Fronius VW AG/VAS 821 001/MIG270i Operating Instruction [EN]

VW AG/VAS 821 001/MIG270i

EN-US

MIG/MAG Power source

Operating Instructions

VOLKSWAGEN

AKTIENGESELLSCHAFT

42,0426,0347,EA 015-18112020

Table of contents

Safety Instructions 7

Explanation of Safety Instructions 7
General 7
Intended Use 7
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 8
Residual current circuit breaker 9
Personal Protection and Protection of Others 9
Data regarding Noise Emission Values 10
Danger from toxic gases and vapors 10
Danger from Flying Sparks 10
Risks from grid current and welding current 11
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 16
Disposal 17
Data backup 17
Copyright 17

EN-US

General information 19

General 21

Device concept 21
Functional principle 21
Application areas 21
Warning notices on the device 22
Description of Warning Notices on the Device 24

Welding packages, welding characteristics and welding processes 26

General 26
Welding characteristics 26
Summary of MIG/MAG pulse synergic welding 28
Summary of MIG/MAG standard synergic welding 28
Summary of the PMC process 29
Summary of the LSC process 29
Summary of SynchroPulse welding 29
Summary of the CMT process 30

System components 31

General 31
Overview 31

Operating controls, connections and mechanical components 33

Control Panel 35

General 35
Safety 35
Control panel 35
Displaying plain text for parameters 40

F1/F2 special function parameters, Favourites button 41

F1 and F2 special function parameters 41

3

The Favourites button 42

Connections, Switches, and Mechanical Components 45

Connections, switches and mechanical components 45

Installation and Startup 47

Minimum equipment for welding operations 49

General 49
MIG/MAG gas-cooled welding 49
Manual CMT welding 49
TIG DC welding 49
MMA welding 49

Before installation and initial operation 50

Safety 50
Intended Use 50
Setup regulations 50
Mains connection 50
Generator-Powered Operation 51
Information on system components 51

Connecting the Mains Cable 52

Safety 52
General 52
Stipulated mains cables 52
Connecting the mains cable - general 52

Commissioning 55

Safety 55
General 55
Connecting the gas cylinder 55
Establishing a ground earth connection 56
Connecting the welding torch 56
Inserting/replacing feed rollers 57
Inserting the wirespool 58
Inserting the basket-type spool 59
Feeding in the wire electrode 60
Setting the contact pressure 61
Adjusting the brake 62
Design of the Brake 62
Performing R/L alignment 63

Welding Mode 65

MIG/MAG Operating Modes 67

General 67
Symbols and their explanations 67
2-step mode 68
4-step mode 68
Special 4-step mode 68
Special 2-step mode 68

MIG/MAG and CMT welding 69

Safety 69
MIG/MAG and CMT welding – overview 69
Switching on the power source 69
Setting the welding process and operating mode 69
Retrieving the currently set filler metal 70
Selecting the filler metal 70
Setting the welding parameters 72
Setting the shielding gas flow rate 72
MIG/MAG or CMT welding 73

MIG/MAG and CMT welding parameters 74

Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding 74
Welding parameters for MIG/MAG standard synergic welding and LSC welding 75
Welding parameters for MIG/MAG standard manual welding 77
Explanation of footnotes 78

4

EasyJob mode 79

General 79
EasyJob mode 79

Spot welding 80

Spot welding 80

TIG welding 82

Safety 82
Preparations 82
TIG welding 82
Igniting the arc 84
Finishing welding 84

Manual Metal Arc Welding 85

Safety 85
Preparations 85
MMA welding 85
Welding parameters for manual metal arc welding 87

Setup Settings 89

Setup menu - overview 91

Entering/exiting the Setup menu 91
Setup menu - overview 92

Process parameters 93

Process parameters for start of welding/end of welding 93
Process parameters for Gas-Setup 94
Process parameters for process control 95
Penetration stabilizer 95
Arc length stabilizer 97
Combination of penetration stabilizer and arc length stabilizer 99
Process parameters for spot welding 100
Process parameters for monitoring and components 100
Process parameters for electrode setup 101
Process parameters for TIG setup 104
Process parameters for SynchroPulse 105
Process parameters for Process Mix 107
R/L alignment 109

Settings 111

General 111
Overview 111
Setting the units 111
Setting the standards 112
Setting the display brightness 112
Displaying replaced characteristics 112
Setting F1 and F2 special function parameters via the Setup menu 112
Setting the Favourites button via the Setup menu 113
Retrieving system data 113
Setting the interior lighting 114
Restoring the factory settings 115
Resetting the password for the power source website 115
Retrieving device information 115
Setting the special display for JobMaster 115
Setting the mode for spot welding 116

