise work over the entire power range.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material transfer.
In the base current phase, the energy supply is reduced to such an extent that the arc is only just stable and the surface of the workpiece is preheated. In the pulsing current phase, a precisely dosed current pulse ensures the targeted detachment of a droplet of welding material.
This principle guarantees low-spatter welding and precise work over the entire power range.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

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. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

PMC = Pulse Multi Control

PMC is a pulsed arc welding process with high-speed data processing, precise recording of the process status and improved droplet detachment. Faster welding possible with a stable arc and even penetration.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

LSC = Low Spatter Control

LSC is a low-spatter dip transfer arc process. Before the short circuit bridge is broken, the current is lowered and re-ignition takes place at significantly lower welding current values.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

SynchroPulse is available for all processes (standard/pulsed/LSC/PMC).
Due to the cyclical change of welding power between two operating points, SynchroPulse achieves a flaking seam appearance and non-continuous heat input.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

CMT = Cold Metal Transfer

A special CMT drive unit is required for the CMT process.

The reversing wire movement in the CMT process results in a droplet detachment with improved dip transfer arc properties.
The advantages of the CMT process are as follows

• Low heat input
• Less spattering
• Reduced emissions
• High process stability

The CMT process is suitable for:

• Joint welding, cladding and brazing – particularly in the case of high requirements in terms of heat input and process stability
• Light-gauge sheet welding with minimal distortion
• Special connections, such as copper, zinc, and steel/aluminium

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

CMT Cycle Step is a further development of the CMT welding process. A special CMT drive unit is also required for this process.

CMT Cycle Step is the welding process with the lowest heat input.
The CMT Cycle Step welding process switches cyclically between CMT welding and pauses of an adjustable duration.
These pauses in the welding process lower the heat input; the continuity of the weld seam is maintained.
Individual CMT cycles are also possible. The size of the CMT spot welds is determined by the number of CMT cycles.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

The SlagHammer function is implemented in all steel characteristics.
In conjunction with a CMT drive unit WF 60i CMT, slag is knocked off the weld seam and wire electrode end by a reversing wire movement without arc before welding.
Knocking off the slag ensures reliable and precise ignition of the arc.

A wire buffer is not required for the SlagHammer function.
The SlagHammer function is automatically executed if a CMT drive unit is present in the welding system.

1. Welding packages, welding characteristics and welding processes
2. Welding methods and processes

With stitch welding, all welding processes can be cyclically interrupted. This facilitates targeted control of the heat input.
Welding time, pause time and the number of interval cycles can be set individually (e.g. for producing a rippled weld seam, for tacking light-gauge sheets or for longer pause times for simple, automatic spot welding mode).

Stitch welding is possible with any operating mode.
In special 2-step mode and special 4-step mode, no interval cycles are performed during the start and end phases. The interval cycles are only executed in the main process phase.

Welding parameters can be easily changed and selected using the adjusting dial.
The parameters are shown on the display while welding is in progress.

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

1. Controls, connections and mechanical components

Welding parameters can be easily changed and selected using the adjusting dial.
The parameters are shown on the display while welding is in progress.

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

1. Controls, connections and mechanical components
2. Control panel

Welding parameters can be easily changed and selected using the adjusting dial.
The parameters are shown on the display while welding is in progress.

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

1. Controls, connections and mechanical components
2. Control panel

1. Controls, connections and mechanical components
2. Control panel

No.	Function
(1)	Process control parameter indicator For the LSC and PMC welding processes Penetration stabilizer indicator Lights up if the penetration stabilizer is active Arc length stabilizer indicator Lights up when the arc length stabilizer is active
(2)	Left parameter selection The corresponding indicator lights up when a parameter is selected. The following parameters can be selected by pressing the button: Material thickness * In mm or inches Welding current * In A Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding. Wire speed * In m/min or ipm Special function Any parameter can be assigned to this The function can be selected if a parameter has been saved. Penetration stabilizer Arc length stabilizer The "Penetration stabilizer" and "Arc length stabilizer" process control parameters can only be selected when the LSC/PMC welding process is used. The currently adjustable parameter is marked with an arrow. * Synergic parameter When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.
(3)	Display For displaying values
(4)	Hold/Intermediate arc indicator Hold indicator The indicator lights up at the end of each welding operation and the actual values for the welding current, welding voltage and wire speed, etc. are automatically shown on the display. Intermediate arc indicator The indicator lights up when a spatter-prone intermediate arc occurs between the dip transfer arc and the spray arc.
(5)	Right parameter selection The corresponding indicator lights up when a parameter is selected. The following parameters can be selected by pressing the button: 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. The actual value is displayed during welding. Pulse/dynamic correction The function varies according to the welding process being used. A description of the various functions can be found in the Welding chapter under the corresponding welding process. Special function Any parameter can be assigned to this The function can be selected if a parameter has been saved. * Synergic parameter When a synergic parameter is changed, the synergic function automatically changes all other synergic parameters to match.
(6)	Indicators SFI indicator Lights up when SFI (Spatter Free Ignition) is active SynchroPulse indicator Lights up when SynchroPulse is active VRD indicator Lights up when the voltage reduction device (VRD) is active
(7)	EasyJob buttons For saving, retrieving and deleting EasyJobs The LED on the corresponding button lights up when an EasyJob is selected.
(8)	Right adjusting dial with turn/press function For setting the arc length correction, welding voltage, pulse/dynamic correction and F2 parameters Turn the adjusting dial: change values, select parameters (in the Setup menu and when selecting the filler metal) Press the adjusting dial: confirm a menu selection, apply values
(9)	Welding process selection The corresponding LED lights up when a welding process is selected. The following welding processes can be selected by pressing the button: PULS SYNERGIC (MIG/MAG pulse synergic welding) SYNERGIC (MIG/MAG standard synergic welding)   MANUAL (MIG/MAG standard manual welding) LSC/PMC (LSC = Low Spatter Control, PMC = Pulse Multi Control) Depending on which function package is enabled STICK/TIG (MMA welding/TIG welding) CMT / SP (CMT welding / special programs)
(10)	USB port To perform the software update using a USB Ethernet adapter. For details on the function of the USB port, see page (→).
(11)	Mode selection The corresponding LED lights up when a mode is selected. The following modes can be selected by pressing the button:   2T (2-step mode)   4T (4-step mode)   S4T (Special 4-step mode) S2T    (Special 2-step mode) MODE (Special modes depending on the function package)
(12)	Gas-test button For setting the required gas flow rate on the gas pressure regulator. After pressing this button, gas flows for 30 seconds. Press the button again to stop the gas flow prematurely.
(13)	Wire threading button To thread the wire electrode into the torch hosepack with no accompanying flow of gas or current
(14)	Left adjusting dial with turn/press function For setting the sheet thickness, welding current, wire speed, F1, penetration stabilizer and arc length stabilizer parameters For displaying help texts Turn the adjusting dial: Select parameters, change values, display long help texts Press the adjusting dial: To confirm a menu selection, apply values, call up help texts for parameters
(15)	Favourites button Individual parameters or parent folders can be assigned to it
(16)	Filler metal info button For showing the currently set filler metal
(17)	Filler metal selection button For selecting the filler metal

