Fortis 270/320/400/500 C, Fortis 320/400/500 Operating instructions

1. General information

1. General information
2. General

1. General information
2. General

• 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. General information
2. General

• 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. General information
2. General

• Directive 2014/30/EU on electromagnetic compatibility
• Directive 2014/35/EU Low Voltage Directive
• Directive 2014/53/EU Radio Equipment Directive
• EN IEC 60974 Arc welding equipment
• and others

The full text of the EU Declaration of Conformity is available at
https://www.fronius.com .

Devices bearing the CSA label satisfy the requirements of the relevant standards for Canada and the USA.

1. General information
2. General

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

1. General information
2. General

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.

1. General information

The device has been manufactured in line with the state of the art and according to recognized safety standards.

The welding machine is only intended for MIG/MAG, MMA, and TIG welding in conjunction with Fronius components.

Any other use shall be deemed to be not in accordance with the intended use.

• Carefully reading and adhering to these operating instructions
• Observing and obeying all safety instructions
• Carrying out all the specified inspection and maintenance work

1. General information
2. Utilization in accordance with "intended purpose"

The device has been manufactured in line with the state of the art and according to recognized safety standards.

The welding machine is only intended for MIG/MAG, MMA, and TIG welding in conjunction with Fronius components.

Any other use shall be deemed to be not in accordance with the intended use.

• Carefully reading and adhering to these operating instructions
• Observing and obeying all safety instructions
• Carrying out all the specified inspection and maintenance work

1. General information
2. Utilization in accordance with "intended purpose"

IMPORTANT! Any use that does not comply with the intended use shall be deemed misuse.

• Using the device to thaw pipes
• Using the device to charge batteries/rechargeable batteries
• Using the device to start motors
• Operation or storage of the device outside the environmental conditions specified in the technical data
• Operation or storage of the device outside the protection class specified in the technical data
• ...

1. General information

* Cooling unit option, ** Toolbox option

The Fortis MIG/MAG welding machine is a digitalized, microprocessor-controlled inverter welding machine.

Depending on the variant, the welding machine is available with integrated 4-roller wire drive or with a separate wirefeeder.

A modular and compact design and the ability to easily extend the system guarantee a high degree of flexibility.

The welding machine can be adapted to any specific situation.

1. General information
2. Information about the device

* Cooling unit option, ** Toolbox option

The Fortis MIG/MAG welding machine is a digitalized, microprocessor-controlled inverter welding machine.

Depending on the variant, the welding machine is available with integrated 4-roller wire drive or with a separate wirefeeder.

A modular and compact design and the ability to easily extend the system guarantee a high degree of flexibility.

The welding machine can be adapted to any specific situation.

1. General information
2. Information about the device

• Fortis 270 C /G
• Fortis 320 C /G

• Fortis 320 C /GW
• Fortis 400 C /GW
• Fortis 500 C /GW

• Fortis 320 /GW
• Fortis 400 /GW
• Fortis 500 /GW

Explanation of the abbreviations:

In addition to the standard version, all welding machines are also available in the following versions:

1. General information
2. Information about the device

The central control and regulation unit of the welding machines 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. Rule algorithms ensure that the desired target state is maintained.

• A precise welding process
• Exact reproducibility of all results
• Excellent weld properties

1. General information
2. Information about the device

The machines are used commercially for manual applications, mainly with steel and galvanized sheets.
However, aluminum, other metals, and alloys as well as flux core wires can also be welded.

Common areas of application include

• Mechanical and equipment engineering
• Steel construction
• Plant and container construction
• Metal and portal construction
• Rail vehicle construction
• Repair and maintenance
• Assembly in shipyards
• Automotive suppliers
• etc.

1. General information

A rating plate and different safety symbols for the specific model are attached to the device.
The safety symbols indicate hazards during welding, which, if not observed, can lead to serious injury and damage to property.

Rating plate and safety symbols:

• Must be kept in a legible state
• Must not be damaged
• Must not be removed
• Must not be covered, have anything stuck on them, or painted over

Safety symbols on the rating plate:

	Welding is dangerous. The following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Exclusion of unauthorized persons
	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

1. General information
2. Notes on the device

A rating plate and different safety symbols for the specific model are attached to the device.
The safety symbols indicate hazards during welding, which, if not observed, can lead to serious injury and damage to property.

Rating plate and safety symbols:

• Must be kept in a legible state
• Must not be damaged
• Must not be removed
• Must not be covered, have anything stuck on them, or painted over

Safety symbols on the rating plate:

	Welding is dangerous. The following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Exclusion of unauthorized persons
	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

1. General information
2. Notes on the device

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

The arrangement of the symbols may vary.

1. General information
2. Notes on the device

(A)	The cooling unit must only be operated using Cooling Liquid FCL10/20. Other coolants are not suitable due to their electrical conductivity and insufficient material compatibility. See also 'Filling the cooling unit' from page (→) onwards.
(B)	Draining the coolant See also 'Replacing the coolant' from page (→) onwards.
(C)	Cleaning the fin element using compressed air
(D)	Cleaning the cooling unit filter See also 'Cleaning the cooling unit filter' from page (→) onwards.

1. General information

The welding machines can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

1. General information
2. System components

The welding machines can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

1. General information
2. System components

System components

Other system components (not shown):

• Welding torch
• Remote control RC Bar / RC Panel
• Trolley and gas cylinder holders
• Wirefeeder trolley Trabant WF /s
• Interconnecting hosepacks
• Grounding and electrode cable
• TIG welding torch
• Human /s hosepack boom
• TIG Multi Connector Automatic Interface
• Options

1. General information
2. System components

OPT/s Duo
Hardware extension for a C /GW welding machine in order to be able to additionally operate an external WF 25s wirefeeder (= DUO operation)

OPT/s CU 1200
Optional water cooling for the welding machines Fortis 320 - 500 C /GW and Fortis 320 - 500 /GW
incl. start-up monitoring and temperature sensors

OPT/s CU 1200 MC
Optional water cooling for the welding machines Fortis 320 - 500 C /GW and Fortis 320 - 500 /GW, also for DUO operation
incl. temperature sensors, coolant connections at the rear and front, bracket, and flow sensor

The filter can also be mounted on the rear of the device.

DUO operation:
The Fortis 320 - 500 C /GW welding machines are also operated with a separate WF 25s wirefeeder.

OPT/s Water Connection DUO
Double water connections on the cooling unit (required for DUO operation)

The filter can also be mounted on the rear of the device.

