LogoTransSteel 2200
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  • Contact
  • Legal Notice
  • T&Cs
  • Data protection
  • 019-13122024
  • Safety Instructions
    • Explanation of Safety Instructions
    • General
    • Intended Use
    • Grid Connection
    • Environmental Conditions
    • Obligations of the Operating Company
    • Obligations of Personnel
    • Residual current circuit breaker
    • Personal Protection and Protection of Others
    • Data on noise emission values
    • Danger from toxic gases and vapors
    • Danger from Flying Sparks
    • Risks from grid current and welding current
    • Stray welding currents
    • EMC Device Classifications
    • EMC measures
    • EMF measures
    • Particular hazard areas
    • Requirement for the shielding gas
    • Danger from Shielding Gas Cylinders
    • Danger Posed by Shielding Gas Leak
    • Safety Measures at the Setup Location and During Transport
    • Safety Measures in Normal Operation
    • Maintenance and repair
    • Safety inspection
    • Disposal
    • Safety symbols
    • Data backup
    • Copyright
  • General information
    • General
      • Device concept
      • "Power limitation" function
      • Application areas
      • Warning notices on the device
      • Description of the warnings on the device
  • Operating controls and connections
    • Control Panel
      • General
      • Safety
      • Control panel
      • Keylock
    • Connections, Switches, and Mechanical Components
      • Safety
      • Front and rear of the power source
      • Side view
  • Before installation and initial operation
    • General
      • Safety
      • Intended use
      • Setup regulations
      • Grid Connection
    • Generator-Powered Operation
      • Required generator output
    • Mains Fuse Protection
      • Adjustable mains fuse protection
    • Fitting the Carrying Strap
      • Fitting the carrying strap to the power source
  • MIG/MAG
    • Commissioning
      • Connecting a MIG/MAG welding torch
      • Inserting the feed rollers
      • Inserting the D100 wirespool
      • Inserting the D200 wirespool
      • Feeding in the wire electrode
      • Selecting the desired country-specific setting
      • Connecting the gas cylinder
      • Connecting the polarity reverser and establishing a ground earth connection
      • Laying the hosepacks correctly
    • Adjusting the Brake of the Wirespool Holders
      • General
      • Adjusting the brake of the D200 wirespool holder
      • Adjusting the brake of the D100 wirespool holder
    • Description of MIG/MAG Operating Modes
      • 2-step mode
      • 4-step mode
      • Special 4-step mode
      • Spot welding
      • 2-step stitch welding
      • 4-step stitch welding
    • MIG/MAG Standard Manual Welding
      • General
      • Adjustable welding parameters:
      • MIG/MAG standard manual welding
      • Corrections during welding
    • MIG/MAG Standard Synergic Welding
      • MIG/MAG standard synergic welding
      • Corrections during welding
    • Spot welding and stitch welding
      • General
      • Spot welding
      • Stitch welding
  • TIG
    • Commissioning
      • Start-Up
      • TIG welding
      • Selecting the desired country-specific setting
      • Laying the hosepacks correctly
    • Description of TIG Operating Modes
      • 2-step mode
      • 4-step mode
    • Pulse welding
      • Applications
      • Operating principle
      • Activating pulse welding
  • Rod Electrode
    • Commissioning
      • Preparation
      • Selecting the desired country-specific setting
      • Manual metal arc welding
      • Laying the hosepacks correctly
    • Functions for Optimizing the Welding Process
      • Arc-Force Dynamic
      • HotStart (Hti) function
      • Anti-stick (Ast) function
  • EasyJobs
    • Saving and Retrieving EasyJobs
      • General
      • Saving an EasyJob
      • Retrieving an EasyJob
      • Deleting an EasyJob
  • Setup Menu
    • Setup Menu Level 1
      • Accessing and exiting the Setup menu, changing parameters
      • Parameters for MIG/MAG Standard Manual Welding
      • Parameters for MIG/MAG standard synergic welding
      • Parameters for TIG welding
      • Parameters for MMA Welding
    • Setup Menu 2nd Level
      • Accessing and exiting the 2nd level of the Setup menu, changing parameters
      • Parameters for MIG/MAG standard manual welding
      • Parameters for MIG/MAG standard synergic welding
      • Parameters for TIG welding
      • Parameters for stick welding (SMAW)
  • Optimizing Weld Quality
    • Measuring the welding circuit resistance
      • General
      • Measuring the welding circuit resistance (MIG/MAG welding)
      • Measuring the welding circuit resistance (stick welding)
    • Displaying the welding circuit inductivity
      • General
      • Displaying the welding circuit inductivity
  • Troubleshooting and Maintenance
    • Displaying Service Parameters
      • Service parameters
    • Troubleshooting
      • Safety
      • Troubleshooting
      • Displayed Service Codes
    • Service, maintenance and disposal
      • General
      • Safety
      • Maintenance at every start-up
      • Maintenance as required, at least every two months
      • Maintenance every 6 months
      • Disposal
    • Removing Stiff Drive Rollers
      • Removing a stiff drive roller
  • Appendix
    • Average consumption values during welding
      • Average wire electrode consumption during MIG/MAG welding
      • Average shielding gas consumption during MIG/MAG welding
      • Average shielding gas consumption during TIG welding
    • Technical data
      • Overview with critical raw materials, year of production of the device
      • Special voltage
      • Explanation of the Term Duty Cycle
      • TransSteel 2200
      • TransSteel 2200 MV
      • China Energy Label
    • Welding program tables
      • TSt 2200 welding program table

TransSteel 2200 Operating instructions

Controls
MIG/MAG commissioning
Setup Settings
Spare parts

TransSteel 2200 Operating instructions

Controls
MIG/MAG commissioning
Setup Settings
Spare parts

Safety Instructions

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are not taken.

NOTE!

Indicates the possibility of flawed results and damage to the equipment.

  1. Safety Instructions

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are not taken.

NOTE!

Indicates the possibility of flawed results and damage to the equipment.

  1. Safety Instructions

General

The device has been manufactured using state-of-the-art technology and according to recognized safety standards. If used incorrectly or misused, however, it can cause
  • Injury or death to the operator or a third party
  • Damage to the device and other material assets belonging to the operating company
  • Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the device must
  • Be suitably qualified
  • Have knowledge of welding
  • Have completely read and followed these Operating Instructions

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

All safety and danger notices on the device must
  • Be kept in a legible state
  • Not be damaged/marked
  • Not be removed
  • Not be covered, pasted, or painted over

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

  1. Safety Instructions

Intended Use

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

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

Proper use also means
  • Completely reading and obeying all instructions in the Operating Instructions
  • Completely reading and obeying all safety instructions and danger notices
  • Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
  • Thawing pipes
  • Charging batteries
  • Starting motors

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

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

  1. Safety Instructions

Grid Connection

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

This may affect a number of device types in terms of:
  • connection restrictions
  • criteria regarding maximum permissible grid impedance *)
  • criteria regarding the minimum required short-circuit power *)

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

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

IMPORTANT! Ensure secure grounding of the grid connection!

  1. Safety Instructions

Environmental Conditions

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

Temperature range of the ambient air:
  • 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)
Relative humidity:
  • Up to 50% at 40°C (104°F)
  • Up to 90% at 20°C (68°F)

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

  1. Safety Instructions

Obligations of the Operating Company

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

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

  1. Safety Instructions

Obligations of Personnel

All persons who are assigned to work with the device must do the following before beginning the work:
  • Follow the basic regulations for occupational safety and accident prevention
  • Read these Operating Instructions, especially the section "Safety Rules," and confirm that they have understood and will follow them by signing

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

  1. Safety Instructions

Residual current circuit breaker

Local regulations and national guidelines may mean that a residual current circuit breaker is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manufacturer can be found in the technical data.

  1. Safety Instructions

Personal Protection and Protection of Others

You are exposed to numerous hazards while handling the device, for example:
  • Flying sparks and pieces of hot metal
  • Arc radiation that poses a risk of injury to the eyes and skin
  • Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers
  • Electrical risks from grid current and welding current
  • Increased noise exposure
  • Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing must have the following properties:
  • Flame resistant
  • Insulating and dry
  • Covering the entire body and in good condition with no damage
  • Safety helmet
  • Cuffless pants
Protective clothing involves the following:
  • Protecting the face and eyes from UV radiation, heat and flying sparks with a face guard featuring a regulation-compliant filter
  • Wearing regulation-compliant protective goggles with side protection behind the face guard
  • Wearing rigid, wet-insulating footwear
  • Protecting hands with appropriate gloves (featuring electrical insulation and thermal protection)
  • Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during the welding process. If persons are in the vicinity, however:
  • Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.)
  • Provide suitable protective equipment or
  • Construct suitable protective walls and curtains.
  1. Safety Instructions

Data on noise emission values

The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation in relation to the maximum permitted operating point at standard loading in accordance with EN 60974-1.

A workplace-specific emission value for welding (and cutting) cannot be specified because this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG welding), the selected current type (direct current, alternating current), the power range, the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors.

  1. Safety Instructions

Danger from toxic gases and vapors

The fumes produced during welding contain toxic gases and vapors.

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

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

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:
  • Do not breathe them in.
  • Extract them from the work area using appropriate equipment.

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

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

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

The following components are factors that determine how toxic the welding fumes are:
  • The metals used for the workpiece
  • Electrodes
  • Coatings
  • Cleaning agents, degreasers, and the like
  • The welding process used

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

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

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

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

  1. Safety Instructions

Danger from Flying Sparks

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

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

Keep suitable, tested fire extinguishers on hand.

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

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

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

  1. Safety Instructions

Risks from grid current and welding current

An electric shock can be fatal.

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

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

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

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

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

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

Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
  • Never immerse it in liquids to cool it
  • Never touch it when the power source is switched on.

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

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

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

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

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

Switch off unused devices.

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

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

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

After opening the device:
  • Discharge all electrically charged components
  • Ensure that all components are disconnected from the power supply.

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

  1. Safety Instructions

Stray welding currents

If the following instructions are not observed, stray welding currents may occur, which pose a risk of the following:
  • Fire
  • Overheating of parts connected to the workpiece
  • Irreparable damage to ground conductors
  • Damage to the device and other electrical equipment

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

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

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

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

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

  1. Safety Instructions

EMC Device Classifications

Devices in emission class A:
  • Are only designed for use in industrial settings
  • Can cause line-bound and radiated interference in other areas
Devices in emission class B:
  • Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage grid.

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

  1. Safety Instructions

EMC measures

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

Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interference-prone equipment that could be affected by the device:
  • Safety devices
  • Grid power lines, signal lines, and data transfer lines
  • IT and telecommunications equipment
  • Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
  1. Grid power supply
    • If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter).
  2. Welding power-leads
    • Keep them as short as possible
    • Route them close together (also to avoid EMF problems)
    • Route them far from other lines
  3. Equipotential bonding
  4. Workpiece grounding
    • If necessary, establish grounding using suitable capacitors.
  5. Shield, if necessary
    • Shield other devices in the vicinity
    • Shield the entire welding installation
  1. Safety Instructions

EMF measures

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

Particular hazard areas

Keep hands, hair, loose clothing, and tools away from moving parts, such as:
  • Fans
  • Gears
  • Rollers
  • Shafts
  • Wirespools and welding wires

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

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

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

The protrusion of welding wire from the welding torch represents a high risk of injury (cuts to the hand, facial and eye injuries, etc.).

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

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

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

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

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

Power sources for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas.

