Fronius TransSteel 4000 / 5000 Pulse Operating Instruction [EN]

Operating
instructions

TransSteel 4000 Pulse
TransSteel 5000 Pulse

EN-US

Operating instructions

42,0426,0353,EA 007-04052022

Table of contents

Safety Instructions 7

Explanation of Safety Instructions 7
General 7
Intended Use 8
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 9
Personal Protection and Protection of Others 9
Danger from toxic gases and vapors 9
Danger from Flying Sparks 10
Risks from grid current and welding current 10
Stray welding currents 12
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Particular hazard areas 13
Requirement for the shielding gas 14
Danger from Shielding Gas Cylinders 14
Danger Posed by Shielding Gas Leak 15
Safety Measures at the Setup Location and During Transport 15
Safety Measures in Normal Operation 16
Maintenance and repair 16
Safety Inspection 17
Disposal 17
Safety symbols 17
Data backup 17
Copyright 17

EN-US

General information 19

General 21

Device concept 21
Operating principle 21
Application areas 21
Warning notices on the device 22

Welding processes, procedures, and welding characteristics for MIG/MAG welding 23

General 23
Brief description of MIG/MAG standard synergic welding 23
Brief description of MIG/MAG pulsed synergic welding 23
Brief description of SynchroPulse welding 23
Brief description of the gouging (Arc Air Gouging) 24

System components 25

General 25
Safety 25
Overview 26

VRD: Safety function 27

VRD: Safety function 27
VRD: Safety principle 27

Operating controls and connections 29

Control Panel 31

General 31
Safety 31
Control panel 32
Service parameters 37
Keylock 38

Connections, Switches, and Mechanical Components 39

TransSteel 4000/5000 Pulse connections 39

3

Installation and Startup 41

Minimum equipment for welding operations 43

General 43
Gas-cooled MIG/MAG welding 43
Water-cooled MIG/MAG welding 43
Manual metal arc welding 43
Minimum equipment for arc air gouging 43

Before installation and initial operation 44

Safety 44
Intended use 44
Setup regulations 44
Grid Connection 45

Connecting the Mains Cable 46

General 46
Stipulated mains cables and strain-relief devices 46
Safety 47
Connecting the mains cable 47
Fitting the strain-relief device for Europe 48
Fitting the strain-relief device for Canada / US 49

Generator-Powered Operation 50

Generator-powered operation 50

Commissioning 51

Safety 51
General 51
Information on system components 51
Assembling system components (overview) 52
Place the wirefeeder on the power source 53
Fit the strain-relief device of the interconnecting hosepack 53
Connecting the interconnecting hosepack 54
Correct routing of the interconnecting hosepack 55
Connecting the gas cylinder 56
Establishing a ground earth connection 57
Connecting a MIG/MAG welding torch 58
Other activities 58
Setting the date and time when starting for the first time 58

MIG/MAG welding 59

Power Limitation 61

Safety function 61

MIG/MAG Operating Modes 62

General 62
Symbols and explanations 62
2-step mode 63
4-step mode 63
Special 2-step mode 64
Special 4-step mode 64
Spot welding 65
2-step stitch welding 65
4-step stitch welding 66

MIG/MAG welding 67

Safety 67
Preparation 67
Overview 67

MIG/MAG synergic welding 68

MIG/MAG synergic welding 68
Corrections during welding 70
SynchroPulse welding 70

MIG/MAG Standard Manual Welding 72

General 72
Available parameters 72

4

MIG/MAG standard manual welding 72
Corrections during welding 73

Spot welding and stitch welding 74

General 74
Spot welding 74
Stitch welding 75

EasyJob mode 77

General 77
Saving EasyJob operating points 77
Retrieving EasyJob operating points 77
Deleting EasyJob operating points 77
Retrieving EasyJob operating points on the Up/Down welding torch 78

MMA welding, arc air gouging 79

Manual Metal Arc Welding 81

Safety 81
Preparation 81
Manual metal arc welding 82
Corrections during welding 83
HotStart function 84
Anti-Stick function 84

Arc Air Gauging 85

Safety 85
Preparation 85
Arc air gouging 85

EN-US

Easy Documentation 87

General 89

General 89
Documented welding data 89
New CSV file 90
PDF report / Fronius signature 90

Activating / deactivating Easy Documentation 91

Activating Easy Documentation 91
Set the date and time 91
Deactivating Easy Documentation 92

Setup Settings 93

Setup Menu 95

General 95
Operation 95
Setup parameters for MIG/MAG synergic welding 96
Setup parameters for MIG/MAG standard manual welding 98
Setup parameters for MMA welding 99

Setup Menu 2nd Level 100

Limitations 100
Operation (Setup Menu 2nd Level) 100
Parameters for MIG/MAG synergic welding in Setup menu 2nd level 101
Parameters for MIG/MAG standard manual welding in Setup menu 2nd level 103
Parameters for manual metal arc welding in Setup menu 2nd level 105

Measuring the Welding Circuit Resistance r 106

General 106
Measuring the welding circuit resistance (MIG/MAG welding) 106
Measuring the welding circuit resistance (MMA welding) 107

Displaying the welding circuit Inductivity L 108

General 108
Displaying the welding circuit inductivity 108
Laying the hosepacks correctly 108

Troubleshooting and Maintenance 109

5

Troubleshooting 111

General 111
Safety 111
Displayed Service Codes 111
Displayed service codes in connection with OPT Easy Documentation 116

Service, maintenance and disposal 118

General 118
Safety 118
At every start-up 118
Every 2 Months 118
Every 6 Months 119
Disposal 119

Appendix 121

Average consumption values during welding 123

Average wire electrode consumption during MIG/MAG welding 123
Average shielding gas consumption during MIG/MAG welding 123
Average shielding gas consumption during TIG welding 123

Technical data 124

Overview with critical raw materials, year of production of the device 124
Special Voltage 124
Explanation of the term duty cycle 124
TransSteel 4000 Pulse TransSteel 4000 Pulse nc 126
TransSteel 4000 Pulse MV nc 128
TransSteel 5000 Pulse TransSteel 5000 Pulse nc 130
TransSteel 5000 Pulse MV nc 132

Welding program tables 134

Welding program label on the device 134
Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse 135
Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse US 137

6

Safety Instructions

EN-US

Explanation of
Safety Instruc­tions

DANGER!

Indicates an immediate danger.

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

▶

WARNING!

Indicates a possibly dangerous situation.

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

▶

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are

▶

not taken.

NOTE!

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

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized safety standards. If used incorrectly or misused, however,
it can cause

Injury or death to the operator or a third party

-

Damage to the device and other material assets belonging to the operating

-

company
Inefficient operation of the equipment

-

All persons involved in the commissioning, operation, maintenance, and servicing
of the device must

Be suitably qualified

-

Have knowledge of welding

-

Have completely read and followed these Operating Instructions

-

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

All safety and danger notices on the device must

Be kept in a legible state

-

Not be damaged/marked

-

Not be removed

-

Not be covered, pasted, or painted over

-

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

Your personal safety is at stake!

7

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

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

Proper use also means

Completely reading and obeying all instructions in the Operating Instruc-

-

tions
Completely reading and obeying all safety instructions and danger notices

-

Carrying out all the specified inspection and servicing work

-

Never use the device for the following applications:

Thawing pipes

-

Charging batteries

-

Starting motors

-

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

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

Environmental
Conditions

Obligations of
the Operating
Company

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

Temperature range of the ambient air:

During operation: -10°C to +40°C (14°F to 104°F)

-

During transport and storage: -20°C to +55°C (-4°F to 131°F)

-

Relative humidity:

Up to 50% at 40°C (104°F)

-

Up to 90% at 20°C (68°F)

-

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

The operating company must only allow persons to work with the device if they

Are familiar with the basic occupational safety and accident prevention regu-

-

lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-

-

tion "Safety Rules," and have confirmed this with their signature
Are trained according to the requirements for the work results

-

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

Obligations of
Personnel

8

All persons who are assigned to work with the device must do the following be­fore beginning the work:

Follow the basic regulations for occupational safety and accident prevention

-

Read these Operating Instructions, especially the section "Safety Rules," and

-

confirm that they have understood and will follow them by signing

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

Grid Connection Devices with a high output can influence the energy quality of the grid due to

their current consumption.

This may affect a number of device types in terms of:

connection restrictions

-

-

criteria regarding maximum permissible grid impedance

-

criteria regarding the minimum required short-circuit power

*)

both at the interface with the public grid

*)

*)

See technical data

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

IMPORTANT! Ensure secure grounding of the grid connection!