OPT/s CU Flow Sensor
Flow sensor for the cooling unit

OPT/s VRD Class A
Safety option to reduce open circuit voltage

OPT/s Toolbox
Removable, lockable toolbox for the gas-cooled welding machines Fortis 320 - 500 C /GW and Fortis 320 - 500 /GW

OPT/s Ethernet
Optional RJ45 Ethernet port to connect the welding machines to a local network

OPT/s MP 400/500, OPT/s MP 400/500 XT /600 V
Multiprocess
incl. additional TIG socket, built-in gas solenoid valve, polarity reverser, and TIG Multi Connector port

• Standard for the welding machines Fortis 270 C /G, Fortis 320 C /G, and Fortis 320 C /GW, in the standard and XT variants
• Optional for the welding machines Fortis 400 C /GW and Fortis 500 C /GW
• Not available for the welding machines Fortis 320 - 500 /GW

OPT/s TMC 400/500
Optional TIG Multi Connector port for non-Multiprocess devices

OPT/s Current Socket Front
Additional current socket on the front for 400 / 500 A welding machines (e.g., for arc air gouging)

OPT/s Welding Torch Holder

OPT/s Organizer
Small parts storage on the top of the welding machine

AI IO TMC /s
Automatic Interface

OPT/s NFC Reader /TMC
External NFC card reader

• To lock or unlock the control panel using an NFC key
• To activate/deactivate user management

OPT/s VRD Class A /IK
VRD Class A functionality

OPT/s MultiProcess
For enhanced TIG and MMA functionality

Standard for the Fortis 270 C /G and Fortis 320 C /G
Optional for the Fortis 400 C and Fortis 500 C

Software options

OPT/s Pulse/Std Mix Fortis
All MIG/MAG mix characteristics and the additional characteristic property "mix" are available on the welding machine.

OPT/s Retro TransSteel
All MIG/MAG standard and pulse characteristics of the TransSteel series and the additional characteristic property "Retro" are available on the welding machine.

OPT/i WeldCube Navigator
Software for creating digital instructions for manual welding processes, which are processed by welders.
The welder is guided through the welding instructions by WeldCube Navigator.

For the OPT/i WeldCube Navigator option to work properly, the OPT/s Job, OPT/s Documentation, and OPT/s NFC Reader options must be available on the welding machine.

For Fortis C devices without multiprocess, the OPT/s TMC 400/500 option must also be available on the welding machine.
For Fortis /GW devices, the OPT/s WF TIG Multi Connector port option must be available on the WF 25s wirefeeder or the OPT/s TMC 400/500 option must be available on the welding machine.

OPT/s Duo
Duo functionality (two welding lines)

For the OPT/s Duo option to work properly, the OPT/s Duo /IK option or the OPT/s Duo CK option must be available on the welding machine.

OPT/s Documentation
To document the welding data

Without OPT/s Documentation only a logbook with events is available.

OPT/s Jobs
With the OPT/s Jobs option, the job process is available, including Load More EasyJobs, Optimize job, Duplicate job, Job correction limits, and Delete job.

Without OPT/s Job, only a maximum of four EasyJobs can be saved and selected.

BLE-WIFI24 inside
WLAN and Bluetooth functionality on the welding machine control panel (for certified countries)

Depending on the country, the option is automatically released on the welding machine.

OPT/i Custom NFC - ISO 14443A
Option to use a custom frequency band for key cards

Option OPT/s NFC Reader /TMC is required for the option OPT/i Custom NFC - ISO 14443A.

1. General information
2. System components

The welding machines have a number of different Welding Packages, welding characteristics, and welding processes so that the broadest range of materials can be effectively processed.

1. Welding packages, welding characteristics and welding processes

The welding machines have a number of different Welding Packages, welding characteristics, and welding processes so that the broadest range of materials can be effectively processed.

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

The welding machines have a number of different Welding Packages, welding characteristics, and welding processes so that the broadest range of materials can be effectively processed.

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

The following Welding Packages (WP) are available for the welding machines:

WP Standard Fortis
4,066,023
(enables MIG/MAG standard welding)

WP Pulse Fortis
4,066,024
(enables MIG/MAG pulse welding)

WP Standard/Pulse Fortis
4,066,025
(enables MIG/MAG standard welding and MIG/MAG pulse welding)

IMPORTANT! On a welding machine without Welding Packages, only the following welding processes are available:

• MIG/MAG manual welding
• TIG welding (with gas-valve welding torch)
• Manual metal arc welding
• CEL welding (only with /XT devices)

1. Welding packages, welding characteristics and welding processes

Depending on the welding process and shielding gas combination, various process-optimized welding characteristics are available when selecting the filler metal.
The welding characteristics have special properties that provide information about usage.

Special properties and use of the welding characteristics
(described according to the following pattern):

Property
Process

Description

dynamic
Puls, Standard

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

mix
Puls

Characteristic for the generation of a rippled weld seam.
The heat input into the component is specifically controlled by the cyclic process change between pulse and dip transfer arc.

PCS 
Puls + Standard

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

retro
Pulse, Standard

The characteristic has the same welding properties as the predecessor TransSteel (TSt) device series.

root
Standard

Characteristics for root passes with powerful arc

universal
Puls, Standard

The characteristic is very well suited for all common welding tasks.

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

Depending on the welding process and shielding gas combination, various process-optimized welding characteristics are available when selecting the filler metal.
The welding characteristics have special properties that provide information about usage.

Special properties and use of the welding characteristics
(described according to the following pattern):

Property
Process

Description

dynamic
Puls, Standard

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

mix
Puls

Characteristic for the generation of a rippled weld seam.
The heat input into the component is specifically controlled by the cyclic process change between pulse and dip transfer arc.

PCS 
Puls + Standard

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

retro
Pulse, Standard

The characteristic has the same welding properties as the predecessor TransSteel (TSt) device series.

root
Standard

Characteristics for root passes with powerful arc

universal
Puls, Standard

The characteristic is very well suited for all common welding tasks.

1. Welding packages, welding characteristics and welding processes

MIG/MAG pulse welding is a pulsed arc process with a controlled material transfer.
In the base current phase, the energy input is reduced to such an extent that the arc barely burns steadily and the surface of the workpiece is preheated. In the pulsing current phase, an accurately timed current pulse guarantees a precise detachment of the weld material droplet.
This principle guarantees low-spatter welding and precise operation throughout the entire power range.

MIG/MAG pulse welding can be set on the control panel of the welding machine under "Pulse" in the welding processes.

