Fronius TPS 2700 MV, TPS 4000 MV, TS 5000 MV, TPS 5000 MV, CMT-A 4000 MV Operation/reference Manual

13 SEP 12

Fronius USA

Fronius USA Fronius USA

Fronius USA

Office: 1-877-376-6487 www.fronius-usa.com

/ Battery Charging Systems / Welding Technology / Solar Electronics

Operations Reference Guide

MIG Welding Equipment

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

General Information

Table of Contents

 Conversion Charts page 1

 3d-Drawing page 2

 Weld System

 Component Layout page 3
 Configurations page 4

 Power Source

 Models page 7
 Nameplate page 9
 Technical Specifications page 10
 Connections and Controls page 11

 Wire Feeder

 Models page 15
 Motor-plate page 17
 Connections and Controls page 18

 Welding Torch page 22

 Cooler page 23

 Weld Process

 Overview page 24
 MIG, short circuit page 26
 MIG, pulse page 27
 Gas Characteristics page 28
 Torch Movement and Position page 32
 Discontinuity page 33

 Use and Operation

 Initial Set-up and Turn-on page 35
 Quick Reference Sheet, TPS page 36
 Weld Correction Value page 41
 Front Panel, TPS page 42
 Front Panel, CMT page 45
 Quick Reference Sheet, TsT page 55
 Front Panel, TsT page 57

 Processes

 Synergic Lines page 48
 Jobs page 49
 Resistance Test page 50
 Push-Pull Alignment page 51
 Cooler Verification page 53
 Output Tests page 54

 Consumables

 Drive Rolls page 61
 Liners page 62
 Contact Tips page 63
 Torch Breakdown page 64
 Changing a Liner page 67
 Part Numbers page 69

 Interface

 Models page 76
 General Information page 77
 Inputs/Outputs page 78
 Signal Interaction page 82

 Fronius Xplorer page 85

 Basic Troubleshooting page 87

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 1

1 1

1 ----

General Information

Conversion Charts

Fraction* Decimal* Millimeters Wire Guage**

2/64 .030 0.8 20

- -- .035 0.9 19

- - - .040 1.0 18

3/64 .045 1.2 17

- - - .052 1.4 16

1/16 .062 1.6 14

- - - .071 1.8 13
5/64 .078 2.0 12
3/32 .094 2.4 11
7/64 .109 2.8 9

¼ .250 6.4 2
1/2 .500 12.7 ­3/4 .750 19.1 -

1 1.00 25.4 -

Meters Feet

0.25 0.8

0.50. 1.6

0.75 2.5

1.00 3.1

1.25 4.1

1.50 4.9

1.75 5.7

2.0 6.6

2.5 8.2

3.0 9.8

3.5 11.5

4.0 13.1

4.5 14.8

5.0 16.4
10 32.8
15 49.2
20 65.6
25 82.0
30 98.4
35 114.8
40 131.2
45 147.6
50 164
55 180.4
60 196.8
65 213.3
70 229.6
75 246.0

Inch/min Mm/sec Cm/min

5 2.12 12.70
10 4.23 25.40
15 6.35 38.10
20 8.47 50.80
25 10.58 63.50
30 12.70 76.20
35 14.82 88.90
40 16.93 101.60
45 19.05 114.30
50 21.17 127.00

55 23.28 139.70
60 25.40 152.40
65 27.51 165.10
70 29.63 177.80
75 31.75 190.50
80 33.86 203.2
85 35.98 215.90
90 38.10 228.60
95 40.21 241.30

100 42.33 254.00
105 44.45 266.70
110 46.56 279.40
115 48.68 292.10
120 50.80 304.80
125 52.91 317.50
130 55.03 330.20
135 57.15 342.90
140 59.26 355.60
145 61.38 368.30
150 63.50 381.00

Conversion Factors

Inch/min to Mm/sec x 0.4233
Inch/min to Cm/min x 2.54
Mm/sec to Inch/min x 2.3622
Cm/min to Inch/min x 0.3937

Ft3/hour to L/min x 0.4719
L/min to Ft3/hour x 2.1189

Meter to Feet x 3.2808
Feet to Meter X 0.3048

Ft3/hour L/min

5 2.36
10 4.72
15 7.08
20 9.44
25 11.80
30 14.16
35 16.52
40 18.88
45 21.24
50 23.60

55 25.95
60 28.31
65 30.67
70 33.03
75 35.39
80 37.75
85 40.11
90 42.47
95 44.83

100 47.19
105 49.55
110 51.91
115 54.27
120 56.63
125 58.99
130 61.35
135 63.71

---- 2

2 2

2 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

GGGG

HHHH

EEEE

FFFF

DDDD

IIII

JJJJ

FFFF

CCCC

JJJJ

DDDD

DDDD

AAAA

1111

10

1010

10

2222

3333

4444

9999

8888

5555

DDDD

CCCC

7777

DDDD

6666

11

1111

11

BBBB

DDDD

 Components consist of

----1111---- Power Source

----2222---- Wire Feeder

----3333---- Torch

----4444---- Work Surface/Fixture

----5555---- Main Power (230 or 460V AC⁄

----6666---- Front Panel

----7777---- Gas Tank

----8888---- Remote Control Unit (RCU⁄

----9999---- Robot Interface

----10

1010

10---- Cooler

----11

1111

11---- PC Interface Tool

Component Layout

Weld System

 Component Management

 Controlled by LocalNet (Fronius communication

protocol⁄.

 Plug and play configuration

 Provides both operating power and

communication to peripheral components.

 Connections consist of

----AAAA---- Ground Connection

----BBBB---- Main Power (230 or 460V AC⁄

----CCCC---- Gas

----DDDD---- LocalNet

----EEEE---- Motor Voltage (55V DC⁄

----FFFF---- Main Current

----GGGG---- Pump Voltage (230 or 400V AC⁄

----HHHH---- Data Lines (non LocalNet⁄

----IIII---- Coolant Out

----JJJJ---- Coolant In

---- 3

3 3

3 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Weld System

Data

Control Voltages

Welding Current

Coolant Lines

Data

Control Voltages

Welding Current

Shielding Gas

Wire

Coolant Lines

Power

PowerPower

Power----Source Mounted Wire Feeder

Source Mounted Wire FeederSource Mounted Wire Feeder

Source Mounted Wire Feeder

The wire feeder can be mounted directly on top of the welding power
source. This configuration can be applied with either robotic or manual
systems. This configuration allows for the following features.

The connections between the wire feeder to the power source, shielding
gas and coolant are made through the Interconnecting Hose Pack.

 The connections between the wire feeder and welder can vary in

length. This allows the operator to relocate the wire feeder if
needed.

 Length of the torch and the interconnecting hose pack must be

taken into consideration when determining if the system should be
a push or push/pull orientation.

---- 4

4 4

4 ----

Configurations

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Weld System

Data

Control Voltages

Welding Current

Shielding Gas

Wire

Coolant Lines

Remote Mounted Wire Feeder

Remote Mounted Wire FeederRemote Mounted Wire Feeder

Remote Mounted Wire Feeder

The wire feeder is placed between the welder and the torch location. This placement may or may not be permanent.
This configuration allow for:

 Varying distances between the power source and wire feeder.

 Enables the wire feeder to torch end distances to be reduced which can reduce the need for a push/pull system.

 The wire feeder can be kept within a restricted area while the welder is easily accessible for parameter

monitoring and changes.

Data

Control Voltages

Welding Current

Coolant Lines

---- 5

5 5

5 ----

Configurations

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Weld System

Data

Control Voltages

Welding Current

Shielding Gas

Wire

Coolant Lines

Robot Mounted Wire Feeder

Robot Mounted Wire FeederRobot Mounted Wire Feeder

Robot Mounted Wire Feeder

The wire feeder can be mounted directly to the robot arm or automated system. This type of configuration has no built
in mechanism for manually starting the torch and is intended only for robotic/automated applications.

 Interconnecting hose packs can vary in length. The length must be accommodate for the distance between the

power source and feeder but also for the motion of the robot.

 This configuration allows for the wire feeder to be kept within a restricted area while the power source is left

accessible area for monitoring and adjusting parameters.

Data

Control Voltages

Welding Current

Coolant Lines

---- 6

6 6

6 ----

Configurations

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Source

Trans Synergic (TS) 3200/4000/5000

 Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,

gas types, and wire diameters

 Power source is equally suited to robotic, automated, and manual tasks based on application

demands.

Trans-Pulse Synergic (TPS) 3200/4000/5000

 Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
 Welder is capable of pulse welding pre-loaded with pulse-designed synergic lines
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of

filler metal, gas types, and wire diameters

 Power source is lightweight, easily updateable, and expanded through a plug and

play interface.

---- 7

7 7

7 ----

Models

TPS 2700

 270-amp pulse machine with a built in wire feeder. Multi-voltage model is available
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of

filler metal, gas types, and wire diameters

 Power source is lightweight, easily updateable, and expanded through a plug and play interface.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Source

Trans-Steel (TsT) 3500/5000 Robotic

 Two amp ranges available (350 and 500⁄. Multi-voltage model available.
 Welder is designed specifically for steel welding, offering a large variety of options at a low price.
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,

gas types, and wire diameters

 Designed with robotic or automated welding in mind.

---- 8

8 8

8 ----

Models

Trans-Steel (TsT) 3500/5000 Manual

 Two amp ranges available (350 and 500⁄. Multi-voltage model available.
 Welder is designed specifically for steel welding, offering a large variety of options at a low price.
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,

gas types, and wire diameters

Trans-Steel (TsT) 3500 Compact

 350-amp pulse machine with a built in wire feeder. Multi-voltage model is NOT available
 Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc

range.

 Welder comes pre-loaded with multiple standard synergic lines over a large variety of filler metal,

gas types, and wire diameters

 Power source is lightweight, easily updateable, and expanded through a plug and play interface.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Source

Name Plate

The name plate is found on the top of the
machine just underneath the carrying handle.
This label includes identification, technical,
upgrade, and duty-cycle information about the
welding power supply.

The identification portion of the label will give a detailed
description of the welder, the full part number, and a unique
serial number.

Using the format below, the serial number can be used to
determine the approximate age of the welding power supply.
This technique can be used to age any Fronius product with an
8-digit serial number.

23080753

23 – subtract “11” to get the year of manufacture
08 – this is the week of manufacture (1 – 52)
0753 – this is the item number for the day of manufacture.

---- 9999 ----

The middle portion of the label include technical that includes
duty cycle, amp drops, input and output voltage ranges, and
maximum outputs.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Source

Tech Specs

TPS 2700 MV TPS 3200 MV TS/TPS 4000 MV TS/TPS 5000 MV CMT-A 4000 MV

Mains Voltage Range

3 x 240
3 x 460

200 – 240 V
380 – 460 V

200 – 240 V
380 – 460 V

200 – 240 V
380 – 460 V

200 – 240 V
380 – 460 V

200 – 240 V
380 – 460 V

Mains Tolerance +/-10% +/-10% +/- 10% +/- 10% +/- 10%
Mains Frequency 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz

Fuse Protection, slow-blow

3 x 460
3 x 240

25 A
16 A

35 A
35 A

63 A
35 A

63 A
35 A

63 A
35 A

Primary Continuous Current (100% dc) 6.4 – 14.2 A 10.6 – 31.2 A 15.3 – 34.4 A 10.1 – 36.1 A n/a
Primary Continuous Power (100% dc) 4.6 – 10.7 KVA 8.7 – 11.5 kVA 10.6 – 12.4 kVA 12.4 – 13.9 kVA 13.0 –16.0 kVA
Electrical Efficiency 88 – 91% 90 – 91% 88 – 91% 88 – 91% n/a

Welding Current Range

MIG

Stick

TIG

3 – 270 A

10 – 270 A

3 – 270 A

3 – 320 A

10 – 320 A

3 – 320 A

3 – 400 A

10 – 400 A

3 – 400 A

3 – 500 A

10 – 500 A

3 – 500 A

3 – 400 A

10 – 400 A

n/a

Welding Voltage Range

MIG

Stick

TIG

14.2 – 27.5 V

20.4 – 30.8 V

10.1 – 20.8 V

14.2 – 30.0 V

20.4 – 32.8 V

10.1 – 22.8 V

14.2 – 34.0 V

20.4 – 36.0 V

10.1 – 26.0 V

14.2 – 30.0 V

20.4 – 40.0 V

10.1 – 30.0 V

14.2 – 34.0 V

20.4 – 36.0 V
n/a

Max Welding Voltage 34.6 V 49.1 – 63.1 V 48 V 49.2 V n/a
Open Circuit Voltage 50 V 64 – 67 V 68 – 78 V 68 – 78 V 90 V

Duty Cycle 77º F (25º C)

60% @ 270 A

100% @ 210 A

89% @ 320 A

100% @ 304 A

75% @ 400 A

100% @ 365 A

75% @ 500 A

100% @ 450 A

85% @ 400 A

100% @ 380 A

Duty Cycle 104º F (40º C)

60% @ 270 A

100% @ 170 A

40% @ 320 A
60% @ 260 A

100% @ 220 A

40% @ 400 A
60% @ 365 A

100% @ 320 A

40% @ 500 A
60% @ 450 A

100% @ 340 A

40% @ 400 A
60% @ 350 A

100% @ 290 A

---- 10

10 10

10 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

((((----⁄ Current Socket Connection

⁄ Current Socket Connection⁄ Current Socket Connection

⁄ Current Socket Connection

The connection depends on the
operating mode of the power source

MIG Welding

MIG WeldingMIG Welding

MIG Welding: Connect the
welding ground to this socket.

TIG Welding

TIG WeldingTIG Welding

TIG Welding: Connect the
current connection on the torch
to this socket.

STICK Welding

STICK WeldingSTICK Welding

STICK Welding: Connect the
electrode cable to this socket
(depending on the type of
electrode being used⁄.

(+⁄ Current Socket Connection

(+⁄ Current Socket Connection(+⁄ Current Socket Connection

(+⁄ Current Socket Connection

The connection depends on the operating mode of the power source

MIG Welding

MIG WeldingMIG Welding

MIG Welding: Connect the current connection of the interconnection
hose pack to this socket.

TIG Welding

TIG WeldingTIG Welding

TIG Welding: Connect the welding ground to this socket.

STICK Welding

STICK WeldingSTICK Welding

STICK Welding: Connect the electrode cable to this socket (depending
on type of electrode being used⁄.

Power Switch

Power SwitchPower Switch

Power Switch

This switch turns the power source on
(1⁄ and off (0⁄.

Current Connection

Current Connection Current Connection

Current Connection
((((

optional

⁄⁄⁄⁄

This connection is reserved for
an optional current socket

Mains Connection

Mains ConnectionMains Connection

Mains Connection

This connection is for the 3­phase input power.

LocalNet Connection

LocalNet ConnectionLocalNet Connection

LocalNet Connection

This connection is for the
LocalNet connection to the wire­feeder and/or interface device.