Setting the language 117

Setting the language 117

Keylock 118

Keylock 118

EN-US

Troubleshooting and Maintenance 119

The Error menu 121

The Error menu 121

Troubleshooting 122

General 122

5

Safety 122
Power Source Troubleshooting 122

Service, maintenance and disposal 126

General 126
Safety 126
At every start-up 126
If necessary 126
Every 2 months 126
Every 6 months 126
Disposal 126

Technical data 127

Average consumption values during welding 129

Average wire electrode consumption during MIG/MAG welding 129
Average shielding gas consumption during MIG/MAG welding 129
Average shielding gas consumption during TIG welding 129

Technical data 130

Explanation of the Term Duty Cycle 130
Special Voltage 130
VW AG/VAS 821 001/MIG270i 131
VW AG/VAS 821 001/MIG270i MV 133
Overview with critical raw materials, year of production of the device 134

Appendix 135

VW AG/VAS 821 001/MIG270i 136

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 according to

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

- Injury or death to the operator or a third party

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

- Inefficient operation of the equipment

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

- Be suitably qualified

- Have knowledge of welding

- Have completely read and followed these Operating Instructions

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

All safety and danger notices on the device must

- Be kept in a legible state

- Not be damaged/marked

- Not be removed

- Not be covered, pasted, or painted over

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

Your personal safety is at stake!

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

7

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

Proper use also means

- Completely reading and obeying all instructions in the Operating Instructions

- Completely reading and obeying all safety instructions and danger notices

- Carrying out all the specified inspection and servicing work

Never use the device for the following applications:

- Thawing pipes

- Charging batteries

- Starting motors

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

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

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 regulations
and are trained in handling the device

- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature

- Are trained according to the requirements for the work results

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

Obligations of
Personnel

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

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.

rent 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

Residual current
circuit breaker

Personal Protec­tion and Protec­tion of Others

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

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

- Flying sparks and pieces of hot metal

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

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

- Electrical risks from grid current and welding current

- Increased noise exposure

- Harmful welding fumes and gases

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

- Flame resistant

- Insulating and dry

- Covering the entire body and in good condition with no damage

- Safety helmet

- Cuffless pants

Protective clothing involves the following:

- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter

- Wearing regulation-compliant protective goggles with side protection behind the face
guard

- Wearing rigid, wet-insulating footwear

- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)

- Wearing ear protection to reduce noise exposure and protect against injury

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

- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)

- Provide suitable protective equipment or

- Construct suitable protective walls and curtains.

9

Data regarding
Noise Emission
Values

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

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

Danger from
toxic gases and
vapors

The fumes produced during welding contain toxic gases and vapors.

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

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

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

- Do not breathe them in.

- Extract them from the work area using appropriate equipment.

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

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

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

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

- The metals used for the workpiece

- Electrodes

- Coatings

- Cleaning agents, degreasers, and the like

- The welding process used

Danger from Fly­ing Sparks

10

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

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

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

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

Flying sparks can cause fires and explosions.

Never undertake welding near flammable materials.

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

Keep suitable, tested fire extinguishers on hand.

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

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

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

EN-US

Risks from grid
current and weld­ing current

An electric shock can be fatal.

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

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

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

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

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

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

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

- Never immerse it in liquids to cool it

- Never touch it when the power source is switched on.

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

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

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

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

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

Switch off unused devices.

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

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

11

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.

Stray welding
currents

EMC Device Clas­sifications

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

- Fire

- Overheating of components connected to the workpiece

- Destruction of ground conductors

- Damage to the device and other electrical equipment

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

Secure the workpiece terminal 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 electrical distributors, double-headed retainers, 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.

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

Devices in emission class B:

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

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

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

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

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

- Safety devices

- Grid power lines, signal lines and data transfer lines

- EMC and telecommunications equipment

- Devices for measuring and calibrating

12

Supporting measures to avoid EMC problems:

1. Grid power supply

- If electromagnetic interference occurs despite a grid connection that complies

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

2. Welding power-leads

- Keep them as short as possible

- Route them close together (also to avoid EMF problems)

- Route them far from other lines

3. Equipotential bonding

4. Workpiece grounding

- If necessary, establish grounding using suitable capacitors

5. Shield, if necessary

- Shield other devices in the vicinity

- Shield the entire welding installation

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 cables and the head/torso of the welder as large
as possible for safety reasons

- Do not carry welding cables and hosepacks over one's shoulder or wrap them
around one's 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 parts must only be opened/removed during maintenance and repair
work.

During operation:

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

- Keep all covers and side parts closed.

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

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

Do not touch the workpiece during or after welding—burning hazard.

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.

13

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

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

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

Only use suitable load-carrying equipment from the manufacturer when transporting
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.

Requirement for
the shielding gas

Danger from
Shielding Gas
Cylinders

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.

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.

14

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

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

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

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

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

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

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

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

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.