1. Controls, connections and mechanical components
2. Control panel

The left adjusting dial can be used to display the corresponding plain text for each parameter abbreviation shown on the display.

Example:

Parameter or entry from the Setup menu has been selected using the right
adjusting dial; the LED on the right adjusting dial lights up.

The plain text for the parameter is displayed; the LED on the left adjusting dial lights up.

The plain text is moved across the display.

1. Controls, connections and mechanical components

Setting F1 and F2 special function parameters

Example: the selected parameter I-S is assigned to F1

F1/F2 flashes while the parameter selection button is pressed.

As soon as the parameter is saved, the indicator for the corresponding special function parameter lights up.
F1 (for example) and a tick is shown next to the parameter:

The selected parameter is now stored under F1.

If a parameter cannot be assigned to the F1 or F2 special function parameters, after approx. 5 seconds F1 (for example) and X is displayed:

This deletes an existing stored parameter.

Retrieving F1 and F2 special function parameters

The stored parameter is shown first, then the currently set value of the parameter.

Deleting F1 and F2 special function parameters

The stored parameter is deleted, F1 (for example) and X is shown on the display:

The F1 and F2 special function parameters can also be set in the Setup menu (page (→)).

1. Controls, connections and mechanical components
2. F1/F2 special function parameters, Favourites button

Setting F1 and F2 special function parameters

Example: the selected parameter I-S is assigned to F1

F1/F2 flashes while the parameter selection button is pressed.

As soon as the parameter is saved, the indicator for the corresponding special function parameter lights up.
F1 (for example) and a tick is shown next to the parameter:

The selected parameter is now stored under F1.

If a parameter cannot be assigned to the F1 or F2 special function parameters, after approx. 5 seconds F1 (for example) and X is displayed:

This deletes an existing stored parameter.

Retrieving F1 and F2 special function parameters

The stored parameter is shown first, then the currently set value of the parameter.

Deleting F1 and F2 special function parameters

The stored parameter is deleted, F1 (for example) and X is shown on the display:

The F1 and F2 special function parameters can also be set in the Setup menu (page (→)).

1. Controls, connections and mechanical components
2. F1/F2 special function parameters, Favourites button

Assigning the Favourites button

Individual parameters or parent folders from the Setup menu can be assigned to the Favourites button. These parameters or parent folders can then be called up directly using the control panel.

Example: The selected SynchroPulse folder is assigned to the Favourites button

Next to the parameter or folder    and a tick are shown:

The selected parameter or folder is now assigned to the Favourites button.

Retrieving favourites

Parameters or folders stored under the Favourites button can be retrieved in any setting, except for when the Setup menu is active.
Ongoing selection processes or called up jobs are cancelled when favourites are retrieved.

The LED on the Favourites button lights up and the stored parameter or folder is shown on the display.

The LED on the Favourites button goes out and the display switches to the welding parameters.

Deleting favourites

The stored parameter or folder is deleted and    and X are shown on the display:

The Favourites button can also be assigned in the Setup menu (page (→)).

1. Controls, connections and mechanical components

Front

No.	Function
(1)	Control panel with display for operating the power source
(2)	(+) current socket with bayonet latch
(3)	Blanking cover reserved for the TMC connection socket of the TIG option
(4)	Welding torch connection for connecting the welding torch
(5)	(-) current socket with bayonet latch used to connect the grounding cable during MIG/MAG welding

Rear

No.	Function
(6)	MIG/MAG shielding gas connection socket
(7)	Blanking cover/TIG shielding gas connection socket (option)
(8)	Blanking cover/Ethernet connection socket (option)
(9)	Blanking cover/SpeedNet Connector connection socket (option)/external sensor (option)
(10)	Mains cable with strain relief device
(11)	Mains switch for switching the power source on and off

Side view

No.	Function
(12)	Wirespool holder with brake for holding standard wirespools weighing up to 19 kg (41.89 lb.) and with a max. diameter of 300 mm (11.81 in)
(13)	4 roller drive

1. Controls, connections and mechanical components
2. Connections, switches and mechanical components

Front

No.	Function
(1)	Control panel with display for operating the power source
(2)	(+) current socket with bayonet latch
(3)	Blanking cover reserved for the TMC connection socket of the TIG option
(4)	Welding torch connection for connecting the welding torch
(5)	(-) current socket with bayonet latch used to connect the grounding cable during MIG/MAG welding

Rear

No.	Function
(6)	MIG/MAG shielding gas connection socket
(7)	Blanking cover/TIG shielding gas connection socket (option)
(8)	Blanking cover/Ethernet connection socket (option)
(9)	Blanking cover/SpeedNet Connector connection socket (option)/external sensor (option)
(10)	Mains cable with strain relief device
(11)	Mains switch for switching the power source on and off

Side view

No.	Function
(12)	Wirespool holder with brake for holding standard wirespools weighing up to 19 kg (41.89 lb.) and with a max. diameter of 300 mm (11.81 in)
(13)	4 roller drive

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 (earthing) cable
• MIG/MAG welding torch, gas-cooled
• Shielding gas supply
• Wire electrode

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

• Power source
• Cooling unit
• Grounding (earthing) cable
• MIG/MAG welding torch, water-cooled
• Shielding gas supply
• Wire electrode

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

• Power source
• Standard, Pulse and CMT welding packages enabled on the power source
• Grounding cable
• PullMig CMT welding torch incl. CMT drive unit and CMT wire buffer
  
  IMPORTANT! For water-cooled CMT applications, a cooling unit is also required!
  