Blanking Cover(s⁄

Blanking Cover(s⁄Blanking Cover(s⁄

Blanking Cover(s⁄

These connections are for
optional upgrades to the power
source.

Front Panel

Front PanelFront Panel

Front Panel

The front panel allows the welder to
control the power sources welding
characteristics.

Connections – TPS 3200/4000/5000

---- 11

11 11

11 ----

Power Source

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Current Connection

Current ConnectionCurrent Connection

Current Connection

Power Switch

Power SwitchPower Switch

Power Switch

Ground Connection (

Ground Connection (Ground Connection (

Ground Connection (

optional

⁄⁄⁄⁄

Mains Connection

Mains ConnectionMains Connection

Mains Connection

LocalNet Connection

LocalNet ConnectionLocalNet Connection

LocalNet Connection

Blanking Cover(s⁄

Blanking Cover(s⁄Blanking Cover(s⁄

Blanking Cover(s⁄

Front Panel

Front PanelFront Panel

Front Panel

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄⁄⁄⁄

Trigger Connection (

Trigger Connection (Trigger Connection (

Trigger Connection (

torch

⁄⁄⁄⁄

Carrying Strap

Carrying StrapCarrying Strap

Carrying Strap

Current Connection (

Current Connection (Current Connection (

Current Connection (

torch

⁄⁄⁄⁄

Ground Connection

Ground ConnectionGround Connection

Ground Connection

Connections – TPS 2700

---- 12

12 12

12 ----

Power Source

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Current Connection

Current ConnectionCurrent Connection

Current Connection

Ground Connection

Ground ConnectionGround Connection

Ground Connection

Power Switch

Power SwitchPower Switch

Power Switch

Mains Connection

Mains ConnectionMains Connection

Mains Connection

LocalNet Connection

LocalNet ConnectionLocalNet Connection

LocalNet Connection

Optional Add

Optional AddOptional Add

Optional Add----ons

onsons

ons

Front Panel

Front PanelFront Panel

Front Panel

Connections – TsT 3500/5000

Power Source

---- 13

13 13

13 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Current

Current Current

Current
Connection

ConnectionConnection

Connection

Ground

Ground Ground

Ground

Connection

ConnectionConnection

Connection

Power

Power Power

Power
Switch

SwitchSwitch

Switch

Mains

Mains Mains

Mains
Connection

ConnectionConnection

Connection

LocalNet

LocalNet LocalNet

LocalNet
Connection

ConnectionConnection

Connection

Gas Purch / Wire

Gas Purch / Wire Gas Purch / Wire

Gas Purch / Wire
Feed Switch

Feed SwitchFeed Switch

Feed Switch

Front Panel

Front PanelFront Panel

Front Panel

Connections – TsT Compact

Power Source

Gas

Gas Gas

Gas
Connection

ConnectionConnection

Connection

Torch

Torch Torch

Torch
Connector

ConnectorConnector

Connector

---- 14

14 14

14 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Wire Feeder

VR 4000

 This wire feeder is designed specifically for manual applications.
 This device has the trigger connections required for manual torches to operate.
 A removable wire-spool holder is mounted to the rear of the feeder.
 Robotic/automated connections and controls can easily be added to this wire feeder
 A push/pull torch requires an additional, internally installed kit.

VR 7000 CMT

 This wire feeder was developed specifically for the Cold Metal Transfer (CMT⁄ process.
 The feeder is equally suited to both manual and robotic/automated needs.
 A wire spool holder is integrated to the feeder allowing for both spool and drum use.
 This feeder is designed to operate with either a push or a push/pull torch.

Models

VR 1500

 This wire feeder is designed specifically for robotic or automated applications.
 Using this wire feeder for manual welding is not feasible without special

modifications

 A push/pull torch requires an additional, internally installed kit.

---- 15

15 15

15 ----

VR 1550

 This wire feeder is designed specifically for robotic or automated applications.
 Using this wire feeder for manual welding is not feasible without special

modifications

 This feeder can be used for CMT and/or push/pull applications using a series of

specially designed kits.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Wire Feeder

VR 5000 ROB

 Newly developed wire feeder specifically designed for the robotic TransSteel Welding

system.

 Designed to have the smallest profile of any Fronius wire feeder while maintaining a high

standard of durability and reliability.

 Multiple versions available based on the robot type and design (PAP, standard, etc.⁄ with a

large range of options and fixtures to choose from.

---- 16

16 16

16 ----

Models

VR 5000 Manual

 Newly developed wire feeder designed specifically for the TransSteel Welding System.
 Built with highly reliable, impact resistant materials. This provides reasonable protection

from dragging, dropping and hanging.

 Multiple control options to handle both manual and synergic welding needs
 Incredibly precise feed system allowing for perfect wire feed
 Specialized current connection with data lines integrated to the connection simplifies setup

and keeps wiring to a minimum.

VR 1500 PAP

 This wire feeder is designed specifically for robotic through-the-arm applications.
 The size and weight was kept as small as possible, keeping only the mandatory components

in the feeder itself and moving the remainder to the welder.

 Using this wire feeder for manual welding is not possible.
 A push/pull torch requires an additional, internally installed kit.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Wire Feeder

Fronius Connector (F++⁄

Fronius Connector (F++⁄Fronius Connector (F++⁄

Fronius Connector (F++⁄

Euro Connector (E⁄

Euro Connector (E⁄Euro Connector (E⁄

Euro Connector (E⁄ Tweeco Connector (T⁄

Tweeco Connector (T⁄Tweeco Connector (T⁄

Tweeco Connector (T⁄

Drive Rolls (

Drive Rolls (Drive Rolls (

Drive Rolls (

top

⁄⁄⁄⁄

Drive Rolls (

Drive Rolls (Drive Rolls (

Drive Rolls (

bottom

⁄⁄⁄⁄

Wire Guide Insert (

Wire Guide Insert (Wire Guide Insert (

Wire Guide Insert (

steel or synthetic

⁄⁄⁄⁄

Main Drive Roll

Main Drive RollMain Drive Roll

Main Drive Roll

Torch Connectors

Torch ConnectorsTorch Connectors

Torch Connectors

Tension Knobs

Tension KnobsTension Knobs

Tension Knobs

---- 17

17 17

17 ----

Motor Plate

Fronius System Connector (FSC⁄

Fronius System Connector (FSC⁄Fronius System Connector (FSC⁄

Fronius System Connector (FSC⁄

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Wire Feeder

Connections & Controls – VR 1500

Current Connection (

Current Connection (Current Connection (

Current Connection (

welder

⁄⁄⁄⁄

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

spare

⁄⁄⁄⁄

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

welder

⁄⁄⁄⁄

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄⁄⁄⁄

Current/Gas Connection (

Current/Gas Connection (Current/Gas Connection (

Current/Gas Connection (

torch

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

torch

⁄⁄⁄⁄

Gas Purge Button

Gas Purge ButtonGas Purge Button

Gas Purge Button

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

torch

⁄⁄⁄⁄

Wire Inch Button

Wire Inch ButtonWire Inch Button

Wire Inch Button

Robacta Connection (

Robacta Connection (Robacta Connection (

Robacta Connection (

torch

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

welder

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

welder

⁄⁄⁄⁄

---- 18

18 18

18 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Wire Feeder

Connections & Controls – VR 7000

Gas Purge (

Gas Purge (Gas Purge (

Gas Purge (up⁄ / Wire Feed (

⁄ / Wire Feed (⁄ / Wire Feed (

⁄ / Wire Feed (

down

⁄ switch

⁄ switch⁄ switch

⁄ switch

LHSB Connection (

LHSB Connection (LHSB Connection (

LHSB Connection (

torch

⁄⁄⁄⁄

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

welder

⁄⁄⁄⁄

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄⁄⁄⁄

Current/Gas Connection (

Current/Gas Connection (Current/Gas Connection (

Current/Gas Connection (

torch

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

torch

⁄⁄⁄⁄

Spool Holder

Spool HolderSpool Holder

Spool Holder

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

torch

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

welder

⁄⁄⁄⁄

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

welder

⁄⁄⁄⁄

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

spare

⁄⁄⁄⁄

Power Control (

Power Control (Power Control (

Power Control (

WFS, Current, etc.

⁄⁄⁄⁄

Arc Length Control

Arc Length ControlArc Length Control

Arc Length Control

LHSB Connection (

LHSB Connection (LHSB Connection (

LHSB Connection (

welder

⁄⁄⁄⁄

Current Connection (

Current Connection (Current Connection (

Current Connection (

welder

⁄⁄⁄⁄

Trigger Connection (

Trigger Connection (Trigger Connection (

Trigger Connection (

torch

⁄⁄⁄⁄

Buffer Connection (

Buffer Connection (Buffer Connection (

Buffer Connection (

torch

⁄⁄⁄⁄

Robacta Connection (

Robacta Connection (Robacta Connection (

Robacta Connection (

torch

⁄⁄⁄⁄

Motor

MotorMotor

Motor----plate

plateplate

plate

---- 19

19 19

19 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

welder

⁄

⁄ ⁄

⁄

 PAP System Only -

Current/Gas Connection (

Current/Gas Connection (Current/Gas Connection (

Current/Gas Connection (

torch

⁄⁄⁄⁄

Current Connection (

Current Connection (Current Connection (

Current Connection (

welder

⁄⁄⁄⁄

Motor

MotorMotor

Motor----plate

plateplate

plate

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄

⁄ ⁄

⁄

----

PAP System Only

----

Wire Inch Button

Wire Inch ButtonWire Inch Button

Wire Inch Button

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄

⁄ ⁄

⁄

----

Standard System Only

----

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

welder

⁄

⁄ ⁄

⁄

 Standard System Only -

Wire Inlet (

Wire Inlet (Wire Inlet (

Wire Inlet (

drum or spool

⁄⁄⁄⁄

Wire Feeder

Connections & Controls – VR 5000 Rob

---- 20

20 20

20 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

LocalNet Connection (

LocalNet Connection (LocalNet Connection (

LocalNet Connection (

welder

⁄⁄⁄⁄

Gas Connection (

Gas Connection (Gas Connection (

Gas Connection (

bottle

⁄⁄⁄⁄

Current/Gas Connection (

Current/Gas Connection (Current/Gas Connection (

Current/Gas Connection (

torch

⁄⁄⁄⁄

Spool Holder

Spool HolderSpool Holder

Spool Holder

Current Connection (

Current Connection (Current Connection (

Current Connection (

welder

⁄⁄⁄⁄

Motor

MotorMotor

Motor----plate

plateplate

plate

Spool Window

Spool WindowSpool Window

Spool Window

Handle

HandleHandle

Handle

Weld Control

Weld Control Weld Control

Weld Control

Panel

PanelPanel

Panel

Synergic Selection

Synergic Selection Synergic Selection

Synergic Selection

----

Synergic version only

----

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

torch

⁄

⁄ ⁄

⁄

----

optional add on

----

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

torch

⁄

⁄ ⁄

⁄

----

optional add on

----

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- hot (

hot (hot (

hot (

welder

⁄

⁄ ⁄

⁄ ----

optional add on

----

Coolant Feed

Coolant Feed Coolant Feed

Coolant Feed ---- cold (

cold (cold (

cold (

welder

⁄

⁄ ⁄

⁄

----

optional add on

----

Wire Feeder

Connections & Controls – VR 5000 Manual

---- 21

21 21

21 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Manual Torches

Manual TorchesManual Torches

Manual Torches

 Trigger to start/stop the arc.

 Water-cooled or Air-cooled

 Several control options

 None

 Up/Down (U/D⁄

 Jobmaster (JM⁄

 Several wire feeder connections

 Fronius (F/F++⁄

 Fronius System Connector (FSC⁄

 Euro (E⁄

 Tweeko (Z⁄

Robotic Torches

Robotic TorchesRobotic Torches

Robotic Torches

 Robotic/Automated control of the arc

 Water-cooled or Air-cooled

 No parameter control options.

 Wire feed and gas control

 Only on drive-based torches.

 Several wire feeder connections

 Fronius (F/F++⁄

 Fronius System Connector (FSC⁄

 Euro (E⁄

 Tweeko (Z⁄

 Will have Robacta in the description

BAAN/Price

BAAN/PriceBAAN/Price

BAAN/Price----book Description Examples

book Description Examplesbook Description Examples

book Description Examples

AL 4000 G/E/UD/4.5m/14.5ft - AL 4000

AL 4000AL 4000

AL 4000 (torch type-manual⁄ GGGG (gas-cooled⁄ EEEE (Euro connector⁄ UD

UDUD

UD (up/down control⁄

Robacta Drive Ext. W/F++/1.75m/5.7ft - Robacta Drive Ext

Robacta Drive ExtRobacta Drive Ext

Robacta Drive Ext (torch type-robotic⁄ WWWW (water-cooled⁄ F++

F++F++

F++ (Fronius connector⁄

PullMig CMT W/F/6m/19.7ft - PullMig CMT

PullMig CMTPullMig CMT

PullMig CMT (torch type-manual⁄ WWWW (water-cooled⁄ FFFF (Fronius connector⁄

Welding Torch

Models

---- 22

22 22

22 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Cooling Units

Cooling UnitsCooling Units

Cooling Units

Standard Features

Standard FeaturesStandard Features

Standard Features



Integrated system linked directly to power source for power and control.



Fuse protection against potential over-voltage damage.



Flow sensor to verify proper coolant movement.



Variable flow measurements to account for lengthy hose-packs.

FK 4000 / FK 5000

FK 4000 / FK 5000FK 4000 / FK 5000

FK 4000 / FK 5000



Standard water cooler for most MIG and TIG packages



Internal reservoir that allows for a completely closed system.

FK 9000

FK 9000FK 9000

FK 9000



High volume water cooler for specialized system that require a larger
coolant capability.



Two separate units with integral components divided between them.

Cooler

Models

---- 23

23 23

23 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 24

24 24

24 ----

Weld Process

Overview

 Shielded Metal Arc Welding (SMAW)

An arc welding process that produces coalescence of metals by heating them with an arc between a covered metal electrode and the workpiece(s).
Shielding is obtained from decomposition of the electrode covering. Pressure is not used, and filler metal is obtained from the electrode.

– Stick Welding
– Performed with a basic constant current (CC) power source that is equipped with an electrode holder and a ground clamp
– Manual

 Gas Tungsten Arc Welding (GTAW)

An arc welding process that produces coalescence of metals by heating them with an arc between a tungsten electrode (non-consumable) and the
workpiece(s). Shielding is obtained from a gas. Pressure may or may not be used, and filler may or may not be used.

– TIG welding
– Performed with a constant current (CC) power source equipped with a GTA welding torch that supplies current through a tungsten electrode

and ground clamp

– GTAW requires an inert gas such as Argon (most commonly used) or Helium (or a mixture of the two) to support the arc
– Manual, Mechanized, and Automated

 Gas Metal Arc Welding (GWAW)

An arc welding process that produces coalescence of metals by heating them with an arc between a continuous filler metal electrode and the
workpiece(s). Shielding is obtained entirely from an externally supplied gas.