EN-US

Personal Protec­tion and Protec­tion of Others

You are exposed to numerous hazards while handling the device, for example:

Flying sparks and pieces of hot metal

-

Arc radiation that poses a risk of injury to the eyes and skin

-

Hazardous electromagnetic fields that pose a risk of death for individuals

-

with pacemakers
Electrical risks from grid current and welding current

-

Increased noise exposure

-

Harmful welding fumes and gases

-

Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:

Flame resistant

-

Insulating and dry

-

Covering the entire body and in good condition with no damage

-

Safety helmet

-

Cuffless pants

-

Protective clothing involves the following:

Protecting the face and eyes from UV radiation, heat and flying sparks with a

-

face guard featuring a regulation-compliant filter
Wearing regulation-compliant protective goggles with side protection behind

-

the face guard
Wearing rigid, wet-insulating footwear

-

Protecting hands with appropriate gloves (featuring electrical insulation and

-

thermal protection)
Wearing ear protection to reduce noise exposure and protect against injury

-

Danger from tox­ic gases and va­pors

Keep persons, especially children, away during the operation of the devices and
during the welding process. If persons are in the vicinity, however:

Instruct them about all hazards (blinding hazard due to arcs, risk of injury

-

from flying sparks, welding fumes hazardous to health, noise exposure, pos­sible hazard due to grid current or welding current, etc.)
Provide suitable protective equipment or

-

Construct suitable protective walls and curtains.

-

The fumes produced during welding contain toxic gases and vapors.

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

9

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

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

Do not breathe them in.

-

Extract them from the work area using appropriate equipment.

-

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

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

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

The following components are factors that determine how toxic the welding
fumes are:

The metals used for the workpiece

-

Electrodes

-

Coatings

-

Cleaning agents, degreasers, and the like

-

The welding process used

-

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

Danger from Fly­ing Sparks

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

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

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

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

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

Keep suitable, tested fire extinguishers on hand.

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

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

Risks from grid
current and
welding current

10

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

An electric shock can be fatal.

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

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

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

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

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

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

Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)

Never immerse it in liquids to cool it

-

Never touch it when the power source is switched on.

-

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

EN-US

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

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

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

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

Switch off unused devices.

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

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

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

After opening the device:

Discharge all electrically charged components

-

Ensure that all components are disconnected from the power supply.

-

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

11

Stray welding
currents

If the following instructions are not observed, stray welding currents may occur,
which pose a risk of the following:

Fire

-

Overheating of parts connected to the workpiece

-

Irreparable damage to ground conductors

-

Damage to the device and other electrical equipment

-

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

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

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

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

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

EMC Device
Classifications

EMC measures In certain cases, even though a device complies with the standard limit values for

Devices in emission class A:

Are only designed for use in industrial settings

-

Can cause line-bound and radiated interference in other areas

-

Devices in emission class B:

Satisfy the emissions criteria for residential and industrial areas. This is also

-

true for residential areas in which the energy is supplied from the public low­voltage grid.

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

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

Test and assess the immunity of equipment in the vicinity of the device in ac­cordance with national and international provisions. Examples of interference­prone equipment that could be affected by the device:

Safety devices

-

Grid power lines, signal lines, and data transfer lines

-

IT and telecommunications equipment

-

Devices for measuring and calibrating

-

12

Supporting measures to avoid EMC problems:

Grid power supply

1.
If electromagnetic interference occurs despite a grid connection that

-

complies with regulations, take additional measures (e.g., use a suitable
grid filter).

Welding power-leads

2.
Keep them as short as possible

-

Route them close together (also to avoid EMF problems)

-

Route them far from other lines

-

Equipotential bonding

3.

Workpiece grounding

4.
If necessary, establish grounding using suitable capacitors.

-

Shield, if necessary

5.
Shield other devices in the vicinity

-

Shield the entire welding installation

-

EMF measures Electromagnetic fields may cause health problems that are not yet known:

Effects on the health of persons close by, e.g., those with pacemakers and

-

hearing aids
Persons with pacemakers must seek advice from their doctor before staying

-

in the immediate vicinity of the device and the welding process
Keep distances between welding power-leads and the head/torso of the

-

welder as great as possible for safety reasons
Do not carry welding power-leads and hosepacks over your shoulder or wrap

-

them around your body or body parts

EN-US

Particular haz­ard areas

Keep hands, hair, loose clothing, and tools away from moving parts, such as:

Fans

-

Gears

-

Rollers

-

Shafts

-

Wirespools and welding wires

-

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

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

During operation

Ensure that all covers are closed, and all side parts have been mounted prop-

-

erly.
Keep all covers and side parts closed.

-

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

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

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

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

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

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

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

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

13

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

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

Attach chains or ropes to all designated attachments of the suitable load-

-

carrying equipment.
Chains or ropes must be the smallest angle possible from vertical.

-

Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

-

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

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

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

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

Requirement for
the shielding gas

Danger from
Shielding Gas
Cylinders

Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:

Solid particle size < 40 µm

-

Pressure condensation point < -20 °C

-

Max. oil content < 25 mg/m³

-

Use filters if necessary.

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

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

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

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

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

14

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

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

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

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

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

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

EN-US

Danger Posed by
Shielding Gas
Leak

Safety Measures
at the Setup
Location and
During Transport

Risk of asphyxiation due to uncontrolled shielding gas leak

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

Ensure there is a sufficient supply of fresh air with a ventilation flow rate of

-

at least 20 m³ per hour.
Please observe the safety and maintenance information for the shielding gas

-

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

-

or the main gas supply.
Always check the shielding gas cylinder or main gas supply for uncontrolled

-

gas leakage before each start-up.

A toppling device can be deadly! Set up the device securely on an even, solid sur­face

The maximum permitted tilt angle is 10°.

-

Special regulations apply in areas at risk of fire or explosion

Follow the appropriate national and international regulations.

-

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

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

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

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

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

Before transporting the device, completely drain the coolant and dismantle the
following components:

wirefeeder

-

wirespool

-

shielding gas cylinder

-

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

15

Safety Measures
in Normal Oper­ation

Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a danger of:

Injury or death to the operator or a third party

-

Damage to the device and other material assets belonging to the operating

-

company
Inefficient operation of the device

-

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

Never bypass or disable safety devices.

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

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

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

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

Only use appropriate original coolant from the manufacturer.

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

Maintenance and
repair

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

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

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

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

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

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

Use only original spare and wearing parts (also applies to standard parts).

-

Do not carry out any modifications, alterations, etc. to the device without the

-

manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.

-

When ordering, please give the exact designation and part number as shown

-

in the spare parts list, as well as the serial number of your device.

16

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

Safety Inspec­tion

Disposal To comply with European directives and national law, waste electrical and elec-

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

The manufacturer recommends calibrating power sources within the same 12­month interval.

A safety inspection by a certified electrician is recommended:

After changes

-

After alterations

-

After repair, care, and maintenance

-

At least every 12 months

-

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

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

tronic equipment must be collected separately and sent for environmentally­friendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices pro­motes the sustainable recycling of material resources. Ignoring this may have po­tentially adverse effects on the environment and your health.

EN-US

Packaging materials

Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.

Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage

and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60974 series).

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

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

Data backup The user is responsible for backing up any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

Copyright Copyright of these Operating Instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing. Fronius reserves the
right to make changes. The contents of the Operating Instructions shall not
provide the basis for any claims whatsoever on the part of the purchaser. If you
have any suggestions for improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your com­ments.

17

18

General information

19

20

General

EN-US

Device concept

Operating prin­ciple

The TransSteel (TSt) 4000 Pulse and
TransSteel 5000 Pulse power sources
are fully digitized, microprocessor­controlled inverter power sources.

A modular design and ability to easily
extend the system ensure high flexibil-

ity.

The devices are designed for the fol­lowing welding processes:

MIG/MAG pulse welding

-

MIG/MAG standard synergic weld-

-

ing
Manual metal arc welding

-

TransSteel 4000 / 5000 Pulse

The devices have a "Power limitation" safety feature. This means that the power
sources can be operated at the power limit without compromising process safety.
For details, refer to the "Welding operations" chapter.

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

Application
areas

This results in:

A precise welding process

-

A high degree of reproducibility on all results

-

Excellent weld properties.

-

The devices are used in trade and industry for manual and automated applica­tions with classical steel and galvanized sheet metal:

Mechanical and equipment engineering

-

Steel construction

-

Plant and container construction

-

Shipyards and the offshore sector

-

Metal and portal construction

-

Rail vehicle construction

-

Metalworking trades

-

21

Warning notices
on the device

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

22

Warning notices on the power source

Welding is dangerous. The following basic requirements must be met:

Adequate welding qualifications

-

Appropriate protective equipment

-

Exclusion of unauthorized persons

-

Do not use the functions described here until you have fully read and understood
the following documents:

These Operating Instructions

-

All system component Operating Instructions, especially the safety rules

-

Welding processes, procedures, and welding char­acteristics for MIG/MAG welding

General In order to process a wide range of materials effectively, various welding pro-

cesses, procedures, and welding characteristics are available on the power
source.