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

Maintenance and
repair

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

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

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

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

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

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

- Do not carry out any modifications, alterations, etc. to the device without the manu­facturer's consent.

- Components that are not in perfect condition must be replaced immediately.

- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.

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

Safety Inspection 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 12-month
interval.

16

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.

Disposal Do not dispose of this device with normal domestic waste! To comply with the European

Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must be returned to your dealer, or you must locate the approved collection and
recycling facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!

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.

EN-US

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

Device concept The MIG/MAG VW AG/VAS 821 001/

MIG270i power source is a completely
digitised, microprocessor-controlled
inverter power source with integrated 4­roller wire drive.

The modular design and potential for sys­tem add-ons ensure a high degree of flex­ibility.
Its compact design makes the power
source particularly suitable for mobile
applications.

The power source can be adapted to any
specific situation.

EN-US

Functional prin­ciple

Application areas The devices are used in trade and industry for manual applications with classical steel,

The central control and regulation unit of the power sources is coupled with a digital sig­nal processor. The central control and regulation unit and the 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.

This results in:

- a precise welding process

- exact reproducibility of all results

- excellent weld properties.

galvanised sheets, chrome/nickel and aluminium.

The integrated 4-roller wire drive, high performance and low weight of the power source
makes it the ideal choice for portable applications on building sites or in repair work­shops.

21

Warning notices

*)

*)

on the device

Warning notices and safety symbols are affixed to power sources with the CSA test mark
for use in North America (USA and Canada). 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 damage.

22

*) on the inside of the device

Welding is dangerous. The following basic requirements must be met to ensure the
equipment is used properly:

- Anyone performing automated welding must be sufficiently qualified

- Suitable protective equipment must be used

- All persons not involved must be kept at a safe distance from the wirefeeder and the
welding process

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

- These Operating Instructions

- All the Operating Instructions for the system components, especially the safety rules

Do not dispose of used devices with domestic waste. Dispose of them according to the
safety rules.

Keep hands, hair, clothing and tools away from moving parts. For example:

- Cogs

- Feed rollers

- Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened / removed while maintenance or repair
work is being carried out.

EN-US

23

Description of

AB

Warning Notices
on the Device

On certain device versions, warning notices are attached to the device.

The arrangement of the symbols may vary.

. Warning! Watch Out!

There are possible hazards as shown by the symbols.

A Drive rolls can injure fingers.

B Welding wire and drive parts are at welding voltage during operation

Keep hands and metal objects away.

1. Electric shock can kill.

1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear

wet or damaged gloves.

1.2 Protect yourself from electric shock by insulating yourself from work and ground.

1.3 Disconnect input plug or power before working on machine

2. Breathing welding fumes can be hazardous to your health.

2.1 Keep your head out of the fumes.

2.2 Use forced ventilation or local exhaust to remove the fumes.

2.3 Use ventilating fan to remove fumes.

24

3 Welding sparks can cause explosion or fire.

xx,xxxx,xxxx *

3.1 Keep flammables away from welding. Don’t weld near flammables.

3.2 Welding sparks can cause fires.Have a fire extinguisher nearby and have a

watchperson ready to use it.

3.3 Do not weld on drums or any closed containers.

EN-US

4. Arc rays can burn eyes and injure skin.

4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use

welding helmet with correct shade of filter. Wear complete body protection.

5. Become trained and read the instructions before working on the machine or

welding.

6. Do not remove or paint over (cover) the label.

* identifying number to order label from manufacturer

25

Welding packages, welding characteristics and
welding processes

General Various welding packages, welding characteristics and welding processes are available

with power sources that enable a wide range of materials to be effectively welded.

Welding charac­teristics

Depending on the welding process and shielding gas mix, various process-optimised
welding characteristics are available when selecting the filler metal.

Examples of welding characteristics:

- MIG/MAG 3700 PMC Steel 1,0mm M21 - arc blow *

- MIG/MAG 3450 PMC Steel 1,0mm M21 - dynamic *

- MIG/MAG 3044 Pulse AlMg5 1.2 mm I1 - universal *

- MIG/MAG 2684 Standard Steel 0.9 mm M22 - root *

The additional designation (*) next to the welding process provides information about the
special properties and use of the welding characteristic.
The description of the characteristics is set out as follows:

Marking

Welding process
Properties

arc blow

PMC
Characteristic with improved arc break properties by deflecting the external magnetic
fields

braze

CMT, LSC, PMC
Characteristics for brazing processes (high brazing speed, reliable wetting and good flow
of braze material)

braze+

CMT
Optimised characteristics for brazing processes with special "Braze+" gas nozzle (narrow
gas nozzle opening, high shielding gas flow rate)

cladding

CMT, LSC, PMC
Characteristic for cladding with low penetration, low dilution and wide weld seam flow for
improved wetting

dynamic

CMT, PMC, Pulse, Standard
Characteristics for high welding speeds with concentrated arc

flanged edge

CMT
Characteristics for flange welds with frequency and energy yield adjustments;
the edge is fully covered with the weld seam but not melted down

galvanized

CMT, LSC, PMC, Pulse, Standard
Characteristics for galvanised sheet surfaces (low zinc pore risk, reduced zinc melting
loss)