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

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

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

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

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

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

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

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

  1. Safety Instructions

Requirement for the shielding gas

Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
  • Solid particle size < 40 µm
  • Pressure condensation point < -20 °C
  • Max. oil content < 25 mg/m³

Use filters if necessary.

  1. Safety Instructions

Danger from Shielding Gas Cylinders

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

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

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

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

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

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

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

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

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

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

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

  1. Safety Instructions

Danger Posed by Shielding Gas Leak

Risk of asphyxiation due to uncontrolled shielding gas leak

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

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

Safety Measures at the Setup Location and During Transport

A toppling device can be deadly! Set up the device securely on an even, solid surface
  • The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
  • Follow the appropriate national and international regulations.

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

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

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

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

Do not lift or transport any active devices. Switch off devices before transport or lifting.

Before transporting the device, completely drain the coolant and dismantle the following components:
  • wirefeeder
  • wirespool
  • shielding gas cylinder

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

  1. Safety Instructions

Safety Measures in Normal Operation

Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a danger of:
  • Injury or death to the operator or a third party
  • Damage to the device and other material assets belonging to the operating company
  • Inefficient operation of the device

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

Never bypass or disable safety devices.

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

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

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

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

Only use appropriate original coolant from the manufacturer.

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

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

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

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

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

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

  1. Safety Instructions

Maintenance and repair

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

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

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

  1. Safety Instructions

Safety inspection

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

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

A safety inspection by a certified electrician is recommended:
  • After changes
  • After alterations
  • After repair, service, and maintenance
  • At least every twelve months

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

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

  1. Safety Instructions

Disposal

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

Packaging materials
  • Collect separately
  • Observe local regulations
  • Crush cardboard boxes
  1. Safety Instructions

Safety symbols

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

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

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

  1. Safety Instructions

Data backup

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

  1. Safety Instructions

Copyright

Copyright of these operating instructions remains with the manufacturer.

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

General information

General

Device concept

The TransSteel (TSt) 2200 power source is a completely digitized, microprocessor-controlled power source.

This power source is designed for the welding of steel and can be used for the following welding processes:
  • MIG/MAG welding
  • SMAW
  • TIG welding with touch-down ignition

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

  1. General information

General

Device concept

The TransSteel (TSt) 2200 power source is a completely digitized, microprocessor-controlled power source.

This power source is designed for the welding of steel and can be used for the following welding processes:
  • MIG/MAG welding
  • SMAW
  • TIG welding with touch-down ignition

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

  1. General information
  2. General

Device concept

The TransSteel (TSt) 2200 power source is a completely digitized, microprocessor-controlled power source.

This power source is designed for the welding of steel and can be used for the following welding processes:
  • MIG/MAG welding
  • SMAW
  • TIG welding with touch-down ignition

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

  1. General information
  2. General

"Power limitation" function

The power source has a "Power limitation" safety feature.

This function is only available for the MIG/MAG standard synergic welding process.

Mode of operation:
If necessary, the power source reduces the welding power to prevent the arc from being extinguished during welding at the power limit of the power source. The reduced parameters are displayed on the control panel until welding starts again or until the next parameter change.

This results in:
  • A more precise welding process
  • A high degree of reproducibility of all results
  • Exceptional weld properties

As soon as the function is active, the indicator for the wire speed parameter on the control panel flashes.

The flashing continues until the next welding start-up, or until the next parameter change.

  1. General information
  2. General

Application areas

MIG/MAG welding
TIG welding
Manual metal arc welding
  1. General information
  2. General

Warning notices on the device

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

Welding is dangerous. To ensure that this device can be used correctly and safely, the following basic requirements must be met:
  • Adequate welding qualifications
  • Appropriate protective equipment
  • Keep unauthorized people away from the power source 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 system component Operating Instructions, especially the safety rules

Dispose of old devices in accordance with safety rules and not in normal domestic waste.

Keep hands, hair, loose clothing, and tools away from moving parts, such as:
  • Gears
  • Feed rollers
  • Wirespools and wire electrodes

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

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

  1. General information
  2. General

Description of the warnings on the device

Warning notices are attached to the device for certain device versions.

The arrangement of the symbols may vary.

!
Warning! Caution!
The symbols represent possible dangers.
A
Drive rollers can injure fingers.
B
The welding wire and drive parts are under welding voltage during operation.
Keep hands and metal objects away!
1.
An electric shock can be fatal.
1.1
Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do not wear wet or damaged gloves.
1.2
Use a base that is insulated from the floor and work area to protect against electric shock.
1.3
Before working on the device, switch off the device and remove the mains plug or disconnect the power supply.
2.
Inhalation of welding fumes can be harmful to health.
2.1
Keep your face away from any welding fumes.
2.2
Use forced-air ventilation or local extraction to remove welding fumes.
2.3
Remove welding fumes with a fan.
3.
Welding sparks can cause an explosion or fire.
3.1
Keep flammable materials away from the welding process. Do not perform welding near flammable materials.
3.2
Welding sparks can cause a fire. Have fire extinguishers ready. If necessary, have a supervisor ready who can operate the fire extinguisher.
3.3
Do not weld on drums or closed containers.
4.
Arc rays can burn the eyes and injure the skin.
4.1
Wear headgear and protective goggles. Use ear protection and wear a shirt collar with button. Use a welding helmet with the correct tinting. Wear suitable protective clothing over the entire body.
5.
Before working on the machine or welding:
undertake training on the device and read the instructions!
6.
Do not remove or paint over the sticker with the warnings.
*
Manufacturer order number of the sticker

Operating controls and connections

Control Panel

General

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

  1. Operating controls and connections

Control Panel

General

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

  1. Operating controls and connections
  2. Control Panel

General

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

  1. Operating controls and connections
  2. Control Panel

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

Serious personal injury and damage to property may result.

Read and understand this document.

Read and understand all the Operating Instructions for the system components, especially the safety rules.

  1. Operating controls and connections
  2. Control Panel

Control panel

(1)
Spot welding indicator
The spot welding indicator lights up if:
  • Spot welding/stitch welding mode is selected
  • The SPt parameter (spot welding time/stitch welding time) in the Setup menu is not set to OFF
(2)
2-step stitch welding indicator
The 2-step stitch welding indicator lights up if:
  • Spot welding/stitch welding mode is selected and
  • The SPb parameter (spot welding/stitch welding pause time) is set to a value greater than 0 and
  • The Int (interval) parameter is set to 2T
(3)
4-step stitch welding indicator
The 4-step stitch welding indicator lights up if:
  • Spot welding/stitch welding mode is selected and
  • The SPb parameter (spot welding/stitch welding pause time) is set to a value greater than 0 and
  • The Int (interval) parameter is set to 4T
(4)
Hold indicator
At the end of each welding operation, the actual values for welding current and welding voltage are stored - the "HOLD" indicator lights up
(5)
Intermediate arc indicator
A spatter-prone intermediate arc occurs between the dip transfer arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical range
(6)
"Parameter selection" button (left)
For selecting the parameters listed below
The relevant symbol lights up when a welding parameter is selected.
Sheet thickness in mm or inch (synergic parameter)1
If, for example, the welding current to be selected is not known, entering the sheet thickness alone is sufficient. Entering one synergic parameter means that all other synergic parameters are set automatically.
Welding current in amperes (synergic parameter)1
Before welding begins, 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 (synergic parameter)1

1 If one of these parameters is selected in the MIG/MAG standard synergic welding process, then the synergic function ensures that all other synergic parameters are adjusted automatically.

(7)
"Parameter selection" button (right)
For selecting the parameters listed below
The relevant symbol lights up when a welding parameter is selected.
Arc length correction
For correcting the arc length
Welding voltage in V (synergic parameter)1
Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.
Arc-force dynamic
For influencing the short-circuiting dynamic at the moment of droplet transfer
- ... Harder and more stable arc
0 ... Neutral arc
+ ... Soft and low-spatter arc
Real Energy Input2
For displaying the energy applied during the welding operation

1 If one of these parameters is selected in the MIG/MAG standard synergic welding process, then the synergic function ensures that all other synergic parameters are adjusted automatically.

2 This parameter can only be selected if the EnE parameter is set to ON in the Setup menu 2nd level.
The value continuously rises during welding in line with the permanently increasing energy input.
The final value is stored after the end of welding until welding starts again or the power source is switched back on - the HOLD indicator lights up.

(8)
"Gas-test" button
For setting the required gas flow rate on the gas pressure regulator/for filling the torch hosepack with shielding gas.
When the "Gas-test" button is pressed, shielding gas will flow for 30 seconds. Press the button again to stop the gas flow prematurely.
(9)
Selection dial (left)
For changing the sheet thickness, welding current, and wire speed parameters, and for changing parameters in the Setup menu
(10)
"Wire threading" button
For threading the wire into the torch hosepack with no accompanying flow of gas.
While the button is being held down, the wire drive runs at feeder inching speed
(11)
Selection dial (right)
For changing the arc length correction, welding voltage, and arc-force dynamic parameters, and for changing parameters in the Setup menu
(12)
"Material" button
For selecting the filler metal to be used
(13)
"Save" button 1
For saving an EasyJob
(14)
"Mode" button
For selecting the operating mode
   2 T = 2-step mode
   4 T = 4-step mode
   S 4 T = Special 4-step mode
   Spot welding/stitch welding
(15)
"Wire diameter" button
For selecting the wire diameter to be used
(16)
"Save" button 2
For saving an EasyJob
(17)
"Process" button 
For selecting the welding process
MANUAL = MIG/MAG standard manual welding
SYNERGIC = MIG/MAG standard synergic welding
STICK = Stick welding (SMAW)
TIG = TIG welding
(18)
"Shielding gas" button
For selecting the shielding gas to be used
  1. Operating controls and connections
  2. Control Panel

Keylock

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

  • Settings cannot be adjusted on the control panel
  • Parameter settings can be displayed
  • It is possible to switch between EasyJobs if an EasyJob was selected before the keylock was activated
Activating/deactivating the keylock:
1

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

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

  1. Operating controls and connections

Connections, Switches, and Mechanical Components

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

Serious personal injury and damage to property may result.

Read and understand this document.

Read and understand all the Operating Instructions for the system components, especially the safety rules.

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

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

Serious personal injury and damage to property may result.

Read and understand this document.

Read and understand all the Operating Instructions for the system components, especially the safety rules.

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

Front and rear of the power source

(1)
Welding torch connection
For connecting the welding torch
(2)
(-) Current socket with bayonet latch
Used for
  • Connecting the grounding cable or polarity reverser for MIG/MAG welding (depending on the wire electrode used)
  • Connecting the electrode cable or grounding cable for manual metal arc welding (depending on the type of electrode used)
  • Connecting the TIG welding torch
(3)
TMC connection (TIG Multi Connector)
For connecting the TIG welding torch
(4)
(+) Current socket with bayonet latch
Used for
  • Connecting the polarity reverser or grounding cable for MIG/MAG welding (depending on the wire electrode used)
  • Connecting the electrode cable or grounding cable for manual metal arc welding (depending on the type of electrode used)
  • Connecting the grounding cable for TIG welding
(5)
Ventilation openings (air outlet vents)
For device cooling
(6)
Polarity reverser
For selecting the welding potential on the MIG/MAG welding torch
(7)
MIG/MAG shielding gas connection socket
For the shielding gas supply to the welding torch connection (1)
(8)
Power switch
For switching the power source on and off
(9)
Ventilation openings (air inlet vents)
For device cooling, the air filter is located behind these vents
(10)
Mains cable with strain relief
Not prefitted on all models
(11)
TIG shielding gas connection socket
For the shielding gas supply for the (-) current socket (2)
  1. Operating controls and connections
  2. Connections, Switches, and Mechanical Components

Side view

(1)
D100 wirespool holder with brake
For holding standard wirespools with a max. diameter of 100 mm (3.94 in)
(2)
D200 wirespool holder with brake
For holding standard wirespools with a max. diameter of 200 mm (7.87 in.) and a max. weight of 6.8 kg (14.99 lbs.)
(3)
2-roller drive

Before installation and initial operation

General

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

  1. Before installation and initial operation

General

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

  1. Before installation and initial operation
  2. General

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

  1. Before installation and initial operation
  2. General

Intended use

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

Intended use also means:
  • Following all the instructions in these Operating Instructions
  • Carrying out all the specified inspection and maintenance work
  1. Before installation and initial operation
  2. General

Setup regulations

The device has been tested according to degree of protection IP 23. This means:
  • Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49 in.)
  • Protection against spraywater at any angle up to 60° from the vertical

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

WARNING!