– MIG/MAG welding
– Performed with a constant voltage (CV) power supply equipped with a wire feeder to supply welding wire through a GMA welding torch to the

workpiece(s) and with a ground clamp to complete the electrical circuit

– Semi–auto process (manual), Mechanized, and Automated

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 25

25 25

25 ----

Weld Process

Overview

 Synergic Welding

– Computer control of the welding arc based on a single user-defined characteristic (wire-

feed speed, material thickness, amps, etc.)

– Changing the wire-feed speed will automatically adjust the voltage necessary for the

filler metal and gas being used. This is done through the use of a digital signal

processor and a synergic line

– Provides an extremely high level of repeatability and precision
– The synergic line can be modified slightly to account for environmental differences

between laboratory testing and production

 Synergic Line

– An arc-characteristic curve that links a number of welding parameters together giving

the most ‘ideal’ values for a specific filler metal, wire diameter, shielding gas, and

operating mode

– This line is created through a complex set of measurements taken while welding with

the specified settings

– A standard line can be chosen/programmed in a matter of seconds with the simple

selection of a few base parameters

 TransSynergic and TransPulseSynergic

– Standard MIG power sources available from Fronius
– Both have the ability to do standard (conventional “2 dial”) welding and synergic welding

(one dial)

– The TransPulse Synergic power source has the added ability to perform pulse-synergic

welding

WIRE-FEED SPEED (current)

VOLTAGE

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 26

26 26

26 ----

Weld Process

MIG – Short Circuit Transfer

 Short Circuit Transfer

This is a transfer mode where the electrode wire touches the work piece “snubbing out” the arc and the heat from electrical resistance violently pinches
off and deposits the molten wire electrode into the weld pool. -The wire heats up forming a ball of metal at the end of the wire which is then reintroduced
into the molten weld pool where it shorts the circuit, then gets pinched off and deposited into the weld pool. The cycle thenrepeats itself.

– Disadvantages include: Limited wire feed speed and therefore lower deposition rates - Cold lapping/lack of fusion is also more likely to occur

(proper technique is needed to avoid cold lapping/lack of fusion) –Moderate amount of spatter (dependent on environmental factors and
parameters).

– Advantages Include: Low heat input -All positions – Gap bridging - Capable Process for thick and thin materials

 Globular Transfer:

This is an uncontrolled spray transfer mode. When CO2 or Argon-CO2 is used, a molten ball tends to form on the end of the electrode and may grow in
size until its diameter is greater than the diameter of the electrode. These droplets, larger in size, may cause short circuits and this mode is known as
“globular transfer.” This method of transfer produces a large amount of spatter and higher heat input when compared to the short circuit transfer mode.

– Disadvantages include: High level of spatter and arc instability
– Advantages: Can use 100% CO2 , an inexpensive gas - Has good penetration on thick metals

 Spray Transfer:

This is a high heat input transfer mode where the shielding gas is an Argon rich (Argon-Oxygen - 8% Oxygen maximum) or (Argon-CO2 -18% CO2
maximum) mixture. The droplets being sprayed across the arc are very fine and never short circuit the arc therefore propelling small molten droplets of
the electrode across an open arc to the workpiece(s).

– Disadvantages include: High heat input - Limited range of welding positions - Higher percentages of argon required thus increasing gas cost

– Advantages include: High deposition rates - Good penetration - Good weld appearance with little to no spatter

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 27

27 27

27 ----

Weld Process

MIG – Pulsed Current Welding (Pulse)

 Pulse Welding (GMAW-P):

This is a GMAW process variation in which the welding current is pulsed resulting in a lower heat input for a given set of welding parameters when
compared to conventional GMAW.

– Disadvantages include: Special power source required to support pulsing current - Higher argon percentages required to support arc –

diameter of spatter balls typically larger than conventional GMAW spatter ball size

– Advantages include: High deposition rates - Lower heat inputs - Viable solution to many welding situations - Less spatter when compared to

conventional GMAW – Good weld appearance

 Note Concerning Synergic Welding:

Synergic is a term used to describe “single dial” manipulation of multiple welding parameters at the same time.

– Disadvantages include: Specific power source designed to allow single dial manipulation of multiple welding parameters at the same time

– Advantages include: Reduced parameter development time due to the ability to change multiple parameters with a single dial turn (current and

voltage with single dial)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

INERT GASES

INERT GASES INERT GASES

INERT GASES  INERT MIXED GASES

INERT MIXED GASESINERT MIXED GASES

INERT MIXED GASES

 Argon

Ionizes easily, deep fusion penetration, finger-shaped, low cost to manufacture (filtered out of ambient air⁄.

 Helium

Difficult to ionize; high heat conductivity; deep, wide penetration; fluid weld pool; good wetting; more expensive
than argon (filtered out of natural gas⁄

 Argon-Helium Mix

The advantages/disadvantage of each gas increases and decreases in relation to the proportion within the mix.

ACTIVE GASES

ACTIVE GASES ACTIVE GASES

ACTIVE GASES  ACTIVE MIXED GASES

ACTIVE MIXED GASESACTIVE MIXED GASES

ACTIVE MIXED GASES

 CO

2

Reacts with the material, deeper reduced-pore fusion penetration, tends towards spattering, cheap to manufacture

 Argon  CO2

Combines advantages of its components, the most used gas combination for unalloyed steel and chrome-nickel

 Argon  Oxygen

Arc more stable, reduced surface tension of weld pool, pore-sensitive, Oxygen 8% maximum

Gas Characteristics

---- 28

28 28

28 ----

Weld Process

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

CO

2

Ar/CO

2

Ar/O

2

Fusion Penetration

 Horizontal

 Positional Welding

Very Good
Very Good

Good
More CO2= better fusion

penetration

Good
Critical

Pores Very Little

Normal
More CO2= fewer pores

Pore-sensitive

Arc Stability Poor, except KL Good Very Good

Spatter Level High Medium Low

Fusion Penetration Profile

---- 29

29 29

29 ----

Weld Process

Overview of Active Mixed Gas

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

The proportion of CO2in the gas is mainly responsible for the shape of the arc and the resulting behavior of it (fusion
penetration, pore creation, etc.).

18% CO

2

• Wider arc range

• Wider fusion penetration

• Little pore creation

5% CO

2

• Narrow arc range

• Deeper, narrower fusion
penetration

• Pore creation possible

Impact of CO2on the Arc

---- 30

30 30

30 ----

Weld Process

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Weld Process

Gas Flow

• The flow rate of the shielding gas is a critical aspect of

the welding process. Too high OR too low will have a
serious impact on weld results.

• Rule of thumb for the flow rate: 10 – 12 times the

diameter in l/min of flow

- 1.2mm x 10 = 12 l/min

- 1 l/min = 2.1 CFH

- 12 l/min x 2.1 = 25 CFH

• Helium and Hydrogen require about 50% more flow

than other gases due to their lighter weights.

Correct flow rate

Excessive flow rate

Gas Pressure Sensor (4,100,343)

Manually set gas valve that reports a gas error to the weld
system when flow is too low. Only errors out for low flow
and doesn’t report specific flow information.

Digital Gas Sensor (4,100,374)

The specific gas flow is set, regulated, and monitored
using this device. Not only is a low or high flow rate
detected, but the system also reports back specific gas
flow data.

---- 31

31 31

31 ----

Fronius Options

Typically, the weld system opens and closes the gas
valve. If flow monitoring is desired within the system, the
following options are available.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Neutral Travel Angle

 Arc heats and transmits its total power into the weld pool
 Stable, quiet arc
 Fusion penetration is

MEDIUM

MEDIUMMEDIUM

MEDIUM

 Weld Width is

MEDIUM

MEDIUMMEDIUM

MEDIUM

Push Travel Angle

 Arc heats and transmits its total power into the weld pool
 Stable, quiet arc
 Fusion penetration is

SHALLOW

SHALLOWSHALLOW

SHALLOW

 Weld Width is

WIDE

WIDEWIDE

WIDE

Drag TravelAngle

 Arc partially heats the base material and the weld pool
 Not a particularly quiet arc
 Fusion penetration is

DEEP

DEEPDEEP

DEEP

 Weld Width is

NARROW

NARROWNARROW

NARROW

Torch Movement and Handling

---- 32

32 32

32 ----

Weld Process

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Excessive Reinforcement

Excessive ReinforcementExcessive Reinforcement

Excessive Reinforcement

Weld bead reinforcement is too high and lumpy

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Travel speed too slow

 Weld current too low

 Improper travel angle

Insufficient Throat

Insufficient ThroatInsufficient Throat

Insufficient Throat

The weld bead is too shallow

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Combination of travel speed too fast and

current too low

 Improper placement of weld beads when

doing multiple passes

Undercut

UndercutUndercut

Undercut

Cutting away at the toe(s⁄

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Amperage too high

 Arc length too long (voltage too high⁄

 Improper work angle

Insufficient Leg (undersized weld⁄

Insufficient Leg (undersized weld⁄Insufficient Leg (undersized weld⁄

Insufficient Leg (undersized weld⁄

Leg size too small

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Using the wrong work angle

 Insufficient wire feed speed for travel speed

Insufficient Penetration

Insufficient PenetrationInsufficient Penetration

Insufficient Penetration

Not penetrated at root or between passes

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Amperage too low

 Travel speeds too fast

 Too large or wrong electrode

 Improper travel angle

Lack of Fusion

Lack of FusionLack of Fusion

Lack of Fusion

Weld not fused completely

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Amperage too low

 Travel speed too high

 Improper work/travel angle

 Improper weave parameters

Weld Process

Discontinuity

---- 33

33 33

33 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Overlap / Weld Bead Rollover

Overlap / Weld Bead RolloverOverlap / Weld Bead Rollover

Overlap / Weld Bead Rollover

Weld metal cold and lapped at toe or root

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Amperage too high

 Travel speed too slow

 Electrode too large

Porosity

PorosityPorosity

Porosity

Pinholes

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Dirty, painted, or galvanized base metal

 Arc length too long

 Moisture in weld

 Insufficient shielding gas coverage

Slag Inclusions

Slag InclusionsSlag Inclusions

Slag Inclusions

Slag trapped in weld

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Improper manipulation of covered electrode

 Improper cleaning and/or slag removal between

passes

Cracking

CrackingCracking

Cracking

Cracks in the weld and/or base metal

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Using the wrong electrode

 Using excessively high amperage

 Underfill or improper crater geometry (crater

cracking⁄

 Moisture in low hydrogen processes

Excessive Spatter

Excessive SpatterExcessive Spatter

Excessive Spatter

Possible Cause(s⁄

Possible Cause(s⁄Possible Cause(s⁄

Possible Cause(s⁄

 Amperage too high

 Electrode angle too extreme

 Arc length too short/long

 Process driven

Weld Process

Discontinuity

---- 34

34 34

34 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Use and Operation

Initial Set-up and Turn On

Step 1:

Step 1:Step 1:

Step 1: Connect main power, gas and wire
to the welder/wire feeder. If equipped with
one, fill the cooler with Fronius Coolant.

Step 2:

Step 2:Step 2:

Step 2: Connect or clamp the ground
connection to the fixture or work piece.
Plug the other end into the welder ground
connection.

Step 3:

Step 3:Step 3:

Step 3: Turn the welder on. Almost
immediately, you will hear a click from the
wire feeder. Within a minute, the display
should come on.

Step 4:

Step 4:Step 4:

Step 4: Load the consumables into the wire feeder and torch as
necessary. Store extras in a safe place for later use.

Step 5:

Step 5:Step 5:

Step 5: Perform a resistance test.

Step 5:

Step 5:Step 5:

Step 5: If using a non-CMT push-pull gun, perform a PPU
alignment

Step 6:

Step 6:Step 6:

Step 6: If using a cooler, verify cooler is turned on and set
properly (C-C and C-T⁄.

Step 7:

Step 7:Step 7:

Step 7: Select proper synergic-line for the application to be
done.

Step 8:

Step 8:Step 8:

Step 8: If using jobs, set and edit them as needed. If
not, select all other needed weld parameters.

Step 9:

Step 9:Step 9:

Step 9: Start welding

Notes

NotesNotes

Notes

 If you encounter an error code

or weld problems, attempt to
perform a basic check-out.

 Note any failure points before

calling support.

 When calling support, please

have the following information
available:

- Welder serial number

- Welder firmware/database

- Error Codes (if any⁄

- Filler metal type,

diameter, and gas.

---- 35

35 35

35 ----

---- 36

36 36

36 ----

---- 37

37 37

37 ----

---- 38

38 38

38 ----

---- 39

39 39

39 ----

---- 40

40 40

40 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Use and Operation

MIG Correction Values

Correction Value 1 Correction Value 2

Standard Synergic

+30 = longer arc length → morevoltage +5 = More inductance → Lower peak current, soft arc

0 = Standard arc length 0 = Standard inductance

-30 = Shorter arc length → Less voltage -5 = Less inductance → Higher peak current, hard arc

Pulse Synergic

+30 = longer arc length → morevoltage +5 = Wider arc → Higher pulse force

0 = Standard arc length 0 = Standard width

-30 = Shorter arc length → Less voltage -5 = Narrower arc → Lower pulse force

Standard CMT

(Steel)

+30 = Lower droplet detach freq → more voltage +5 = Less SC2 Current → Colder melt pool

0 = Standard Plasma WFS 0 = Standard SC2 Current

-30 = Higher droplet detach freq → Less voltage -5 = More SC2 Current → Hotter melt pool

Standard CMT

(Aluminum and

Stainless)

+30 = Slower Burn WFS → morevoltage +5 = Increased arc length at ignition

0 = Standard Burn WFS 0 = No increased arc length at ignition

-30 = Faster Burn WFS → Less voltage -5 = No impact

CMT Pulse

(Steel)

+30 = longer arc length → morevoltage +5 = More energy → Drop falls with more pressure

0 = Standard arc length 0 = Standard energy

-30 = Shorter arc length → Less voltage -5 = Less energy → Drop falls with less pressure

CMT Pulse

(Aluminum and

Stainless)

+30 = Slower Pulse WFS → more voltage +5 = More energy → Drop falls with more pressure

0 = Standard Pulse WFS 0 = Standard energy

-30 = Faster Pulse WFS → Less voltage -5 = Less energy → Drop falls with less pressure

---- 41

41 41

41 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Adjustment Dial

Adjustment DialAdjustment Dial

Adjustment Dial

Used to change the
value of a parameter
or setting.

Mode Selection

Mode Selection Mode Selection

Mode Selection

Buttons (

Buttons (Buttons (

Buttons (

up/down

⁄⁄⁄⁄

Used to change the
welding process of the
power source.