Brief description
of MIG/MAG
standard syner­gic welding

MIG/MAG standard synergic

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

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

Intermediate arc
The droplet increases in size at the end of the wire electrode and is transferred in
the mid power range during the short circuit.

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

EN-US

Brief description
of MIG/MAG
pulsed synergic
welding

Brief description
of SynchroPulse
welding

MIG/MAG pulsed synergic

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

SynchroPulse is available for the standard synergic and pulsed synergic pro­cesses.
The cyclic change of the welding power between two operating points with Syn­chroPulse achieves a finely rippled weld appearance and a non-continuous heat
input.

23

Brief description
of the gouging
(Arc Air Gou­ging)

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

Applications:

Removal of shrink holes, pores, or slag inclusions from workpieces

-

Detaching sprues or the processing of entire workpiece surfaces in foundries

-

Edge preparation for heavy plates

-

Preparation and repair of weld seams

-

Finishing of roots or defects

-

Production of air gaps

-

24

System components

General The power sources can be operated with various system components and op-

tions. This makes it possible to optimize procedures and to simplify machine
handling and operation, depending on the field of application for the power
source.

EN-US

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

25

Overview

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

(1) Welding torch
(2) Wirefeeder
(3) Wirefeeder holder
(4) Interconnecting hosepacks
(5) Power source
(6) Cooling unit
(7) Trolley and gas cylinder holders
(8) Grounding and electrode cable

26

VRD: Safety function

EN-US

VRD: Safety
function

The Voltage Reduction Device (VRD) is an optional safety device for voltage re­duction. It is recommended for environments where arc welding significantly in­creases the risk of electric shock or electrical accident:

Due to low body resistance of the welder

-

If the welder is exposed to a significant risk of touching the workpiece or

-

other parts of the welding circuit

A low body resistance is likely in the event of:

Water in the environment

-

Humidity

-

Heat, especially at ambient temperatures above 32 °C (89.6 °F)

-

In wet, damp, or hot places, moisture or sweat can significantly reduce skin res­istance, as well as the insulation resistance of protective equipment and clothing.

Such environments may include:

Temporary dam structures for draining certain areas of a construction site

-

during the construction period (cofferdams)
Ditches

-

Mines

-

Rain

-

Areas partially covered by water

-

Spray water zones

-

The VRD option reduces the voltage between the electrode and the workpiece. In
the safe state, the indicator for the currently selected welding process lights up
continuously. The safe state is defined as follows:

In an open circuit, the output voltage is limited to a maximum of 35 V.

-

VRD: Safety
principle

As long as the welding operation is active (welding circuit resistance < 200 ohms),
the indicator of the currently selected welding process flashes and the output
voltage can exceed 35 V.

The welding circuit resistance is great­er than the minimum body resistance
(greater than or equal to 200 ohms):

VRD is active

-

Open circuit voltage is limited to

-

35 V
Unintentional contact with the

-

output voltage does not pose any
danger

The welding circuit resistance is less
than the minimum body resistance
(less than 200 ohms):

VRD is inactive

-

No limitation of the output voltage

-

to ensure adequate welding power
Example: welding start

-

27

Applies to MMA welding mode:
Within 0.3 seconds of the end of welding:

VRD is active again

-

Restriction of the output voltage to 35 V is ensured again

-

28

Operating controls and connec-

tions

29

30

Control Panel

General The functions are all arranged in a logical way on the control panel. The individual

parameters required for welding can be

Selected by means of buttons

-

Changed using buttons or the selection dial

-

Shown on the digital display during welding.

-

Due to the synergic function, all other parameters are also adjusted if a single
parameter is changed.

NOTE!

Because of software updates, certain functions may be available for your device
but not described in these Operating Instructions or vice versa.

In addition, individual figures may also differ slightly from the operating ele­ments of your device. However, the function of these operating elements is
identical.

EN-US

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

31

Control panel

(1)
(2)

(3)
(4)

(5)

(6)(7)

(14)(13) (17)

(12)

(11)

(10) (8)

(9)

(15)(16)

No. Function

(1) "Parameter selection" button (right)

a) for selecting the following parameters

Arc length correction

For correcting the arc length

Welding voltage in V *)

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

32

Pulse / arc-force dynamic correction

For continuously correcting the droplet detachment force in MIG/MAG
pulsed synergic welding

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

For influencing the short-circuiting dynamic at the instant of droplet
transfer in MIG/MAG standard synergic welding, MIG/MAG standard
manual welding, and manual metal arc welding

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

b) for changing parameters in the Setup menu

(2) "Parameter selection" button (left)

a) for selecting the following parameters

EN-US

Sheet thickness

Sheet thickness in mm or in.
If the welding current to be selected is not known, it is sufficient to enter
the sheet thickness. The required welding current and any other paramet­ers marked with *) will then be adjusted automatically.

Welding current *)
Welding current in A
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed dur­ing welding.

Wire speed

*)

Wire speed in m/min or ipm.

b) for changing parameters in the Setup menu

(3) Selection dial (right)

For changing the arc length correction, welding voltage, and arc-force dy­namic parameters

33

For changing parameters in the Setup menu

(4) Selection dial (left)

For changing the sheet thickness, welding current, and wire speed para­meters
For selecting parameters in the Setup menu

(5) EasyJob save buttons

For saving up to 5 operating points

(6)

"Process" button

For selecting the welding process

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

Manual metal arc welding

(7) "Mode" button

For selecting the operating mode

**)

2-step mode

4-step mode

Special 4-step mode

Spot welding/stitch welding

(8) "Shielding gas" button

For selecting the shielding gas used. The SP parameter is reserved for ad­ditional shielding gases.

34

When the shielding gas is selected, the LED behind the corresponding
shielding gas lights up.

(9) "Wire diameter" button

For selecting the wire diameter used. The SP parameter is reserved for
additional wire diameters.

When the wire diameter is selected, the LED behind the corresponding
wire diameter lights up.

(10) "Material" button

For selecting the filler metal used. The SP parameter is reserved for addi­tional materials.

When the material type is selected, the LED behind the corresponding
filler metal lights up.

(11) "Wire threading" button

Press and hold the button:
Gasless wire threading into the torch hosepack

While the button is being held, the wire drive operates at feeder inching
speed.

EN-US

(12) Gas-test button

For setting the required gas volume on the gas pressure regulator.

Tap the button once: shielding gas flows out
Tap the button again: shielding gas flow stops

If the Gas-test button is not tapped again, the shielding gas flow will stop
after 30 s.

(13) SF - spot/stitch/SynchroPulse welding indicator

Lights up if a value is set for the spot welding/stitch welding time

-

(SPt) setup parameter when spot welding or stitch welding mode is
activated
Lights up if a value is set for the Frequency (F) setup parameter when

-

the MIG/MAG synergic welding process is activated.

(14) Intermediate arc indicator

A spatter-prone "intermediate arc" occurs between the dip transfer arc
and the spray arc. The intermediate arc indicator lights up to alert you to
this critical area.

(15) HOLD indicator

At the end of each welding operation, the actual values for welding cur­rent and welding voltage are stored - the "HOLD" indicator lights up.

(16) Pulse indicator

Lights up when the MIG/MAG pulsed synergic welding process is selected

(17) Real Energy Input

For displaying the energy applied during the welding operation.

The Real Energy Input indicator must be activated in level 2 of the Setup

35

menu – EnE parameter. The value continuously rises during welding in line
with the permanently increasing energy input. The final value is stored
after the end of welding until welding starts again or the power source is
switched back on - the HOLD indicator lights up.

*) During the MIG/MAG standard synergic welding process and MIG/MAG

pulsed synergic welding process, if one of these parameters is selected,
then the synergic function ensures that all other parameters, including
the welding voltage parameter, are adjusted automatically.

**) In conjunction with the VRD option, the indicator of the currently selec-

ted welding process is also used as status indicator:

The indicator lights up continuously: the voltage reduction (VRD) is

-

active and limits the output voltage to less than 35 V.
The indicator flashes as soon as a welding operation occurs, which can

-

cause the output voltage to be greater than 35 V.

36

Service para-

+

meters

Various service parameters can be retrieved by pressing the "Parameter selec­tion" buttons at the same time.

Opening the display

EN-US

1

Selecting parameters

2

Available parameters

Example:

1.00 | 4.21

Example:
2 | 491

Example:
r 2 | 290

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

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

Explanation

Firmware version

Welding program configuration

Number of the currently selected
welding program

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

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

Example:
iFd | 0.0

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

2nd 2nd menu level for service technicians

37

Keylock A keylock can be selected to prevent the settings from being inadvertently

+

changed on the control panel. As long as the keylock is active:

Settings cannot be adjusted on the control panel

-

Only parameter settings can be retrieved

-

Any assigned "Save" button can be retrieved provided that an assigned "Save"

-

button was selected when the keylock was enabled

Activating/deactivating the keylock:

1

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

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

The keylock can also be activated and deactivated using the keylock switch op­tion.