• OPT/i PushPull
• CMT interconnecting hosepack
• Wire electrode
• Gas connection (shielding gas supply)

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

• Power source
• Grounding (earthing) cable
• TIG gas-valve torch
• Gas connection (shielding gas supply)
• Filler metal (depending on the application)

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

• Power source
• Grounding (earthing) cable
• Electrode holder with welding cable
• 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, MMA and TIG welding. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage 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 solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

The device can be set up and operated outdoors in accordance with protection class IP23. Direct moisture (e.g., from rain) must be avoided.

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

1. Installation and commissioning
2. Before installation and commissioning

• The devices are designed for the mains voltage specified on the rating plate.
• Devices with a rated welding voltage of 3 x 575 V must be operated on three-phase systems with earth neutral.
• If your version of the appliance does not come with mains cables and mains plugs ready-fitted, these must be fitted by a qualified person in accordance with national standards.
• The fuse protection for the mains lead is indicated in the technical data.

1. Installation and commissioning
2. Before 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. Before installation and commissioning

• Trolley
• Welding torch
• etc.

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

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.
Strain-relief devices for the following cable cross-sections are fitted to TPS 270i C power sources:

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

1. Installation and commissioning
2. Connecting the mains cable

AWG = American wire gauge

1. Installation and commissioning
2. Connecting the mains cable

IMPORTANT! The ground conductor should be approx. 20 - 25 mm (0.8 - 1 in.) longer than the phase conductors.

1

6 x TX25

2

5 x TX25

3

4

Tightening torque = 1.2 Nm

IMPORTANT! When connecting the cable to the switch, ensure:

• To route the conductors near to the switch
• Not to make the conductors unnecessarily long
• To fit the protective hose supplied over the cable and insert the covered cable into the strain-relief device if cable diameters are small
  

5

Tightening torque = 1.2 Nm

6

Tightening torque = 1.2 Nm

7

5 x TX25, tightening torque = 3 Nm

8

6 x TX25, tightening torque = 3 Nm

1. Installation and commissioning

1. Installation and commissioning
2. Start-up

1. Installation and commissioning
2. Start-up

Commissioning the power source is described with reference to a manual gas-cooled MIG/MAG application.

1. Installation and commissioning
2. Start-up

Connecting the gas hose

1Place the gas cylinder on a solid, level surface in such a way that it remains stable

2Secure the gas cylinder to prevent it from toppling over (but not around the neck of the cylinder)

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 pressure regulator to the shielding gas connection on the power source using the gas hose

1. Installation and commissioning
2. Start-up

Connecting the return lead cable

1Plug the return lead cable into the (-) current socket

2Lock the return lead cable in place

3Use the other end of the return lead cable to establish a connection to the workpiece

1. Installation and commissioning
2. Start-up

1Before connecting the welding torch, check that all cables, lines and hosepacks are undamaged and properly insulated.

2Open the wire-feed unit cover

3

1. Installation and commissioning
2. Start-up

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

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

3

4

Notes on wire threading

If contact is made with the earth during wire threading, the wire electrode is automatically stopped.

When the torch trigger is pressed once, the wire electrode moves forwards 1 mm.

With a push wire feeding system:
If contact is made with the workpiece during threading, the wire play in the inner liner is measured. If the measurement is successful, a wire play value is entered in the event logbook, which is used to control the system.

1. Installation and commissioning
2. Start-up

1

Contact pressure standard 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 is for information purposes only.

1. Installation and commissioning
2. Start-up

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system.

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding
2. MIG/MAG modes

See the Setup menu for information on settings, setting range and units of measurement for the available parameters.

1. Welding
2. MIG/MAG modes

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

GPr
Gas pre-flow

I-S
Starting-current phase: the base material is heated up rapidly, despite the high thermal dissipation that occurs at the start of welding

t-S
Starting current time

Start arc length correction

SL1
Slope 1: the starting current is steadily lowered until it reaches the welding current

I
Welding-current phase: uniform thermal input into the base material, whose temperature is raised by the advancing heat

I-E
Final current phase: to prevent any local overheating of the base material due to heat build-up towards the end of welding. This eliminates any risk of weld seam drop-through.

t-E
Final current time

End arc length correction

SL2
Slope 2: the welding current is steadily lowered until it reaches the final current

GPo
Gas post-flow

SPt
Spot welding time

A detailed explanation of the parameters can be found in the section headed "Process parameters".

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" is particularly suitable for welding aluminium materials. The special slope of the welding current curve takes account of the high thermal conductivity of aluminium.

1. Welding
2. MIG/MAG modes

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

1. Welding
2. MIG/MAG modes

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

1. Welding

1. Welding
2. MIG/MAG and CMT welding

1. Welding
2. MIG/MAG and CMT welding

The "MIG/MAG and CMT welding" section comprises the following steps:

• Switching on the power source
• Selecting the welding process and operating mode
• Retrieving the currently set filler metal
• Selecting the filler metal
• Setting the welding parameters
• Setting the shielding gas flow rate
• MIG/MAG or CMT welding

1. Welding
2. MIG/MAG and CMT welding

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system.

1. Welding
2. MIG/MAG and CMT welding

1. Welding
2. MIG/MAG and CMT welding

The LED on the button lights up and the currently set filler metal is shown on the display:

The currently set wire diameter is shown on the display:

The currently set shielding gas is shown on the display:

The currently set characteristic is shown on the display:

The currently set welding parameter values are shown on the display.

1. Welding
2. MIG/MAG and CMT welding

The LED on the button lights up and "filler metal?" is shown on the display:

The first available filler metal is displayed:

"diameter?" is shown on the display: *

The first available wire diameter is displayed:

"gas?" is shown on the display: *

The first available shielding gas is displayed:

If available, the first available characteristic is displayed: *

A prompt to apply the new filler metal is displayed: *

The set filler metal is saved.