Trigger Selection Buttons

Trigger Selection Buttons Trigger Selection Buttons

Trigger Selection Buttons
((((

up/down

⁄⁄⁄⁄

Used to changed the type of trigger
setting for the welding torch.

Material Selection Buttons (

Material Selection Buttons (Material Selection Buttons (

Material Selection Buttons (

up/down

⁄⁄⁄⁄

Used to select the shielding gas and filler metal to
be used during the welding process.

Diameter Selection Button

Diameter Selection ButtonDiameter Selection Button

Diameter Selection Button

Used to select the diameter of the filler metal to be
used during the welding process.

Store Button

Store ButtonStore Button

Store Button

Used in conjunction with
other buttons to get into
various other menus. Can
also be used to exit any
menu.

Purge Button

Purge ButtonPurge Button

Purge Button

Used to test the gas flow.
One press will allow gas
flow for 30s, a second
press will stop the flow.

Inch Forward Button

Inch Forward ButtonInch Forward Button

Inch Forward Button

Used to inch the filler wire
forward through the torch
without gas or current flow.

Parameter Selection Button

Parameter Selection ButtonParameter Selection Button

Parameter Selection Button

Used to determine what welding parameter
will be displayed on the SECOND 3-digit
display (arc-length correction, dynamic,
welding voltage, or job number⁄

Parameter Selection Button

Parameter Selection ButtonParameter Selection Button

Parameter Selection Button

Used to determine what welding parameter will be
displayed on the first 3 digit display (sheet thickness,
welding current, wire-feed speed, or drive current⁄.

Keylock Switch (

Keylock Switch (Keylock Switch (

Keylock Switch (

optional

⁄⁄⁄⁄

Used to lock and unlock the front panel control,
limiting access to who can change welding settings.

---- 42

42 42

42 ----

Use and Operation

Front Panel – Controls (TPS)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Indicators

Power IndicatorsPower Indicators

Power Indicators

When lit, the first 3-digit display shows one of several power
values depending on the power source mode.

Sheet Thickness

Sheet ThicknessSheet Thickness

Sheet Thickness: When lit, the first 3-digit display will
show the sheet thickness of the material to be
welded to. This value is adjustable in any synergic
mode.

Welding Current

Welding CurrentWelding Current

Welding Current: When lit, the first 3-digit display will
show the welding current that will be welded with.
This value is adjustable in any synergic mode.

Wire Feed Speed

Wire Feed SpeedWire Feed Speed

Wire Feed Speed: When lit, the first 3-digit display
will show the wire feed speed that will be welded
with. This value is adjustable in any synergic mode..

Synergic & Pulse

Synergic & PulseSynergic & Pulse

Synergic & Pulse: The three values are linked to each other.
As you change one, the other two will adjust automatically.

Standard

StandardStandard

Standard: Only current and wire feed are available as
selections. Wire feed speed is the ONLY parameter that can
be adjusted.

Temperature

Temperature Temperature

Temperature
Indicator

IndicatorIndicator

Indicator

When lit, the internal
temperature for the
power source is too
high.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the first 3-digit display is active and
adjustable when applicable.

Wire Feeder Current Indicator

Wire Feeder Current IndicatorWire Feeder Current Indicator

Wire Feeder Current Indicator

When lit, the wire-feeder motor current is
shown on the first 3-digit display.

Torch Motor Current Indicator

Torch Motor Current Indicator Torch Motor Current Indicator

Torch Motor Current Indicator
((((

if equipped

⁄⁄⁄⁄

When lit, the torch motor current is
shown on the first 3-digit display.

3333----Segment Display

Segment DisplaySegment Display

Segment Display

When lit, the first 3-digit display is active
and adjustable when applicable.

3333----Segment Display

Segment DisplaySegment Display

Segment Display

When lit, the second 3-digit display is
active and adjustable when
applicable.

Hold Indicator

Hold IndicatorHold Indicator

Hold Indicator

When lit, the last welding values are
shown on the 3-digit displays. Only
lights after a weld has completed.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the parameter being looked at
can be adjusted to a new value.

Coolant Flow (

Coolant Flow (Coolant Flow (

Coolant Flow (

if equipped

⁄⁄⁄⁄

When lit and equipped with a digital flow
meter the 3-segment display will show
the coolant flow.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the second 3-digit display is
active and adjustable when applicable.

Job Number Indicator

Job Number IndicatorJob Number Indicator

Job Number Indicator

When lit, the second 3-digit display
shows the number of the job being used.

Welding Voltage

Welding Voltage Welding Voltage

Welding Voltage
Indicator

IndicatorIndicator

Indicator

When lit, the second 3­digit display will show
the voltage that will be
welded with. This value
is adjustable.

Arc Length

Arc Length Arc Length

Arc Length
Correction

Correction Correction

Correction
Indicator

IndicatorIndicator

Indicator

When lit, the second 3­digit display shows the
current arc length
correction. This value
is adjustable.

Dynamic/Droplet

Dynamic/Droplet Dynamic/Droplet

Dynamic/Droplet
Correction Indicator

Correction IndicatorCorrection Indicator

Correction Indicator

When lit, the second 3­digit display will show
either the dynamic
correction (synergic⁄ or
the droplet-detachment
(pulse⁄.

Use and Operation

Front Panel – Indicators (TPS)

---- 43

43 43

43 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Globular Transfer Arc Indicator

Globular Transfer Arc IndicatorGlobular Transfer Arc Indicator

Globular Transfer Arc Indicator

When lit, conditions are correct for the
power source to weld between short
circuit and spray arcs.

Wire Diameter Indicator

Wire Diameter IndicatorWire Diameter Indicator

Wire Diameter Indicator

When lit, this will indicate which wire
diameter is selected to weld with.

Wire Diameter Special Indicator

Wire Diameter Special IndicatorWire Diameter Special Indicator

Wire Diameter Special Indicator

When lit, this indicates that a size other
than the normal ones are selected to
weld with.

Filler Metal/Gas Indicator

Filler Metal/Gas IndicatorFiller Metal/Gas Indicator

Filler Metal/Gas Indicator

When lit, this indicates the shielding gas and
filler metal combination used during the
welding process.

Trigger Indicators

Trigger IndicatorsTrigger Indicators

Trigger Indicators

These indicators determine how the torch trigger reacts
during the welding process.

Conventional

ConventionalConventional

Conventional: Press and hold torch trigger to start
arc. Release trigger to stop.

Trigger Lock (

Trigger Lock ( Trigger Lock (

Trigger Lock ( 2-step⁄⁄⁄⁄: Press and release torch
trigger to start arc. Press (and release⁄ trigger to
stop arc.

Special 4

Special 4Special 4

Special 4----Step:

Step:Step:

Step: Press and hold torch trigger to begin
welding at Current start value. Release trigger to
move to normal welding current. Press and hold
trigger to move to ending current value. Finally,
release torch trigger to stop the arc.

Spot Mode

Spot ModeSpot Mode

Spot Mode: Press and release torch trigger to start
the weld, it will run until the time runs out and then
stop automatically. You can abort the weld by
pressing and releasing the torch trigger a second
time.

Filler Metal/Gas Special Indicator

Filler Metal/Gas Special IndicatorFiller Metal/Gas Special Indicator

Filler Metal/Gas Special Indicator

When lit, this indicated that a special filler
metal/gas combination has been selected.
These two lines generally vary based on the
synergic data loaded into the power source.

Mode Indicators

Mode IndicatorsMode Indicators

Mode Indicators

These indicators determine which welding mode the power
source is in for welding.

Pulse Synergic:

Pulse Synergic:Pulse Synergic:

Pulse Synergic: This will set the power source
for welding in pulse MIG welding using stored
synergic line.

Synergic:

Synergic:Synergic:

Synergic: This will set the power source for
conventional MIG welding using a stored
synergic line.

Standard:

Standard:Standard:

Standard: This will set the power source for
conventional MIG welding using NO synergic
line.

JOB:

JOB:JOB:

JOB: This will set the power source for welding
based on the JOB previously set up (there will
be a second indicator showing the saved
mode for the JOB⁄.

TIG:

TIG:TIG:

TIG: This will set the power source for TIG
welding (assuming optional components are
installed⁄.

Stick:

Stick:Stick:

Stick: This will set the power source for Stick
(CV⁄ welding.

---- 44

44 44

44 ----

Use and Operation

Front Panel – Indicators (TPS)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Adjustment Dial

Adjustment DialAdjustment Dial

Adjustment Dial

Used to change the
value of a parameter or
setting.

Mode Selection

Mode Selection Mode Selection

Mode Selection
Buttons (

Buttons (Buttons (

Buttons (

up/down

⁄⁄⁄⁄

Used to change the
welding process of the
power source.

Trigger Selection Buttons (

Trigger Selection Buttons (Trigger Selection Buttons (

Trigger Selection Buttons (

up/down

⁄⁄⁄⁄

Used to changed the type of trigger setting for the
welding torch.

Material Selection Buttons (

Material Selection Buttons (Material Selection Buttons (

Material Selection Buttons (

up/down

⁄⁄⁄⁄

Used to select the shielding gas and filler metal to
be used during the welding process.

Diameter Selection Button

Diameter Selection ButtonDiameter Selection Button

Diameter Selection Button

Used to select the diameter of the filler metal to be
used during the welding process.

Store Button

Store ButtonStore Button

Store Button

Used in conjunction with
other buttons to get into
various other menus. Can
also be used to exit any
menu.

Purge Button

Purge ButtonPurge Button

Purge Button

Used to test the gas flow.
One press will allow gas
flow for 30s, a second
press will stop the flow.

Inch Forward Button

Inch Forward ButtonInch Forward Button

Inch Forward Button

Used to inch the filler wire
forward through the torch
without gas or current flow.

Parameter Selection Button

Parameter Selection ButtonParameter Selection Button

Parameter Selection Button

Used to determine what welding parameter will be
displayed on the RIGHT 3-digit display (arc-length
correction, dynamic, welding voltage, or job
number⁄

Parameter Selection Button

Parameter Selection ButtonParameter Selection Button

Parameter Selection Button

Used to determine what welding parameter will be
displayed on the LEFT 3 digit display (sheet
thickness, welding current, wire-feed speed, or drive
current⁄.

Keylock Switch (

Keylock Switch (Keylock Switch (

Keylock Switch (

if equipped

⁄⁄⁄⁄

Used to lock and unlock the front panel control,
limiting access to who can change welding settings.

---- 45

45 45

45 ----

Use and Operation

Front Panel – Controls (CMT)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Power Indicators

Power IndicatorsPower Indicators

Power Indicators

When lit, the first 3-digit display shows one of several power
values depending on the power source mode.

Sheet Thickness

Sheet ThicknessSheet Thickness

Sheet Thickness: When lit, the first 3-digit display will
show the sheet thickness of the material to be
welded to. This value is adjustable in any synergic
mode.

Welding Current

Welding CurrentWelding Current

Welding Current: When lit, the first 3-digit display will
show the welding current that will be welded with.
This value is adjustable in any synergic mode.

Wire Feed Speed

Wire Feed SpeedWire Feed Speed

Wire Feed Speed: When lit, the first 3-digit display
will show the wire feed speed that will be welded
with. This value is adjustable in any mode.

Synergic & Pulse

Synergic & PulseSynergic & Pulse

Synergic & Pulse: The three values are linked to each other.
As you change one, the other two will adjust automatically.

Standard

StandardStandard

Standard: Only current and wire feed are available as
selections. Wire feed speed is the ONLY parameter that can
be adjusted.

Temperature

Temperature Temperature

Temperature
Indicator

IndicatorIndicator

Indicator

When lit, the internal
temperature for the
power source is too
high.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the left3-digit display is active and
adjustable when applicable.

Wire Feeder Current Indicator

Wire Feeder Current IndicatorWire Feeder Current Indicator

Wire Feeder Current Indicator

When lit, the wire-feeder motor current is
shown on the first 3-digit display.

Torch Motor Current Indicator

Torch Motor Current Indicator Torch Motor Current Indicator

Torch Motor Current Indicator
((((

if equipped

⁄⁄⁄⁄

When lit, the torch motor current is
shown on the first 3-digit display.

3333----Segment Display

Segment DisplaySegment Display

Segment Display

When lit, the first 3-digit display is active
and adjustable when applicable.

3333----Segment Display

Segment DisplaySegment Display

Segment Display

When lit, the right 3-digit display is
active and adjustable when
applicable.

Hold Indicator

Hold IndicatorHold Indicator

Hold Indicator

When lit, the last welding values are
shown on the 3-digit displays. Only
lights after a weld has completed.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the parameter being looked at
can be adjusted to a new value.

Parameter Adjustment Indicator

Parameter Adjustment IndicatorParameter Adjustment Indicator

Parameter Adjustment Indicator

When lit, the second 3-digit display is
active and adjustable when applicable.

Job Number Indicator

Job Number IndicatorJob Number Indicator

Job Number Indicator

When lit, the second 3-digit display
shows the number of the job being used.

Welding Voltage

Welding Voltage Welding Voltage

Welding Voltage
Indicator

IndicatorIndicator

Indicator

When lit, the second 3­digit display will show
the voltage that will be
welded with. This value
is adjustable.

Arc Length

Arc Length Arc Length

Arc Length
Correction

Correction Correction

Correction
Indicator

IndicatorIndicator

Indicator

When lit, the second 3­digit display shows the
current arc length
correction. This value
is adjustable.

Dynamic/Droplet

Dynamic/Droplet Dynamic/Droplet

Dynamic/Droplet
Correction Indicator

Correction IndicatorCorrection Indicator

Correction Indicator

When lit, the second 3­digit display will show
either the dynamic
correction (synergic⁄ or
the droplet-detachment
(pulse⁄.

---- 46

46 46

46 ----

Use and Operation

Front Panel – Indicators (CMT)

Coolant Flow (

Coolant Flow (Coolant Flow (

Coolant Flow (

if equipped

⁄⁄⁄⁄

When lit and equipped with a digital flow
meter the 3-segment display will show
the coolant flow.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

CMT

CMTCMT

CMT----Pulse Indicator

Pulse IndicatorPulse Indicator

Pulse Indicator

This will light when a CMT-Pulse
synergic line has been selected.

Wire Diameter Indicator

Wire Diameter IndicatorWire Diameter Indicator

Wire Diameter Indicator

When lit, this will indicate which wire
diameter is selected to weld with.

Wire Diameter Special Indicator

Wire Diameter Special IndicatorWire Diameter Special Indicator

Wire Diameter Special Indicator

When lit, this indicates that a size other
than the normal ones are selected to
weld with.

Filler Metal/Gas Indicator

Filler Metal/Gas IndicatorFiller Metal/Gas Indicator

Filler Metal/Gas Indicator

When lit, this indicates the shielding gas and
filler metal combination used during the
welding process.

Trigger Indicators

Trigger IndicatorsTrigger Indicators

Trigger Indicators

These indicators determine how the torch trigger reacts
during the welding process.