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

MIG/MAG pulse welding is a pulsed arc process with a controlled material transfer.
In the base current phase, the energy input is reduced to such an extent that the arc barely burns steadily and the surface of the workpiece is preheated. In the pulsing current phase, an accurately timed current pulse guarantees a precise detachment of the weld material droplet.
This principle guarantees low-spatter welding and precise operation throughout the entire power range.

MIG/MAG pulse welding can be set on the control panel of the welding machine under "Pulse" in the welding processes.

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

MIG/MAG standard welding is a MIG/MAG welding process covering the entire power range of the welding machine with the following arc types:

Dip transfer arc
Droplet transfer occurs in the lower power range during the short circuit.

Intermediate arc
The intermediate arc alternates irregularly between short circuits and spray transfers. This results in increased spatter. It is not possible to use this arc effectively, so it is better to avoid it.

Spray arc.
A short circuit-free transfer of material in the high power range.

MIG/MAG standard welding can be set on the control panel of the welding machine under "Standard" in the welding processes.

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

MIG/MAG manual welding is a MIG/MAG welding process in which the wire speed, the welding voltage, and the arc-force dynamic (a correction parameter) are set separately.

MIG/MAG manual welding can be set on the control panel of the welding machine under "Manual" in the welding processes.

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

SynchroPulse is available for all process (Standard / Pulse).
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat input.

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

With stitch welding, all welding processes can be interrupted cyclically. As such, the heat input is controlled in a targeted manner.
The welding time, pause time and the number of interval cycles can be set individually (e.g. for producing a rippled weld seam, for tacking thin sheets or, in the case of longer pause times, for simple, automatic spot welding operation).

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

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

TIG welding is a welding process in which the arc is ignited between the workpiece and a non-consumable, heat-resistant tungsten electrode. The arc fuses the base material. Depending on the application, filler metal can be fed into the weld pool in the form of rods or welding wires.
The weld pool is surrounded by an inert shielding gas environment in order to protect the weld pool from reactions with the ambient air.

TIG welding can be set on the control panel of the welding machine under "TIG" in the welding processes.

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

Manual metal arc welding is a manual welding process in which a sheathed stick electrode is melted.
The sheath of the stick electrode melts during welding, releasing gas and slag that protect the weld pool from reactions with the ambient air.

Manual metal arc welding can be set on the control panel of the welding machine under "MMA" in the welding processes.

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

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

Applications:

• Removal of shrink holes, pores, or slag inclusions from workpieces
• Detaching sprues or the processing of entire workpiece surfaces in foundries
• Edge preparation for heavy plates
• Preparation and repair of weld seams
• Finishing of roots or defects
• Production of air gaps

IMPORTANT! Arc air gouging is only possible with steel materials!

The parameters necessary for welding can be easily selected and changed using dials.
The parameters are shown on the display during welding.

1. Operating controls, connections and mechanical components

The parameters necessary for welding can be easily selected and changed using dials.
The parameters are shown on the display during welding.

1. Operating controls, connections and mechanical components
2. Control Panel

The parameters necessary for welding can be easily selected and changed using dials.
The parameters are shown on the display during welding.

1. Operating controls, connections and mechanical components
2. Control Panel

1. Operating controls, connections and mechanical components
2. Control Panel

1. Operating controls, connections and mechanical components
2. Control Panel

Turning the selection dial

Select elements on the display Change values For some parameters, a value that has been changed by turning the selection dial is automatically applied without having to press the selection dial.

A selected element is highlighted in white on the display between two blue lines:

Examples of selected elements

The shielding gas ArCO2 is selected.

The main welding parameter wire speed is selected. The outer circle in the setting area is displayed in blue.

The correction parameter 'arc length correction' is selected.

To change the values of selected elements, press the corresponding selection dial.

Pressing the selection dial

Open a selected element to change its value. The value is changed by turning the selection dial. Apply values of specific parameters. Confirm or cancel queries, settings, or operations.

Examples of value changes for selected elements

1. Operating controls, connections and mechanical components
2. Control Panel

The following information or parameters are displayed in the individual sections of the display.
The displayed parameters vary according to the selected welding process.

		Current welding process line (in Duo operation) INT = wire drive of the welding machine EXT = separate wirefeeder
		Wire threading indicator lights up during wire threading if the wire threading graphic is hidden
		MIG/MAG:
		Intermediate arc indicator during standard welding
		TIG:
		On Multiprocess welding machines, the symbol for the overloaded electrode is displayed here.
		Gas-test indicator lights up after pressing the Gas-test button if the gas-test graphic is hidden
		MIG/MAG:
		SynchroPulse indicator
		TIG:
		During TIG welding, the symbol for TIG pulsing (pulse frequency) is displayed here:
		Interval indicator

1. Operating controls, connections and mechanical components
2. Control Panel

Depending on the selected welding process, an additional menu is available for displaying a parameter on the welding screen.

1With the correction parameter selected, press the left-hand selection dial for longer than 2 seconds

The additional menu is opened and the possible welding parameters are displayed.

Alternative way to open the additional menu:

Additional menu selected (blue line at the top and bottom)

Additional menu

The parameter selection with the right-hand selection dial is performed in the same way.

1. Operating controls, connections and mechanical components
2. Control Panel

For certain parameters, animated graphics are shown on the display.
These animated graphics change when the value of the parameter is changed.

Example: Welding parameters for pulse correction -10 / 0 / +10

Example: Welding parameters for arc length correction -10 / 0 / +10

1. Operating controls, connections and mechanical components

EasyJobs or parameters from the setup menu can be assigned to the four multifunctional buttons on the control panel.
The EasyJobs or the setup parameters can then be easily retrieved with the press of a button.

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

EasyJobs or parameters from the setup menu can be assigned to the four multifunctional buttons on the control panel.
The EasyJobs or the setup parameters can then be easily retrieved with the press of a button.

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

The assignment of the multifunctional buttons is shown on the display as per the following example:

Example of different button assignments

Button 1:
The button is assigned but not currently activated.
A thin line (1) is shown on the right edge of the display at the height of the button.

Button 2:
The button is assigned and currently activated.
At the right edge of the display, the left end of a button (2a) is shown at the height of the button.
In addition, the currently active function (2b) is shown in the central display section (e.g., EasyJob 2, as shown in the figure).

Button 3:
Same as button 1

Button 4:
The button is not assigned.
When the button is pressed, a symbolized empty button (4) is displayed along with info text.