Danger from machines falling or toppling over.

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

Always place the device on a solid, level surface.

WARNING!

Danger of electrical current due to electrically conductive dust in the device.

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

Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.

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

  1. Before installation and initial operation
  2. General

Grid Connection

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

CAUTION!

Danger due inadequately dimensioned electrical installations.

This can lead to serious damage

The grid lead and its fuse protection should be designed to suit the existing power supply.
The technical data on the rating plate should be followed.

  1. Before installation and initial operation

Generator-Powered Operation

Required generator output

The power source is generator-compatible.

The maximum apparent power S1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S1max of the power source is calculated as follows:
S1max = I1max x U1

I1max and U1 according to the device rating plate or technical data.

The generator apparent power SGEN needed is calculated using the following rule of thumb:
SGEN = S1max x 1.35

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

NOTE!

The generator apparent power SGEN must not be less than the maximum apparent power S1max of the power source!

When single phase devices are being operated with a three-phase generator, note that the stated apparent power of the generator is often just the total that can be present across all three phases of the generator. If necessary, obtain further information about the single-phase power of the generator from the generator manufacturer.

NOTE!

The voltage delivered by the generator must never fall outside of the mains voltage tolerance range.

The mains voltage tolerance is specified in the "Technical data" section.

  1. Before installation and initial operation
  2. Generator-Powered Operation

Required generator output

The power source is generator-compatible.

The maximum apparent power S1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S1max of the power source is calculated as follows:
S1max = I1max x U1

I1max and U1 according to the device rating plate or technical data.

The generator apparent power SGEN needed is calculated using the following rule of thumb:
SGEN = S1max x 1.35

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

NOTE!

The generator apparent power SGEN must not be less than the maximum apparent power S1max of the power source!

When single phase devices are being operated with a three-phase generator, note that the stated apparent power of the generator is often just the total that can be present across all three phases of the generator. If necessary, obtain further information about the single-phase power of the generator from the generator manufacturer.

NOTE!

The voltage delivered by the generator must never fall outside of the mains voltage tolerance range.

The mains voltage tolerance is specified in the "Technical data" section.

  1. Before installation and initial operation

Mains Fuse Protection

Adjustable mains fuse protection

The mains fuse protection selected on the power source limits the power drawn in from the grid and in turn the possible welding current. This prevents the automatic circuit breaker (e.g., in the fuse box) from tripping straight away.

The desired mains fuse protection can be selected on the power source depending on the grid voltage and automatic circuit breaker used.

The following table shows which grid voltages and fuse ratings limit the welding current.

TSt 2200:

Grid voltage
Country-specific setting
Power source fuse rating

Welding current limitation

230 V
Std
10 A

 

MIG/MAG welding:
max. 145 A; 110 A at 100%*
SMAW:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*

230 V
Std
13 A

 

MIG/MAG welding:
max. 170 A; 140 A at 100%*
SMAW:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*

230 V
Std
16 A

 

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

TSt 2200 MV:

Grid voltage
Country-specific setting
Power source fuse rating

Welding current limitation

120 V
Std
10 A

 

MIG/MAG welding:
max. 100 A; 75 A at 100%*
SMAW:
max. 85 A; 55 A at 100%*
TIG welding:
max. 130 A; 95 A at 100%*

120 V
Std
13 A

 

MIG/MAG welding:
max. 105 A; 80 A at 100%*
SMAW:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*

120 V
US
15 A

MIG/MAG welding:
max. 105 A; 80 A at 100%*
SMAW:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*

120 V
Std
16 A

 

MIG/MAG welding:
max. 115 A; 105 A at 100%*
SMAW:
max. 100 A; 85 A at 100%*
TIG welding:
max. 140 A; 130 A at 100%*

120 V
US
20 A

MIG/MAG welding:
max. 135 A; 105 A at 100%*
SMAW:
max. 110 A; 90 A at 100%*
TIG welding:
max. 160 A; 130 A at 100%*

230 V
Std
10 A

 

MIG/MAG welding:
max. 145 A; 110 A at 100%*
SMAW:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*

230 V
Std
13 A

 

MIG/MAG welding:
max. 170 A; 140 A at 100%*
SMAW:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*

230 V
Std
16 A

 

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

240 V
US
15 A

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

A 20 A fuse can only be selected if:
  • The country-specific setting has been set to "US"
  • The grid lead has a 20 A fuse
  • The power source is supplied with a grid voltage of 120 V

*

100% values = welding with no time limits and without cooling breaks.

The welding current data applies at an ambient temperature of 40 °C (104 °F).

A safety cut-out prevents the automatic circuit breaker from tripping at higher welding powers. The safety cut-out defines the possible welding duration without the automatic circuit breaker tripping. If the precalculated weld time is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immediately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again. After this time, the message disappears, and the power source is ready for operation again.

Depending on the selected fuse, the safety cut-out limits the maximum currents of the selected process. As a result, it is possible that welding can no longer occur at the saved operating points if these were saved before selecting the fuse.

If welding is nevertheless carried out at one of these operating points, the power source operates at the limit value of the selected fuse – the power limitation is active. The operating point should be re-saved in accordance with the power limitation.

  1. Before installation and initial operation
  2. Mains Fuse Protection

Adjustable mains fuse protection

The mains fuse protection selected on the power source limits the power drawn in from the grid and in turn the possible welding current. This prevents the automatic circuit breaker (e.g., in the fuse box) from tripping straight away.

The desired mains fuse protection can be selected on the power source depending on the grid voltage and automatic circuit breaker used.

The following table shows which grid voltages and fuse ratings limit the welding current.

TSt 2200:

Grid voltage
Country-specific setting
Power source fuse rating

Welding current limitation

230 V
Std
10 A

 

MIG/MAG welding:
max. 145 A; 110 A at 100%*
SMAW:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*

230 V
Std
13 A

 

MIG/MAG welding:
max. 170 A; 140 A at 100%*
SMAW:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*

230 V
Std
16 A

 

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

TSt 2200 MV:

Grid voltage
Country-specific setting
Power source fuse rating

Welding current limitation

120 V
Std
10 A

 

MIG/MAG welding:
max. 100 A; 75 A at 100%*
SMAW:
max. 85 A; 55 A at 100%*
TIG welding:
max. 130 A; 95 A at 100%*

120 V
Std
13 A

 

MIG/MAG welding:
max. 105 A; 80 A at 100%*
SMAW:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*

120 V
US
15 A

MIG/MAG welding:
max. 105 A; 80 A at 100%*
SMAW:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*

120 V
Std
16 A

 

MIG/MAG welding:
max. 115 A; 105 A at 100%*
SMAW:
max. 100 A; 85 A at 100%*
TIG welding:
max. 140 A; 130 A at 100%*

120 V
US
20 A

MIG/MAG welding:
max. 135 A; 105 A at 100%*
SMAW:
max. 110 A; 90 A at 100%*
TIG welding:
max. 160 A; 130 A at 100%*

230 V
Std
10 A

 

MIG/MAG welding:
max. 145 A; 110 A at 100%*
SMAW:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*

230 V
Std
13 A

 

MIG/MAG welding:
max. 170 A; 140 A at 100%*
SMAW:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*

230 V
Std
16 A

 

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

240 V
US
15 A

MIG/MAG welding:
max. 210 A; 150 A at 100%*
SMAW:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

A 20 A fuse can only be selected if:
  • The country-specific setting has been set to "US"
  • The grid lead has a 20 A fuse
  • The power source is supplied with a grid voltage of 120 V

*

100% values = welding with no time limits and without cooling breaks.

The welding current data applies at an ambient temperature of 40 °C (104 °F).

A safety cut-out prevents the automatic circuit breaker from tripping at higher welding powers. The safety cut-out defines the possible welding duration without the automatic circuit breaker tripping. If the precalculated weld time is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immediately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again. After this time, the message disappears, and the power source is ready for operation again.

Depending on the selected fuse, the safety cut-out limits the maximum currents of the selected process. As a result, it is possible that welding can no longer occur at the saved operating points if these were saved before selecting the fuse.

If welding is nevertheless carried out at one of these operating points, the power source operates at the limit value of the selected fuse – the power limitation is active. The operating point should be re-saved in accordance with the power limitation.

  1. Before installation and initial operation

Fitting the Carrying Strap

Fitting the carrying strap to the power source

1
2
3
4
5
6
  1. Before installation and initial operation
  2. Fitting the Carrying Strap

Fitting the carrying strap to the power source

1
2
3
4
5
6

MIG/MAG

Commissioning

Connecting a MIG/MAG welding torch

1Before connecting the welding torch to the power source, equip the welding torch according to the welding torch Operating Instructions: Fit wearing parts to the torch body, fit the inner liner.
2
3Unscrew the knurled screw (1) slightly so that the welding torch can be easily pushed into the welding torch connection.
4
5

CAUTION!

Danger if the welding torch is not fully inserted.

The device may be damaged.

After inserting the welding torch, ensure it is in the correct end position.

6

CAUTION!

Danger if welding torch is not screwed tight.

The device may be damaged.

Always tighten the welding torch to the specified tightening torque.

  1. MIG/MAG

Commissioning

Connecting a MIG/MAG welding torch

1Before connecting the welding torch to the power source, equip the welding torch according to the welding torch Operating Instructions: Fit wearing parts to the torch body, fit the inner liner.
2
3Unscrew the knurled screw (1) slightly so that the welding torch can be easily pushed into the welding torch connection.
4
5

CAUTION!

Danger if the welding torch is not fully inserted.

The device may be damaged.

After inserting the welding torch, ensure it is in the correct end position.

6

CAUTION!

Danger if welding torch is not screwed tight.

The device may be damaged.

Always tighten the welding torch to the specified tightening torque.

  1. MIG/MAG
  2. Commissioning

Connecting a MIG/MAG welding torch

1Before connecting the welding torch to the power source, equip the welding torch according to the welding torch Operating Instructions: Fit wearing parts to the torch body, fit the inner liner.
2
3Unscrew the knurled screw (1) slightly so that the welding torch can be easily pushed into the welding torch connection.
4
5

CAUTION!

Danger if the welding torch is not fully inserted.

The device may be damaged.

After inserting the welding torch, ensure it is in the correct end position.

6

CAUTION!

Danger if welding torch is not screwed tight.

The device may be damaged.

Always tighten the welding torch to the specified tightening torque.