Conventional

ConventionalConventional

Conventional: Press and hold torch trigger to start
arc. Release trigger to stop.

Trigger Lock (

Trigger Lock ( Trigger Lock (

Trigger Lock ( 2-step⁄⁄⁄⁄: Press and release torch
trigger to start arc. Press (and release⁄ trigger to
stop arc.

Special 4

Special 4Special 4

Special 4----Step:

Step:Step:

Step: Press and hold torch trigger to begin
welding at Current start value. Release trigger to
move to normal welding current. Press and hold
trigger to move to ending current value. Finally,
release torch trigger to stop the arc.

Spot Mode

Spot ModeSpot Mode

Spot Mode: Press and release torch trigger to start
the weld, it will run until the time runs out and then
stop automatically. You can abort the weld by
pressing and releasing the torch trigger a second
time.

Filler Metal/Gas Special Indicator

Filler Metal/Gas Special IndicatorFiller Metal/Gas Special Indicator

Filler Metal/Gas Special Indicator

When lit, this indicated that a special filler
metal/gas combination has been selected.
These two lines generally vary based on the
synergic data loaded into the power source.

Mode Indicators

Mode IndicatorsMode Indicators

Mode Indicators

These indicators determine which welding mode the power
source is in for welding.

Pulse Synergic:

Pulse Synergic:Pulse Synergic:

Pulse Synergic: This will set the power source
for welding in pulse MIG welding using stored
synergic line.

Synergic:

Synergic:Synergic:

Synergic: This will set the power source for
conventional MIG welding using a stored
synergic line.

CMT / CMT Pulse:

CMT / CMT Pulse:CMT / CMT Pulse:

CMT / CMT Pulse: This mode will set the
power source for CMT and CMT Pulse using
selected synergic lines.

STANDARD:

STANDARD:STANDARD:

STANDARD: This will set the power source for
conventional MIG welding using NO synergic
lines.

JOB:

JOB:JOB:

JOB: This will set the power source for welding
based on the JOB previously set up (there will
be a second indicator showing the saved
mode for the JOB⁄.

Stick:

Stick:Stick:

Stick: This will set the power source for Stick
(CV⁄ welding.

---- 47

47 47

47 ----

Use and Operation

Front Panel – Indicators (CMT)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Step 1

Step 1Step 1

Step 1: Choose the desired filler metal wire diameter

Step 2

Step 2Step 2

Step 2: Choose the desired shield gas/filler metal

combination.

Step 3

Step 3Step 3

Step 3: Choose the desired trigger type.

Step 4

Step 4Step 4

Step 4: Choose the desired welding mode.

Select a Synergic Line

Select a Synergic LineSelect a Synergic Line

Select a Synergic Line

1111

2222

3333

4444

Checking Software

Checking SoftwareChecking Software

Checking Software

Step 1

Step 1Step 1

Step 1: Press and hold the STORE button and then press

the MATERIAL SELECTION button. Release
both buttons. One of four numbers will appear.

UST Firmware:

UST Firmware: UST Firmware:

UST Firmware: 4.25.016 (sample number⁄

Welding Database:

Welding Database: Welding Database:

Welding Database: 03.0139 (sample number⁄

SR41 Firmware:

SR41 Firmware: SR41 Firmware:

SR41 Firmware: A2.02.02 (sample number⁄

Arc Hours:

Arc Hours: Arc Hours:

Arc Hours: 00131.1 (sample number⁄

Synergic Line:

Synergic Line: Synergic Line:

Synergic Line: r0209 (sample number⁄

The machine may enter any of the four codes above,
but will cycle through in the same order.

Step 2

Step 2Step 2

Step 2: Use the MATERIAL SELECTION buttons to cycle

through the software codes.

Step 3

Step 3Step 3

Step 3: Press and release the STORE button to return to

the main welding screen.

2222

1 / 3

1 / 31 / 3

1 / 3

---- 48

48 48

48 ----

Processes

Use and Operation

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Program a Job

Program a JobProgram a Job

Program a Job

Step 1

Step 1Step 1

Step 1: Choose the desired synergic line.

Step 2

Step 2Step 2

Step 2: Dial in the desired power rating if known, if unknown

this step may be skipped.

Step 3

Step 3Step 3

Step 3: Press and release the STORE button. The first 3-

digit display should change to nPG and the second
should have a number on it. This is the first
available job number.

Step 4

Step 4Step 4

Step 4: Select the desired job number (note: if a job is

already saved, the first display will change to PrG.

Step 5

Step 5Step 5

Step 5: Press and hold the STORE button until the first

display changes from Pro to PrG. Release the
STORE button once this happens.

Step 6

Step 6Step 6

Step 6: Press and release the STORE button to return to

the main screen.

2/4

2/42/4

2/4

1/3/5/

1/3/5/1/3/5/

1/3/5/

6666

Editing a Job

Editing a JobEditing a Job

Editing a Job

Step 1

Step 1Step 1

Step 1: Press and hold the STORE button and then press

the 1

st

PARAMETER SELECTION button. The

display should change to Job 0.

Step 2

Step 2Step 2

Step 2: Dial in the number of the job you wish to modify.

Step 3

Step 3Step 3

Step 3: Use the up/down arrows to cycle through the

available parameters until you find the one you wish
edit.

Step 4

Step 4Step 4

Step 4: Dial in the new value (note the starting value since

there is no way to undo a change⁄.

Step 5

Step 5Step 5

Step 5: Repeat steps 3 and 4 until all parameters have been

changed.

Step 6

Step 6Step 6

Step 6: Press and release the STORE button to return to

the main screen.

1111

1 / 6

1 / 61 / 6

1 / 6

2 / 4

2 / 42 / 4

2 / 4

3333

---- 49

49 49

49 ----

Processes

Job Programing and Editing

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Step 1:

Step 1:Step 1:

Step 1: Remove gas nozzle from torch and retract wire so

that no wire inside the tip.

Step 2:

Step 2:Step 2:

Step 2: Firmly touch the contact tip as close to the welding

point as possible. If the work-piece is not
available, use a bare part of the fixture instead.

Step 3:

Step 3:Step 3:

Step 3: On the front panel, press the store button (A⁄ and

the process select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

Step 4:

Step 4:Step 4:

Step 4: Use the process select up arrow (B⁄ to cycle

through the parameters until 2nd appears on the
display.

Step 5:

Step 5:Step 5:

Step 5: On the front panel, press the store button (A⁄ and

the process select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

AAAA

BBBB

CCCC

---- 50

50 50

50 ----

Processes

Resistance Test

Step 6:

Step 6:Step 6:

Step 6: Use the process select up arrow to cycle through

the parameters until r appears in the display.

Step 7:

Step 7:Step 7:

Step 7: Ensure that no one is touching any part of the

welding circuit.

Step 8:

Step 8:Step 8:

Step 8: Press the wire feed button (C⁄ on the front panel,

the trigger on the torch, or the arc-on command
through the robot to activate the test.

Step 9:

Step 9:Step 9:

Step 9: Display value should change to a new number.

Repeat this process three times.

Step 10:

Step 10:Step 10:

Step 10: Press the Store button (A⁄ twice to return to main

menu.

Error Codes

Error CodesError Codes

Error Codes

r E30

r E30 r E30

r E30  There is an open measurement in the welding

circuit

r E31

r E31 r E31

r E31  Calibration procedure was interrupted by a

repeated pressing of the start button (wire feed,
torch trigger, etc.⁄ before test is finished.

r E32

r E32 r E32

r E32  Measured value is too low (.5 m⁄ or too high (30

m⁄.

r E33

r E33 r E33

r E33  Poor contact between the contact tip and the

work-piece.

r E34

r E34 r E34

r E34  Poor contact between the contact tip and the

work-piece.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Processes

Push Pull Alignment

Step 1:

Step 1:Step 1:

Step 1: On the front panel, press the Store button (A⁄ and

the Process Select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

Step 2:

Step 2:Step 2:

Step 2: Use the Process Select up arrow (B⁄ to cycle

through the parameters until 2nd appears on the
display.

Step 3:

Step 3:Step 3:

Step 3: On the front panel, press the Store button (A⁄ and

the Process Select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

Step 4:

Step 4:Step 4:

Step 4: Use the process select up arrow (B⁄ to cycle

through the parameters until PPU appears in the
display.

Step 5

Step 5Step 5

Step 5: Use the red selection knob (C⁄ to select the PPU

number that corresponds to the torch being used.

AAAA

B

DDDD

CCCC

Step 6:

Step 6:Step 6:

Step 6: Press the torch trigger or the wire feed button (D⁄

on the front panel. The display should change to
St.1.

Step 7:

Step 7:Step 7:

Step 7: Open all drive rolls on the wire feeder and torch.

Step 8:

Step 8:Step 8:

Step 8: Press the torch trigger or the wire feed button (D⁄

again. The display should change to St. 1 run
and the drive rolls in the torch and gun should
both run.

Step 9:

Step 9:Step 9:

Step 9: When the test is finished, the display will read St.

2. Ensure there is wire loaded and close the
drive rolls on the wire feeder and torch.

Step 10:

Step 10:Step 10:

Step 10: Press the torch trigger or wire feed button (D⁄ on

the front panel. Depending on the PPU number,
the display with either immediately change to
PPU # or run both sets of drive rolls (and wire⁄.
Once finished, it will then display PPU #.

Step 11:

Step 11:Step 11:

Step 11: Press the Store button (A⁄ twice to return to main

menu.

Step 12:

Step 12:Step 12:

Step 12: Once finished, press the Store button (A⁄ twice,

cut off the excess wire and dispose of it.

Note: when using a standard torch with a CMT wire
feeder, select PPU 0 and press the wire feed button. You
can then set up the torch as normal.

---- 51

51 51

51 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

PPU Number for Push Pull Torch

PPU Number for Push Pull TorchPPU Number for Push Pull Torch

PPU Number for Push Pull Torch

PPU 2

PPU 2 PPU 2

PPU 2  Fronius KD Drive push-pull

PPU 3

PPU 3 PPU 3

PPU 3  Fronius Robacta Drive, master (3.5m or more⁄

PPU 4

PPU 4 PPU 4

PPU 4  Fronius Robacta Drive, slave (less than 3.5m⁄

PPU 5

PPU 5 PPU 5

PPU 5  Fronius PullMig, with potentiometer

PPU 6

PPU 6 PPU 6

PPU 6  Fronius PullMig, without potentiometer

PPU 16

PPU 16 PPU 16

PPU 16  MK Cobra Gold

PPU 26

PPU 26 PPU 26

PPU 26  MK Python

PPU 28

PPU 28 PPU 28

PPU 28  Fronius CMT PullMIG, with potentiometer

PPU 29

PPU 29 PPU 29

PPU 29  Fronius CMT PullMIG, without potentiometer

PPU 50

PPU 50 PPU 50

PPU 50  Fronius PT Drive, .030 aluminum

PPU 51

PPU 51 PPU 51

PPU 51  Fronius PT Drive, .040 aluminum

PPU 52

PPU 52 PPU 52

PPU 52  Fronius PT Drive, .045 aluminum

PPU 53

PPU 53 PPU 53

PPU 53  Fronius PT Drive, 1/16 aluminum

PPU 59

PPU 59 PPU 59

PPU 59  Fronius PT Drive, .040 steel

PPU 60

PPU 60 PPU 60

PPU 60  Fronius PT Drive, .045 steel

PPU 61

PPU 61 PPU 61

PPU 61  Fronius PT Drive, .030 steel

Processes

PPU - Additional Information

PPU Error Codes

PPU Error Codes PPU Error Codes

PPU Error Codes

Err Eto  Incorrect measurement during PPU alignment

St1 E1  No feedback from wire-feeder motor at min speed

St1 E2  No feedback from wire-feeder motor at max speed

St1 E3  No feedback from wire-feeder motor at min speed

St1 E4  No feedback from torch motor at min speed

St1 E5  No feedback from wire-feeder motor at max speed

St1 E6  No feedback from torch motor at max speed

St1 E16  PPU alignment interrupted by torch trigger press

St2 E7  PPU open drive roll has not been accomplished

St2 E8  No feedback from wire-feeder motor at min speed

St2 E9  No feedback from torch motor at min speed

St2 E10  Wire-feeder motor current out of range at min speed

St2 E11  Torch motor current out of range at min speed

St2 E12  No speed value from wire-feeder at max speed

St2 E13  No speed value from torch motor at max speed

St2 E14  Wire-feeder motor current out of range at min speed

St2 E15  Torch motor current out of range at max speed

St2 E16  PPU alignment interrupted by torch trigger press

---- 52

52 52

52 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

---- 53

53 53

53 ----

Processes

Functional Tests

Step 5:

Step 5:Step 5:

Step 5: Use the red selection knob (C⁄ to select from one

of three options

ON

ON ON

ON  Turns the cooler on as soon as the welder
powers up.

OFF

OFF OFF

OFF  Turns the cooler off and disables flow­monitoring

Auto

Auto Auto

Auto  Turns the cooler on during welding and for 2
minutes after welding stops.

Step 6:

Step 6:Step 6:

Step 6: Use the process select up arrow (B⁄ to cycle

through parameters until C-T appears in the
display.

Step 7:

Step 7:Step 7:

Step 7: Use red selection knob (C⁄ to select the amount of

time before flow sensor shuts the welding process
down. If unsure, set to ten.

Step 8:

Step 8:Step 8:

Step 8: Press the Store button (A⁄ twice to return to main

display.

Cooler Verification

Cooler VerificationCooler Verification

Cooler Verification

Step 1:

Step 1:Step 1:

Step 1: On the front panel, press the Store button (A⁄ and

the Process Select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

Step 2:

Step 2:Step 2:

Step 2: Use the Process Select up arrow (B⁄ to cycle

through the parameters until 2nd appears on the
display.

Step 3:

Step 3:Step 3:

Step 3: On the front panel, press the Store button (A⁄ and

the Process Select up arrow (B⁄ at the same time.
Once the display changes, release both buttons.

Step 4:

Step 4:Step 4:

Step 4: Use the process select up arrow (B⁄ to cycle

through the parameters until C-C appears in the
display.

AAAA

B

DDDD

CCCC

Note: the flow switch will only shut the system down after
the first weld has been done. When initially turned on, the
flow sensor is ignored.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Processes

Functional Tests

Step 1:

Step 1:Step 1:

Step 1: Press the Parameter Selection button (A⁄ until the

main motor indicator (B⁄ is lit.

Step 2:

Step 2:Step 2:

Step 2: First test the motor without load by opening up the

drive rolls on the wire feeder

Step 3:

Step 3:Step 3:

Step 3: Press the Wire Feed button (C⁄ and check the left

most display (D⁄. It should be ~.7 amps (+/- 1
amp⁄.