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

A symbolized EasyJob button is shown on the right edge of the display at the height of the button, and the active EasyJob is shown in the central display section.

Example: EasyJob 2

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

After approx. 3 seconds, a symbolized button with a green frame, the parameter, and the Save symbol are shown on the display, e.g.:

The parameter has been saved under the selected multifunctional button and can be retrieved using this button.

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

A symbolized button with the saved parameter is shown on the right edge of the display at the height of the button, and the active storage location is shown in the central display section.

Example: Multifunctional button 3 is assigned SynchroPulse, storage location "Memory 3"

The parameter can now be changed.

1. Operating controls, connections and mechanical components
2. Multifunctional buttons

After approx. 3 seconds, a symbolized button with a green frame and the Save symbol is shown on the display.
The EasyJob or setup parameter saved under the multifunctional button is overwritten with the current settings.

After a total of approx. 5 seconds, the symbolized button is displayed with a red frame and the Delete symbol.

The EasyJob or setup parameter has been deleted from the storage location.

1. Operating controls, connections and mechanical components

Fortis 270 C /G, Fortis 320 C /G
Fortis 320 C /GW, Fortis 400 C /GW, Fortis 500 C /GW

4-roller wire drive

For the welding machines Fortis 320 C /GW, Fortis 400 C /GW, and Fortis 500 C /GW, a cooling unit or a toolbox is optionally available.
For details on the optional cooling unit, see from page (→) onwards.
For details on the optional toolbox, see from page (→) onwards.

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

Fortis 270 C /G, Fortis 320 C /G
Fortis 320 C /GW, Fortis 400 C /GW, Fortis 500 C /GW

4-roller wire drive

For the welding machines Fortis 320 C /GW, Fortis 400 C /GW, and Fortis 500 C /GW, a cooling unit or a toolbox is optionally available.
For details on the optional cooling unit, see from page (→) onwards.
For details on the optional toolbox, see from page (→) onwards.

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

Fortis 320 /GW, Fortis 400 /GW, Fortis 500 /GW

Storage compartments with open side cover

Welding machine without cooling unit and without toolbox, side cover not shown

For the welding machines Fortis 320 /GW, Fortis 400 /GW, and Fortis 500 /GW, a cooling unit or a toolbox is optionally available.
For details on the optional cooling unit, see from page (→) onwards.
For details on the optional toolbox, see from page (→) onwards.

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

Fortis 320 C /GW, Fortis 400 C /GW, Fortis 500 C /GW
Fortis 320 /GW, Fortis 400 /GW, Fortis 500 /GW

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

Fortis 320 C /GW, Fortis 400 C /GW, Fortis 500 C /GW
Fortis 320 /GW, Fortis 400 /GW, Fortis 500 /GW

The toolbox option can only be installed on gas-cooled welding machines.

Lockable toolbox

A standard padlock with a shackle diameter of 6-8 mm is required to lock the toolbox.

Depending on the welding process, a minimum level of equipment is required to work with the welding system.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Before installation and initial operation

Depending on the welding process, a minimum level of equipment is required to work with the welding system.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Before installation and initial operation
2. Minimum equipment for welding operations

Depending on the welding process, a minimum level of equipment is required to work with the welding system.
The following describes the welding processes and the corresponding minimum equipment for welding operations.

1. Before installation and initial operation
2. Minimum equipment for welding operations

For welding machines with Integrated wire drive:

• Welding machine
• Return lead cable
• MIG/MAG welding torch, gas-cooled
• Shielding gas supply
• Wire electrode

In addition, for welding machines with separate wirefeeder:

• Wirefeeder
• Interconnecting hosepack

1. Before installation and initial operation
2. Minimum equipment for welding operations

For welding machines with Integrated wire drive:

• Welding machine with cooling unit
• Return lead cable
• MIG/MAG welding torch, water-cooled
• Shielding gas supply
• Wire electrode

In addition, for welding machines with separate wirefeeder:

• Wirefeeder
• Interconnecting hosepack

1. Before installation and initial operation
2. Minimum equipment for welding operations

• Welding machine
• Return lead cable
• TIG gas-valve welding torch
• Shielding gas supply
• Filler metal, depending on application

1. Before installation and initial operation
2. Minimum equipment for welding operations

• Welding machine
• Return lead cable
• Electrode holder with welding power-lead
• Stick electrodes

1. Before installation and initial operation
2. Minimum equipment for welding operations

• Welding machine (400 / 500 A)
• Return lead cable 120 mm²
• KRIS 13 arc air gouging torch
• Compressed air supply

1. Before installation and initial operation

1. Before installation and initial operation
2. Before installation and initial operation

1. Before installation and initial operation
2. Before installation and initial operation

The welding machine is generator-compatible.

The maximum apparent power S_1max of the welding machine must be known in order to select the correct generator output.
The maximum apparent power S_1max of the welding machine is calculated for 3-phase devices as follows:

S_1max = I_1max x U₁ x √3

I_1max and U₁ according to the device rating plate and 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 can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the welding machine!

1. Before installation and initial operation
2. Before installation and initial operation

• Trolleys
• Cooling units
• Wire-feed unit holders
• Wire-feed units
• Interconnecting hosepacks
• Welding torches
• etc.

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

1. Before installation and initial operation

The XT variants of the welding machines can also be operated with a single-phase power supply.

With a single-phase power supply, a corresponding message is shown on the display every time the welding machine is started up:

Welding machine is in single-phase mode.
Mains fuse and reaction must be checked or set.

This message can be confirmed or disappears after a timer has expired.
Once the message has been confirmed/disappears, the symbol for single-phase mode remains on the display.
The symbol can change color, for example, if "warning" or "power limitation" has been set for the reaction.

For details on the mains fuse and reaction, see from page (→) onwards.

IMPORTANT! With a single-phase power supply, the output power of the welding machines is reduced as follows:

For a single-phase power supply of the welding machine, the mains cable must be correctly connected.
For details on connecting a single-phase mains cable, see from page (→) onwards.

1. Before installation and initial operation
2. Single-phase power supply

The XT variants of the welding machines can also be operated with a single-phase power supply.

With a single-phase power supply, a corresponding message is shown on the display every time the welding machine is started up:

Welding machine is in single-phase mode.
Mains fuse and reaction must be checked or set.

This message can be confirmed or disappears after a timer has expired.
Once the message has been confirmed/disappears, the symbol for single-phase mode remains on the display.
The symbol can change color, for example, if "warning" or "power limitation" has been set for the reaction.