38

Connections, Switches, and Mechanical Compon-

(1)

(2)

(3)

(4)

(6)

(7)

(9)

(8)

(5)

ents

TransSteel
4000/5000
Pulse connec­tions

No. Function

(1) (-) Current socket with bayonet latch

Used for

Connecting the grounding cable for MIG/MAG welding

-

Connecting the electrode cable or grounding cable for manual metal

-

arc welding (depending on the type of electrode used)

EN-US

(2) Power switch

For switching the power source on and off

(3) (+) Current socket with bayonet latch

Used for

Connecting the mains cable from the interconnecting hosepack for

-

MIG/MAG welding
Connecting the electrode cable or grounding cable for manual metal

-

arc welding (depending on the type of electrode used)

(4) Gas pre-heater socket (option)

(5) Automatic Interface (option)

(6) EASY DOCUMENTATION label

(7) Mains cable with strain relief

(8) LocalNet connection

Standardized connection for wirefeeder (interconnecting hosepack)

(9) Air filter

Pull out from the side for cleaning

39

40

Installation and Startup

41

42

Minimum equipment for welding operations

General Depending on the welding process, a minimum level of equipment is required to

work with the power source.
The following describes the welding processes and the corresponding minimum
equipment for welding operations.

EN-US

Gas-cooled
MIG/MAG weld­ing

Water-cooled
MIG/MAG weld­ing

Manual metal
arc welding

Power source

-

Grounding cable

-

Gas-cooled MIG/MAG welding torch

-

Gas connection (shielding gas supply)

-

Wirefeeder (VR 5000 Remote)

-

Gas-cooled interconnecting hosepack

-

Wire electrode

-

Power source

-

Cooling unit

-

Grounding cable

-

Water-cooled MIG/MAG welding torch

-

Gas connection (shielding gas supply)

-

Wirefeeder (VR 5000 Remote)

-

Water cooling option (for VR 5000 Remote)

-

Water-cooled interconnecting hosepack

-

Wire electrode

-

Power source

-

Grounding cable

-

Electrode holder

-

Rod electrodes

-

Minimum equip­ment for arc air
gouging

TransSteel 4000 / 5000 Pulse, TransSteel 5000 Syn power source

-

Grounding cable 120 mm²

-

KRIS 13 arc air gouging torch

-

Compressed air supply

-

43

Before installation and initial operation

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back

▶

on.
After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Intended use The power source is intended exclusively for MIG/MAG, MMA, and TIG welding.

Utilization for any other purpose, or in any other manner, shall be deemed to be
not in accordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such use.

Intended use also means

Following all the instructions in these Operating Instructions

-

Carrying out all the specified inspection and maintenance work

-

Setup regula­tions

The device has been tested according to degree of protection IP 23. This means:

Protection against penetration by solid foreign bodies with diameters > 12

-

mm (0.49 in.)
Protection against spraywater at any angle up to 60° from the vertical

-

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

WARNING!

Danger from machines toppling over or falling.

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

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

44

WARNING!

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

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

Only operate the device if an air filter is fitted. The air filter is a very import-

▶

ant safety device for achieving IP 23 protection.

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

Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the

mains cable or mains plug has not been attached to your version of the appli­ance, these must be installed according to national standards. Fuse protection
for the grid lead can be found in the technical data.

CAUTION!

Danger due inadequately dimensioned electrical installations.

This can lead to serious damage

The grid lead and its fuse protection should be designed to suit the existing

▶

power supply.
The technical data on the rating plate should be followed.

EN-US

45

Connecting the Mains Cable

General If no mains cable is connected, a mains cable that is suitable for the connection

voltage must be fitted before commissioning.
A strain-relief device for the following cable cross-sections is fitted to the power
source:

Power source Cable cross-section

Fitted strain-relief device
for
Canada/US

TransSteel 4000 Pulse AWG 12 *) 4G2.5

TransSteel 5000 Pulse AWG 10 *) 4G4

Europe

Stipulated mains
cables and
strain-relief
devices

TransSteel 4000 MV
Pulse

TransSteel 5000 MV
Pulse

*) Canada / US cable type: Extra-hard usage

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

Power source Grid voltage Cable cross-sec-

TransSteel 4000
Pulse

3 x 460 V AWG 12 *) 4G2.5

TransSteel 5000
Pulse

3 x 460 V AWG 10 *) 4G4

AWG 10 *) 4G4

AWG 6 *) 4G10

tion

Canada / US

3 x 380 / 400 V AWG 12 *) 4G2.5

3 x 380 / 400 V AWG 8 *) 4G4

Europe

46

TransSteel 4000 MV
Pulse

TransSteel 5000 MV
Pulse

*) Canada / US cable type: Extra-hard usage

The item numbers of the different cables can be found in the Spare Parts List for
the devices.

AWG ... American Wire Gauge

3 x 208 / 230 / 400 /460VAWG 10 *) 4G4

3 x 208 / 230 / 400 /
460 V

AWG 6 *) 4G10

Safety

WARNING!

Danger from work that is not carried out properly.

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

The work described below may only be performed by trained specialist per-

▶

sonnel.
Follow national standards and guidelines.

▶

CAUTION!

Danger from improperly prepared mains cable.

Short circuits and damage to property may result.

Fit ferrules to all phase conductors and the ground conductor of the

▶

stripped mains cable.

EN-US

Connecting the
mains cable

If no mains cable is connected, a mains cable that is suitable for the connection
voltage must be fitted before commissioning.

The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than
the phase conductors.

A graphic representation of the mains cable connection is provided in the sec­tions "Fitting the strain-relief device" or "Fitting the strain-relief device for
Canada / US." To connect the mains cable, proceed as follows:

Remove the side panel of the device

1

Push in the mains cable so that the ground conductor and phase conductor

2

can be properly connected to the block terminal.

Fit a ferrule to the ground conductor and phase conductor

3

Connect the ground conductor and phase conductor to the block terminal

4

Secure the mains cable with a strain-relief device

5

Fit the side panel of the device

6

47

Fitting the

3

1

2

5

4

7

3

4

100mm

(4inch)

PE

2

1

3

3

3

3

3

4

4x

3

1,2 Nm

1

4

3

2

5

6

strain-relief
device for
Europe

1

2

3

5

4

IMPORTANT! Tie the phase conduct-

ors near the block terminal using cable
ties.

48

Fitting the

3

1

2

5

4

7

1

3

3

3

3

3

4

4x

3

3,5 Nm

1

4

3

2

5

6

strain-relief
device for
Canada / US

1 2

EN-US

3

5

4

IMPORTANT! Tie the phase conduct-

ors near the block terminal using cable
ties.

49

Generator-Powered Operation

Generator­powered opera­tion

The power source is generator-compatible.

The maximum apparent power S

of the power source must be known in order

1max

to select the correct generator output.
The maximum apparent power S

of the power source is calculated for 3-

1max

phase devices as follows:

S

= I

1max

I

and U1 according to the device rating plate and technical data

1max

The generator apparent power S

1max

x U1 x √3

needed is calculated using the following rule

GEN

of thumb:

S

GEN

= S

1max

x 1.35

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

IMPORTANT! The generator apparent power S
maximum apparent power S

of the power source!

1max

must not be less than the

GEN

NOTE!

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

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

50

Commissioning

EN-US

Safety

An electric shock can be fatal.

If the power source is connected to the grid during installation, there is a danger
of serious personal injury and property damage.

▶
▶

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

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

▶

General Commissioning is described with reference to a manual, water-cooled MIG/MAG

application.

WARNING!

Only carry out work on the device when the power source's power switch is in
the - O - position.
Only carry out work on the device when the power source has been discon­nected from the grid.

WARNING!

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

Information on
system compon­ents

The steps and activities described below include references to various system
components, such as

Trolley

-

Upright bracket

-

Cooling units

-

Wirefeeders

-

Interconnecting hosepacks

-

Welding torches, etc.

-

For more detailed information about installing and connecting the system com­ponents, please refer to the appropriate Operating Instructions for the system
components.

51

Assembling sys­tem components
(overview)

WARNING!

Work performed incorrectly can cause serious injury and damage.

The following activities must only be carried out by trained and qualified per-

▶

sonnel.
Please note the information in the "Safety instructions" chapter!

▶

The following diagram is intended to provide you with an overview of how the in­dividual system components are put together.

52

Place the

1

1

2

3

4

2

1

3

4

wirefeeder on
the power source

CAUTION!

Danger of personal injury and damage to equipment due to falling wirefeeder.

Ensure that the wirefeeder is firmly seated on the pivot pin and that the

▶

devices, upright brackets, and trolley are positioned securely.