Step 4:

Step 4:Step 4:

Step 4: Check the motor under load by closing the drive

rolls on the wire feeder

Step 5:

Step 5:Step 5:

Step 5: Press the Wire Feed button (C⁄ and check the left

most display (D⁄. It should be ~1.0 amps. (+/­20%⁄

AAAA

BBBB

CCCC

DDDD

Step 1:

Step 1:Step 1:

Step 1: Press the Parameter Selection button (A⁄ until the

voltage indicator (B⁄ is lit.

Step 2:

Step 2:Step 2:

Step 2: Disconnect the ground connection from the front of

the power supply.

Step 3:

Step 3:Step 3:

Step 3: Press the process select button (C⁄ until the Stick

indicator (D⁄ lights up.

Step 4:

Step 4:Step 4:

Step 4: The right most display (E⁄ should indicate 40V

within one minute.

Step 5:

Step 5:Step 5:

Step 5: Press the process select button (C⁄ until the

process changes to something other than TIG or
Stick.

AAAA

BBBB

CCCC

EEEE

Motor Draw Test

Motor Draw TestMotor Draw Test

Motor Draw Test

Output

Output Output

Output Voltage

VoltageVoltage

Voltage Test

TestTest

Test

DDDD

---- 54

54 54

54 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Use and Operation

TsT Parameter Reference (MIG)

---- 55

55 55

55 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Use and Operation

TsT Parameter Reference (Stick)

---- 56

56 56

56 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

3333----digit Display (

digit Display (digit Display (

digit Display (

Amperage

⁄⁄⁄⁄

This value will increase as the wire
feed speed increases

3333----digit Display (

digit Display (digit Display (

digit Display (

Voltage

⁄⁄⁄⁄

This value will display the voltage
dialed into the machine.

Hold Indicator

Hold IndicatorHold Indicator

Hold Indicator

This indicator will light up after a weld has been completed and the
3-digit displays will show the last values used during welding. When
welding starts up again or the values are changed, this indicator will
go out.

Inductance Controls and Indicators

Inductance Controls and IndicatorsInductance Controls and Indicators

Inductance Controls and Indicators

This is used to control and display the
inductance for the welding machine.

The buttons increase and
decreased the inductance
to the desired value.

The value is then
displayed as a
representation with one
bar being the minimum
value and 7 bars being
the maximum.

Control Knob (

Control Knob (Control Knob (

Control Knob (

Voltage

⁄⁄⁄⁄

This control will vary the voltage
the machine is set for and will
directly change the value
displayed on the 3-digit display.

Process Control and Indicators

Process Control and IndicatorsProcess Control and Indicators

Process Control and Indicators

The button switches between the
machines processes.

The indicator displays the process the
machine is currently set up for.

Control Knob (

Control Knob (Control Knob (

Control Knob (

Wire Feed Speed

⁄⁄⁄⁄

This control will vary the wire feed
speed the machine is set for. The
value corresponds with the
numbers around the dial and will
increase or decrease the current
value displayed on the 3-digit
display. .

Trigger Control and Indicators

Trigger Control and IndicatorsTrigger Control and Indicators

Trigger Control and Indicators

The button switches between the two trigger options, 2-step (2T⁄ and
4-step (4T⁄.

2222----step:

step:step:

step: Press and hold torch trigger to start the arc. Release trigger

to stop the arc.

4444----step:

step:step:

step: Press and release trigger to start the arc, press and release

trigger to stop the arc.

Use and Operation

Front Panel – (TsT - Manual)

---- 57

57 57

57 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Weld Power Controls and Indicators

Weld Power Controls and IndicatorsWeld Power Controls and Indicators

Weld Power Controls and Indicators

These controls and indicators are used to
display and change the weld power values.

The three segment display will show
the value of the power indicator lit
below.

The button control switches between
the three power values.

Material Thickness:

Material Thickness: Material Thickness:

Material Thickness: The display will
show the sheet thickness of the
material to be welded to. This value
is adjustable in synergic mode only.

Welding Current:

Welding Current: Welding Current:

Welding Current: The display will
show the value of the welding
current that will be welded with. This
value is adjustable in any process.

Wire

WireWire

Wire----Feed Speed:

Feed Speed:Feed Speed:

Feed Speed: The display will
show the value of the feed speed
that will be welded with.

Control Knob (

Control Knob (Control Knob (

Control Knob (

power

⁄:

⁄:⁄:

⁄: This will
control the value on the 3-digit
display.

Please note that the three power values
(material thickness, welding current, and wire­feed speed⁄ are linked to one another in
synergic mode.

Weld Adjustment Controls and Indicators

Weld Adjustment Controls and IndicatorsWeld Adjustment Controls and Indicators

Weld Adjustment Controls and Indicators

These controls and indicators are used to
display and change the weld adjustment
values.

The three segment display will show
the value of the adjustment indicator
lit below.

The button control switches between
the three adjustment values.

Arc Length Correction:

Arc Length Correction: Arc Length Correction:

Arc Length Correction: The display
will show the current arc length
correction set into the machine.
Note that this value is NOT available
in manual mode.

Welding Voltage:

Welding Voltage: Welding Voltage:

Welding Voltage: The display will
show the welding voltage currently
set in the machine. Note that this is
only adjustable in manual mode.

Dynamic Correction:

Dynamic Correction:Dynamic Correction:

Dynamic Correction: The display will
show the value of the current
dynamic set in the machine.

Control Knob (

Control Knob (Control Knob (

Control Knob (

adjustment

⁄:

⁄:⁄:

⁄: This will
control the value on the 3-digit
display.

Globular Transfer Mode

Globular Transfer ModeGlobular Transfer Mode

Globular Transfer Mode

This indicator will light when the
settings on the synergic line will result
in globular arc.

Hold Indicator

Hold IndicatorHold Indicator

Hold Indicator

This indicator will light up after a weld has been
completed and the 3-digit displays will show the last
values used during welding. When welding starts up
again or the values are changed, this indicator will go out.

Use and Operation

Front Panel – (TsT - Synergic)

---- 58

58 58

58 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Process Control and Indicators

Process Control and IndicatorsProcess Control and Indicators

Process Control and Indicators

The button switches between the
machines processes.

Manual Mode:

Manual Mode:Manual Mode:

Manual Mode: Welding will occur
using with no link between wire­feed speed and voltage.

Synergic Mode:

Synergic Mode:Synergic Mode:

Synergic Mode: Welding will occur
using one of several synergic lines
that establishes a link between
current, wire-feed speed, and
voltage.

Stick Mode:

Stick Mode:Stick Mode:

Stick Mode: This mode is for
welding using the MMA process.

Trigger Control and Indicators

Trigger Control and IndicatorsTrigger Control and Indicators

Trigger Control and Indicators

The button switches between the
three trigger options, 2-step (2T⁄,
4-step (4T⁄, and special 4-step
(S4T⁄

2222----step:

step:step:

step: Press and hold torch
trigger to start the arc. Release
trigger to stop the arc.

4444----step:

step:step:

step: Press and release trigger
to start the arc, press and release
trigger to stop the arc.

Special 4

Special 4Special 4

Special 4----step:

step:step:

step: Press and hold the
trigger to begin welding at the
starting value, release trigger to
change to normal power value,
press and hold for ending power
value, and finally release trigger to
stop the weld.

Operating Point Save/Selection Buttons

Operating Point Save/Selection ButtonsOperating Point Save/Selection Buttons

Operating Point Save/Selection Buttons

These buttons are used to save and recall weld
settings stored in memory by the user.

Filler Metal Selection and

Filler Metal Selection and Filler Metal Selection and

Filler Metal Selection and
Indicator

IndicatorIndicator

Indicator

The button is used to cycle
through the different filler metal
types available. The finals SP
selection is designed for
customized synergic selections.

Wire Diameter Selection and

Wire Diameter Selection and Wire Diameter Selection and

Wire Diameter Selection and
Indicator

IndicatorIndicator

Indicator

The button is used to cycle
through the different wire
diameters available. The finals
SP selection is designed for
customized synergic selections.

Shield Gas Selection and

Shield Gas Selection and Shield Gas Selection and

Shield Gas Selection and
Indicator

IndicatorIndicator

Indicator

The button is used to cycle
through the different shielding gas
types available. The finals SP
selection is designed for
customized synergic selections.

Use and Operation

Front Panel – (TsT - Synergic)

---- 60

60 60

60 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Standard T Rolls

Standard T RollsStandard T Rolls

Standard T Rolls

Tension ~ 2

Standard drive rolls for steel and stainless wire
when working through single shift operations.

Three points of contact on the wire (red dots⁄

Standard H Rolls

Standard H RollsStandard H Rolls

Standard H Rolls

Tension ~ 1.5 to 2

Standard drive rolls for aluminum and CuSi wire
when working through single shift operations.

Two points of contact on the wire (red dots⁄

Knurled K

Knurled KKnurled K

Knurled K Rolls

 Rolls Rolls

 Rolls

Tension ~ 2 to 3

Ridged drive rolls for flux and solid-cored wire.
One style for single or multiple shift operations.

Four points of contact on the wire (red dots⁄

Professional U Rolls

Professional U RollsProfessional U Rolls

Professional U Rolls

Tension ~ 2.5 to 3

Heavy duty drive rolls for steel and stainless wire
when working through multiple shift operations.
These are designed to last much longer than the
standard rolls.

Four points of contact on the wire (red dots⁄

Professional H Rolls

Professional H RollsProfessional H Rolls

Professional H Rolls

Tension ~ 1.5 to 2

Heavy duty drive rolls for aluminum and CuSi
wire when working through multiple shift
operations. These are designed to last much
longer than the standard rolls.

Two points of contact on the wire (red dots⁄

Synthetic Rolls

Synthetic RollsSynthetic Rolls

Synthetic Rolls

Tension ~ 3

Specialized drive rolls for soft aluminum or
special care wire. Tend to wear out quickly
and must be replaced regularly.

Total point of contact on the wire (red dots⁄

Please note that drive rolls are wire diameter specific and the wires

Please note that drive rolls are wire diameter specific and the wires Please note that drive rolls are wire diameter specific and the wires

Please note that drive rolls are wire diameter specific and the wires

mentioned above are suggestions based on past experience.

mentioned above are suggestions based on past experience. mentioned above are suggestions based on past experience.

mentioned above are suggestions based on past experience.

Consumables

---- 61

61 61

61 ----

Drive Rolls

13 SEP 12

Consumables

Liners

Teflon

TeflonTeflon

Teflon

 Teflon is a specialty liner that is used when precise wire feed is needed or

for high heat applications that would typically melt graphite liners.

Graphite

GraphiteGraphite

Graphite

 Graphite liners are used for aluminum and other wires that are susceptible

to marring or damage from the liner.

Graphite

Graphite Graphite

Graphite ---- Combi

CombiCombi

Combi

 Combi liners are graphite liners with a brass end. The brass is used in the

contact tip end for withstanding higher heat applications with malleable
wire.

Bare Steel

Bare SteelBare Steel

Bare Steel

 Standard for steel and metal core/flux core wires with a water-cooled torch.

Insulated Steel

Insulated SteelInsulated Steel

Insulated Steel

 This is the standard steel liner for gas cooled, steel applications.

---- 62

62 62

62 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Quality (

Quality (Quality (

Quality (

standard or high

⁄⁄⁄⁄

This trait refers to the tolerance of
the wire diameter the tip is designed
for. Standard

StandardStandard

Standard quality tips have a

much looser tolerance than High

High High

High

Quality

QualityQuality

Quality tips. High Quality

High QualityHigh Quality

High Quality tips wear

at a slower rate than Standard

StandardStandard

Standard

quality tips.

Thread Size (

Thread Size (Thread Size (

Thread Size (

M6, M8, and M10

⁄⁄⁄⁄

This trait refers to the size of the
threads the contact tip will screw
into. M8 and M10 are typical sizes
for most MIG applications.

Wire Size (

Wire Size (Wire Size (

Wire Size (

see below

⁄⁄⁄⁄

The wire size refers to the diameter
of the wire the tip is designed for.
This size can be either standard
(US⁄ or metric (EU⁄. Basic sizes
used in the US are

Fraction

FractionFraction

Fraction Standard

StandardStandard

Standard Metric

MetricMetric

Metric

- - - .035 .9

3/64 .045 1.2

1/16 .062 1.6

Bore Size (

Bore Size (Bore Size (

Bore Size (

none, Center-Bore

⁄⁄⁄⁄

This trait refers to how the inner
linger fits into the contact tip. This
is critical with Aluminum wire
especially.

None

NoneNone

None: There is no center bore,
the contact tip end is cone
shaped to guide the wire through
the tip.

Center Bore (

Center Bore (Center Bore (

Center Bore (CB⁄⁄⁄⁄: The contact tip
is squared off internally (see
figure 2⁄ and will come in one of
two sizes (4.1mm or 4.8mm⁄
depending on the size of the
inner liner.

CB tips are required for aluminum
welding. This type of tip allows
the liner to be exactly centered in
the tip.

Figure 2: no bore versus center-bore

1111

2222

3333

1111

2222

3333

Consumables

Contact Tips

---- 63

63 63

63 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Fixing

Sleeve

Nozzle

Stock

Spatter

Guard

Contact

Tip

Gas

Nozzle

Guide Nozzle

(if used⁄

Clamping

Nut

Clamping

Lock

Insulating

Ring

(if used⁄

Teflon Liner

Combi Liner

Steel Liner

---- 64

64 64

64 ----

Torch Breakdown – No Drive

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Fixing

Sleeve

Nozzle

Stock

Spatter

Guard

Contact

Tip

Gas

Nozzle

Guide Nozzle

(if used⁄

Clamping

Nut

Clamping

Lock

Insulating

Ring

(if used⁄

Teflon Insert/Liner

Combi Insert/Liner

Steel Insert/Liner

Ceramic Insert/Liner

Brass Insert/Liner

Teflon Liner

Graphite Liner

Steel Liner

or

Guide

Nozzle

2-piece

Drive Roll

1-piece

Drive Roll

2-piece Drive

Roll (keyed⁄

1-piece Drive

Roll (keyed⁄

Torch Breakdown – Whip Drive

---- 65

65 65

65 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Fixing

Sleeve

Nozzle

Stock

Spatter

Guard

Contact

Tip

Gas

Nozzle

Guide Nozzle

(if used⁄

Clamping

Nut

Clamping

Lock

Insulating

Ring

(if used⁄

Teflon Insert/Liner

Combi Insert/Liner

Steel Insert/Liner

Ceramic Insert/Liner

Brass Insert/Liner

Teflon Liner

Graphite Liner

Steel Liner

1-piece

Drive Roll

1-piece Drive

Roll (keyed⁄

Teflon Liner

Teflon Insert/Liner

Torch Breakdown - CMT

---- 66

66 66

66 ----

13 SEP 12

Consumables

Liner Installation Procedure

1 - Whips should be laid out straight prior to installation
2 - Be sure liner is fully inserted in the whip and remove all of the free play.
3 - Cut liner flush with the diffuser and remove any burrs present after cutting.
4 - Contact tip should apply pressure against the inner liner as it is threaded into the diffuser.