For details on the mains fuse and reaction, see from page (→) onwards.

IMPORTANT! With a single-phase power supply, the output power of the welding machines is reduced as follows:

For a single-phase power supply of the welding machine, the mains cable must be correctly connected.
For details on connecting a single-phase mains cable, see from page (→) onwards.

1. Before installation and initial operation

In the case of /nc and /XT welding machines, no mains cable is connected when delivered.
Before commissioning, a mains cable corresponding to the connection voltage must be installed with a minimum cross-section according to the following table.

1. Before installation and initial operation
2. Connecting the mains cable to the welding machine

In the case of /nc and /XT welding machines, no mains cable is connected when delivered.
Before commissioning, a mains cable corresponding to the connection voltage must be installed with a minimum cross-section according to the following table.

1. Before installation and initial operation
2. Connecting the mains cable to the welding machine

1. Before installation and initial operation
2. Connecting the mains cable to the welding machine

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

1

2

3

4

1. Before installation and initial operation
2. Connecting the mains cable to the welding machine

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

1

2

3

4

1. Before installation and initial operation
2. Connecting the mains cable to the welding machine

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

1

2

3

4

1. Before installation and initial operation

1. Before installation and initial operation
2. Transport and setup regulations

1. Before installation and initial operation
2. Transport and setup regulations

Example of a welding system with the following components:
	Trolley Cooling unit Welding machine Wirefeeder mount Wirefeeder Gas cylinder holder Shielding gas cylinder Welding torch

1. Before installation and initial operation
2. Transport and setup regulations

1. Before installation and initial operation
2. Transport and setup regulations

Welding during crane transport is possible and permissible if this is stated in the intended use of the device (for intended use, see from page (→) onwards).

1. Before installation and initial operation
2. Transport and setup regulations

• Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

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

1. Before installation and initial operation

IMPORTANT! Ensure secure grounding of the mains connection.

Due to local regulations and national guidelines, a residual-current circuit breaker may be required when connecting a device to the public grid. The residual-current circuit breaker recommended for the device can be found in the technical data.

1. Before installation and initial operation
2. Mains connection

IMPORTANT! Ensure secure grounding of the mains connection.

Due to local regulations and national guidelines, a residual-current circuit breaker may be required when connecting a device to the public grid. The residual-current circuit breaker recommended for the device can be found in the technical data.

1. Before installation and initial operation
2. Mains connection

• The devices are designed for the mains voltage stated on the rating plate.
• Devices with a rated welding voltage of 3 x 600 V and XT devices operated with 3 x 600 V must be operated on three-phase grids grounded at the neutral point.
• If the mains cable or mains plug has not been attached to your version of the appliance, these must be installed by qualified personnel according to national standards.
• The fuse protection of the mains lead is specified in the technical data.

1. Dangers when welding

1. Dangers when welding
2. Danger from incorrect operation or misuse

1. Dangers when welding

1. Dangers when welding
2. Danger from grid current and welding current

1. Dangers when welding
2. Danger from grid current and welding current

Electromagnetic compatibility (EMC) describes the unwanted mutual influence of electrical/electronic devices.

The EMC device classification is stated on the rating plate of the device or in the technical data.

Despite compliance with the standard limit values for emissions, in certain cases electrical devices can influence each other in the intended application area.

• Safety devices
• Mains leads, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating
• Medical devices
• etc.

1. Dangers when welding

1. Dangers when welding
2. Danger from flying sparks, arc radiation, and noise

1. Dangers when welding
2. Danger from flying sparks, arc radiation, and noise

1. Dangers when welding
2. Danger from flying sparks, arc radiation, and noise

1. Dangers when welding
2. Danger from flying sparks, arc radiation, and noise

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. Dangers when welding
2. Danger from flying sparks, arc radiation, and noise

1. Dangers when welding

1. Dangers when welding
2. Danger from toxic gases and vapors

1. Dangers when welding

1. Dangers when welding
2. Danger due to missing safety equipment and moving components

1. Dangers when welding
2. Danger due to missing safety equipment and moving components

1. Dangers when welding
2. Danger due to missing safety equipment and moving components

1. Dangers when welding

1. Dangers when welding
2. Danger from shielding gas cylinders and shielding gas supply

1. Dangers when welding

1. Dangers when welding
2. Danger due to hot parts and slag

1. Commissioning

1. Commissioning
2. Commissioning of Fortis C

1. Commissioning
2. Commissioning of Fortis C

1. Commissioning
2. Commissioning of Fortis C

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

Online spare parts catalog (O-ETK): https://spareparts.fronius.com

1

2

3

4

1. Commissioning
2. Commissioning of Fortis C

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

2

3

4

1. Commissioning
2. Commissioning of Fortis C

Connecting the gas hose

1. Commissioning
2. Commissioning of Fortis C

NOTE!

When establishing a ground earth connection, observe the following points:

Failure to do so may impair welding results and pulse welding.

Use a separate return lead cable for each welding machine

Keep positive cables and return lead cables together as long and as close as possible

Physically separate the welding circuits of individual welding machines

Do not route several return lead cables in parallel;
if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits

Keep the return lead cables as short as possible and use cables with a large cross-section

Do not cross over return lead cables

Avoid ferromagnetic materials between the return lead cables and the interconnecting hosepack

Do not reel up long return lead cables—coil effect!
Route long return lead cables in loops

Do not route return lead cables in iron pipes, metal cable trays, or along steel beams, avoid cable ducts;
(routing positive cables and return lead cables together in an iron pipe does not cause any problems)

If several return lead cables are being used, separate the grounding points on the component as far as possible and do not allow crossed current paths between the individual arcs.

1. Commissioning
2. Commissioning of Fortis C

1

1. Commissioning
2. Commissioning of Fortis C

1

2

1. Commissioning
2. Commissioning of Fortis C

1

1. Commissioning
2. Commissioning of Fortis C

1

2

3

Instructions for wire threading

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

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

1. Commissioning
2. Commissioning of Fortis C

1

The standard values for the contact pressure can be found on the sticker on the 4-roller drive.

1. Commissioning
2. Commissioning of Fortis C

1

2

1. Commissioning
2. Commissioning of Fortis C

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

1. Commissioning
2. Commissioning of Fortis C

IMPORTANT! For optimum welding results, the manufacturer recommends carrying out an R/L alignment whenever the device is commissioned and whenever changes are made to the welding system.
Further information on the R/L alignment can be found in the setup menu / MIG/MAG / R/L alignment as of page (→).