  1. MIG/MAG
  2. Commissioning

Inserting the feed rollers

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. MIG/MAG
  2. Commissioning

Inserting the D100 wirespool

1
2
  1. MIG/MAG
  2. Commissioning

Inserting the D200 wirespool

1
2
3
  1. MIG/MAG
  2. Commissioning

Feeding in the wire electrode

CAUTION!

Danger from springiness of spooled wire electrode.

It can cause injuries.

When inserting the wire electrode into the wire drive, hold the end of the wire electrode firmly.

1
2
3
4
Adjust the contact pressure as shown below
  • Doing so will prevent deformation of the wire electrode and ensure that the wire is transported properly
Standard values for contact pressure with smooth feed rollers:
  • Steel = 3 - 4
  • CrNi = 3 - 4
Standard values for contact pressure with toothed feed rollers:
  • Tubular covered electrodes = 3
  • Aluminum = 1 - 3
5
6

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

CAUTION!

Danger from wire electrode emerging unexpectedly as it is being threaded.

It can cause injuries.

Wear suitable protective goggles

Keep the tip of the welding torch away from your face and body

Do not point the tip of the welding torch at people

Make sure that the wire electrode does not touch any conductive or grounded parts (e.g., housing)

7
8
Wire threading process (press the "Wire threading" button on the control panel):
  • Hold down the button for up to one second (briefly press the button): the wire speed stays at 1 m/min (39.37 ipm) for the first second
  • Hold down the button for up to 2.5 seconds: after one second, the wire speed increases over the next 1.5 seconds.
  • Hold down the button for longer than 2.5 seconds: after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the Fdi welding parameter.
  1. MIG/MAG
  2. Commissioning

Selecting the desired country-specific setting

  • The country-specific setting of the power source defines the unit (cm + mm or inch) in which the set welding parameters are displayed
  • The country-specific setting can be changed in the Setup menu 2nd level (Parameter SEt)
    • A description of the SEt parameter and how to adjust the SEt parameter can be found in section Setup Menu 2nd Level from page (→)
  1. MIG/MAG
  2. Commissioning

Connecting the gas cylinder

WARNING!

Danger from gas cylinders falling over.

Serious personal injury and damage to property may result.

Place the gas cylinders on a level and stable surface.

Secure the gas cylinders to prevent them from falling over

Observe the safety rules of the gas cylinder manufacturer.

1
2
  1. MIG/MAG
  2. Commissioning

Connecting the polarity reverser and establishing a ground earth connection

1

NOTE!

Risk from incorrectly connected polarity reverser.

This can result in poor-quality weld properties.

Connect the polarity reverser according to the wire electrode being used. Check the wire electrode packaging to determine whether the wire electrode is for (+) or (-) welding

2
3
  1. MIG/MAG
  2. Commissioning

Laying the hosepacks correctly

  1. MIG/MAG

Adjusting the Brake of the Wirespool Holders

General

D200 wirespool holder:
Adjust the brake when using the wirespool holder for the first time and after changing the wirespool. To do so, proceed as described in the following section Adjusting the brake of the D200 wirespool holder.

D100 wirespool holder:
Adjust the brake when using the wirespool holder for the first time and after changing the wirespool. To do so, proceed as described in the following section Adjusting the brake of the D100 wirespool holder

After releasing the torch trigger (end of welding, end of wirefeeding), the wirespool must stop unreeling.
If it fails to do so, adjust the brake.

  1. MIG/MAG
  2. Adjusting the Brake of the Wirespool Holders

General

D200 wirespool holder:
Adjust the brake when using the wirespool holder for the first time and after changing the wirespool. To do so, proceed as described in the following section Adjusting the brake of the D200 wirespool holder.

D100 wirespool holder:
Adjust the brake when using the wirespool holder for the first time and after changing the wirespool. To do so, proceed as described in the following section Adjusting the brake of the D100 wirespool holder

After releasing the torch trigger (end of welding, end of wirefeeding), the wirespool must stop unreeling.
If it fails to do so, adjust the brake.

  1. MIG/MAG
  2. Adjusting the Brake of the Wirespool Holders

Adjusting the brake of the D200 wirespool holder

CAUTION!

Danger from emerging wire electrode and moving parts.

Personal injury and damage to property may result.

Before starting work, turn the mains switch of the power source to - O - and disconnect the power source from the mains

Secure all devices and components involved so they cannot be switched back on.

To adjust the brake:
1
  • Turn the brake to the right = increase braking force
  • Turn the brake to the left = decrease braking force
  1. MIG/MAG
  2. Adjusting the Brake of the Wirespool Holders

Adjusting the brake of the D100 wirespool holder

CAUTION!

Danger from emerging wire electrode and moving parts.

Personal injury and damage to property may result.

Before starting work, turn the mains switch of the power source to - O - and disconnect the power source from the mains

Secure all devices and components involved so that they cannot be switched back on.

Adjust the brake:
1Tighten the knurled screw (1)
  • Knurled screw fully tightened = high braking force
  • Knurled screw slightly tightened = low braking force
  1. MIG/MAG

Description of MIG/MAG Operating Modes

2-step mode

"2-step mode" is suitable for
  • Tacking work
  • Short weld seams
2-step mode

Explanation of symbols:

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

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

2-step mode

"2-step mode" is suitable for
  • Tacking work
  • Short weld seams
2-step mode

Explanation of symbols:

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

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

4-step mode

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

4-step mode

Explanation of symbols:

Press the torch trigger
Release the torch trigger

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

Special 4-step mode

"Special 4-step mode" is ideal for welding in higher power ranges. In special 4-step mode, the arc starts at a lower power, which makes it easier to stabilize.

Special 4-step mode

Explanation of symbols:

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

Abbreviations used:

GPr
Gas pre-flow time
I-S
Starting current
SL
Slope: continuous increasing / lowering of welding current
I
Main current
I-E
Final current
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

Spot welding

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

Spot welding

Explanation of symbols:

Press the torch trigger
Release the torch trigger

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
SPt
Spot welding time / stitch welding time
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

2-step stitch welding

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

2-step stitch welding

Explanation of symbols:

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

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
SPt
Spot welding time / stitch welding time
SPb
Stitch pause time
GPo
Gas post-flow time
  1. MIG/MAG
  2. Description of MIG/MAG Operating Modes

4-step stitch welding

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

4-step stitch welding

Explanation of symbols:

Press the torch trigger
Release the torch trigger

Abbreviations used:

GPr
Gas pre-flow time
I
Welding current
SPt
Spot welding time / stitch welding time
SPb
Stitch pause time
GPo
Gas post-flow time
  1. MIG/MAG

MIG/MAG Standard Manual Welding

General

The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters – all variable parameters must be adjusted individually.

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

General

The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters – all variable parameters must be adjusted individually.

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

Adjustable welding parameters:

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

   Wire speed
   Welding voltage
   Arc-force dynamic - for influencing the short-circuiting dynamic at the instant of droplet transfer
  1. MIG/MAG
  2. MIG/MAG Standard Manual Welding

MIG/MAG standard manual welding

1Press the "Process" button to select MANUAL
2Press the "Mode" button
to select the desired MIG/MAG mode:
   2-step mode
   4-step mode
   Spot welding/stitch welding
3Select and set the wire speed parameter
  
4Select and set the welding voltage parameter
  

All parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again.

5Ensure that the ground earth connection has been established
6Ensure that the shielding gas supply has been established
  • Power source is ready for welding
  1. MIG/MAG
  2. MIG/MAG Standard Manual Welding

Corrections during welding

The arc-force dynamic parameter can be used to optimize the welding result.

The arc-force dynamic parameter is used to influence the short-circuiting dynamic at the moment of droplet transfer:

-
= hard, stable arc
0
= neutral arc
+
= soft, low-spatter arc
  1. MIG/MAG

MIG/MAG Standard Synergic Welding

MIG/MAG standard synergic welding

1Press the "Process" button to select SYNERGIC
2Press the "Mode" button
to select the desired MIG/MAG mode:
   2-step mode
   4-step mode
   S 4 T = Special 4-step mode
   Spot welding/stitch welding
Under certain circumstances, it may not be possible to change welding parameters that have been set for a system component (remote control, etc.) on the control panel of the power source.
3Press the "Material" button to select the filler metal being used
4Press the "Wire diameter" button to select the diameter of the wire electrode being used
5Press the "Shielding gas" button to select the shielding gas being used
6Press the "Parameter selection" buttons
to select the welding parameter with which the welding power is to be specified:
   Sheet thickness
   Welding current
   Wire speed
   Welding voltage
7Set the welding parameters

All parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again.

8Ensure that the ground earth connection has been established
9Ensure that the shielding gas supply has been established
  • Power source is ready for welding
  1. MIG/MAG
  2. MIG/MAG Standard Synergic Welding

MIG/MAG standard synergic welding

1Press the "Process" button to select SYNERGIC
2Press the "Mode" button
to select the desired MIG/MAG mode:
   2-step mode
   4-step mode
   S 4 T = Special 4-step mode
   Spot welding/stitch welding
Under certain circumstances, it may not be possible to change welding parameters that have been set for a system component (remote control, etc.) on the control panel of the power source.
3Press the "Material" button to select the filler metal being used
4Press the "Wire diameter" button to select the diameter of the wire electrode being used
5Press the "Shielding gas" button to select the shielding gas being used
6Press the "Parameter selection" buttons
to select the welding parameter with which the welding power is to be specified:
   Sheet thickness
   Welding current
   Wire speed
   Welding voltage
7Set the welding parameters

All parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again.

8Ensure that the ground earth connection has been established
9Ensure that the shielding gas supply has been established
  • Power source is ready for welding
  1. MIG/MAG
  2. MIG/MAG Standard Synergic Welding

Corrections during welding

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

 Arc length correction:

-
= shorter arc, reduced welding voltage
0
= neutral arc
+
= longer arc, increased welding voltage

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

-
= hard, stable arc
0
= neutral arc
+
= soft, low-spatter arc
  1. MIG/MAG

Spot welding and stitch welding

General

The spot and stitch welding modes are MIG/MAG welding processes.

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

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

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

General

The spot and stitch welding modes are MIG/MAG welding processes.

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

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

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

Spot welding

1Press the "Process" button to select MANUAL or SYNERGIC
2Press the "Mode" button
to select spot welding/stitch welding mode
  
3Set the SPt parameter in the Setup menu (spot welding time/stitch welding time) to the desired value
4Set the desired parameters depending on the process (MANUAL or SYNERGIC)
5Ensure that the ground earth connection has been established
6Ensure that the shielding gas supply has been established
  • Power source is ready for welding
  1. MIG/MAG
  2. Spot welding and stitch welding

Stitch welding

1Press the "Process" button to select MANUAL or SYNERGIC
2Press the "Mode" button
to select spot welding/stitch welding mode
  
3Set the SPt parameter in the Setup menu (spot welding time/stitch welding time) to the desired value
4Set the SPb parameter in the Setup menu (spot welding/stitch pause time) to the desired value
5Set the Int parameter (interval) in the Setup menu to the desired value
6Set the desired parameters depending on the process (MANUAL or SYNERGIC)
7Ensure that the ground earth connection has been established
8Ensure that the shielding gas supply has been established
  • Power source is ready for welding

TIG

Commissioning

Start-Up

1
2
3
4
5
6

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

7

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the tungsten electrode does not accidentally, or in an uncontrolled manner, touch any electrically conductive or grounded parts (e.g., the housing, etc.).