1.

2. 3.

Graphite/Teflon Liner Tools

---- 67

67 67

67 ----

13 SEP 12

Consumables

Liner Installation Procedure

Feeder End of Torch

Fully insert inner liner

Cut liner flush

Install clamp nut

install wire guide

---- 68

68 68

68 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Feeder and Cooler

TS/TPS/KD Standard – Steel (T-groove)

42,0001,1732 Pressure Roll, smooth
42,0001,3275 Feeder Roll, .035 (.9)
42,0001,1361 Feeder Roll, .045 (1.2)
42,0001,3570 Feeder Roll, .052 (1.4)
42,0001,1362 Feeder Roll, 1/16 (1.6)

TsT Standard – Steel (U-groove)

44,0001,1406 Feeder Roll, .035 (.9)
44,0001,1407 Feeder Roll, .045 (1.2)
44,0001,1408 Feeder Roll, .052 (1.4)
44,0001,1408 Feeder Roll, 1/16 (1.6)

TsT Flux-cored (R-groove)

44,0001,1431 Feeder Roll, .045 (1.2)
44,0001,1432 Feeder Roll, .052 (1.4)
44,0001,1433 Feeder Roll, 1/16 (1.6)

TS/TPS/KD Standard – Aluminum (H-groove)

42,0001,1613 Feeder Roll, .035 (.9)
42,0001,0385 Feeder Roll, .045 (1.2)
42,0001,3053 Feeder Roll, .052 (1.4)
42,0001,0386 Feeder Roll, 1/16 (1.6)

TS/TPS/KD Flux-cored (K-groove)

42,0001,0404 Feeder Roll, .045 (1.2)
42,0001,0352 Feeder Roll, 1/16 (1.6)

TS/TPS/KD Heavy – Steel (U-groove)

44,0001,1376 Feeder Roll, .035 (.9)
44,0001,1378 Feeder Roll, .045 (1.2)
44,0001,1379 Feeder Roll, .052 (1.4)
44,0001,1323 Feeder Roll, 1/16 (1.6)

TS/TPS/KD Heavy Aluminum (H-groove)

44,0001,1185 Feeder Roll, .045 (1.2)
44,0001,1209 Feeder Roll, 1/16 (1.6)

TS/TPS/KD Misc Wire Feeder Consumables

42,0100,0333 Wire Guide Insert, synthetic, .035 - .045
42,0100,0334 Wire Guide Insert, synthetic, .052+
42,0001,3481 Wire Guide Insert, steel
44,0001,1203 Main Drive Roll

Cooler Consumables

40,0009,0046

Coolant, standard, -10° outside

40,0009,0079

Coolant, pipe, up to -50° outside

40,0009,0084 Coolant, indoor

---- 69

69 69

69 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Manual Torch-body Consumables

---- 70

70 70

70 ----

AL 4000 / AW 5000

1

42,0100,1018
42,0100,1016

Insulating Ring, AL 4000

Insulating Ring, AW 5000
2 42,0001,2970 Fixing Sleeve
3 42,0001,5122 Nozzle Stock, M10
4 42,0100,1007 Spatter Guard

5

42,0001,3277
42,0001,1578
42,0001,1930
42,0001,1579

Contact Tip, standard, .035 (.9)

Contact Tip, standard, .045 (1.2)

Contact Tip, standard, .056 (1.4)

Contact Tip, standard, 1/16 (1.6)

5

42,0001,5405
42,0001,3592
42,0001,5059
42,0001,5060

Contact Tip, center-bore (CB), .035 (.9)

Contact Tip, center-bore (CB), .045 (1.2)

Contact Tip, center-bore (CB), .056 (1.4)

Contact Tip, center-bore (CB), 1/16 (1.6)
6 42,0001,5128 Gas Nozzle, standard

AL 5000

1 42,0100,1205 Insulating Ring, AL 5000
2 42,0100,0312 Insulating Sleeve
3 42,0001,5912 Nozzle Stock, M10

4

42,0001,3277
42,0001,1578
42,0001,1930
42,0001,1579

Contact Tip, standard, .035 (.9)
Contact Tip, standard, .045 (1.2)
Contact Tip, standard, .056 (1.4)
Contact Tip, standard, 1/16 (1.6)

4

42,0001,5405
42,0001,3592
42,0001,5059
42,0001,5060

Contact Tip, center-bore (CB), .035 (.9)
Contact Tip, center-bore (CB), .045 (1.2)
Contact Tip, center-bore (CB), .056 (1.4)
Contact Tip, center-bore (CB), 1/16 (1.6)

5 42,0001,5652 Gas Nozzle, standard

d1 d2 d3 L

..669” (17mm) .984” (25mm) n/a 3.110” (79mm)

d1 d2 d3 L

.709” (18mm) 1.063” (27mm) n/a 3.031” (77mm)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Manual Torch-body Consumables

---- 71

71 71

71 ----

AL 3000 / AW 4000

1

42,0100,1014
42,0100,1010

Insulating Ring, AL 3000

Insulating Ring, AW 4000
2 42,0001,2930 Fixing Sleeve
3 42,0001,5084 Nozzle Stock, M8

4

42,0001,3082
42,0001,2913

Contact Tip, standard, .035 (.9)

Contact Tip, standard, .045 (1.2)

4

42,0001,3653
42,0001,5052
42,0001,5053
42,0001,3485

Contact Tip, center-bore (CB), .035 (.9)

Contact Tip, center-bore (CB), .045 (1.2)

Contact Tip, center-bore (CB), .056 (1.4)

Contact Tip, center-bore (CB), 1/16 (1.6)
5 42,0001,5096 Gas Nozzle, standard

MTG 5300 S

1 42,0100,1205 Insulating Ring, MTG 5300
2 42,0100,0312 Nozzle Stock, M8

3

42,0001,3889
42,0001,3891
42,0001,3892
42,0001,3893

Contact Tip, sharp, .035 (.9)
Contact Tip, sharp, .045 (1.2)
Contact Tip, sharp, .056 (1.4)
Contact Tip, sharp, 1/16 (1.6)

4 44,0350,3180 Gas Nozzle, standard

d1 d2 d3 L

.679” (13mm) .984” (22mm) .669” (17mm) 2.637” (67mm)

d1 d2 d3 L

.709” (18mm) 1.063” (27mm) n/a 3.465” (88mm)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Robotic Torch-body Consumables

---- 72

72 72

72 ----

MTG 4000

1 44,0350,2616 Gas Nozzle Holder, twist-lock
2 42,0100,0510 Insulating Ring, MTG 4000
3 42,0001,5528 Nozzle Stock, M10

4

42,0001,3277
42,0001,1578
42,0001,1930
42,0001,1579

Contact Tip, standard, .035 (.9)

Contact Tip, standard, .045 (1.2)

Contact Tip, standard, .056 (1.4)

Contact Tip, standard, 1/16 (1.6)

4

42,0001,5405
42,0001,3592
42,0001,5059
42,0001,5060

Contact Tip, center-bore (CB), .035 (.9)

Contact Tip, center-bore (CB), .045 (1.2)

Contact Tip, center-bore (CB), .056 (1.4)

Contact Tip, center-bore (CB), 1/16 (1.6)
5 42,0001,5532 Gas Nozzle, standard

Robacta 5000

1 42,0001,2970 Fixing Sleeve
2 42,0100,1016 Insulating Ring, Robacta 5000
3 42,0001,5122 Nozzle Stock, M10
4 42,0100,1007 Spatter Guard

5

42,0001,3277
42,0001,1578
42,0001,1930
42,0001,1579

Contact Tip, standard, .035 (.9)
Contact Tip, standard, .045 (1.2)
Contact Tip, standard, .056 (1.4)
Contact Tip, standard, 1/16 (1.6)

5

42,0001,5405
42,0001,3592
42,0001,5059
42,0001,5060

Contact Tip, center-bore (CB), .035 (.9)
Contact Tip, center-bore (CB), .045 (1.2)
Contact Tip, center-bore (CB), .056 (1.4)
Contact Tip, center-bore (CB), 1/16 (1.6)

6 42,0001,5128 Gas Nozzle, standard

d1 D2 d3 L

.669” (17mm) 1.063” (27mm) .827” (21mm) 2.874” (73mm)

d1 d2 d3 L

.669” (17mm) .984” (25mm) .787” (20mm) 3.110” (79mm)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Torch Drive Consumables

---- 73

73 73

73 ----

PullMig

1 42,0001,6210 Wire Inlet Guide, PullMig

2

42,0100,1114
42,0100,1121

Intake Nozzle, .045 (1.2)
Intake Nozzle, 1/16 (1.6)

3

42,0001,0456
42,0001,0457

Pressure Roll, .035 - .045 (.9 – 1.2)
Pressure Roll, 1/16 (1.6)

4

42,0001,0452
42,0001,0453

Driver Roll, .035 - .045 (.9 – 1.2)
Driver Roll, 1/16 (1.6)

5

42,0100,1003
42,0100,1008

Guide Nozzle, .045 (1.2)
Guide Nozzle, 1/16 (1.6)

6

44,0350,1788
44,0350,1798

Torch Body Insert, combi, .045 (1.2)
Torch Body Insert, combi, 1/16 (1.6)

7

44,0350,1806
44,0350,1838

Torch-body Insert, ceramic, .045 (1.2)
Torch-body Insert, ceramic, 1/16 (1.2)

Pre-cut Liners, F++

42,0300,0343 Inner Liner, graphite, 1/16 (1.6), 19.7ft (6m)
42,0300,0344 Inner Liner, graphite, 1/16 (1.6), 26.2ft (8m)
42,0300,0345 Inner Liner, graphite, 1/16 (1.6), 32.8ft (10m)

Inner Liner, bulk (ordered by the meter)

40,0002,0002 Inner Liner, steel, .045 (1.2)
40,0002,0004 Inner Liner, steel, 1/16 (1.6)
40,0001,0074 Inner Liner, graphite, .045 (1.2)
40,0001,0054 Inner Liner, graphite, 1/16 (1.6)
40,0001,0415 Inner Liner, teflon, .045 (1.2)
40,0001,0416 Inner Liner, teflon, 1/16 (1.6)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Torch Drive Consumables

---- 74

74 74

74 ----

Robacta Drive

1

42,0100,1003
42,0100,1008

Guide Nozzle, .045 (1.2)
Guide Nozzle, 1/16 (1.6)

2

42,0403,0143
42,0403,0147
42,0403,0149
42,0403,0151

Pressure Roll, .035 (.9)
Pressure Roll, .045 (1.2)
Pressure Roll, .056 (1.4)
Pressure Roll, 1/16 (1.6)

3

42,0403,0144
42,0403,0148
42,0403,0150
42,0403,0152

Driver Roll, slot, .035 (.9)
Driver Roll, slot, .045 (1.2)
Driver Roll, slot, .056 (1.4)

Driver Roll, slot, 1/16 (1.6)
4 42,0400,1024 Clamping Nut, threaded
5 42,0001,5412 Clamping Piece

6

44,0350,1788
44,0350,1798

Torch Body Insert, combi, .045 (1.2)

Torch Body Insert, combi, 1/16 (1.6)

7

44,0350,1806
44,0350,1838

Torch-body Insert, ceramic, .045 (1.2)

Torch-body Insert, ceramic, 1/16 (1.2)

Basic Kit

44,0350,2006 Basic Kit, .035 (.9)
44,0350,2008 Basic Kit, .045 (1.2)
44,0350,2009 Basic Kit, 1/16 (1.6)

Basic kits include items 1-6 and graphite liner.

Inner Liner, bulk (ordered by the meter)

40,0002,0002 Inner Liner, steel, .045 (1.2)
40,0002,0004 Inner Liner, steel, 1/16 (1.6)
40,0001,0074 Inner Liner, graphite, .045 (1.2)
40,0001,0054 Inner Liner, graphite, 1/16 (1.6)
40,0001,0415 Inner Liner, teflon, .045 (1.2)
40,0001,0416 Inner Liner, teflon, 1/16 (1.6)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Consumables

Torch Drive Consumables

---- 75

75 75

75 ----

CMT Robacta - PullMig

1

42,0100,1003
42,0100,1008

Guide Nozzle, .045 (1.2)

Guide Nozzle, 1/16 (1.6)

2

42,0001,5774
42,0001,5735
42,0001,5736

Pressure Roll, .035 (.9)

Pressure Roll, .045 (1.2)

Pressure Roll, 1/16 (1.6)

3

42,0001,5772
42,0001,5730
42,0001,5729

Driver Roll, slot, .035 (.9)

Driver Roll, slot, .045 (1.2)

Driver Roll, slot, 1/16 (1.6)
4 42,0400,1024 Clamping Nut, threaded
5 42,0001,5412 Clamping Piece

6

44,0350,2444
42,0404,1012

Wire Buffer Insert, .045 (1.2)

Wire Buffer Insert, 1/16 (1.6)

7

44,0350,1788
44,0350,1798

Torch Body Insert, combi, .045 (1.2)

Torch Body Insert, combi, 1/16 (1.6)

8

44,0350,1806
44,0350,1838

Torch-body Insert, ceramic, .045 (1.2)

Torch-body Insert, ceramic, 1/16 (1.2)

Basic Kit

44,0350,2399 Basic Kit, aluminum, .035 (.9)
44,0350,2383 Basic Kit, aluminum, .045 (1.2)
44,0350,2384 Basic Kit, aluminum, 1/16 (1.6)
44,0350,2401 Basic Kit, steel, .035 (.9)
44,0350,2391 Basic Kit, steel, .045 (1.2)

Basic kits include items 1-6 and graphite liner.

Inner Liner, bulk (ordered by the meter)

40,0002,0002 Inner Liner, steel, .045 (1.2)
40,0002,0004 Inner Liner, steel, 1/16 (1.6)
40,0001,0074 Inner Liner, graphite, .045 (1.2)
40,0001,0054 Inner Liner, graphite, 1/16 (1.6)
40,0001,0415 Inner Liner, teflon, .045 (1.2)
40,0001,0416 Inner Liner, teflon, 1/16 (1.6)

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Interface

Ethernet (Ethernet IP, WeldCOm)

 Each interface signal is converted to a TCP/IP protocol and digitally transferred between the

weldign power supply and the automation controller.

 A single bit is used for on/off based interface signals
 Multiple bits are put together for form a binary value for variable signals.
 The bit-map can be changed (though time-consuming and expensive⁄
 Offers the most versatile and capable of all interfaces.

Models

Discrete I/O (Rob 3000, 4000, 5000, 5000 OC)

 Each interface signal is indivually wired into the robot/automation controller
 Source/sync signal for on/off based interface signals
 0-10 VDC analog signal for variable signals
 No modification or changes are possible with the signal set.