1

EN-US

Fit the strain-re­lief device of the
interconnecting
hosepack

1

Fit the strain-relief device on the trolley

2

Fit the strain-relief device on the wirefeeder

IMPORTANT! In order to prevent wear, the cables should form a "loop inwards"
when fitted. For interconnecting hosepacks with a length of 1.2 m (3 ft. 11.24 in.),
no strain-relief device is provided.

53

Connecting the

1

2

7

4

5

6

3

interconnecting
hosepack

WARNING!

Fitting the device incorrectly can cause serious injury and damage to property.

Do not perform the steps described here until you have fully read and under-

▶

stood the Operating Instructions.

NOTE!

When connecting the interconnecting hosepack, check that

All connections are connected properly

▶

All cables, leads, and hosepacks are undamaged and correctly insulated

▶

IMPORTANT! Gas-cooled systems are not fitted with a cooling unit. The water
connections therefore do not need to be connected for gas-cooled systems.

1

2

54

Correct routing
of the intercon­necting hosep­ack

IMPORTANT! The duty cycle values (D.C.) of the interconnecting hosepack can

only be achieved if it is correctly routed.

EN-US

Correct routing of the interconnecting hosepack

55

Connecting the
gas cylinder

WARNING!

Danger of severe injury and damage to property if gas cylinders fall over.

When using gas cylinders:

Place them on a solid, level surface in such a way that they remain stable

▶

Secure the gas cylinders to prevent them from falling over

▶

Install the VR holder option

▶

Observe the safety rules of the gas cylinder manufacturer

▶

Place the gas cylinder on the base

1

of the trolley

Secure the gas cylinder against

2

falling using the cylinder strap in
the upper area of the gas cylinder
(but not on the neck of the cylin­der)

Remove the protective cap of the

3

gas cylinder

Briefly open the gas cylinder valve

4

to remove any dirt

Inspect the seal on the gas pres-

5

sure regulator

Screw the pressure regulator onto

6

the gas cylinder and tighten it

Connect the protective gas shield

7

hose of the interconnecting hosep­ack to the pressure regulator using
a gas hose

NOTE!

US devices are supplied with an adapter for the gas hose:

Seal the outside thread on the gas solenoid valve using suitable means be-

▶

fore screwing on the adapter.
Test the adapter to ensure that it is gas-tight.

▶

56

Establishing a

1

3

2

ground earth
connection

NOTE!

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

Use a separate grounding cable for each power source

▶

Keep positive cables and grounding cables together as long and as close as

▶

possible
Physically separate the welding circuits of individual power sources

▶

Do not route several grounding cables in parallel;

▶

if parallel routing cannot be avoided, keep a minimum distance of 30 cm
between the welding circuits
Keep the grounding cables as short as possible, provide a large cable cross-

▶

section
Do not cross over grounding cables

▶

Avoid ferromagnetic materials between the grounding cables and the inter-

▶

connecting hosepack
Do not wind long grounding cables - coil effect!

▶

Route long grounding cables in loops
Do not route grounding cables in iron pipes, metal cable trays, or on steel

▶

beams, avoid cable ducts;
(routing positive cables and grounding cables together in an iron pipe does
not cause any problems)
If several grounding cables are used, separate the part's ground points as far

▶

as possible and do not allow crossed current paths under the individual arcs.
Use compensated interconnecting hosepacks (interconnecting hosepacks

▶

with integrated grounding cable)

EN-US

1

57

Connecting a
MIG/MAG weld-

1

* with integrated water connection op­tion and water-cooled welding torch

ing torch

Other activities Carry out the following steps according to the Operating Instructions for the

wirefeeder:

Insert feed rollers into the wirefeeder

1

Insert wirespool or basket-type spool with basket-type spool adapter into the

2

wirefeeder

Feed in the wire electrode

3

Set the contact pressure

4

Adjust the brake

5

Setting the date
and time when
starting for the
first time

After switching on the power source for the first time, the date and time must be
set. For this purpose, the power source changes to the second level of the ser­vice menu; the yEA parameter is selected.

To set the date and time see page 91, step 5

58

MIG/MAG welding

59

60

Power Limitation

Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the

power source can be operated at the power limit whilst maintaining process
safety.

Wire speed is a determining parameter for welding power. If it is too high, the arc
gets smaller and smaller and may be extinguished. In order to prevent this, the
welding power is lowered.

If the "MIG/MAG standard synergic welding" or "MIG/MAG pulsed synergic weld­ing" process is selected, the symbol for the "Wire speed" parameter flashes as
soon as the safety function trips. The flashing continues until the next welding
start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire
speed is displayed.

EN-US

61

MIG/MAG Operating Modes

General

Symbols and ex­planations

WARNING!

Operating the device incorrectly can cause serious injury and damage to prop­erty.

Do not use the functions described here until you have fully read and under-

▶

stood the Operating Instructions.
Do not use the functions described here until you have fully read and under-

▶

stood all of the Operating Instructions of the system components, especially
the safety rules.

For details of the meaning, settings, setting range and units of the available
welding parameters (e.g., gas pre-flow time), please refer to the "Setup paramet­ers" chapter.

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

GPr Gas pre-flow time

I-S Starting current

Can be increased or decreased depending on the application

SL Slope

Starting current is continuously lowered as far as the welding current and
the welding current as far as the final current

I Welding current phase

Even heat input into the parent material whose temperature is raised by
the advancing heat

I-E Final current

To fill up end-craters

GPo Gas post-flow time

SPt Spot welding time / interval welding time

SPb Interval pause time

62

2-step mode

t

I

+

I

GPr

GPo

t

I

+

I

GPr GPo

+

"2-step mode" is suitable for

Tacking work

-

Short weld seams

-

Automatic and robot operation

-

EN-US

4-step mode

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

63

Special 2-step

GPr

GPo

I

I-S

SLt-S t-ESL

I-E

+

t

I

+ +

I

I-S I-E

GPr SL SL

GPo

mode

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

To activate special 2-step mode:

Special 4-step
mode

Select 2-step mode

1

In the Setup menu, set the t-S (starting current duration) and t-E (final cur-

2

rent duration) parameters to a value > 0

Special 2-step mode is activated.

In the Setup menu, set the SL (Slope), I-S (starting current), and I-E (final

3

current) parameters

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

64

Spot welding

I

+

I

GPr GPoSPt

t

< SPt

GPr SPt SPtSPb

GPo

I I

+

EN-US

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

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

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

2-step stitch
welding

2-step stitch welding

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

65

4-step stitch

I

I

GPr SPt SPtSPb

GPo

+

+

welding

4-step stitch welding

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

66

MIG/MAG welding

EN-US

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back

▶

on.
After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

Overview MIG/MAG welding is composed of the following sections:

Connect the water hoses of the welding torch to the corresponding connec-

1

tion sockets on the wirefeeder
(when using the cooling unit and water-cooled welding torch)

Insert mains plug

2

Set the power switch to - I -:

3

All displays on the control panel briefly illuminate

-

If present: The cooling unit starts to work

-

IMPORTANT! Observe the safety rules and operating conditions in the Operating
Instructions for the cooling unit.

MIG/MAG synergic welding

-

MIG/MAG standard manual welding

-

Spot welding and stitch welding

-

67

MIG/MAG synergic welding

MIG/MAG syner­gic welding

Press the "Material" button to select the filler metal to be used.

1

Press the "Wire diameter" button to select the diameter of the wire electrode

2

used.

Press the "Shielding gas" button to select the shielding gas to be used.

3

The assignment of the SP position is in the welding program tables in the ap­pendix.

Press the "Process" button to select the desired welding process:

4

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

Press the "Mode" button to select the desired MIG/MAG mode:

5

2-step mode

4-step mode

Special 4-step mode

IMPORTANT! Under certain circumstances, it may not be possible to change
welding parameters that have been set on the control panel of a system compon­ent - such as remote control or wirefeeder - on the control panel of the power
source.

68

Use the "Parameter selection" buttons to select the welding parameters to be

6

used to specify the welding power:

Sheet thickness

Welding current

Wire speed

Welding voltage

Use the appropriate selection dial to set the welding parameter.

7

The value of the parameter is displayed on the digital display located above.

The sheet thickness, welding current, wire speed, and welding voltage paramet­ers are directly linked. It is sufficient to change one of the parameters, as the re­maining parameters are immediately adjusted accordingly

EN-US

All welding parameter set values remain stored until the next time they are
changed. This applies even if the power source is switched off and on again. To
display the actual welding current during welding, select the welding current
parameter.

Open the gas cylinder valve

8

Adjust quantity of shielding gas:

9

Tap the Gas-test button

-

Turn the adjusting screw on the bottom of the gas pressure regulator un-

-

til the manometer displays the desired quantity of gas
Tap the Gas-test button again

-

CAUTION!