1. Welding
2. MIG/MAG and CMT welding

	Material thickness
	Welding current
	Wire speed
	Special function

	Arc length correction
	Welding voltage
	Pulse/dynamic correction
	Special function

The amended parameter values are applied immediately.
If one of the wire speed, material thickness, welding current or welding voltage parameters are changed during synergic welding, the remaining welding parameters are immediately altered accordingly.

1. Welding
2. MIG/MAG and CMT welding

1. Welding
2. MIG/MAG and CMT welding

Whenever welding ends, the actual values for the welding current, welding voltage and wire speed are stored, and HOLD appears on the display.

1. Welding

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

Spot welding can be carried out in the following welding processes:
PULSE SYNERGIC | SYNERGIC | MANUAL | LSC/PMC | SP (CMT)

"Spot" appears briefly on the display.

The SPt (spot welding time) parameter is shown.

Procedure for producing a welding spot:

1. Welding
2. Spot and stitch welding

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

Spot welding can be carried out in the following welding processes:
PULSE SYNERGIC | SYNERGIC | MANUAL | LSC/PMC | SP (CMT)

"Spot" appears briefly on the display.

The SPt (spot welding time) parameter is shown.

Procedure for producing a welding spot:

1. Welding
2. Spot and stitch welding

Procedure for stitch welding:

Notes on stitch welding

With PMC characteristics, the setting of the SFI parameter influences the re-ignition behaviour in interval operation:

SFI = on
Re-ignition takes place with SFI.

SFI = off
Re-ignition takes place by means of touchdown ignition.

For aluminium alloys, SFI is always used for pulse and PMC ignition. SFI ignition cannot be deactivated.

If the SlagHammer function is stored on the selected characteristic, faster and more stable SFI ignition takes place in conjunction with a CMT drive unit and a wire buffer.

1. Welding

The following welding parameters can be set and displayed for MIG/MAG pulse synergic welding and PMC welding:

using the left adjusting dial:

Material thickness ¹⁾

Setting range: 0.1 - 30.0 mm ²⁾ / 0.004 - 1.18 in. ²⁾

Welding current ¹⁾
in A

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Wire speed ¹⁾

Setting range: 0.5 - 25 m/min ²⁾ / 20 - 980 ipm. ²⁾

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

Penetration stabilizer ⁴⁾ (see page (→))

Setting range: 0 - 10 m/min / 0 - 393.7 ipm
Factory setting: 0

Arc length stabilizer ⁴⁾ (see page (→))

Setting range: 0 - 5
Factory setting: 0

using the right adjusting dial:

Arc length correction
for correcting the arc length;

Setting range: -10 - +10
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

Welding voltage ¹⁾
in V

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction
for correcting the pulsing energy of a pulsed arc

Setting range: -10 - +10
Factory setting: 0

- ... lower droplet detachment force
0 ... neutral droplet detachment force
+ ... increased droplet detachment force

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

1. Welding
2. MIG/MAG and CMT welding parameters

The following welding parameters can be set and displayed for MIG/MAG pulse synergic welding and PMC welding:

using the left adjusting dial:

Material thickness ¹⁾

Setting range: 0.1 - 30.0 mm ²⁾ / 0.004 - 1.18 in. ²⁾

Welding current ¹⁾
in A

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Wire speed ¹⁾

Setting range: 0.5 - 25 m/min ²⁾ / 20 - 980 ipm. ²⁾

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

Penetration stabilizer ⁴⁾ (see page (→))

Setting range: 0 - 10 m/min / 0 - 393.7 ipm
Factory setting: 0

Arc length stabilizer ⁴⁾ (see page (→))

Setting range: 0 - 5
Factory setting: 0

using the right adjusting dial:

Arc length correction
for correcting the arc length;

Setting range: -10 - +10
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

Welding voltage ¹⁾
in V

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction
for correcting the pulsing energy of a pulsed arc

Setting range: -10 - +10
Factory setting: 0

- ... lower droplet detachment force
0 ... neutral droplet detachment force
+ ... increased droplet detachment force

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

1. Welding
2. MIG/MAG and CMT welding parameters

The following welding parameters for MIG/MAG standard synergic welding, LSC welding and CMT welding can be set and displayed:

using the left adjusting dial:

Material thickness ¹⁾

Setting range: 0.1 - 30.0 mm ²⁾ / 0.004 - 1.18 in. ²⁾

Welding current ¹⁾
in A

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Wire speed ¹⁾
for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min ²⁾ / 20 - 980 ipm. ²⁾

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

Penetration stabilizer ⁴⁾ (see page (→))

Setting range: 0 - 10 m/min / 0 - 393.7 ipm
Factory setting: 0

using the right adjusting dial:

Arc length stabilizer ⁴⁾ (see page (→))

Setting range. 0 - 2
Factory setting: 0

Arc length correction
for correcting the arc length, which is pre-set by the characteristic or the synergic program

Setting range: -10 - +10
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

Welding voltage ¹⁾
in V

Setting range: depends on the welding process and welding program selected

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction
for influencing the short-circuiting dynamic at the instant of droplet transfer

Setting range: -10 - +10
Factory setting: 0

- ... harder and more stable arc
0 ... neutral arc
+ ... soft and low-spatter arc

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

1. Welding
2. MIG/MAG and CMT welding parameters

The following welding parameters can be set and displayed for MIG/MAG standard manual welding:

using the left adjusting dial:

Wire speed ¹⁾
for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min ²⁾ / 20 - 980 ipm. ²⁾

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

using the right adjusting dial:

Welding voltage ¹⁾
in V

Setting range: depends on the welding process and welding program selected

Pulse/dynamic correction
for influencing the short-circuiting dynamic at the instant of droplet transfer

Setting range: 0 - 10
Factory setting: 0

0 ... harder and more stable arc
10 ... soft and low-spatter arc

Special function
any parameter can be assigned to this (see page (→))

The function can be selected if a parameter has been saved.

1. Welding
2. MIG/MAG and CMT welding parameters

1. Welding

The 5 EasyJob buttons enable up to 5 operating points to be saved quickly.
The current welding settings are saved.