  1. TIG

Commissioning

Start-Up

1
2
3
4
5
6

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

7

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the tungsten electrode does not accidentally, or in an uncontrolled manner, touch any electrically conductive or grounded parts (e.g., the housing, etc.).

  1. TIG
  2. Commissioning

Start-Up

1
2
3
4
5
6

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

7

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the tungsten electrode does not accidentally, or in an uncontrolled manner, touch any electrically conductive or grounded parts (e.g., the housing, etc.).

  1. TIG
  2. Commissioning

TIG welding

1Press the "Process" button to select TIG
2 Set the desired welding current
When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting):
3Position the gas nozzle at the ignition point so that there is a distance of approximately 2 to 3 mm (0.078 to 0.118 in.) between the tungsten electrode and the workpiece
4Gradually tilt the welding torch up until the tungsten electrode touches the workpiece
5Pull back the torch trigger and hold it in this position
- Shielding gas flows
6Raise the welding torch and rotate it into its normal position
- The arc ignites
7Carry out welding
  1. TIG
  2. Commissioning

Selecting the desired country-specific setting

  • The country-specific setting of the power source defines the unit (cm + mm or inch) in which the set welding parameters are displayed
  • The country-specific setting can be changed in the Setup menu 2nd level (Parameter SEt)
    • A description of the SEt parameter and how to adjust the SEt parameter can be found in section Setup Menu 2nd Level from page (→)
  1. TIG
  2. Commissioning

Laying the hosepacks correctly

  1. TIG

Description of TIG Operating Modes

2-step mode

Welding with 2-step mode:
1Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold => shielding gas flows
2Raise the tungsten electrode => arc ignites
3Release torch trigger => end of welding

Explanation of symbols:

Pull back the torch trigger and hold it in this position
Release the torch trigger forwards

Abbreviations used:

GPo
Gas post-flow time
tup
UpSlope phase: the welding current is continually increased
Duration: 0.5 seconds
tdown
DownSlope phase: the welding current is continuously reduced
Duration: 0.5 seconds
  1. TIG
  2. Description of TIG Operating Modes

2-step mode

Welding with 2-step mode:
1Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold => shielding gas flows
2Raise the tungsten electrode => arc ignites
3Release torch trigger => end of welding

Explanation of symbols:

Pull back the torch trigger and hold it in this position
Release the torch trigger forwards

Abbreviations used:

GPo
Gas post-flow time
tup
UpSlope phase: the welding current is continually increased
Duration: 0.5 seconds
tdown
DownSlope phase: the welding current is continuously reduced
Duration: 0.5 seconds
  1. TIG
  2. Description of TIG Operating Modes

4-step mode

4-step mode with intermediate lowering I-2

Intermediate lowering means that the welder uses the torch trigger during the main current phase to lower the welding current to the specified reduced current I-2 .

Welding with 4-step mode:
1Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold => shielding gas flows
2Raise the tungsten electrode => start of welding with starting current I-S
3Release torch trigger => welding with main current I-1
4Push forward and hold the torch trigger => activation of intermediate lowering with reduced current I-2
5Release torch trigger => welding with main current I-1
6Pull back and hold the torch trigger => lowering to final current I-E
7Release torch trigger => end of welding

Explanation of symbols:

Pull back the torch trigger and hold it in this position
Release the torch trigger forwards
Pull back the torch trigger and hold it in this position
Release the torch trigger forwards

Abbreviations used:

GPo
Gas post-flow time
I-S
Starting-current phase: the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly
I-1
Main current phase (welding current phase): uniform thermal input into the parent material, whose temperature is raised by the advancing heat
I-E
Final current phase: to prevent crater cracks or shrink holes
I-2
Reduced current phase: intermediate lowering of the welding current in order to prevent any local overheating of the parent material
tS
Starting current duration
tup
UpSlope phase: the welding current is continually increased
Duration: 0.5 seconds
tE
Final current duration
tdown
DownSlope phase: the welding current is continuously reduced
Duration: 0.5 seconds
  1. TIG

Pulse welding

Applications

Pulsed welding is welding with a pulsing welding current. It is used to weld steel pipes out-of-position or to weld thin sheet metal.

In these applications, the welding current set at the start of welding is not always optimum for the entire welding process:
  • If the amperage is too low, the parent material will not be melted enough
  • If overheating occurs, there is a danger that the liquid weld pool may drip.
  1. TIG
  2. Pulse welding

Applications

Pulsed welding is welding with a pulsing welding current. It is used to weld steel pipes out-of-position or to weld thin sheet metal.

In these applications, the welding current set at the start of welding is not always optimum for the entire welding process:
  • If the amperage is too low, the parent material will not be melted enough
  • If overheating occurs, there is a danger that the liquid weld pool may drip.
  1. TIG
  2. Pulse welding

Operating principle

  • A low base current I-G rises steeply to the significantly higher pulse current I-P and drops back to the base current I-G after the Duty cycle dcY time.
  • This results in an average current that is lower than the set pulse current I-P.
  • During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.

The power source controls the "Duty cycle dcY" and "Base current I-G" parameters according to the set pulse current (welding current) and pulse frequency.

Welding current progression curve

Adjustable parameters:

I-S
Starting current
I-E
Final current
F-P
Pulse frequency (1/F-P = Time between two pulses)
I-P
Pulse current (set welding current)

Fixed parameters:

tup
UpSlope
tdown
DownSlope
dcY
Duty cycle
I-G
Base current
  1. TIG
  2. Pulse welding

Activating pulse welding

1 Set a value for the F-P setup parameter (pulse frequency)
  • Setting range: 1 - 990 Hz

For a parameter description see section Parameters for TIG welding from page (→).

Rod Electrode

Commissioning

Preparation

1

Check the rod electrode packaging to determine whether the rod electrode is for (+) or (-) welding.

2
3
4

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

5

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the rod electrode does not unintentionally touch electrically conductive or grounded parts (such as housing).

  1. Rod Electrode

Commissioning

Preparation

1

Check the rod electrode packaging to determine whether the rod electrode is for (+) or (-) welding.

2
3
4

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

5

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the rod electrode does not unintentionally touch electrically conductive or grounded parts (such as housing).

  1. Rod Electrode
  2. Commissioning

Preparation

1

Check the rod electrode packaging to determine whether the rod electrode is for (+) or (-) welding.

2
3
4

It is only necessary to connect the mains cable to the power source for multivoltage power sources.

5

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the rod electrode does not unintentionally touch electrically conductive or grounded parts (such as housing).

  1. Rod Electrode
  2. Commissioning

Selecting the desired country-specific setting

  • The country-specific setting of the power source defines the unit (cm + mm or inch) in which the set welding parameters are displayed
  • The country-specific setting can be changed in the Setup menu 2nd level (Parameter SEt)
    • A description of the SEt parameter and how to adjust the SEt parameter can be found in section Setup Menu 2nd Level from page (→)
  1. Rod Electrode
  2. Commissioning

Manual metal arc welding

1Press the "Process" button to select STICK
2Set the desired welding current
  • Power source is ready for welding
  1. Rod Electrode
  2. Commissioning

Laying the hosepacks correctly

  1. Rod Electrode

Functions for Optimizing the Welding Process

Arc-Force Dynamic

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

-
= hard, stable arc
0
= neutral arc
+
= soft, low-spatter arc
  1. Rod Electrode
  2. Functions for Optimizing the Welding Process

Arc-Force Dynamic

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

-
= hard, stable arc
0
= neutral arc
+
= soft, low-spatter arc
  1. Rod Electrode
  2. Functions for Optimizing the Welding Process

HotStart (Hti) function

This function is activated at the factory.

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

Key

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

The Hti and HCU parameters can be set in the Setup menu. For a parameter description see section Parameters for MMA Welding from page (→).

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

  1. Rod Electrode
  2. Functions for Optimizing the Welding Process

Anti-stick (Ast) function

This function is activated at the factory.

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

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

Deactivating the function:
1Set the Ast (anti-stick) setup parameter to OFF

For a parameter description see section Parameters for MMA Welding from page (→).

EasyJobs

Saving and Retrieving EasyJobs

General

  • The "Save" buttons allow two EasyJobs to be saved
  • The adjustable parameters on the control panel are saved
  • Setup parameters are not saved at this time
  1. EasyJobs

Saving and Retrieving EasyJobs

General

  • The "Save" buttons allow two EasyJobs to be saved
  • The adjustable parameters on the control panel are saved
  • Setup parameters are not saved at this time
  1. EasyJobs
  2. Saving and Retrieving EasyJobs

General

  • The "Save" buttons allow two EasyJobs to be saved
  • The adjustable parameters on the control panel are saved
  • Setup parameters are not saved at this time
  1. EasyJobs
  2. Saving and Retrieving EasyJobs

Saving an EasyJob

1Press and hold one of the "Save" buttons to save the current settings on the control panel, e.g., Number 1
  • The left indicator displays "Pro"
  • After a short time, the left indicator switches to the original value
2Release the "Save" button
  1. EasyJobs
  2. Saving and Retrieving EasyJobs

Retrieving an EasyJob

1To retrieve saved settings, press the corresponding "Save" button briefly, e.g., Number 1
  • The control panel will show the saved settings
  1. EasyJobs
  2. Saving and Retrieving EasyJobs

Deleting an EasyJob

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

Setup Menu

Setup Menu Level 1

Accessing and exiting the Setup menu, changing parameters

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

Accessing the Setup menu:

1

Press the "Process" button to select the SYNERGIC welding process

2

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

To change a parameter:

1

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

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

To exit the Setup menu:

1
  1. Setup Menu

Setup Menu Level 1

Accessing and exiting the Setup menu, changing parameters

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

Accessing the Setup menu:

1

Press the "Process" button to select the SYNERGIC welding process

2

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

To change a parameter:

1

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

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

To exit the Setup menu:

1
  1. Setup Menu
  2. Setup Menu Level 1

Accessing and exiting the Setup menu, changing parameters

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

Accessing the Setup menu:

1

Press the "Process" button to select the SYNERGIC welding process

2

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

To change a parameter:

1

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

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

To exit the Setup menu:

1
  1. Setup Menu
  2. Setup Menu Level 1

Parameters for MIG/MAG Standard Manual Welding

GPr
Gas pre-flow time
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0.1
GPo
Gas post-flow time
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0.5
Fdi
Feeder inching speed
Unit: m/min (ipm)
Setting range: 1 - 18.5 (39.37 - 728.35)
Factory setting: 10 (393.7)
IGc
Ignition current
Unit: Ampere
Setting range: 100 - 390
Factory setting: 300
Ito
Length of wire that is fed before the safety cut-out trips
Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF
The ignition time-out function (Ito) is a safety feature.
If the power source determines that no ignition has occurred after the preset wire length has been fed, wirefeeding is stopped.
SPt
Spot welding time
Unit: seconds
Setting range: OFF, 0.3 - 5
Factory setting: 1
SPb
Spot pause time
Unit: seconds
Setting range: OFF, 0.3 - 10 (in 0.1 s increments)
Factory setting: OFF
Int
Interval
Unit: -
Setting range: 2T (2-step), 4T (4-step)
Factory setting: 2T (2-step)
FAC
Reset power source to factory settings
Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings
- when "PrG" appears on the digital display, the power source has been reset
When the power source is reset, the majority of the applied settings are deleted. The following values remain:
  • Welding circuit resistance and welding circuit inductivity
  • Country-specific setting
2nd
Second level of the Setup menu (see "Setup Menu 2nd Level")
  1. Setup Menu
  2. Setup Menu Level 1