1. Commissioning

1. Commissioning
2. Commissioning Fortis with external wirefeeder

1. Commissioning
2. Commissioning Fortis with external wirefeeder

1

2

1. Commissioning
2. Commissioning Fortis with external wirefeeder

1

Attach the strain-relief device to the trolley

2

Attach the strain-relief device to the wirefeeder

1. Commissioning
2. Commissioning Fortis with external wirefeeder

1

Connect interconnecting hosepack to the welding machine

2

Connect interconnecting hosepack to the wirefeeder

1. Commissioning
2. Commissioning Fortis with external wirefeeder

Correct routing of the interconnecting hosepack

IMPORTANT!

• The duty cycle values (ED) of the interconnecting hosepacks can only be achieved if the hosepacks are correctly routed.
• If the routing of an interconnecting hosepack changes, carry out an R/L alignment (see page (→))!

1. Commissioning
2. Commissioning Fortis with external wirefeeder

2Open the wire drive cover

3Open the clamping lever on the wire drive

4Push the correctly equipped welding torch with the marking facing up from the front into the welding torch connection of the wirefeeder

5For water-cooled welding torches:
Connect the coolant supply hose to the coolant supply connection (blue)

6Connect the coolant return hose to the coolant return connection (red)

7Close the clamping lever on the wire drive

8Close the wire drive cover

9Check that all connections are secure

1. Commissioning
2. Commissioning Fortis with external wirefeeder

1. Commissioning
2. Commissioning Fortis with external wirefeeder

NOTE!

When establishing a ground earth connection, observe the following points:

Failure to do so may impair welding results and pulse welding.

Use a separate return lead cable for each welding machine

Keep positive cables and return lead cables together as long and as close as possible

Physically separate the welding circuits of individual welding machines

Do not route several return lead cables in parallel;
if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits

Keep the return lead cables as short as possible and use cables with a large cross-section

Do not cross over return lead cables

Avoid ferromagnetic materials between the return lead cables and the interconnecting hosepack

Do not reel up long return lead cables - coil effect!
Route long return lead cables in loops

Do not route return lead cables in iron pipes, metal cable trays, or along steel beams, avoid cable ducts;
(routing positive cables and return lead cables together in an iron pipe does not cause any problems)

If several return lead cables are being used, separate the grounding points on the component as far as possible and do not allow crossed current paths between the individual arcs.

IMPORTANT! For optimum weld properties, route the return lead cable as close as possible to the interconnecting hosepack.

1. Commissioning
2. Commissioning Fortis with external wirefeeder

IMPORTANT! For optimum welding results, the manufacturer recommends carrying out an R/L alignment whenever the device is commissioned and whenever changes are made to the welding system. Further information on the R/L alignment can be found in the setup menu / MIG/MAG / R/L alignment as of page(→).

1. Commissioning
2. Commissioning Fortis with external wirefeeder

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

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

1. Commissioning

The filter and mounting plate are included in the scope of supply of the optional cooling unit.

1

2

Connect coolant hoses from the welding torch or from the interconnecting hosepack to the cooling unit of the welding machine according to their color coding

1. Commissioning
2. Commissioning the cooling unit

The filter and mounting plate are included in the scope of supply of the optional cooling unit.

1

2

Connect coolant hoses from the welding torch or from the interconnecting hosepack to the cooling unit of the welding machine according to their color coding

1. Commissioning
2. Commissioning the cooling unit

When the optional cooling unit is installed in the factory, a 5 l canister containing coolant is included in the scope of supply.

1

IMPORTANT! The filter insert in the filler pipe must be checked before each filling or refilling of the coolant tank to ensure that:

• It is present
• It is correctly positioned (flat side at the top)
• It is not contaminated (clean if necessary)
  

1. Commissioning
2. Commissioning the cooling unit

• The fan runs for approx. 5 seconds
• The coolant pump runs for approx. 3 minutes. If welding does not start after approx. 3 minutes, the coolant pump switches off again

In the component menu of the welding machine, the following operating modes can be set for the cooling unit:

• auto
• off

For details on the cooling unit settings, see from page (→) onwards.

After the end of welding, the pump continues to operate for 2 minutes, after which the pump switches off.

1. Commissioning
2. Commissioning the cooling unit

Draining the coolant

1

* Hose for draining the coolant

NOTE!

As soon as the hose for draining the coolant is plugged in at the coolant drainage point, the coolant will run out.

Lifting the welding machine on the front side facilitates complete emptying of the cooling unit.

Do not dispose of coolant in the sewage system.

Coolants should be disposed of according to applicable national and local regulations.

When changing the coolant, make sure all the coolant is replaced.

2

* Hose for draining the coolant – press in the ring at the coolant drainage point to unplug

3Fill the cooling unit
(See from page (→) onwards)

1. Commissioning

In Duo operation, a welding machine with integrated wire drive is operated with an additional external wirefeeder.
Duo operation enables the joint use of two welding process lines with one welding machine. The welding process lines can be changed using the torch trigger, on the welding machine, via the operating controls on the wirefeeder, or on a remote control.

With Multiprocess devices, it is also possible to switch to a TIG welding process line in addition to the two MIG/MAG welding process lines.
The TIG welding torch is connected to the welding machine; the welding process lines can also be switched over via the TIG welding torch.
For the TIG welding process line, the polarity reverser on the welding machine must be reconnected manually.

Duo operation is possible with gas and water-cooled welding systems.

1. Commissioning
2. Commissioning Fortis Duo

In Duo operation, a welding machine with integrated wire drive is operated with an additional external wirefeeder.
Duo operation enables the joint use of two welding process lines with one welding machine. The welding process lines can be changed using the torch trigger, on the welding machine, via the operating controls on the wirefeeder, or on a remote control.

With Multiprocess devices, it is also possible to switch to a TIG welding process line in addition to the two MIG/MAG welding process lines.
The TIG welding torch is connected to the welding machine; the welding process lines can also be switched over via the TIG welding torch.
For the TIG welding process line, the polarity reverser on the welding machine must be reconnected manually.

Duo operation is possible with gas and water-cooled welding systems.