1. Welding
2. EasyJob mode

The 5 EasyJob buttons enable up to 5 operating points to be saved quickly.
The current welding settings are saved.

1. Welding
2. EasyJob mode

Storing EasyJob operating points

1To store the current welding settings, press one of the EasyJob buttons for approx. 3 seconds.

"Job", the button number and a tick are shown on the display and the EasyJob button LED lights up, e.g.:  
The settings have now been stored.

IMPORTANT! If an operating point has already been saved under an EasyJob button it will be overwritten without any prior warning.

Retrieving EasyJob operating points

2To retrieve a saved EasyJob operating point, press the corresponding EasyJob button briefly (< 3 seconds).

The EasyJob button LED lights up and the saved values are shown on the display.  
If no values are displayed after pressing an EasyJob button, an operating point is not stored under this EasyJob button.

Deleting EasyJob operating points

3To delete an EasyJob operating point, press the relevant EasyJob button for approx. 5 seconds.

After approx. 3 seconds the saved operating point will be overwritten with the current settings and "Job", the button number and a tick are shown on the display.
After a total of approx. 5 seconds the EasyJob button LED goes out and "Job", the button number and an X are shown on the display, e.g.:  
The EasyJob operating point has been deleted.

1. Welding

1. Welding
2. TIG welding

1. Welding
2. TIG welding

1. Welding
2. TIG welding

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system.

After a short time, the currently set welding current is shown on the display. The welding current indicator lights up.

The welding voltage is applied to the welding socket with a three second time lag.

The altered welding current is applied immediately.

1. Welding
2. TIG welding

The welding arc is ignited by touching the workpiece with the tungsten electrode.

1. Welding
2. TIG welding

1. Welding

1. Welding
2. MMA welding

1. Welding
2. MMA welding

1. Welding
2. MMA welding

IMPORTANT! For optimum welding results, the manufacturer recommends performing an R/L alignment when starting the device for the first time and when any changes are made to the welding system.

After a short time, the currently set welding current and the currently set dynamic are shown on the display. The welding current and dynamic indicators light up.

The welding voltage is applied to the welding socket with a three second time lag.

The amended values are applied immediately.

1. Welding
2. MMA welding

The following welding parameters can be set and displayed for manual metal arc welding:

using the left adjusting dial:

Main current ¹⁾
in A

Setting range: depends on the power source available

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.

using the right adjusting dial:

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

Setting range: 0 - 100
Factory setting: 20

0 ... soft and low-spatter arc
100 ... harder and more stable arc

"Process parameters" is shown on the display.

1. Setup settings

"Process parameters" is shown on the display.

1. Setup settings
2. Setup menu - overview

"Process parameters" is shown on the display.

1. Setup settings
2. Setup menu - overview

Process param. (1)

Settings

Language xx 2)

Start/End (3)

View

System

back

Gas-setup

Process c. (4)

Spot welding

Interval

Unit (9) xx (10)

CLS [s] (16)

Components (5)

Standard (11) xx (12)

FAC (17)

STICK (6)

UIBS (13)

Web-PWreset(18)

TIG (7)

DRSL. (14)

USB

SynchroPulse

F1/F2 Param (15)

Information

Process Mix (8)

Favourite

iJob xx (19)

R/L-check/alignment

System data

SPm (20)

< back

< back

< back

	...	Turn the right adjusting dial
	...	Press the right adjusting dial
	...	Press the left adjusting dial: The parameter is shown in plain text
	...	Turn the left adjusting dial: To read long plain texts for parameters; the plain text for the parameter is moved to the left on the display

1. Setup settings

The following process parameters can be set and displayed for the start and end of welding:

I-S
Starting current 
For setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up)

Setting range: 0 - 200 % (of welding current)
Factory setting: 135%

AlS
Start arc length correction
For correcting the arc length at the start of welding

Setting range: -10 - -0.1 / auto / 0.0 - 10.0
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

t-S
Starting current time
For setting the length of time the starting current is to be active 

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SL1
Slope 1 
For setting the time during which the starting current is decreased or increased to the welding current

Setting range: 0 - 9.9 s
Factory setting: 1 s

SL2
Slope 2 
For setting the time during which the welding current is decreased or increased to the final current.

Setting range: 0 - 9.9 s
Factory setting: 1 s

I-E
Final current 
For setting the final current so that

1. heat build-up towards the end of welding is prevented and
2. the end-crater can be filled when welding aluminium

Setting range: 0 - 200% (of welding current)
Factory setting: 50

AlE
End arc length correction
For correcting the arc length at the end of welding

Setting range: -10 - -0.1 / auto / 0.0 - 10.0 (of welding voltage)
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

t-E
Final current time
For setting the length of time for which the final current is to be active

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SFI
to activate/deactivate the SFI function (Spatter-Free Ignition of the arc)

Setting range: off / on
Factory setting: off

SFI-HS
SFI HotStart
For setting a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase occurs within the set HotStart time. This increases the heat input irrespective of the mode, thus ensuring deeper penetration right from the very start of welding.

Setting range: off / 0.01 - 2.00 s
Factory setting: off

W-r
Wire retract 
For setting the wire withdrawal value (= composite value based on backward movement of wire and a time).
The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0
Factory setting: 0.0

IgC
Ignition current (manual mode) 
For setting the ignition current for MIG/MAG standard manual welding

Setting range: 100 - 450 A
Factory setting: 450

W-r (man.)
Wire retract (manual mode) 
For setting the wire withdrawal value (= composite value based on backward movement of wire and a time) for MIG/MAG standard manual welding.
The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0
Factory setting: 0.0

CHS
Characteristic slope
(with MIG/MAG standard manual welding)

auto / U constant / 1000 - 8 A/V
Factory setting: auto

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for the start and end of welding:

I-S
Starting current 
For setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up)

Setting range: 0 - 200 % (of welding current)
Factory setting: 135%

AlS
Start arc length correction
For correcting the arc length at the start of welding

Setting range: -10 - -0.1 / auto / 0.0 - 10.0
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

t-S
Starting current time
For setting the length of time the starting current is to be active 

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SL1
Slope 1 
For setting the time during which the starting current is decreased or increased to the welding current

Setting range: 0 - 9.9 s
Factory setting: 1 s

SL2
Slope 2 
For setting the time during which the welding current is decreased or increased to the final current.