Parameters for MIG/MAG standard synergic welding

GPr
Gas pre-flow time
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0.1
GPo
Gas post-flow time
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0.5
SL
Slope
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 1
I-S
Starting current
Unit: % of welding current
Setting range: 0 - 200
Factory setting: 100
I-E
Final current
Unit: % of welding current
Setting range: 0 - 200
Factory setting: 50
t-S
Start current duration
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0
t-E
Final current duration
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 0
Fdi
Feeder inching speed
Unit: m/min (ipm)
Setting range: 1 - 18.5 (39.37 - 728.35)
Factory setting: 10 (393.7)
Ito
Length of wire that is fed before the safety cut-out trips
Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF
The "Ignition time-out" function (Ito) is a safety function. If the power source determines that no ignition has occurred after the preset wire length has been fed, wirefeeding is stopped.
SPt
Spot welding time
Unit: seconds
Setting range: 0.3 - 5
Factory setting: 1
SPb
Spot pause time
Unit: seconds
Setting range: OFF, 0.3 - 10 (in 0.1 s increments)
Factory setting: OFF
Int
Interval
Unit: -
Setting range: 2T (2-step), 4T (4-step)
Factory setting: 2T (2-step)
FAC
Reset power source to factory settings
Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings
- when "PrG" appears on the digital display, the power source has been reset.
When the power source is reset, the majority of the applied settings are deleted. The following values remain:
  • Welding circuit resistance and welding circuit inductivity
  • Country-specific setting
2nd
Second level of the Setup menu (see "Setup Menu 2nd Level")
  1. Setup Menu
  2. Setup Menu Level 1

Parameters for TIG welding

F-P
Pulse frequency
Unit: Hertz
Setting range: OFF; 1 - 990
(up to 10 Hz: in 0.1 Hz increments)
(up to 100 Hz: in 1 Hz increments)
(over 100 Hz: in 10 Hz increments)
Factory setting: OFF
tUP
UpSlope
Unit: seconds
Setting range: 0.01 - 9.9
Factory setting: 0.5
tdo
DownSlope
Unit: seconds
Setting range: 0.01 - 9.9
Factory setting: 1
I-S
Starting current
Unit: % of main current
Setting range: 1 - 200
Factory setting: 35
I-2
Lowering current
Unit: % of main current
Setting range: 1 - 100
Factory setting: 50
I-E
Final current
Unit: % of main current
Setting range: 1 - 100
Factory setting: 30
GPo
Gas post-flow time
Unit: seconds
Setting range: 0 - 9.9
Factory setting: 9.9
tAC
Tacking
Unit: seconds
Setting range: OFF, 0.1 - 9.9
Factory setting: OFF
FAC
Reset power source to factory settings
Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings
- when "PrG" appears on the digital display, the power source has been reset.
When the power source is reset, the majority of the applied settings are deleted. The following values remain:
  • Welding circuit resistance and welding circuit inductivity
  • Country-specific setting
2nd
Second level of the Setup menu (see "Setup Menu 2nd Level")
  1. Setup Menu
  2. Setup Menu Level 1

Parameters for MMA Welding

HCU
HotStart current
Unit: %
Setting range: 100 - 200
Factory setting: 150
Hti
Hot current time
Unit: seconds
Setting range: 0 - 2.0
Factory setting: 0.5
Ast
Anti-stick function
Unit: -
Setting range: On, OFF
Factory setting: On
FAC
Reset power source to factory settings
Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings
- when "PrG" appears on the digital display, the power source has been reset.
When the power source is reset, the majority of the applied settings are deleted. The following values remain:
  • Welding circuit resistance and welding circuit inductivity
  • Country-specific setting
2nd
Second level of the Setup menu (see "Setup Menu 2nd Level")
  1. Setup Menu

Setup Menu 2nd Level

Accessing and exiting the 2nd level of the Setup menu, changing parameters

Accessing the 2nd level of the Setup menu:

1

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

2

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



3

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

4

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



To change a parameter:

1

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

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

To exit the Setup menu:

1

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



2

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



  1. Setup Menu
  2. Setup Menu 2nd Level

Accessing and exiting the 2nd level of the Setup menu, changing parameters

Accessing the 2nd level of the Setup menu:

1

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

2

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



3

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

4

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



To change a parameter:

1

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

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

To exit the Setup menu:

1

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



2

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



  1. Setup Menu
  2. Setup Menu 2nd Level

Parameters for MIG/MAG standard manual welding

SEt
Country-specific setting (Standard/USA) ... Std/US
Unit: -
Setting range: Std, US (Standard/USA)
Factory setting:
Standard device: Std (measurements in cm/mm)
USA device: US (measurements: inches)
FUS
Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse protection used.
Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage)
Factory setting: OFF
r
Welding circuit resistance (in mOhm)
See section Measuring the welding circuit resistance (MIG/MAG welding) from page (→)
L
Welding circuit inductivity (in microhenrys)
See section Displaying the welding circuit inductivity from page (→)
EnE
Real Energy Input
Unit: kJ
Setting range: ON / OFF
Factory setting: OFF
Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three-digit display, the following display format has been selected:
Value in kJ: 1 to 999 / indicator on display: 1 to 999
Value in kJ: 1000 to 9999 / indicator on display: 1.00 to 9.99 (without unit digit, e.g., 5270 kJ -> 5.27)
Value in kJ: 10,000 to 99,999 / indicator on display: 10.0 to 99.9
(without unit digit or tens digit, e.g., 23580 kJ -> 23.6)
  1. Setup Menu
  2. Setup Menu 2nd Level

Parameters for MIG/MAG standard synergic welding

SEt
Country-specific setting (Standard/USA) ... Std/US
Unit: -
Setting range: Std, US (Standard/USA)
Factory setting:
Standard device: Std (measurements in cm/mm)
USA device: US (measurements: inches)
FUS
Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse protection used.
Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage)
Factory setting: OFF
r
Welding circuit resistance (in mOhm)
See section Measuring the welding circuit resistance (MIG/MAG welding) from page (→)
L
Welding circuit inductivity (in microhenrys)
See section Displaying the welding circuit inductivity from page (→)
EnE
Real Energy Input
Unit: kJ
Setting range: ON / OFF
Factory setting: OFF
Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three-digit display, the following display format has been selected:
Value in kJ: 1 to 999 / indicator on display: 1 to 999
Value in kJ: 1000 to 9999 / indicator on display: 1.00 to 9.99 (without unit digit, e.g., 5270 kJ -> 5.27)
Value in kJ: 10,000 to 99,999 / indicator on display: 10.0 to 99.9
(without unit digit or tens digit, e.g., 23580 kJ -> 23.6)
ALC
Arc length correction display
(For setting how the arc length correction parameter is displayed)
Setting range: ON / OFF
Factory setting: OFF
Set to ON if the welding voltage parameter is selected and set on the control panel
  • The left-hand display shows the arc correction value for three seconds
  • The right-hand display shows the value for the welding voltage at the same time
  1. Setup Menu
  2. Setup Menu 2nd Level

Parameters for TIG welding

SEt
Country-specific setting (Standard/USA) ... Std/US
Unit: -
Setting range: Std, US (Standard/USA)
Factory setting:
Standard device: Std (measurements in cm/mm)
USA device: US (measurements: inches)
FUS
Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse protection used.
Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage)
Factory setting: OFF
  1. Setup Menu
  2. Setup Menu 2nd Level

Parameters for stick welding (SMAW)

SEt
Country-specific setting (Standard/USA) ... Std/US
Unit: -
Setting range: Std, US (Standard/USA)
Factory setting:
Standard device: Std (measurements in cm/mm)
USA device: US (measurements: inches)
r
Welding circuit resistance (in mOhm)
See section Measuring the welding circuit resistance (stick welding) from page (→)
L
Welding circuit inductivity (in microhenrys)
See section Displaying the welding circuit inductivity from page (→)
FUS
Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse protection used.
Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage)
Factory setting: OFF

Optimizing Weld Quality

Measuring the welding circuit resistance

General

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

The welding circuit resistance depends on the hosepack used:
  • If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
  • Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads
  1. Optimizing Weld Quality

Measuring the welding circuit resistance

General

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

The welding circuit resistance depends on the hosepack used:
  • If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
  • Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads
  1. Optimizing Weld Quality
  2. Measuring the welding circuit resistance

General

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

The welding circuit resistance depends on the hosepack used:
  • If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
  • Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads
  1. Optimizing Weld Quality
  2. Measuring the welding circuit resistance

Measuring the welding circuit resistance (MIG/MAG welding)

NOTE!

Risk of incorrect measurement of the welding circuit resistance.

This can have a negative effect on the welding results.

Ensure that the workpiece has an optimum contact surface in the area of the earthing clamp (clean surface, no rust, etc.).

1Ensure that either the MANUAL or SYNERGIC welding process is selected
2Establish a ground earth connection to the workpiece
3Access the Setup menu 2nd level (2nd)
4Select parameter "r"
5Remove the gas nozzle from the welding torch
6Screw on the contact tip
7Ensure that the wire electrode does not protrude from the contact tip

NOTE!

Risk of incorrect measurement of the welding circuit resistance.

This can have a negative effect on the welding results.

Ensure that the workpiece has an optimum contact surface for the contact tip (clean surface, no rust, etc.).

8Place the contact tip flush against the workpiece surface
9Press the torch trigger briefly
  • The welding circuit resistance is calculated. "run" is shown on the display during the measurement

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

10Fit the gas nozzle back onto the welding torch
  1. Optimizing Weld Quality
  2. Measuring the welding circuit resistance

Measuring the welding circuit resistance (stick welding)

NOTE!

Risk of incorrect measurement of the welding circuit resistance.

This can have a negative effect on the welding results.

Ensure that the workpiece has an optimum contact surface in the area of the earthing clamp (clean surface, no rust, etc.).

1Ensure that the STICK welding process is selected
2Establish a ground earth connection to the workpiece
3Access the Setup menu 2nd level (2nd)
4Select parameter "r"

NOTE!

Risk of incorrect measurement of the welding circuit resistance.

This can have a negative effect on the welding results.

Ensure that the workpiece has an optimum contact surface for the electrode flush (clean surface, no rust, etc.).

5Place the electrode flush against the workpiece surface
6Press the "Parameter selection" button (right)
  • The welding circuit resistance is calculated. "run" is shown on the display during the measurement

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

  1. Optimizing Weld Quality

Displaying the welding circuit inductivity

General

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

  1. Optimizing Weld Quality
  2. Displaying the welding circuit inductivity

General

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

  1. Optimizing Weld Quality
  2. Displaying the welding circuit inductivity

Displaying the welding circuit inductivity

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

1Access the Setup menu 2nd level (2nd)
2Select parameter "L"

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

L ... Welding circuit inductivity (in microhenrys)

Troubleshooting and Maintenance

Displaying Service Parameters

Service parameters

Various service parameters can be retrieved by pressing the left and right-hand "Parameter selection" buttons at the same time.

Opening the display:

1

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

Selecting parameters:

1

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

Available parameters

Example:
1.00 | 4.21

Firmware version

Example:
2 | 491

Welding program configuration

Example:
r 2 | 290

Number of the currently selected welding program

Example:
654 | 32.1
= 65,432.1 hours
= 65,432 hours 6 mins

Indicates the actual arc time since first use.
Note: The arc time indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.

Example:
iFd | 0.0

Motor current for wire drive in A
The value changes as soon as the motor is running.