1. Commissioning
2. Commissioning Fortis Duo

• TU Move 4 Pro trolley
  + OPT/TU gas cylinder holder Duo
  + OPT/TU swivel pin holder
• Fortis C /GW
  + OPT/s Duo
  + software activation Duo
  + OPT/s CU 1200 MC (for water-cooled welding systems)
• WF 25s wirefeeder
  + OPT/s WF control unit
  + OPT/s WF water cooling (for water-cooled welding systems)
• Interconnecting hosepack HP xx /s
• 2 gas cylinders
• 2 MIG/MAG welding torches

1. Commissioning
2. Commissioning Fortis Duo

1. Commissioning
2. Commissioning Fortis Duo

1. Commissioning

The welding machine can be locked by pressing a key combination or by means of an external NFC key reader, e.g., to prevent unauthorized access or the modification of welding parameters.

To lock and unlock the welding machine, the welding machine must be turned on.

NFC key = NFC card or NFC key fob

User Management on the welding machine or SmartManager offers further locking and unlocking functions as well as functions for different people logging in and out.

For details, see

• from page (→) onwards ... User Management on the welding machine
• from page (→) onwards ... User Management on the SmartManager

1. Commissioning
2. Locking and unlocking the welding machine

The welding machine can be locked by pressing a key combination or by means of an external NFC key reader, e.g., to prevent unauthorized access or the modification of welding parameters.

To lock and unlock the welding machine, the welding machine must be turned on.

NFC key = NFC card or NFC key fob

User Management on the welding machine or SmartManager offers further locking and unlocking functions as well as functions for different people logging in and out.

For details, see

• from page (→) onwards ... User Management on the welding machine
• from page (→) onwards ... User Management on the SmartManager

1. Commissioning
2. Locking and unlocking the welding machine

Unlocking the welding machine

For details on the predefined role "locked", see User Management from page (→) onwards.

1. Commissioning
2. Locking and unlocking the welding machine

To lock and unlock the welding machine using an NFC key, the OPT/s NFC Reader /TMC option must be connected to the welding machine.

Locking the welding machine

Unlocking the welding machine

For details on the predefined role "locked", see User Management from page (→) onwards.

If the OPT/s NFC Reader /TMC option is connected, User Management is also available in the welding machine Setup menu.
For details on User Management, see from page (→) onwards.

1. Commissioning
2. Locking and unlocking the welding machine

With the OPT/s NFC Reader /TMC option connected, the following status indicators can be displayed on the NFC key reader:

• Green chaser light:
  The system is starting up after plugging in the NFC key reader.
• Lights up green:
  The NFC key reader is ready.
• The status indicator fills green from left to right:
  An NFC key is detected.
• The status indicator fills red from left to right:
  An NFC key is not detected.

• Tacking work
• Short weld seams
• Automatic and robot operation

1. MIG/MAG welding

• Tacking work
• Short weld seams
• Automatic and robot operation

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

• Tacking work
• Short weld seams
• Automatic and robot operation

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

To activate special 2-step mode:

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

Start by pressing and releasing the torch trigger – GPr gas pre-flow – welding current phase over the SPt spot welding time duration – GPo gas post-flow.

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

2-step stitch welding

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

4-step stitch welding

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

1. MIG/MAG welding
2. MIG/MAG operating modes and interval

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

GPr
Gas pre-flow time

I_S
Starting-current phase: rapid heating of the base material despite high heat dissipation at the start of welding

t_S
Starting current duration

SL1
Slope 1: continuous reduction of the starting current to the welding current

I
Welding current phase: even heat input into the base material whose temperature is raised by the advancing heat

I_E
Final current phase:

• To fill in the end-crater
• To avoid local overheating of the base material caused by heat accumulation at the end of welding. This prevents possible sagging of the weld.

t_E
Final current duration

SL2
Slope 2: continuous reduction of the welding current to the final current

GPo
Gas post-flow

SPt
Spot welding time

Iwt
Stitch welding time

Ibt
Stitch pause time

1. MIG/MAG welding

A cooling unit in the welding system starts to work.

IMPORTANT! For optimum welding results, the manufacturer recommends carrying out an R/L alignment whenever the device is commissioned and whenever changes are made to the welding system.
Further information on the R/L alignment can be found in the setup menu / MIG/MAG / R/L alignment as of page (→).

1. MIG/MAG welding
2. MIG/MAG welding

A cooling unit in the welding system starts to work.

IMPORTANT! For optimum welding results, the manufacturer recommends carrying out an R/L alignment whenever the device is commissioned and whenever changes are made to the welding system.
Further information on the R/L alignment can be found in the setup menu / MIG/MAG / R/L alignment as of page (→).

1. MIG/MAG welding
2. MIG/MAG welding

Control panel with welding screen for MIG/MAG

1. MIG/MAG welding
2. MIG/MAG welding

1. MIG/MAG welding
2. MIG/MAG welding

1. MIG/MAG welding
2. MIG/MAG welding

If one of the welding parameters is changed in the pulsed and standard welding processes, the remaining parameters are also adjusted.

1. MIG/MAG welding
2. MIG/MAG welding

Wire speed * 

1.0-25 m/min / 39.4-984.3 ipm (depending on characteristic)

Current [A] * 

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

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

Sheet thickness [mm/inch] * 

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

Pulse correction
For correcting the pulse energy in pulsed welding

Pulse correction is set using the left-hand dial.

-10-+10
Factory setting: 0

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

Dynamic correction
For setting the short circuit current and the current to short circuit breakup during standard welding

The dynamic correction is set using the left-hand dial.

-10-+10
Factory setting: 0

Arc length correction
For correcting the arc length

The arc length correction is set using the right-hand dial.

-10-+10
Factory setting: 0

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

The following parameters can be set for Pulse and Standard for display on the welding screen:

• For the left-hand selection dial: pulse/dynamic correction, gas pre-flow, stitch welding time, frequency
• For the right-hand dial: arc length correction, gas post-flow, stitch pause time, stitch cycles, delta wire feed, duty cycle (high)

For details on setting the parameter displayed on the welding screen, see from page (→) onwards.

Wire speed 
For setting a harder and more stable arc

1.0-25 m/min / 39.4-984.3 ipm

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

The arc-force dynamic is set using the left-hand dial.

0-10
Factory setting: 1.5

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

Voltage [V]

The voltage is set using the right-hand dial.

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

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

The following parameters can be set for Manual for display on the welding screen:

• For the left-hand selection dial: arc-force dynamic, gas pre-flow, stitch welding time
• For the right-hand dial: welding voltage, ignition current (manual), wire retraction (manual), gas post-flow, stitch pause time, stitch cycles

For details on setting the parameter displayed on the welding screen, see from page (→) onwards.

For details on the setup parameters, see from page (→) onwards.