Setting range: 0 - 9.9 s
Factory setting: 1 s

I-E
Final current 
For setting the final current so that

1. heat build-up towards the end of welding is prevented and
2. the end-crater can be filled when welding aluminium

Setting range: 0 - 200% (of welding current)
Factory setting: 50

AlE
End arc length correction
For correcting the arc length at the end of welding

Setting range: -10 - -0.1 / auto / 0.0 - 10.0 (of welding voltage)
Factory setting: 0

- .... shorter arc length
0 ... neutral arc length
+ ... longer arc length

auto:
the value set in the welding parameters is taken over

t-E
Final current time
For setting the length of time for which the final current is to be active

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SFI
to activate/deactivate the SFI function (Spatter-Free Ignition of the arc)

Setting range: off / on
Factory setting: off

SFI-HS
SFI HotStart
For setting a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase occurs within the set HotStart time. This increases the heat input irrespective of the mode, thus ensuring deeper penetration right from the very start of welding.

Setting range: off / 0.01 - 2.00 s
Factory setting: off

W-r
Wire retract 
For setting the wire withdrawal value (= composite value based on backward movement of wire and a time).
The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0
Factory setting: 0.0

IgC
Ignition current (manual mode) 
For setting the ignition current for MIG/MAG standard manual welding

Setting range: 100 - 450 A
Factory setting: 450

W-r (man.)
Wire retract (manual mode) 
For setting the wire withdrawal value (= composite value based on backward movement of wire and a time) for MIG/MAG standard manual welding.
The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0
Factory setting: 0.0

CHS
Characteristic slope
(with MIG/MAG standard manual welding)

auto / U constant / 1000 - 8 A/V
Factory setting: auto

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for Gas-Setup:

GPr
Gas pre-flow 
For setting the gas flow time before the arc is ignited

Setting range: 0 - 9.9  s
Factory setting: 0.1 s

GPo
Gas post-flow 
For setting the gas flow time after the arc has gone out

Setting range: 0 - 9.9 s
Factory setting: 0.5 s

GCF
Gas factor
For setting the gas correction factor

Setting range: auto / 0.90 - 20.0
Factory setting: auto
(the correction factor is automatically set for standard gases from the Fronius welding database)

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for the process control:

• PSt - penetration stabilizer
• AlSt - arc length stabilizer

Penetration stabilizer and arc length stabilizer can also be set in combination with one another.

1. Setup settings
2. Process parameters

The penetration stabilizer is used to set the max. permitted change in the wire speed to ensure that the welding current and hence the penetration is kept stable or constant with variable stick out.

The penetration stabilizer parameter is only available when the WP PMC (Welding Process Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has been enabled on the power source.

auto / 0.0 - 10.0 m/min (ipm
)Factory setting: 0 m/min

auto
A value of 10 m/min is stored for all characteristics, the penetration stabilizer is activated.

0
The penetration stabilizer is not activated.
The wire speed remains constant.

0.1 - 10.0
The penetration stabilizer is activated.
The welding current remains constant.

Application examples

Penetration stabilizer = 0 m/min (not activated)

Penetration stabilizer = 0 m/min (not activated)

Changing the contact tube distance (h) alters the resistance in the welding circuit due to the longer stick out (s₂).
The constant voltage control for constant arc length causes a reduction in the mean current value and hence a smaller penetration (x₂).

Penetration stabilizer = n m/min (activated)

Penetration stabilizer = n m/min (activated)

Specifying a value for the penetration stabilizer ensures a constant arc length without large current variations if the stick out is changed (s₁ ==> s₂).
The penetration (x₁, x₂) remains virtually unchanged and stable.

Penetration stabilizer = 0.5 m/min (activated)

Penetration stabilizer = 0.5 m/min (activated)

To minimise the change in welding current if the stick out is changed (s₁ ==> s₃), the wire speed is increased or reduced by 0.5 m/min.
In the example shown, the stabilising effect is obtained without a change in current up to the set value of 0.5 m/min (Position 2).

I ... Welding current v_D  ... Wire speed

1. Setup settings
2. Process parameters

Arc length stabilizer
The arc length stabilizer forces short arcs, advantageous for welding, via a short circuit current control and keeps them stable even with a variable stick out or external interference.

The arc length stabilizer welding parameter is only available if the WP PMC (Welding Process Pulse Multi Control) option has been enabled on the power source.

0.0 / auto / 0.1 - 5,0 (effect of stabilizer)
Factory setting: 0.0

0.0
The arc length stabilizer is deactivated.

auto

• For inert gases (100% Ar, He, etc.) a value = 0 is stored.
• For the remaining materials / gas combinations, a characteristic-dependent value between 0.2 - 0.5 is stored.
• From a wire speed of 16 m/min a value = 0 is deposited

0.1 - 5.0
The arc length stabilizer is activated.
The arc length is decreased until short circuits start to occur.

Application examples

Arc length stabilizer = 0 / 0.5 / 2.0

  Arc length stabilizer = 0

  Arc length stabilizer = 0.5

  Arc length stabilizer = 2

Arc length stabilizer = 0 / 0.5 / 2.0

Activating the arc length stabilizer reduces the arc length until short circuits start to occur. In this way, the advantages of a short, stable and controlled arc can be used more effectively.

Increasing the arc length stabilizer causes a further shortening of the arc length (L1 ==> L2 ==> L3). The advantages of a short, stable and controlled arc can be used more effectively.

Arc length stabilizer with change of weld seam profile and position

Arc length stabilizer not activated

A change of weld seam profile or welding position can negatively affect the welding result

Arc length stabilizer activated

Since the number and duration of the short circuits is controlled, the properties of the arc stay the same if the weld seam profile or welding position is changed.

I ... Welding current v_D ... Wire speed U ... Welding voltage

1. Setup settings
2. Process parameters

Example: Stick out change

Arc length stabilizer without penetration stabilizer

The advantages of a short arc are maintained even if the stick out is changed, since the short-circuit properties stay the same.