2nd

Second menu level for service technicians

  1. Troubleshooting and Maintenance

Displaying Service Parameters

Service parameters

Various service parameters can be retrieved by pressing the left and right-hand "Parameter selection" buttons at the same time.

Opening the display:

1

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

Selecting parameters:

1

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

Available parameters

Example:
1.00 | 4.21

Firmware version

Example:
2 | 491

Welding program configuration

Example:
r 2 | 290

Number of the currently selected welding program

Example:
654 | 32.1
= 65,432.1 hours
= 65,432 hours 6 mins

Indicates the actual arc time since first use.
Note: The arc time indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.

Example:
iFd | 0.0

Motor current for wire drive in A
The value changes as soon as the motor is running.

2nd

Second menu level for service technicians

  1. Troubleshooting and Maintenance
  2. Displaying Service Parameters

Service parameters

Various service parameters can be retrieved by pressing the left and right-hand "Parameter selection" buttons at the same time.

Opening the display:

1

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

Selecting parameters:

1

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

Available parameters

Example:
1.00 | 4.21

Firmware version

Example:
2 | 491

Welding program configuration

Example:
r 2 | 290

Number of the currently selected welding program

Example:
654 | 32.1
= 65,432.1 hours
= 65,432 hours 6 mins

Indicates the actual arc time since first use.
Note: The arc time indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.

Example:
iFd | 0.0

Motor current for wire drive in A
The value changes as soon as the motor is running.

2nd

Second menu level for service technicians

  1. Troubleshooting and Maintenance

Troubleshooting

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and disconnect them from the grid.

Secure all devices and components involved so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger due to insufficient ground conductor connection.

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

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

  1. Troubleshooting and Maintenance
  2. Troubleshooting

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and disconnect them from the grid.

Secure all devices and components involved so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger due to insufficient ground conductor connection.

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

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

  1. Troubleshooting and Maintenance
  2. Troubleshooting

Troubleshooting

Make a note of the serial number and configuration of the device, and provide the service team with a detailed error description if:

  • Errors occur that are not covered in this document
  • The troubleshooting measures provided in this document are unsuccessful

Power source not working
Power source switched on, displays do not illuminate
Cause:Grid lead damaged or broken, grid plug not inserted
Remedy:Check grid lead, if necessary insert grid plug
Cause:Grid socket or grid plug faulty
Remedy:Replace faulty parts
Cause:Grid fuse
Remedy:Replace grid fuse
Nothing happens when the torch trigger is pressed
Power source mains switch is ON and indicators are lit up
Cause:Welding torch or welding torch control line faulty
Remedy:Replace welding torch
No welding current
Power switch is on, one of the overtemperature service codes "to" is displayed. Detailed information on the service codes "to0" to "to6" can be found in the section Displayed Service Codes from page (→).
Cause:Overloading
Remedy:Observe the duty cycle
Cause:Thermal automatic circuit breaker has tripped
Remedy:Wait until the power source automatically comes back on after the end of the cooling phase
Cause:Limited supply of cooling air
Remedy:Clean the air filter, ensure accessibility to the ventilation openings - see section Maintenance as required, at least every two months from page (→)
Cause:Fan in the power source is faulty
Remedy:Contact After-Sales Service
No welding current
Power source switched on, displays illuminate
Cause:Incorrect ground connection
Remedy:Check ground connection for polarity
Cause:Power cable in welding torch damaged or broken.
Remedy:Replace welding torch
No shielding gas
All other functions are OK
Cause:Gas hose is not connected to the correct connection socket for the current welding process
Remedy:Connect the gas hose to the correct connection socket for the current welding process
Cause:Gas cylinder empty
Remedy:Change gas cylinder
Cause:Gas pressure regulator faulty
Remedy:Replace gas pressure regulator
Cause:Gas hose is not fitted or is damaged
Remedy:Fit or change gas hose
Cause:Welding torch faulty
Remedy:Change welding torch
Cause:Gas solenoid valve faulty
Remedy:Inform service team
Irregular wire speed
Cause:Braking force has been set too high
Remedy:Loosen the brake
Cause:Contact tip hole too narrow
Remedy:Use suitable contact tip
Cause:Faulty inner liner in welding torch
Remedy:Check the inner liner for kinks, dirt, etc. and replace if necessary
Cause:Feed rollers not suitable for wire electrode used
Remedy:Use suitable feed rollers
Cause:Incorrect contact pressure of feed rollers
Remedy:Optimize contact pressure
Wirefeed problems
Cause:Incorrect arrangement of welding torch hosepack
Remedy:Arrange the welding torch hosepack in as straight a line as possible, avoiding bends
Welding torch gets very hot
Cause:Welding torch is inadequately sized
Remedy:Observe duty cycle and load limits
Poor-quality weld properties
Cause:Incorrect welding parameters
Remedy:Check settings
Cause:Poor ground earth connection
Remedy:Establish good contact with workpiece
Cause:Too little or no shielding gas
Remedy:Check gas pressure regulator, gas hose, gas solenoid valve, welding torch gas connection, etc.
Cause:Welding torch leaks
Remedy:Change welding torch
Cause:Incorrect or heavily worn contact tip
Remedy:Change contact tip
Cause:Incorrect wire alloy or incorrect wire diameter
Remedy:Check wire electrode in use
Cause:Incorrect wire alloy or incorrect wire diameter
Remedy:Check weldability of the base material
Cause:Shielding gas not suitable for wire alloy
Remedy:Use correct shielding gas
  1. Troubleshooting and Maintenance
  2. Troubleshooting

Displayed Service Codes

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

1Switch the power source power switch to the -O- position
2Wait ten seconds
3Switch the power switch to the -I- position


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

1Make a note of the error message displayed
2Note down the configuration of the power source
3Contact our After-Sales Service team with a detailed description of the error

ELn | 13
Cause:Impermissible change of welding process during welding
Remedy:During welding do not make any impermissible change to the welding process, reset error message by pressing any button
Err | IP
Cause:The power source control has detected a primary overvoltage
Remedy:Check the grid voltage.
If the service code persists, switch off the power source, wait for 10 seconds and then switch the power source on again.
If the error still persists, contact the After-Sales Service team
Err | 51
Cause:Mains undervoltage: Mains voltage has fallen below the tolerance range
Remedy:Check the mains voltage. If the service code remains, contact After-Sales Service
Err | 52
Cause:Mains overvoltage: the grid voltage has risen above the tolerance range
Remedy:Check the grid voltage.
If the service code persists, contact After-Sales Service
EFd | 14, EFd | 81, EFd | 83
Cause:Fault in the wirefeed system - overcurrent in the wirefeeder motor (2-roller drive)
Remedy:Arrange the hosepack in as straight a line as possible; check that there are no kinks or dirt in the inner liner; check the contact pressure on the 2-roller drive; check that there is no entangled wire in the 2-roller drive
Cause:Wirefeeder motor is sticking or defective
Remedy:Check the wirefeeder motor or contact After-Sales Service
to0 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the PC board LSTMAG20 (secondary circuit)
Remedy:Allow power source to cool down, check air filter and clean if necessary, check that fan is on
to2 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature in the secondary circuit of the power source
Remedy:Allow power source to cool down, check air filter and clean if necessary (see section Maintenance as required, at least every two months on page (→)), check whether the fan is running
to3 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the PC board LSTMAG20 (wirefeeder)
Remedy:Allow power source to cool down, check air filter and clean if necessary (see section Maintenance as required, at least every two months on page (→)), check whether the fan is running
to6 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the PC board LSTMAG20 (voltage doubler)
Remedy:Allow power source to cool down, check air filter and clean if necessary (see section Maintenance as required, at least every two months on page (→)), check whether the fan is running
to7 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature in the power source
Remedy:Allow power source to cool down, check air filter and clean if necessary, check that fan is on
to8 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the power module
Remedy:Allow power source to cool down, check that fan is on
to9 | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the PFC module
Remedy:Allow power source to cool down, check that fan is on
toA | xxx
Note: xxx stands for a temperature value
Cause:Overtemperature on the PC board LSTMAG20 (PFC)
Remedy:Allow power source to cool down, check that fan is on
toF | xxx
Cause:The power source's safety cut-out reacted in order to prevent tripping of the mains fuse.
Remedy:After a pause in welding of around 90 s, the message disappears and the power source is operational again.
tu0 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the PC board (secondary circuit)
Remedy:Place power source in a heated room and allow it to warm up
tu2 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature in the power source secondary circuit
Remedy:Place power source in a heated room and allow it to warm up
tu3 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the PC board LSTMAG20 (wirefeeder)
Remedy:Place power source in a heated room and allow it to warm up
tu6 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the PC board LSTMAG20 (voltage doubler)
Remedy:Place power source in a heated room and allow it to warm up
tu7 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature in power source
Remedy:Place power source in a heated room and allow it to warm up
tu8 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the power module
Remedy:Place power source in a heated room and allow it to warm up
tu9 | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the PFC module
Remedy:Place power source in a heated room and allow it to warm up
tuA | xxx
Note: xxx stands for a temperature value
Cause:Undertemperature on the PC board LSTMAG20 (PFC)
Remedy:Place power source in a heated room and allow it to warm up
no | Prg
Cause:No saved program selected
Remedy:Select saved program
no | IGn
Cause: "Ignition time-out" function is active; current did not start flowing before the length of wire specified in the Setup menu had been fed. The power source safety cut-out has tripped
Remedy:Shorten the wire stick-out; press the torch trigger again; clean the surface of the workpiece; if necessary, set the "Ito" parameter in the Setup menu
no | ARC
Cause:Arc break during TIG welding
Remedy:Press the torch trigger repeatedly, clean the surface of the workpiece
EPG | 17
Cause: The selected welding program is invalid
Remedy:Select a valid welding program
EPG | 35
Cause: Measurement of the welding circuit resistance failed
Remedy:Check grounding cable, current cable, or hosepack and replace if necessary, re-measure the welding circuit resistance
  1. Troubleshooting and Maintenance

Service, maintenance and disposal

General

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

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

General

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

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

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried out by technically trained and qualified personnel.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and disconnect them from the grid.

Secure all devices and components involved so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger due to insufficient ground conductor connection.

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

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

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

Maintenance at every start-up

  • Ensure that the mains plug and mains cable as well as the welding torch / electrode holder are undamaged. Replace any damaged components.
  • Ensure that the welding torch / electrode holder and the grounding cable are properly connected to the power source and screwed/locked in place as described in this document
  • Ensure a proper ground earth connection to the component.
  • Ensure that the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that cooling air can circulate unimpeded. Air inlet and outlet openings must not be blocked or even partially covered.
  1. Troubleshooting and Maintenance
  2. Service, maintenance and disposal

Maintenance as required, at least every two months

1
2

CAUTION!

Danger from wet air filter.

This can result in damage to property.

Ensure that the air filter is dry when it is fitted.

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

Maintenance every 6 months

CAUTION!

Danger due to the effect of compressed air.

This can result in damage to property.

Do not bring the air nozzle too close to electronic parts.

1Remove the right-hand device side panel (as viewed from the front) and blow the inside of the device clean with dry, reduced compressed air
2Also clean the ventilation openings if there is a large accumulation of dust
  1. Troubleshooting and Maintenance
  2. Service, maintenance and disposal

Disposal

Materials should be disposed of according to valid local and national regulations.