---- 76

76 76

76 ----

Fieldbus (DeviceNet, Profibus, CANbus)

 Each interface signal is converted to a fieldbus protocol and digitally transferred

between the welding power supply and the robot/automation controller

 A single bit is used for on/off based interface signals
 Multiple bits are put together to form a binary value for variable signals.
 No modification or changes are possible with the signal set.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Interface

General Information

• Provide communication between the welding system and an automated controller (PLC, robot,

automation, etc.).

• Connects to the power source through LocalNet

 Power source is a slave to the controller.
 STOP is displayed on the power source until the Robot Ready and the Source Error Reset signal is

initialized.

 An additional LocalNet connect is provided that connects directly to the ROB 5000.
 If no LocalNet connection is available, a passive distributor (4,100,261⁄ may be used.

• Power source functions are controlled through the use of analog command values

 0-10 VDC (or binary equivalent⁄ for welding power and arc length correction.
 Welding programs may be selected on the by the robot/PLC, the power source control panel, or through an

RCU.

• Digital inputs/outputs are galvanically separated (ROB series only):

 From one another,
 From the LocalNet and the welding potential.
 For a maximum voltage difference of 100 V.

---- 77

77 77

77 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Major Digital Inputs (Robot to the Power Source)

Robot Ready: This signal indicated that the robot is communicating, functioning, and ready to weld. This is one of two

signals REQUIRED for any sort of operation or adjustment of the welding system. Without this signal, the power
supply will continuously display “STOP” on the front panel display and send an error code to the robot.

Source Error Reset: This signal is designed to clear any error state the welder is currently in. For proper use, this signal

should be toggled on and then off again. So long as the error is no longer valid, the error will clear and a normal
display will appear on the front panel. Otherwise an error code will be displayed (such as the “STOP” error code).

Arc On: This signal will start the welding process, beginning with pre-welding (gas pre-flow, hot start) and then

automatically moving to the welding process. Once this signal goes low, the post welding process (crater fill and gas
post-flow) will then start automatically.

Welding Mode: This is a combination of three signals joined together to form a single binary number. Each number

corresponds to a specific mode the welding power source can be set to. Some of the major modes are…

Mode 2 - Job: When the welder is in this mode, the welding characteristics are controlled by a schedule

number (0-99) that will link to a set of welding parameters stored on the welding power source. This
mode allows for the maximum capability of the welding process as all activated parameters are usuable.

Mode 3 – Set Up: When the welder is in this mode, the front panel is fully functional and anything can be

programmed in. If welding occurs while the welder is set to this mode, the weld will be based on
whatever is currently programmed into the power source.

Job Number: This is a combination of several bits joined together to form a binary number between 0 and 99. When the

welder is in job mode, this set of bits tells the welder which schedule specifically to use.

Interface

Major Signals

---- 78

78 78

78 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Major Digital Inputs (Robot to the Power Source)

Gas Test: This signal is used to purge gas from the robot controller or through the robot pendant. This can be used as a gas

pre-flow and/or post flow as necessary.

Wire Inching/Retracting: These signals are used to move the wire forward and backward from the robot controller or

through the robot pendant without gas or current flow.

Weld Simulation: When this signal is turned on, the power source will go through the welding process and respond with/to

all the proper inputs/outputs WITHOUT feeding wire, moving gas, or current flow.

Major Analog Inputs (Robot to the Power Source)

Welding Power: This combination of bits will form an analog value that will measure the welders wire feed speed (or current⁄

between 0% and 100% (with 0 being the lowest welding value and 100% being the maximum⁄. This input is only used
when welding in synergic, pulse synergic, or manual mode WITHOUT the use of the Job mode. This can be used
during JOB mode, but the job settings will limit how much it can be adjusted up or down.

Arc Length Correction: This combination of bits will form an alalog value that will measure the welders arc length correction

value between -30 and +30. This value is controllable in any mode though job settings will limit how much this value
can be adjusted.

Pulse or Dynamic Correction: This combination of bits will form an alalog value that will measure the welders arc length

correction value between -5 and +5. This value is controllable in any mode though job settings will limit how
much this value can be adjusted.

Interface

Major Signals

---- 79

79 79

79 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Major Digital Outputs (Power Source to the Robot)

Power Source Ready: This signal is sent to the robot when the power source has established successful communication

AND there are no errors that will interfere with the function of the welder. Note this signal will not be active is a STOP
or E-STOP is displayed on the power source for any reason⁄.

Arc Stable: This signal is sent to the robot once an arc has been started AND that arc is within acceptable parameters as

determined by the welding power source.

Process Active: This signal will go high once the welding process has started (after an Arc On signal⁄ beginning with the

gas pre-flow if set by the welder (note this signal will not go high is the gas is controlled by the robot instead⁄.

Interface

Major Signals

---- 80

80 80

80 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Interface

Major Signals

 Standard Mode: This allows the power source to weld using the synergic mode.

 Pulse-Synergic Mode: This allows the power source to weld using the pulse-synergic mode.

 Job Mode: This allows the power source to weld in job mode using one or more jobs specified by the robot.

 Parameter Selection: Set-up mode for operator to make weld changes. Use caution when in this mode.

 Manual Mode: This allows the power source to be controlled using analog inputs. There are NO job/program options.

 CC/CV Mode: This allows the power source to be operated in a constant current or constant voltage mode.

 TIG Mode: This allows the power source to be operated in TIG mode.

 CMT/Special Process: This allows the power source to weld using CMT or a special process.

Bit 0 (X2:6⁄

Bit 0 (X2:6⁄Bit 0 (X2:6⁄

Bit 0 (X2:6⁄ Bit 1 (X8:1⁄

Bit 1 (X8:1⁄Bit 1 (X8:1⁄

Bit 1 (X8:1⁄ Bit 2 (X8:2⁄

Bit 2 (X8:2⁄Bit 2 (X8:2⁄

Bit 2 (X8:2⁄ Dec

DecDec

Dec Hex

HexHex

Hex

Standard Mode

LOW LOW LOW 0 0

Pulse-Synergic Mode

HIGH LOW LOW 1 1

Job Mode

LOW HIGH LOW 2 2

Parameter Selection (internal mode⁄

HIGH HIGH LOW 3 3

Manual

HIGH HIGH LOW 4 4

CC/CV

HIGH LOW HIGH 5 5

TIG

LOW HIGH HIGH 6 6

CMT/Special Process

HIGH HIGH HIGH 7 7

---- 81

81 81

81 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Interface

Signal Interaction – Job Mode

---- 82

82 82

82 ----

• Regardless of the mode, the welder must see

the Robot Ready and Source Error Reset
signals before it will allow any sort of welding or
selections to occur:

• When using this mode, the welder controls the

entire weld process. The robot will put the
welder in job mode, call out a job number, and
control the weld travel speed. Everything else
is typically handled by the welder itself.

• Robot movement usually based off of the

process active signal.

• This mode allows for the most customization of

the weld and ensures that the timing between
weld factors are smooth, efficient, and quick.

• Adjust the weld parameters is typically done

from the welder or a separate pendant. This is
not true of every interface, however.

• NOTE: The points above are intended as a

general guide. Exceptions can be made as the
application requires.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Interface

Signal Interaction – Program Mode

---- 83

83 83

83 ----

• Regardless of the mode, the welder must see

the Robot Ready and Source Error Reset
signals before it will allow any sort of welding or
selections to occur:

• When using this mode, the robot controls all of

the weld and gas parameters it is capable of
and the travel speed. The welder is only
responsible for creating and controlling the arc.

• Robot movement usually based off of the

process active signal.

• This mode will only have weld parameter

adjustments based on the capability of the
robot interface and almost never as completely
as job mode

• Usually the robot will need to be scaled based

on the synergic line being used. If multiple
lines are being used a separate scale file may
be required.

• NOTE: The points above are intended as a

general guide. Exceptions can be made as the
application requires.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Fronius Xplorer

General Info

The main entry screen gives an overview of the entire
welding network the software is connected to.

This screen can be divided into an unlimited number of
customized locations that can represent factories,
departments, sub-departments, cells, and even individual
welding machines.

A total machine listing is also given that will detail how
many machines are ready , in an error state , have a
warning , or offline . These listings can be clicked on
for a list of specific welders in each category.

Finally, a quick list is available on the side that will display
recently viewed machines and some basic information
including status, name, IP address, and current
connection.

The machine specific screen is made up of several
different tabs. The core software includes the Overview
and Panel tabs. Additional tabs are activated based on
software and hardware additions to the Weld system.

Overview

OverviewOverview

Overview:::: Details the hardware attached to each system
through LocalNet and allows configuration changes.

Panel

PanelPanel

Panel:::: Simulates the front panel of the machine. Will
NOT allow unsafe actions to be activated (wire feed⁄.

Jobs

JobsJobs

Jobs ((((

extra

⁄:

⁄:⁄:

⁄: Allows jobs to be viewed and edited both
online and offline. When offline, the jobs will be updated
when the machine is back online.

Docu

DocuDocu

Docu ((((

extra

⁄:

⁄:⁄:

⁄: Displays weld data once a weld has been

completed.

Logbook

LogbookLogbook

Logbook ((((

extra

⁄:

⁄:⁄:

⁄: Displays changes and errors that occurs

with the machine.

---- 84

84 84

84 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Fronius Xplorer

Fronius XplorerFronius Xplorer

Fronius Xplorer

Overview Tab

This display shows everything that is
currently connected through
LocalNet.

In addition, hardware, firmware, and
database information will be
displayed for each piece of
equipment that is selected (yellow bar
indicated selection⁄.

By using these buttons, Weld Jobs
can be saved to a computer (Backup⁄
or loaded from one (Restore⁄.

As long as the synergic lines exist in
the database loaded into the
machine, any Weld Job set can be
used.

These job sets are NOT compatible
with other Backup/Restore tools.

The license button is used to see which
software options are loaded into the
machine. Unlocked options are displayed
as green locks while locked ones are red
locks. New ones can be loaded in using
the Enter new software code button.

The Options button opens up a
submenu that has several useful
functions including the Show
connection data and Machine
Configuration selections.

Show connection data shows
the IP and connection interface for
any Ethernet card connected to
LocalNet. This option also allows
for these settings to be changed as
needed.

Machine Configuration outputs a
text file that includes all equipment
connected through LocalNet. Serial
numbers, firmware, and hardware
versions are also saved.

---- 85

85 85

85 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Fronius Xplorer

Job and Docu Tab

The Job tab give a quick view of jobs
loaded into the welder, the weld
parameters for these jobs, and any
changes that have been made recently.

Group and job names can be changed to
reflect the application and/or production
floor.

A job can be copied to one or more
other locations and than customized to
suit the needs of the application.

When a change is made, there is an
option to either accept the change or
undo the change.

Finally, a history of job changes is kept
that can not only be reviewed but also
loaded from should the need arise.

The Docu tab allows you to monitor the

weld parameters of one or more welders
AFTER they have completed a weld.

The parameters can be customized
based on the user desires by right
clicking on the data screen.

Previous data can be viewed by opening
up older files. Each days welding is
stored for future viewing and/or
importing.

The Options button opens up a
submenu that has several useful
functions including the Set
consumption figures and the
Country settings selections.

The Set consumption figures
allows you to set the costs of your
wire, gas and energy as well as
specify the travel speeds used during
the welding process.

The Country settings changes
the unit of measurement between metric
and imperial depending on the needs of the
plant.

- 86

8686

86 -

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Troubleshooting

---- 87

87 87

87 ----

Weld System

• Many factors can effect weld quality and many times the poor quality will come from wear parts rather than weld

settings. However in some cases the weld quality can be effected by the weld settings. This would be the case if the
settings have been adjusted from settings that were known to work for specific process. Also a change in base
materials or parts can make the predetermined settings no longer the best viable settings to produce quality welds.

• When trouble shooting weld quality it is very important to go through a number of checks prior to designating a

certain cause to the problem.

• These checks include:

 Consumables
 Loose Connections
 Settings that differ from pre determined settings
 Torch Quality

 Torch Itself internal/externally or liner itself

 Wire Drive unit

 Damaged or loose connections
 Damage to drive motor or drive rolls
 Firmware

 Hose Pack

 Damage to any connections, hoses or cabling included in the hose pack

 Power Source

 Internal Hardware or Firmware

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Troubleshooting

---- 88

88 88

88 ----

Welder Error Codes

DSP xxx

Error with the Digital Signal Processor – Reload firmware/database or replace UST

EFD xxx

Error with the wire feed system, refer to wire feeder error codes for more details

Err 049, 051, and 052

Error detected in mains power input (phase missing or voltage too low/high). Check mains and then replace NT 24

Err 050

Intermediate circuit imbalance. Further troubleshooting needed

Err IP

Primary transformer over-current detected. Check the secondary power module and the BPS board.

Err PE

Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points.

No H2O

Error with the coolant system, check cooler for operation and system for good flow.

No Prg

Synergic line selected doesn’t exist. Verify synergic line settings, reprogram UST, or replace UST.

STOP

Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.

Tsx xxx and Tpx xxx

Internal temperature errors on the secondary or primary side. Check for duty cycle and proper air flow.

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

 Error Codes

Error CodesError Codes

Error Codes

- Few error codes refer directly to a problem with the torch. However, a large

number of them can indirectly be caused by the torch or the torch position.

 Physical Clues

Physical CluesPhysical Clues

Physical Clues

- The torch neck needs to be inspected for excessive wear or damage

caused by the welding process. As needed, it should be cleaned of build­up spatter and other contaminates.

- Consumables should be checked regularly and cleaned/changed as

needed. Consumables include

 Gas Nozzle: free of spatter build-up and excessive conal damage.

 Torch Tip: free spatter build-up and excessive wire wear.

 Spatter Guard: gas holes free of blockage and excessive part

damage

 Nozzle Stock: gas holes free of blockage, excessive spatter build-

up, and stripped threads.

- Ensure pressure and drive rolls (if equipped⁄ are clean and not excessively

worn or damaged.

 Electronics/Settings

Electronics/SettingsElectronics/Settings

Electronics/Settings

- Some problems with the torch can be addressed by 1stlevel welding

settings in the power source.

Troubleshooting

Torches

---- 89

89 89

89 ----

13 SEP 12

/ Battery Charging Systems / Welding Technology / Solar Electronics

Troubleshooting

---- 90

90 90

90 ----

Wire Feeder Error Codes

EFD 1.x through 7.x

These are all internal logic errors and require a software update or SR board change

EFD 7.1

Configuration Memory (config mem) error

EFD 8.x

Main motor or push pull motor current errors

EFD 9.x

Main motor voltage errors

EFD 10.x

Internal logic errors between the SR-xx and the PM-xx board

EFD 11.x

Main motor and push pull motor alignment errors

EFD 12.x

Main motor and push pull motor movement errors (not to be confused with encoder errors)

EFD 15.x

Wire buffer errors (CMT, only active when welding)

EFD 30.x

Local High Speed Bus (LHSB) communication error

EFD 31.x

Encoder feedback errors.