Arc length stabiliser with penetration stabilizer

If the stick out is changed with the penetration stabilizer activated, the penetration also stays the same.
The short circuit behaviour is controlled by the arc length stabilizer.

I ... Welding current v_D ... Wire speed U ... Welding voltage

1. Setup settings
2. Process parameters

SPt
Spot welding time 

0.1 - 10.0  s
Factory setting: 1.0 s

1. Setup settings
2. Process parameters

Int
Interval

off / on
Factory setting: off

Int-t
Stitch welding time

0.1 - 10.0  s
Factory setting: 1.0 s

Int-b
Interval break time

off / 0.1 - 10 s
Factory setting: 1.0 s

Int-C
Interval cycles

constant / ...
Factory setting: constant

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for the system components of a welding system:

C-C
Cooling unit mode 
To determine whether a cooling unit is to be switched on or off, or operated automatically

Setting range: eco / auto / on / off (depending on the cooling unit)
Factory setting: auto

C-t
Delay time flow sensorFor setting the time from when the flow sensor responds until a warning message is output

Setting range: 5 - 25 s
Factory setting: 10 s

CFU
Cooler flow warning limit

Setting range: off / 0.75 - 0.95 l/min
Factory setting: off

Fdi
Feeder inching speed
in m/min (ipm)
For setting the wire speed at which the wire electrode is threaded into the torch hosepack

Setting range:
min. - max. (depending on the wire speed)
Factory setting: 10.0 m/min

ito
Ignition time-out
Length of wire that is fed before the safety cut-out trips

Setting range: off / 5 - 100 mm (0.2 - 3.94 in.)
Factory setting: off

The ignition time-out process parameter is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire speeds.

How it works:
Once the torch trigger is pressed, gas pre-flow begins immediately. Wirefeeding then begins, followed by ignition. If no current starts flowing before the specified length of wire has been fed, the power source cuts out automatically.
To try again, press the torch trigger again.

GSL
Lower gas flow rate limit

Setting range: 0.5 - 30.0 l/min
Factory setting: 7.0 l/min

GSt
Maximum duration of gas flow deviation

Setting range: off; 0.1 - 10.0 s
Factory setting: 2.0 s

GSF
Gas factor sensor
Dependent on the shielding gas used
(only in conjunction with the OPT/i gas controller option)

Setting range: auto, 0.90 - 20.0
Factory setting: auto
(the correction factor is automatically set for standard gases from the Fronius welding database)

FFR
Reaction in case of deviation of the wire speed force

Setting range: Ignore / Warning / Error
Factory setting: Ignore

FFu
Upper wire feed speed force

Setting range: 0 - 999 N
Factory setting: 0 N

FFt
Max. duration of wire speed deviation

Setting range: 0.1 - 10.0 s
Factory setting: 3.0 s

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for manual metal arc welding (STICK):

I-S
Starting current 
For setting the starting current

Setting range: 0 - 200%
Factory setting: 150%

Hti
Starting current time 
For setting the length of time for which the starting current is to be active

Setting range: 0.0 - 2.0 s
Factory setting: 0.5 s

Eln
Characteristic
For selecting the electrode characteristic

Setting range: I-constant / 0.1 - 20.0 A/V / P-constant
Factory setting: I-constant

(1)	Load line for rod electrode
(2)	Load line for rod electrode where arc length is increased
(3)	Load line for rod electrode where arc length is reduced
(4)	Characteristic where "I-constant" parameter is selected (constant welding current)
(5)	Characteristic where "0.1 - 20" parameter is selected (drooping characteristic with adjustable slope)
(6)	Characteristic where "P-constant" parameter is selected (constant welding power)

I-constant (constant welding current)

• If the "I-constant" parameter is set, the welding current will be kept constant, irrespective of the welding voltage. This results in a vertical characteristic (4).
• The "I-constant" parameter is particularly suitable for rutile electrodes and basic electrodes.

0.1 - 20.0 A/V (drooping characteristic with adjustable slope)

• Parameter "0.1 - 20" is used to set a drooping characteristic (5). The setting range extends from 0.1 A / V (very steep) to 20 A / V (very flat).
• Setting a flat characteristic (5) is only advisable for cellulose electrodes.
  

P-constant (constant welding power)

• If the "P-constant" parameter is set, the welding power is kept constant, irrespective of the welding voltage and welding current. This results in a hyperbolic characteristic (6).
• The "P-constant" parameter is particularly suitable for cellulose electrodes, as well as for arc air gouging.
• For arc air gouging, set the arc-force dynamic to "100".

(1)	Load line for rod electrode
(2)	Load line for rod electrode where arc length is increased
(3)	Load line for rod electrode where arc length is reduced
(4)	Characteristic where "I-constant" parameter is selected (constant welding current)
(5)	Characteristic where "0.1 - 20" parameter is selected (drooping characteristic with adjustable slope)
(6)	Characteristic where "P-constant" parameter is selected (constant welding power)

The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose characteristic corresponds - at a given arc length - to the load line (1).

Depending on what welding current (I) has been set, the point of intersection (operating point) of characteristics (4), (5) and (6) will be displaced along the load line (1). The operating point provides information on the actual welding voltage and the actual welding current.

Where the welding current (I_H) is permanently set, the operating point may migrate along the characteristics (4), (5) and (6) according to the welding voltage at a given moment. The welding voltage U is dependent upon the arc length.

If the arc length changes (e.g. in accordance with the load line (2)) the resulting operating point will be the point where the corresponding characteristic (4), (5) or (6) intersects with the load line (2).

Applies to characteristics (5) and (6): Depending upon the welding voltage (arc length), the welding current (I) will also become either smaller or larger, even though the value set for I_H remains the same.

Ast
Anti-stick 
To activate/deactivate the anti-stick function

Setting range: off / on
Factory setting: on

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.

The anti-stick function prevents the electrode from burning out. If the rod electrode begins to stick, the power source switches the welding current off after 1.5 seconds. After the rod electrode has been lifted off the workpiece, the welding process can be continued without any problems.

Uco
Break voltage
For setting a voltage, at which the welding process can be ended by slightly lifting the rod electrode.