Danger of injury and damage from electric shock and from the wire electrode
emerging from the torch.

When you press the torch trigger:

Keep the welding torch away from your face and body

▶

Wear suitable protective goggles

▶

Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or groun-

▶

ded parts (e.g., housing, etc.)

Press the torch trigger and start welding

10

69

Corrections dur­ing welding

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

Arc length correction:

- = shorter arc, reduced welding voltage

0 = neutral arc
+ = longer arc, increased welding voltage

Pulse / arc-force dynamic correction

For continuous correction of the droplet detachment force in MIG/MAG pulsed
synergic welding

- reduced droplet detachment force

0 neutral droplet detachment force
+ increased droplet detachment force

For influencing the short-circuiting dynamic at the instant of droplet transfer
during MIG/MAG standard synergic welding

- = hard, stable arc

0 = neutral arc
+ = soft, low-spatter arc

SynchroPulse
welding

SynchroPulse is recommended for welded joints with aluminum alloys whose
weld seams should have a rippled appearance. This effect is achieved using a
welding power that changes between two operating points.

The two operating points result from a positive and negative change in the weld­ing power to a dFd (delta wire feed) value that can be adjusted in the Setup menu
(delta wire feed: 0.0 - 3.0 m/min or 0.0 - 118.1 ipm).

Other parameters for SynchroPulse:

Frequency F of the operating point change (set in the Setup menu)

-

Arc length correction for the lower operating point (set via the arc length

-

correction parameter on the control panel)
Arc length correction for the higher operating point (set in the Setup menu,

-

parameter Al.2)

To enable SynchroPulse, you must change at least the value of the F (Frequency)
parameter from OFF to a variable in the range of 0.5 to 5 Hz in the process
Setup menu.

NOTE!

SynchroPulse is not supported with standard manual welding selected.

70

How SynchroPulse works when used in "Special 4-step" mode

I v

D

Al.2

LSLS

+ +

dFd

1/F

v

I-S

dFd

t

I-E

I-S = starting-current phase, SL = Slope, I-E = crater-fill phase, v = wire speed

SynchroPulse mode of operation

EN-US

71

MIG/MAG Standard Manual Welding

General The MIG/MAG standard manual welding process is a MIG/MAG welding process

with no synergic function.
Changing one parameter does not result in any automatic adjustments to the
other parameters. All of the variable parameters must therefore be adjusted indi­vidually, as dictated by the welding process in question.

Available para­meters

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

Wire speed

1 m/min (39.37 ipm.) - maximum wire speed, e.g., 25 m/min (984.25 ipm.)

Welding voltageTransSteel 4000 Pulse: 15.5 - 31.5 V
TransSteel 5000 Pulse: 14.5 - 39 V

Arc-force dynamic:

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

Welding current

Only the actual value is displayed

MIG/MAG
standard manual
welding

72

Press the "Process" button to select the desired welding process:

1

MIG/MAG standard manual welding

Press the "Mode" button to select the desired MIG/MAG mode:

2

2-step mode

4-step mode

In MIG/MAG standard manual welding, special 4-step mode corresponds to con­ventional 4-step mode.

IMPORTANT! Under certain circumstances, it may not be possible to change
welding parameters that have been set on the control panel of a system compon­ent - such as remote control or wirefeeder - on the control panel of the power
source.

Press the "Parameter selection" button to select the wire speed parameter

3

Use the selection dial to set the desired wire speed value

4

Press the "Parameter selection" button to select the welding voltage para-

5

meter

Use the selection dial to set the desired welding voltage value

6

The welding parameter values are shown in the digital display located above.

All welding parameter set values remain stored until the next time they are
changed. This applies even if the power source is switched off and on again. To
display the actual welding current during welding, select the welding current
parameter.

To display the actual welding current during welding:

Press the "Parameter selection" button to select the welding current para-

-

meter
The actual welding current is shown on the digital display during welding.

-

Open the gas cylinder valve

7

Adjust quantity of shielding gas:

8

Tap the Gas-test button

-

Turn the adjusting screw on the bottom of the gas pressure regulator un-

-

til the manometer displays the desired quantity of gas
Tap the Gas-test button again

-

EN-US

Corrections dur­ing welding

CAUTION!

Danger of injury and damage from electric shock and from the wire electrode
emerging from the torch.

When you press the torch trigger:

Keep the welding torch away from your face and body

▶

Wear suitable protective goggles

▶

Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or groun-

▶

ded parts (e.g., housing, etc.)

Press the torch trigger and start welding

9

To obtain the best possible welding results, the arc-force dynamic parameter will
sometimes need to be adjusted.

Press the "Parameter selection" button to select the arc-force dynamic para-

1

meter

Use the selection dial to set the desired arc-force dynamic value

2

The welding parameter value is shown in the digital display located above it.

73

Spot welding and stitch welding

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

spot welding and stitch welding modes are activated on the control panel.

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

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

Spot welding

In the Setup menu, set the spot welding time / stitch welding time SPt

1

IMPORTANT! Stitch pause time SPb = OFF must be set for spot welding!

Only for synergic welding:

2

Use the corresponding buttons to select the filler metal used, the wire dia­meter, and the shielding gas

Select the desired welding process:

3

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

Select spot welding/stitch welding mode:

4

74

Spot welding/stitch welding
The spot/stitch/SynchroPulse (SF) indicator lights up on the control panel.

Depending on the welding process selected, select the desired welding para-

5

meters and adjust them using the appropriate selection dial

Open the gas cylinder valve

6

Adjust quantity of shielding gas

7

CAUTION!

Stitch welding

Danger of injury and damage from electric shock and from the wire electrode
emerging from the torch.

When you press the torch trigger:

Keep the welding torch away from your face and body

▶

Wear suitable protective goggles

▶

Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or groun-

▶

ded parts (e.g., housing, etc.)

Spot welding

8

Procedure for establishing a welding spot:

Keep the welding torch vertical

1

Press and release the torch trigger

2

Maintain the position of the welding torch

3

Wait for the gas post-flow time

4

Raise the welding torch

5

In the Setup menu, set the stitch pause time SPb

1

EN-US

Stitch welding is enabled.
The Int (Interval) parameter is displayed in the Setup menu.

In the Setup menu for the Int parameter, set the operating mode for stitch

2

welding (2T / 4T)

In the Setup menu, set the spot welding/stitch welding time SPt

3

Only for synergic welding:

4

Use the corresponding buttons to select the filler metal used, the wire dia­meter, and the shielding gas

Select the desired welding process:

5

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

MIG/MAG pulsed synergic welding

Select spot welding/stitch welding mode:

6

Spot welding/stitch welding
The spot/stitch/SynchroPulse (SF) indicator lights up on the control panel.

75

Depending on the welding process selected, select the desired welding para-

7

meters and adjust them using the appropriate selection dial

Open the gas cylinder valve

8

Adjust quantity of shielding gas

9

CAUTION!

Danger of injury and damage from electric shock and from the wire electrode
emerging from the torch.

When you press the torch trigger:

Keep the welding torch away from your face and body

▶

Wear suitable protective goggles

▶

Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or groun-

▶

ded parts (e.g., housing, etc.)

Stitch welding

10

Procedure for stitch welding:

Keep the welding torch vertical

1

Depending on the stitch mode set under the Int parameter:

2

Press and hold the torch trigger (2-step mode)
Press and release the torch trigger (4-step mode)

Maintain the position of the welding torch

3

Wait for the welding interval

4

Position the welding torch at the next point

5

To stop stitch welding, depending on the stitch mode set under the Int para-

6

meter:
Release the torch trigger (2-step mode)
Press and release the torch trigger (4-step mode)

Wait for the gas post-flow time

7

Raise the welding torch

8

76

EasyJob mode

General The "Save" buttons allow up to five EasyJob operating points to be saved. Each

operating point corresponds to the settings made on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

EN-US

Saving EasyJob
operating points

Retrieving Easy­Job operating
points

Deleting Easy­Job operating
points

Press and hold one of the "Save" buttons to save the current set-

1

tings on the control panel, e.g.

The left display reads "Pro"

-

After a short time, the left display switches to the original

-

value

Release the "Save" button

2

To retrieve saved settings, press the corresponding "Save" button

1

briefly, e.g.

The control panel will show the saved settings

-

Press and hold the relevant "Save" button to delete the memory

1

content of that "Save" button, e.g.

The left display reads "Pro".

-

After a short time, the left display switches to the original

-

value

Keep the "Save" button held down

2

The left display reads "CLr".

-

After a while, both displays show "---"

-

Release the "Save" button

3

77

Retrieving Easy­Job operating
points on the Up/
Down welding
torch

Press one of the "Save" buttons on the control panel to retrieve the saved set­tings using the Up/Down welding torch.

Press one of the "Save" buttons on the control panel, e.g.:

1

The control panel will show the saved settings.

