TransSteel 2200 Operating instructions

1. Safety Instructions

1. Safety Instructions

• Injury or death to the operator or a third party
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the equipment

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

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

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

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

1. Safety Instructions

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

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

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

• Thawing pipes
• Charging batteries
• Starting motors

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

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

1. Safety Instructions

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

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

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

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

IMPORTANT! Ensure secure grounding of the grid connection!

1. Safety Instructions

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

• During operation: -10°C to +40°C (14°F to 104°F)
• During transport and storage: -20°C to +55°C (-4°F to 131°F)

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

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

1. Safety Instructions

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

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

1. Safety Instructions

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

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

1. Safety Instructions

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

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

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

• Electrical risks from grid current and welding current

• Increased noise exposure

• Harmful welding fumes and gases

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

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

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

1. Safety Instructions

The 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

The fumes produced during welding contain toxic gases and vapors.

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

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

Keep your head out of the welding fumes and gases.

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

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

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

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

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

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

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

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

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

1. Safety Instructions

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

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

Keep suitable, tested fire extinguishers on hand.

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

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

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

1. Safety Instructions

An electric shock can be fatal.

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

During MIG/MAG welding and TIG welding, the welding wire, the 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.

• 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.

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

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

1. Safety Instructions

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

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

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

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

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

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

1. Safety Instructions

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

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

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

1. Safety Instructions

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

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

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

1. Safety Instructions

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

1. Safety Instructions

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

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

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

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

The 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

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

Use filters if necessary.

1. Safety Instructions

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

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

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

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

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

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

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

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

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

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

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

1. Safety Instructions

Risk of asphyxiation due to uncontrolled shielding gas leak

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

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

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• Follow the appropriate national and international regulations.

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

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

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

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

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

• 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

• Injury or death to the operator or a third party
• Damage to the device and other material assets belonging to the operating company
• Inefficient operation of the device

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

Never bypass or disable safety devices.

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

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

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

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

Only use appropriate original coolant from the manufacturer.

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

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

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

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

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

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

1. Safety Instructions

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

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

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

1. Safety Instructions

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

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

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

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

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

1. Safety Instructions

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

• Collect separately
• Observe local regulations
• Crush cardboard boxes

1. Safety Instructions

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

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

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

1. Safety Instructions

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 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.

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

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

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

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.

• 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

MIG/MAG welding

TIG welding

Manual metal arc welding

1. General information
2. General

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

• Adequate welding qualifications
• Appropriate protective equipment
• Keep unauthorized people away from the power source and the welding process

• 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.

• 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

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

The arrangement of the symbols may vary.

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

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

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

1. Operating controls and connections
2. Control Panel

(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.

(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

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

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

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

(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

(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

(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

1. Before installation and initial operation

1. Before installation and initial operation
2. General

1. Before installation and initial operation
2. General

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.

• 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

• 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.

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

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

1. Before installation and initial operation

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated as follows:
S_1max = I_1max x U₁

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

The generator apparent power S_GEN needed is calculated using the following rule of thumb:
S_GEN = S_1max x 1.35

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

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.

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

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated as follows:
S_1max = I_1max x U₁

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

The generator apparent power S_GEN needed is calculated using the following rule of thumb:
S_GEN = S_1max x 1.35

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

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.

1. Before installation and initial operation

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:

TSt 2200 MV:

• 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

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

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:

TSt 2200 MV:

• 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

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

1

2

3

4

5

6

1. Before installation and initial operation
2. Fitting the Carrying Strap

1

2

3

4

5

6

1. MIG/MAG

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

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

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

1

2

1. MIG/MAG
2. Commissioning

1

2

3

1. MIG/MAG
2. Commissioning

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

• 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

1

2

1. MIG/MAG
2. Commissioning

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

1. MIG/MAG

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

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

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

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

• 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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

• 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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

"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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

"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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

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:

1. MIG/MAG
2. Description of MIG/MAG Operating Modes

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:

1. MIG/MAG

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

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

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

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.

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

1. MIG/MAG

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 weldingUnder 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.

1. MIG/MAG
2. 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 weldingUnder 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.

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

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

 Arc length correction:

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

1. MIG/MAG

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

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

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

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

1. TIG

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

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

1. TIG
2. Commissioning

• 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

1. TIG

Explanation of symbols:

Pull back the torch trigger and hold it in this position

Release the torch trigger forwards

Abbreviations used:

1. TIG
2. Description of TIG Operating Modes

Explanation of symbols:

Pull back the torch trigger and hold it in this position

Release the torch trigger forwards

Abbreviations used:

1. TIG
2. Description of TIG Operating Modes

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 .

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:

1. TIG

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.

• 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

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.

• 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

• 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:

Fixed parameters:

1. TIG
2. Pulse welding

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

1. Rod Electrode

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

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

• 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

1Press the "Process" button to select STICK

2Set the desired welding current

• Power source is ready for welding

1. Rod Electrode
2. Commissioning

1. Rod Electrode

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

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

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

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

This function is activated at the factory.

• 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 (I_H).

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

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.

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

• 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

• 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

• 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

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

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

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

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

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 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

1. Setup Menu
2. Setup Menu Level 1

1. Setup Menu
2. Setup Menu Level 1

1. Setup Menu
2. Setup Menu Level 1

1. Setup Menu

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 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

1. Setup Menu
2. Setup Menu 2nd Level

1. Setup Menu
2. Setup Menu 2nd Level

1. Setup Menu
2. Setup Menu 2nd Level

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

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

1. Optimizing Weld Quality

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

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

1. Optimizing Weld Quality
2. Measuring the welding circuit resistance

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

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

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

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

1. Optimizing Weld Quality
2. Measuring the welding circuit resistance

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

1. Optimizing Weld Quality
2. Measuring the welding circuit resistance

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

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

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

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

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

L ... Welding circuit inductivity (in microhenrys)

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

1. Troubleshooting and Maintenance

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

1. Troubleshooting and Maintenance
2. Displaying 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

1. Troubleshooting and Maintenance

1. Troubleshooting and Maintenance
2. Troubleshooting

1. Troubleshooting and Maintenance
2. Troubleshooting

Make a note of the serial number and configuration of the device, and 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

1. Troubleshooting and Maintenance
2. Troubleshooting

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

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

1. Troubleshooting and Maintenance

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

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

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

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

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

• 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

1

2

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

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

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

1. Troubleshooting and Maintenance

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

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. Appendix

1. Appendix
2. Average consumption values during welding

1. Appendix
2. Average consumption values during welding

1. Appendix
2. Average consumption values during welding

1. Appendix

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

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

1. Appendix
2. Technical data

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

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

1. Appendix
2. Technical data

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

1. Appendix
2. Technical data

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.

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:

1. Appendix
2. Technical data