1. MIG/MAG welding
2. MIG/MAG welding

1. MIG/MAG welding
2. MIG/MAG welding

At the end of each welding operation, the welding data is stored as an average value and shown on the display.

1. MIG/MAG welding

The welding parameter wizard supports the welder in selecting the welding parameters. The parameter recommendation can be accepted or saved as a job.

1. MIG/MAG welding
2. The welding parameter wizard

The welding parameter wizard supports the welder in selecting the welding parameters. The parameter recommendation can be accepted or saved as a job.

1. MIG/MAG welding
2. The welding parameter wizard

1Select the filler metal and shielding gas
see page (→)

2Select the Pulse or Standard welding process
see page (→)

3Turn the right-hand selection dial and select "Wizard"

4Press the right-hand selection dial

The welding parameter wizard is started.

5Select the appropriate weld shape by turning and pressing the middle selection dial.

6Press the right-hand selection dial (Next)

The welding positions are displayed.

7Select the appropriate welding position by turning and pressing the middle selection dial.

8Press the right-hand selection dial (Next)

The weld geometry is displayed.

9Select and set the geometry parameters sheet thickness, a-dimension, and air gap by turning and pressing the middle selection dial

10Press the right-hand selection dial (Next)

The recommended welding parameters are displayed:
on page 1

• Welding speed [cm/min]
  The welding speed is also animated.
• Welding process - Characteristic property - Number of weld layers
• Welding current [A] - Welding voltage [V] - Wire speed [m/min]
  Parameters can be changed by turning the middle selection dial. When the parameters are changed, the welding speed and the displayed welding power value also change.
• Welding power [kW] - Gas flow volume [l/min] - a-dimension [mm]

on page 2

• Graphical overview of the weld layers
• Welding current, welding voltage, and wire speed for the weld layers
• Tilt angle
• Stick out
  

11Press the right-hand selection dial (Next)

The proposed welding parameters are adopted, the MIG/MAG welding screen is displayed.
The wizard is displayed in the middle of the display.

The welding parameters can now be welded or saved as an EasyJob.

1. MIG/MAG welding

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

Procedure for creating a welding spot:

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

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

Procedure for creating a welding spot:

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

Procedure for stitch welding:

If the OPT/s Job option is available, up to 1000 jobs can be stored and reproduced on the welding machine.

Jobs can only be saved when you are not welding. In addition to the current welding settings, the process parameters and certain machine defaults are also taken into account when saving jobs.

1. Job Mode

If the OPT/s Job option is available, up to 1000 jobs can be stored and reproduced on the welding machine.

Jobs can only be saved when you are not welding. In addition to the current welding settings, the process parameters and certain machine defaults are also taken into account when saving jobs.

1. Job Mode
2. Saving and retrieving jobs

If the OPT/s Job option is available, up to 1000 jobs can be stored and reproduced on the welding machine.

Jobs can only be saved when you are not welding. In addition to the current welding settings, the process parameters and certain machine defaults are also taken into account when saving jobs.

1. Job Mode
2. Saving and retrieving jobs

1Set the parameters to be saved as a job:

• Welding process
• Material, wire diameter, shielding gas, characteristic property
• Welding parameters, correction parameters
• Setup parameters
  

2Turn the right-hand selection dial and select Easy JOB

3Press the right-hand selection dial

The list of jobs is displayed.

4Turn a selection dial and select a corresponding storage space

Existing job selected:
"Overwrite job" is displayed above the middle selection dial.

Free storage space selected:
"Save job" is displayed above the middle selection dial.

5Press the middle selection dial

A confirmation prompt is displayed when overwriting a job.
Press the right-hand selection dial to confirm - the text input* is displayed.

When saving the job, the text input* is displayed.

6Enter the desired job name in the text input* by turning and pressing the middle selection dial (max. 30 characters)

7Press the right-hand selection dial (Save)

The welding screen is displayed.
The job name is displayed in the middle of the display.

1. Job Mode
2. Saving and retrieving jobs

IMPORTANT! In Job Mode, only the "JOB" welding parameter can be changed; the remaining welding parameters can only be viewed or changed as part of the job correction limits.

1. Job Mode
2. Saving and retrieving jobs

Use the Load EasyJob function to load the data for a stored job or EasyJob onto the welding screen. The corresponding welding parameters are displayed and can be welded, modified, or saved as a new job or EasyJob.

1Turn the right-hand selection dial and select Easy JOB

2Press the right-hand selection dial

The list of jobs is displayed.

3Turn a selection dial and select the job to be loaded as an EasyJob

4Press the right-hand selection dial (Load EasyJob)

The welding screen is displayed.
The job name is displayed in the middle of the display.

The data for the loaded job can now be welded (no job mode), modified, or saved as a new job or EasyJob.

1. Job Mode

1Activate Job Mode
(see page (→), steps 1 - 4)

2Turn the right-hand selection dial and select "Edit JOB"

3Turn the right-hand or middle selection dial and select "Optimize"

4Press the right-hand or middle selection dial

The list of jobs is displayed.

5Turn a selection dial and select the job to be optimized

6Press the middle selection dial

The job parameters are displayed.

• Job Name
• Working parameters
• Welding process parameters
• Stitch settings
• Special 2-step/4-step parameters
• Wire retraction
• Spot welding
• SynchroPulse
• Gas default settings
• Components
• Job slope
• Documentation
  

7Turn the middle selection dial:
Select parameter group / parameter

Press the middle selection dial:
Edit parameter group / parameter

Turn the middle selection dial:
Change the value of a parameter

Press the middle selection dial:
Accept value change

8Then press the right-hand selection dial (OK)

1. Job Mode
2. Optimizing a job

1Activate Job Mode
(see page (→), steps 1 - 4)

2Turn the right-hand selection dial and select "Edit JOB"

3Turn the right-hand or middle selection dial and select "Optimize"

4Press the right-hand or middle selection dial

The list of jobs is displayed.

5Turn a selection dial and select the job to be optimized

6Press the middle selection dial

The job parameters are displayed.

• Job Name
• Working parameters
• Welding process parameters
• Stitch settings
• Special 2-step/4-step parameters
• Wire retraction
• Spot welding
• SynchroPulse
• Gas default settings
• Components
• Job slope
• Documentation
  

7Turn the middle selection dial:
Select parameter group / parameter

Press the middle selection dial:
Edit parameter group / parameter

Turn the middle selection dial:
Change the value of a parameter

Press the middle selection dial:
Accept value change

8Then press the right-hand selection dial (OK)