The "Save" buttons can now be selected using the buttons on the Up/Down weld­ing torch. Vacant "Save" buttons are skipped.

In addition to the "Save" button number lighting up, a number is displayed dir­ectly on the Up/Down welding torch:

Display on the Up/Down welding
torch

EasyJob operating point on the con­trol panel

78

MMA welding, arc air gouging

79

80

Manual Metal Arc Welding

EN-US

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back

▶

on.
After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

Set the power switch to - O -

1

Unplug mains plug

2

On the power source, disconnect all leads to the wirefeeder

3

IMPORTANT! Check the rod electrode packaging to determine whether the

rod electrodes are for (+) or (-) welding.

Depending on the type of electrode, insert the grounding cable into the (-)

4

current socket or into the (+) current socket and lock

Connect the other end of the grounding cable to the workpiece

5

Depending on the type of electrode, insert the bayonet connector of the

6

electrode holder cable into the free current socket with opposite polarity and
twist it clockwise to lock

Insert mains plug

7

81

Manual metal
arc welding

CAUTION!

Danger of injury and damage from electric shock.

When the power switch is switched to position - I -, the rod electrode in the elec­trode holder is live.

Ensure that the rod electrode is not touching any people or electrically con-

▶

ductive or grounded parts (housing, etc.).

Set the power switch to position - I -: all indicators on the control panel

1

briefly illuminate

Press the "Process" button to select the MMA welding process:

2

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

If the MMA welding process is selected, a cooling unit, if present, is automat­ically deactivated. It is not possible to turn it on.

IMPORTANT! Under certain circumstances, it may not be possible to change
welding parameters that have been set on the control panel of a system compon­ent - such as remote control or wirefeeder - on the control panel of the power
source.

Press the "Parameter selection" button to select the amperage parameter.

3

Use the selection dial to set the desired amperage.

4

The amperage value is displayed on the left-hand digital display.

All parameter set values that are set using the selection dial are saved until
their next alteration. This applies even if the power source is switched off and
on again.

Initiate welding process

5

To display the actual welding current during welding:

Press the "Parameter selection" button to select the welding current para-

-

meter
The actual welding current is shown on the digital display during welding.

-

82

Corrections dur­ing welding

To obtain the best possible welding results, the arc-force dynamic parameter will
sometimes need to be adjusted.

Press the "Parameter selection" button to select the arc-force dynamic para-

1

meter

Use the selection dial to set the desired arc-force dynamic value

2

The welding parameter value is shown in the digital display located above it.

To influence the short-circuiting dynamic at the instant of droplet transfer:

- = hard, stable arc

0 = neutral arc
+ = soft, low-spatter arc

EN-US

83

HotStart func-

I (A)

300

200

HCU

I

H

HCU > I

H

t (s)

0,5

1

1,5

Hti

tion

To obtain the best possible welding result, the HotStart function will sometimes
need to be adjusted.

Advantages

Improved ignition properties, even when using electrodes with poor ignition

-

properties
Better fusion of the parent material during the start-up phase, meaning few-

-

er cold-shut defects
Slag inclusions largely avoided

-

The setting of the available parameters is described in the section "Setup set­tings", "Setup menu - level 2".

Key

Hti Hot-current time,

0 - 2 s,
Factory setting 0.5 s

HCU HotStart current,

100 - 200%,
Factory setting 150%

Anti-Stick func­tion

I

Main current = set welding cur-

H

rent

Function

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

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

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

The anti-stick (Ast) function can be activated and deactivated in the Setup menu
for the setup parameters for MMA welding.

84

Arc Air Gauging

EN-US

Safety

WARNING!

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

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel.
Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid.
Secure all devices and components involved so they cannot be switched back

▶

on.
After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation IMPORTANT! A grounding cable with a cable cross-section of 120 mm² is re-

quired for arc air gouging.

Set the power switch to - O -

1

Unplug the mains plug

2

Remove the MIG/MAG welding torch

3

Insert the grounding cable into the (-) current socket and lock

4

Connect the other end of the grounding cable to the workpiece

5

Insert the bayonet connector of the arc air gouging torch into the (+) current

6

socket and twist it clockwise to lock

Connect the compressed air connection of the arc air gouging torch to the

7

compressed air supply
Working pressure: 5 - 7 bar (constant)

Clamp the carbon electrode so that the electrode tip protrudes approx. 100

8

mm from the arc air gouging torch;
the air outlet openings of the arc air gouging torch must be at the bottom

Insert the mains plug

9

Arc air gouging

CAUTION!

Danger of injury and damage from electric shock.

When the power switch is switched to position - I -, the electrode in the arc air
gouging torch is live.

Ensure that the electrode is not touching any people or electrically conduct-

▶

ive or grounded parts (housing, etc.).

85

CAUTION!

Risk of personal injury due to loud operating noise.

Use suitable hearing protection during arc air gouging!

▶

Set the power switch to position - I -: all indicators on the control panel

1

briefly illuminate

Press the "Process" button to select the MMA welding process:

2

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

If the MMA welding process is selected, a cooling unit, if present, is automat­ically deactivated. It is not possible to turn it on.

IMPORTANT! Under certain circumstances, it may not be possible to change
welding parameters that have been set on the control panel of a system compon­ent - such as remote control or wirefeeder - on the control panel of the power
source.

In the setup menu for MMA welding, set the AAG parameter to "on";

3

to enter the setup menu, see page 95.

NOTE!

Settings of the break voltage and the starting current time are ignored.

Exit the setup menu for MMA welding

4

Press the "Parameter selection" button to select the amperage parameter.

5

Use the selection dial to set the main current depending on the electrode

6

diameter and in accordance with the specifications on the electrode pack­aging

The amperage value is displayed on the left-hand digital display.

NOTE!

At higher amperages, use both hands to guide the arc air gouging torch!

Use a suitable welding helmet.

▶

Open the compressed air valve on the arc air gouging torch handle

7

Initiate machining operation

8

The angle of contact of the carbon electrode and gouging speed determine the
depth of an air gap.

The parameters for arc air gouging correspond to the welding parameters for
MMA welding, see page 99.

86

Easy Documentation

87

88

General

General If the Easy Documentation option is available on the power source, the most im-

portant welding data for each welding operation can be documented and saved
as a CSV file on a USB thumb drive.
A Fronius signature is stored with the welding data, which can be used to check
and guarantee the authenticity of the data.

Easy Documentation is activated / deactivated by plugging / unplugging the sup­plied Fronius USB thumb drive with FAT32 formatting into the back of the power
source.

IMPORTANT! To document the welding data, the date and time must be set cor­rectly.

EN-US

Documented
welding data

The following data are documented:

Device type
File name
Part number
Serial number
Firmware version of power source
Firmware of PC board DOCMAG (Easy Documentation)
Document version
https://www.easydocu.weldcube.com (A PFDF report of selected welding data
can be created under this link)

Nr. Meter

Start by plugging in the USB thumb drive;
when switching the power source off and on, the meter continues
at the last weld seam number.
A new CSV file is created after 1000 welding operations.

Date Date yyyy-mm-dd

Time Time hh:mm:ss

at the start of current flow

Duration Duration in [s]

from start of current flow to end of current (current flow signal)

I Welding current * in [A]

U Welding voltage * in [V]

vd Wire speed * in [m/min]

wfs Wire speed * in [ipm]

IP Power * from current values in [W]

IE Energy from instantaneous values in [kJ]

over the entire welding operation

I-Mot Motor current * in [A]

Synid Characteristic number

for each welding operation

Job EasyJob number

per weld seam

89

Process Welding process

Mode Operating mode

Status PASS: regular welding

IGN: Welding canceled during the ignition phase
Err | xxx: Welding canceled due to an error; the corresponding ser­vice code is documented

Interval Weld seam number for "Interval" operating mode

Signa­ture

* in each case from the main process phase;

The welding data are documented as average values in the main process phase
and for each welding operation.

New CSV file A new CSV file is generated

When the USB thumb drive is disconnected and reconnected with the power

-

source switched on
When the date and time are changed

-

From 1000 welding operations

-

During a firmware update

-

When the USB thumb drive is disconnected and reconnected to another

-

power source
(= change of serial number).

Signature for each weld seam number

in the event of termination in the ignition phase, the average value
in the ignition phase is stored and an identifier is output to indicate
that the main process phase has been reached

PDF report /
Fronius signa­ture

By scanning this link...

A PDF report of the selected welding data can be created

-

The authenticity of the welding data can be checked and

-

guaranteed via the Fronius signature read out with the
welding data.

https://easydocu.weldcube.com

90

Activating / deactivating Easy Documentation

1

USB 3.1

FAT32

1

+

...

+

...