Setting range: 20.0 - 90.0 V
Factory setting: 90.0 V

The arc length depends on the welding voltage. To end the welding process, it is usually necessary to significantly lift the rod electrode away from the workpiece. With the break-voltage parameter, the welding voltage can be limited to a value that makes it possible to end the welding operation simply by lifting the rod electrode slightly.

IMPORTANT! If, during welding, you often find that the welding operation is ended unintentionally, increase the value of the break voltage.

1. Setup settings
2. Process parameters

The following process parameters can be set and displayed for TIG welding:

Uco
Break voltage
For setting a voltage, at which the welding process can be ended by slightly lifting the TIG welding torch.

Setting range: 10.0 - 30.0 V
Factory setting: 14.0 V

CSS
Comfort Stop Sensitivity
To activate/deactivate the TIG Comfort Stop function

Setting range: off / 0.1 - 2.0 V
Factory setting: 0.8 V

At the end of the welding operation, the welding current is switched off automatically if the arc length increases by more than a defined amount. This prevents the arc being unnecessarily elongated when the TIG gas-valve torch is lifted off the workpiece.

Sequence:

1. Setup settings
2. Process parameters

The following process parameters can be set for SynchroPulse welding:

Syn-Puls
SynchroPulse 
To activate/deactivate SynchroPulse

Setting range: off / on
Factory setting: off

vd (1)
Wire speed
For setting the average wire speed and therefore the welding power for SynchroPulse

Setting range: 1.0 - 25.0 m/min (40 - 985 ipm)
Factory setting: 5 m/min

dFd (2)
Delta wire feed
For setting the Delta wire feed:
with SynchroPulse, the set wire speed is alternately increased/decreased by the Delta wire feed. The parameters concerned adapt themselves to this wire speed acceleration/delay accordingly.

Setting range: 0.1 - 6.0 m/min (5 - 235 ipm)
Factory setting: 2.0 m/min

F (3)
Frequency
For setting the frequency for SynchroPulse

Setting range: 0.5 - 3.0 Hz
Factory setting: 3.0 Hz

DC (4)
Duty Cycle (high) 
For weighting the duration of the higher operating point in a SynchroPulse period

Setting range: 10 - 90%
Factory setting: 50%

Al-h (5)
Arc length correction high 
For correcting the arc length for SynchroPulse in the upper operating point (= average wire speed plus Delta wire feed)

Setting range: -10.0 - +10.0
Factory setting: 0

- .... short arc
0 ... uncorrected arc length
+ ... longer arc

Al-l (6)
Arc correction low
For correcting the arc length for SynchroPulse in the lower operating point (= average wire speed less Delta wire feed)

Setting range: -10.0 - +10.0
Factory setting: 0

- .... short arc
0 ... uncorrected arc length
+ ... longer arc

1. Setup settings
2. Process parameters

The following process parameters for mixed processes can be set under "Process mix":

Mixed process between PMC and LSC welding process. A cold LSC process phase follows a hot PMC process phase as part of a cycle.

Mixed process between PMC and wire movement reversal using a PushPull drive unit. A cold low power phase with calibration movement follows a hot PMC process phase.

Mixed process between CMT and PMC welding process. Cold CMT process phases follow hot PMC process phases.

vd
Wire speed
Is taken from the welding parameters

Setting range: 1.0 - 25.0 m/min (40 - 985 ipm)

The wire speed value can also be specified or changed in the Process mix parameters.

Alc
Arc length correction
Is taken from the welding parameters

Setting range: -10.0 - +10.0

The arc length correction value can also be specified or changed in the Process mix parameters.

For CMT mix:

Positive correction:
increase in the pulsed voltage for the PMC phase
longer reverse movement in the CMT phase (increases arc length)

Negative correction:
reduction in the pulsed voltage for the PMC phase
shorter reverse movement in the CMT phase (reduces arc length)

PDc
Pulse/dynamic correction
Is taken from the welding parameters

Setting range: -10.0 - +10.0

The pulse/dynamic correction value can also be specified or changed in the Process mix parameters.

For CMT mix:

Positive correction:
increase in the pulse energy (pulse current height, pulse current width)
Reduction in the pulse frequency in the PMC phase

Negative correction:
reduction in the pulse energy (pulse current height, pulse current width)
Increase in the pulse frequency in the PMC phase

Hptc (3)
Upper power time correction 
To set the duration of the hot process phase in a mixed process

Setting range: -10.0 - +10.0
Factory setting: 0

Lptc (2)
Lower power time correction
To set the duration of the cold process phase in a mixed process

Setting range: -10.0 - +10.0
Factory setting: 0.0

Upper and lower power time correction is used to define the relationship between hot and cold process phases.

If the lower power time correction is increased, the process frequency reduces and the LSC process phase becomes longer.

If the lower power time correction is reduced, the process frequency increases and the LSC process phase becomes shorter.

Lpc (1)
Lower power correction
To set the energy input in the cold process phase in a mixed process

Setting range: -10.0 - +10.0
Factory setting: 0

If the lower power correction is increased, this results in a higher wire speed and therefore higher energy yield in the cold LSC process phase.

1. Setup settings
2. Process parameters

Align the welding circuit resistance (R) and welding circuit inductivity (L) if one of the following components of the welding system is changed:

• Torch hosepacks
• Return lead cables, welding power-leads
• Welding torches, electrode holders
• Push-pull units

Prerequisites for R/L alignment:

The welding system must be complete: closed welding loop with torch and torch hosepack, wirefeeders, return lead cable, interconnecting hosepacks.

Performing R/L alignment:

The current welding circuit inductivity values in µH and welding circuit resistance values in mOhm are displayed.

"Connect earth" is shown on the display.

"Remove nozzle" is shown on the display.

"Contact workp." is shown on the display.

After a successful measurement, the current values are displayed.

1. Setup settings

1. Setup settings
2. Settings

1. Setup settings
2. Settings

The settings contain the following options:

Under "View"

• Unit
• Standard
• Hold mode
• UIBS - display brightness
• DRSL - display replaced characteristics
• F1/F2 - setting F1 and F2 special function parameters
• Setting the parameters for the Favourites button
• System data