  1. Troubleshooting and Maintenance

Removing Stiff Drive Rollers

Removing a stiff drive roller

If a drive roller is difficult to remove by hand, the knurled screw on the D100 brake can be used to remove it.
1
2
3
4
  1. Troubleshooting and Maintenance
  2. Removing Stiff Drive Rollers

Removing a stiff drive roller

If a drive roller is difficult to remove by hand, the knurled screw on the D100 brake can be used to remove it.
1
2
3
4

Appendix

Average consumption values during welding

Average wire electrode consumption during MIG/MAG welding

Average wire electrode consumption at a wire speed of 5 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

1.8 kg/h

2.7 kg/h

4.7 kg/h

Aluminum wire electrode

0.6 kg/h

0.9 kg/h

1.6 kg/h

CrNi wire electrode

1.9 kg/h

2.8 kg/h

4.8 kg/h

Average wire electrode consumption at a wire speed of 10 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

3.7 kg/h

5.3 kg/h

9.5 kg/h

Aluminum wire electrode

1.3 kg/h

1.8 kg/h

3.2 kg/h

CrNi wire electrode

3.8 kg/h

5.4 kg/h

9.6 kg/h

  1. Appendix

Average consumption values during welding

Average wire electrode consumption during MIG/MAG welding

Average wire electrode consumption at a wire speed of 5 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

1.8 kg/h

2.7 kg/h

4.7 kg/h

Aluminum wire electrode

0.6 kg/h

0.9 kg/h

1.6 kg/h

CrNi wire electrode

1.9 kg/h

2.8 kg/h

4.8 kg/h

Average wire electrode consumption at a wire speed of 10 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

3.7 kg/h

5.3 kg/h

9.5 kg/h

Aluminum wire electrode

1.3 kg/h

1.8 kg/h

3.2 kg/h

CrNi wire electrode

3.8 kg/h

5.4 kg/h

9.6 kg/h

  1. Appendix
  2. Average consumption values during welding

Average wire electrode consumption during MIG/MAG welding

Average wire electrode consumption at a wire speed of 5 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

1.8 kg/h

2.7 kg/h

4.7 kg/h

Aluminum wire electrode

0.6 kg/h

0.9 kg/h

1.6 kg/h

CrNi wire electrode

1.9 kg/h

2.8 kg/h

4.8 kg/h

Average wire electrode consumption at a wire speed of 10 m/min

 

1.0 mm wire electrode diameter

1.2 mm wire electrode diameter

1.6 mm wire electrode diameter

Steel wire electrode

3.7 kg/h

5.3 kg/h

9.5 kg/h

Aluminum wire electrode

1.3 kg/h

1.8 kg/h

3.2 kg/h

CrNi wire electrode

3.8 kg/h

5.4 kg/h

9.6 kg/h

  1. Appendix
  2. Average consumption values during welding

Average shielding gas consumption during MIG/MAG welding

Wire electrode diameter

1.0 mm

1.2 mm

1.6 mm

2.0 mm

2 x 1.2 mm (TWIN)

Average consumption

10 l/min

12 l/min

16 l/min

20 l/min

24 l/min

  1. Appendix
  2. Average consumption values during welding

Average shielding gas consumption during TIG welding

Gas nozzle size

4

5

6

7

8

10

Average consumption

6 l/min

8 l/min

10 l/min

12 l/min

12 l/min

15 l/min

  1. Appendix

Technical data

Overview with critical raw materials, year of production of the device

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

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

Overview with critical raw materials, year of production of the device

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

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

Special voltage

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

  1. Appendix
  2. Technical data

Explanation of the Term Duty Cycle

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

NOTE!

The D.C. values cited on the rating plate relate to an ambient temperature of 40 °C.

If the ambient temperature is higher, the D.C. or power must be lowered accordingly.

Example: Welding with 150 A at 60% D.C.

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

To use the device without interruptions:

1Search for a 100% D.C. value in the technical data, which corresponds to the existing ambient temperature.
2Reduce the power or amperage value correspondingly so that the device can operate without a cool-down phase.
  1. Appendix
  2. Technical data

TransSteel 2200

Grid voltage (U1)

 

 

 

1 x

230 V

Max. effective primary current (I1eff)

 

 

 

 

16 A

Max. primary current (I1max)

 

 

 

26 A

Mains fuse protection

16 A slow-blow

Max. apparent power (S1max)

5.98 kVA

 

 

 

 

 

 

 

Mains voltage tolerance

-20 / +15%

Grid frequency

50 / 60 Hz

Cos phi (1)

0.99

Max. permitted grid impedance Zmax on PCC1)

 

250.02 mOhm

Recommended residual-current circuit breaker

 

Type B

 

 

 

 

 

 

 

Welding current range (I2)

 

 

 

 

 

MIG/MAG

 

 

10 - 210 A

MMA

 

 

10 - 180 A

TIG

 

 

10 - 230 A

Welding current at

10 min / 40 °C (104 °F)

 

30%

60%

100%

MIG/MAG

U1 230 V

 

 

210 A

170 A

150 A

Welding current at

10 min / 40 °C (104 °F)

 

35%

60%

100%

MMA

U1 230 V

 

 

180 A

150 A

130 A

Welding current at

10 min / 40 °C (104 °F)

 

35%

60%

100%

TIG

U1 230 V

 

 

230 A

200 A

170 A

Output voltage range according to standard characteristic (U2)

 

 

MIG/MAG

 

 

14.5 - 24.5 V

MMA

 

 

20.4 - 27.2 V

TIG

 

 

10.4 - 19.2 V

Open circuit voltage (U0 peak / U0 r.m.s)

 

90 V

 

 

 

 

 

 

 

Protection class

 

 

IP 23

Type of cooling

 

 

AF

Overvoltage category

 

 

III

Pollution degree according to IEC60664

 

3

EMC device class

 

A 2)

Safety markings

 

S, CE

Dimensions l x w x h

 

560 x 215 x 370 mm
22.05 x 8.46 x 14.57 in.

Weight

 

 

15 kg
33.07 lb.

 

 

 

 

 

 

 

Max. shielding gas pressure

 

 

5 bar
72.52 psi

 

 

 

 

 

 

 

Wire speed

 

1.5 - 18 m/min
59.06 - 708.66 ipm

Wire drive

 

2-roller drive

Wire diameter

0.6 - 1.2 mm
0.025 - 0.047 in.

Wirespool diameter

 

max. 200 mm
max. 7.87 in.

Wirespool weight

 

max. 6.8 kg
max. 14.99 lb.

Max. noise emission (LWA)

 

65.5 dB

Idle state power consumption at
230 V

 

17.4 W

Power source efficiency at
210 A / 24.5 V

 

89 %

1)
Interface to a 230 V, 50 Hz public grid
2)
A device in emissions class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid.
The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.
  1. Appendix
  2. Technical data

TransSteel 2200 MV

Grid voltage (U1)

 

 

 

1 x

120 V

Max. effective primary current (I1eff)

 

 

 

 

15 A

Max. primary current (I1max)

 

 

 

20 A

Mains fuse protection

15 A slow-blow

Max. apparent power (S1max)

2.40 kVA

 

 

 

 

 

 

 

Grid voltage (U1)

 

 

 

1 x

120 V

Max. effective primary current (I1eff)

 

 

 

 

20 A

Max. primary current (I1max)

 

 

 

29 A

Mains fuse protection

20 A slow-blow

Max. apparent power (S1max)

3.48 kVA

 

 

 

 

 

 

 

Grid voltage (U1)

 

 

 

1 x

230 V

Max. effective primary current (I1eff)

 

 

 

 

16 A

Max. primary current (I1max)

 

 

 

26 A

Mains fuse protection

16 A slow-blow

Max. apparent power (S1max)

5.98 kVA

 

 

 

 

 

 

 

Grid voltage (U1)

 

 

 

1 x

240 V

Max. effective primary current (I1eff)

 

 

 

 

15 A

Max. primary current (I1max)

 

 

 

26 A

Mains fuse2)

20 A time-delay fuse3)

Max. apparent power (S1max)

6.24 kVA

 

 

 

 

 

 

 

Mains voltage tolerance

-20 / +15%

Grid frequency

50 / 60 Hz

Cos phi

0.99

Max. permitted grid impedance Zmax on PCC1)

 

250.02 mOhm

Recommended residual-current circuit breaker

 

Type B

 

 

 

 

 

 

 

Welding current range (I2)

 

 

 

 

 

MIG/MAG

 

 

10 - 210 A

MMA

 

 

10 - 180 A

TIG

 

 

10 - 230 A

Welding current at

10 min / 40 °C (104 °F)

 

30%

60%

100%

MIG/MAG

U1 120 V

(15 A)

 

105 A

95 A

80 A

 

U1 120 V

(20 A)

 

135 A

120 A

105 A

 

U1 230 V

 

 

210 A

170 A

150 A

Welding current at

10 min / 40 °C (104 °F)

 

35%

60%

100%

MMA

U1 120 V

(15 A)

 

90 A

80 A

70 A

 

U1 120 V

(20 A)

 

110 A

100 A

90 A

 

U1 230 V

 

 

180 A

150 A

130 A

Welding current at

10 min / 40 °C (104 °F)

 

35%

60%

100%

TIG

U1 120 V

(15 A)

 

135 A

120 A

105 A

 

U1 120 V

(20 A)

 

160 A

150 A

130 A

 

U1 230 V

 

 

230 A

200 A

170 A

Output voltage range according to standard characteristic (U2)

 

 

 

MIG/MAG

 

 

14.5 - 24.5 V

MMA

 

 

20.4 - 27.2 V

TIG

 

 

10.4 - 19.2 V

Open circuit voltage (U0 peak / U0 r.m.s)

 

90 V

 

 

 

 

 

 

 

Protection class

 

 

IP 23

Type of cooling

 

 

AF

Overvoltage category

 

 

III

Pollution degree according to IEC60664

 

3

EMC device class

 

A 4)

Safety markings

 

S, CE, CSA

Dimensions l x w x h

 

560 x 215 x 370 mm
22.05 x 8.46 x 14.57 in.

Weight

 

 

15.2 kg
33.51 lb.

 

 

 

 

 

 

 

Max. shielding gas pressure

 

 

5 bar
72.52 psi

 

 

 

 

 

 

 

Wire speed

 

1.5 - 18 m/min
59.06 - 708.66 ipm

Wire drive

 

2-roller drive

Wire diameter

0.6 - 1.2 mm
0.025 - 0.047 in.

Wirespool diameter

 

max. 200 mm
max. 7.87 in.

Wirespool weight

 

max. 6.8 kg
max. 14.99 lb.

Max. noise emission (LWA)

 

65.5 dB

Idle state power consumption at
230 V

 

17.4 W

Power source efficiency at
210 A / 24.5 V

 

89 %

1)
Interface to a 230 V, 50 Hz public grid.
2)
Only applies to USA:
If an automatic circuit breaker is used instead of a fuse, the current/time characteristic of the automatic circuit breaker must match that of the mains fuse specified above.
It is permitted for the tripping current of the automatic circuit breaker to be higher than the tripping current of the mains fuse specified above.
3)
Only applies to USA:
Time-delay fuse conforming to UL Class RK5 (see UL 248).
4)
A device in emissions class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid.
The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.
  1. Appendix
  2. Technical data

China Energy Label

TransSteel 2200c EF

TransSteel 2200 Set EF

 

 

 

 

 

  1. Appendix

Welding program tables

TSt 2200 welding program table

Welding program database: DB 3815

  1. Appendix
  2. Welding program tables

TSt 2200 welding program table

Welding program database: DB 3815