EN-US

Activating Easy
Documentation

The power source display shows:

Easy Documentation is activated.

doc | on is also displayed when the
power source is switched off and on
again with the USB thumb drive con­nected.

Easy Documentation remains activ-

Plug in the USB thumb drive

Acknowledge the display by pressing the arrow key

2

Set the date and time

3

ated.

Set the date and

Setting the date and time is carried out in the 2nd level of the service menu.

time

1

The first parameter in the service
menu is displayed.

2

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

3

The first parameter in the 2nd level of
the service menu is displayed.

4

Select the "yEA" (= year) setup para­meter using the left-hand selection
dial

91

5

NOTE!

If the power source is reset to factory settings via setup parameter FAC, the
date and time remain stored.

To set the date and time:

Left-hand selection dial:

-

select parameter
Right-hand selection dial:

-

change values

Setting ranges:

yEA Year (20yy; 0 - 99)
Mon Month (mm; 1 -1 12)
dAY Day (dd; 1 - 31)
Hou Hour (hh; 0 - 24)
Min Minute (mm; 0 - 59)

Deactivating
Easy Document­ation

CAUTION!

Risk of data loss or data damage due to premature disconnection of the USB
thumb drive

Do not disconnect the USB thumb drive until approx. 10 seconds after the

▶

end of the last welding operation to ensure correct data transfer.

Unplug the USB thumb drive from the power source

1

The power source display shows:

Easy Documentation is deactivated.

Acknowledge the display by pressing the arrow key

2

92

Setup Settings

93

94

Setup Menu

MANUAL
STD SYNERGI C
PULSE SYNER GIC

MANUAL
STD SYNERGI C
PULSE SYNER GIC

2T
4T

+

+

MANUAL
STD SYNERGI C
PULSE SYNER GIC

2T
4T

+

+

General The Setup menu offers easy access to expert knowledge related to the power

source, as well as additional functions. The Setup menu makes it possible to eas­ily adjust the parameters for various tasks.

Operation Accessing the Setup menu is described with reference to the MIG/MAG standard

synergic welding process.
Access is the same for the other welding processes.

Accessing the Setup menu

EN-US

1

2

Adjusting parameters

1

Exiting the Setup menu

1

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

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

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

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

95

Setup paramet­ers for
MIG/MAG syner­gic welding

The specifications "min." and "max." are used for setting ranges that vary accord­ing to the power source, welding program, etc.

GPr Gas pre-flow time

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

GPo Gas post-flow time

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

SL Slope (for special 2-step mode and special 4-step mode)

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

I-S Starting current (for special 2-step mode and special 4-step mode)

Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 100

I-E Final current (for special 2-step mode and special 4-step mode)

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

t-S Starting current duration (only for special 2-step mode)

Unit: s
Setting range: 0.0 - 9.9
Factory setting: 0.0

t-E Final current duration (only for special 2-step mode)

Unit: s
Setting range: 0.0 - 9.9
Factory setting: 0.0

Fdi Feeder inching speed

Unit: m/min (ipm)
Setting range: 1 - max (39.37 - max)
Factory setting: 10 (393.7)

bbc Burnback effect

Burnback effect due to wire retraction at the end of welding
When the welding current is switched off, the wire electrode is retracted
at 7.5 m/min for the duration of the set bbc value.

Unit: s
Setting range: 0 - 0.2
Factory setting: 0

96

Ito Length of wire that is fed before the safety cut-out trips

Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF

NOTE!

The Ito function (length of wire fed until safety cut-out trips) is a safety func­tion.

At high wire speeds in particular, the length of wire fed until the safety cut-out
trips can deviate from the set wire length.

SPt Spot welding time / interval welding time

Unit: s
Setting range: 0.3 - 5
Factory setting: 1

SPb Interval pause time

Unit: s
Setting range: OFF, 0.3 - 10 (in 0.1 s increments)
Factory setting: OFF

IMPORTANT! SPb = OFF must be set for spot welding!

Int Interval

Displayed only if a value has been set for SPb
Unit:
Setting range: 2T (2-step), 4T (4-step)
Factory setting: 2T (2-step)

EN-US

F Frequency for SynchroPulse

Unit: Hz
Setting range: OFF, 0.5 - 5
Factory setting: OFF

dFd Delta wire feed

Offset welding power for SynchroPulse option

Unit: m/min (ipm)
Setting range: 0 - 3 (0 - 118.1)
Factory setting: 2 (78.7)

AL2 Arc length correction for upper SynchroPulse operating point

Unit: % (of welding power)
Setting range: 30 - +30
Factory setting: 0

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds
to restore the factory settings

- when "PrG" appears on the digital display, the power source has been re­set

IMPORTANT! If the power source is reset, all the personal settings in the
Setup menu are lost.
Operating points stored using save buttons remain stored when the power
source is reset. The functions in the second level of the setup menu (2nd)
are also not deleted. Exception: Ignition time-out function parameter (ito).

2nd Second level of the Setup menu (see "Setup Menu 2nd Level")

97

Setup paramet­ers for
MIG/MAG
standard manual
welding

The specifications "min." and "max." are used for setting ranges that vary accord­ing to the power source, welding program, etc.

GPr Gas pre-flow time

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

GPo Gas post-flow time

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

Fdi Feeder inching speed

Unit: m/min (ipm)
Setting range: 1 - max (39.37 - max)
Factory setting: 10 (393.7)

bbc Burnback effect

Burnback effect due to a delayed switch-off of the welding current after
the wire electrode has come to a stop. A ball forms on the wire electrode.

Unit: s
Setting range: AUt, 0 - 0.3
Factory setting: AUt

IGC Ignition current

Unit: A
Setting range: 100 - 650
Factory setting: 500

Ito Length of wire that is fed before the safety cut-out trips

Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF

NOTE!

The Ito function (length of wire fed until safety cut-out trips) is a safety func­tion.

At high wire speeds in particular, the length of wire fed until the safety cut-out
trips can deviate from the set wire length.

SPt Spot welding time / interval welding time

Unit: s
Setting range: 0.3 - 5
Factory setting: 0.3

SPb Interval pause time

Unit: s
Setting range: OFF, 0.3 - 10 (in 0.1 s increments)
Factory setting: OFF

98

Int Interval

Displayed only if a value has been set for SPb
Unit:

Setting range: 2T (2-step), 4T (4-step)
Factory setting: 2T (2-step)

Setup paramet­ers for MMA
welding

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds
to restore the factory settings

- when "PrG" appears on the digital display, the power source has been re­set

IMPORTANT! If the power source is reset, all the personal settings in the
Setup menu are lost.
Operating points stored using save buttons remain stored when the power
source is reset. The functions in the second level of the setup menu (2nd)
are also not deleted. Exception: Ignition time-out function parameter (ito).

2nd Second level of the Setup menu (see "Setup Menu 2nd Level")

IMPORTANT! When resetting the power source using the Factory FAC setup
parameter, the hot current time (Hti) and HotStart current (HCU) setup paramet­ers are also reset.

HCU HotStart current

Unit: %
Setting range: 100 - 200
Factory setting: 150

EN-US

Hti Hot current time

Unit: s
Setting range: 0 - 2.0
Factory setting: 0.5

ASt Anti-stick

Unit: ­Setting range: On, OFF
Factory setting: OFF

AAG Gouging (Arc Air Gauging)

Arc air gouging with a carbon electrode, e.g., for joint preparation
Unit: ­Setting range: on / OFF
Factory setting: oFF

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds
to restore the factory settings - when "PrG" appears on the digital display,
the power source has been reset.
IMPORTANT! If the power source is reset, all the personal settings are
lost.
Operating points stored using save buttons are not deleted when the
power source is reset - they remain stored. The functions in the second
level of the setup menu (2nd) are also not deleted. Exception: Ignition
time-out function parameter (ito).

2nd Second level of the Setup menu (see "Setup Menu 2nd Level")

99

Setup Menu 2nd Level

MANUAL
STD SYNERGI C
PULSE SYNER GIC

MANUAL
STD SYNERGI C
PULSE SYNER GIC

2T
4T

+

+

MANUAL
STD SYNERGI C
PULSE SYNER GIC

2T
4T

+

+

Limitations The following restrictions occur in relation to the Setup menu 2nd level:

Setup menu 2nd level cannot be selected:

during welding

-

if the "Gas test" function is active

-

if the "Wire threading" function is active

-

if the "Wire withdrawal" function is active

-

if the "Gas purging" function is active

-

If level 2 of the Setup menu is selected, the following functions are not available,
even in robot mode:

Welding start-up - the "Power source ready" signal will not be emitted for ro-

-

bot mode
Gas test

-

Wire inching

-

Wire withdrawal

-

Gas purging

-

Operation
(Setup Menu 2nd
Level)

Accessing the 2nd level of the Setup menu:

1

2

3

4

Adjusting parameters

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

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

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

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

1

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

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

100