26

galvannealed

PMC
Characteristics for iron-zinc coated sheet surfaces

gap-bridging

CMT, PMC
Characteristics with very low heat input for optimum gap-bridging ability

hot spot

CMT
Characteristics with hot start sequence, specifically for plug welds and MIG/MAG spot
weld joints

mix **
PMC

also required: Pulse and PMC welding packages

Characteristics with process switch between pulsed and dip transfer arc
Specially for welding vertical-up seams with cyclic change between a hot and cold sup­porting process phase.

mix ** / ***
CMT

EN-US

also required: CMT drive unit WF 60i Robacta Drive CMT, Pulse, Standard and CMT
welding packages

Characteristics with process switch between pulsed and CMT, where the CMT process is
initiated by wire movement reversal.

mix drive ***
PMC

also required: PushPull drive unit WF 25i Robacta Drive or WF 60i Robacta Drive CMT,
Pulse and PMC welding packages

Characteristics with process switch between pulsed and dip transfer arc, where the dip
transfer arc is initiated by wire movement reversal.

multi arc

PMC
Characteristics for components being welded by several arcs each influencing the other

PCS **
PMC
Pulse Controlled Sprayarc - Direct transition from the concentrated pulsed arc to a short
spray arc. The advantages of pulsed and standard arcs combined in a single character­istic

pipe

PMC
Characteristic for pipe applications and positional welding on narrow gap applications

retro

CMT, Pulse, PMC, Standard
older characteristics

ripple drive ***
PMC

also required:
CMT drive unit WF 60i Robacta Drive CMT

27

Characteristics that behave like interval mode for clear weld rippling, especially with alu­minium

root

CMT, LSC, Standard
Characteristics for root passes with powerful arc

seam track

PMC, Pulse
Characteristics with increased seam tracking signal, especially for use with several weld­ing torches on one component.

TIME

PMC
Characteristics for welding with long stick out and TIME shielding gases
(T.I.M.E. = Transferred Ionized Molten Energy)

universal

CMT, PMC, Pulse, Standard
Characteristics for conventional welding tasks

WAAM

CMT
Characteristics with reduced heat input and greater stability at a higher deposition rate
for welding bead onto bead in adaptive structures

Summary of
MIG/MAG pulse
synergic welding

weld+

CMT
Characteristics for welding with short Stick out and Braze+ gas nozzle (Gas nozzle with
small opening and high flow velocity)

** Mixed process characteristics
*** Welding characteristics with special properties provided by additional hardware

MIG/MAG pulse synergic

MIG/MAG pulse synergic welding is a pulsed-arc process with controlled material trans­fer.
In the base current phase, the energy supply is reduced to such an extent that the arc is
only just stable and the surface of the workpiece is preheated. In the pulsing current
phase, a precise current pulse ensures the targeted detachment of a droplet of welding
material.
This principle guarantees a low-spatter weld and precise working across the entire power
range, as unwelcome short circuits with simultaneous droplet explosion and uncontrolled
welding spatter are virtually eliminated.

Summary of
MIG/MAG stand­ard synergic
welding

28

MIG/MAG standard synergic

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

Short circuit arc
Droplet transfer takes place during a short circuit in the lower power range.

Intermediate arc
The droplet increases in size on 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

Summary of the
PMC process

Summary of the
LSC process

Summary of Syn­chroPulse weld­ing

PMC = Pulse Multi Control

PMC is a pulsed arc welding process with high-speed data processing, precise recording
of the process status and improved droplet detachment. Faster welding possible with a
stable arc and even fusion penetration.

LSC = Low Spatter Control

LSC is a new, low-spatter dip transfer arc process.The current is reduced before break­ing the short-circuit bridge; re-ignition takes place at significantly lower welding current
values.

SynchroPulse is available for all processes (standard/pulsed/LSC/PMC).
Due to the cyclical change of welding power between two operating points, Syn­chroPulse achieves a flaking seam appearance and non-continuous heat input.

29

Summary of the
CMT process

CMT = Cold Metal Transfer

A special CMT drive unit is required for the CMT process.

The reversing wire movement in the CMT process results in a droplet detachment with
improved dip transfer arc properties.
The advantages of the CMT process are as follows

- Low heat input

- Less spattering

- Reduced emissions

- High process stability

The CMT process is suitable for:

- Joint welding, cladding and brazing – particularly in the case of high requirements in
terms of heat input and process stability

- Welding on light-gauge sheet with minimal distortion

- Special connections, such as copper, zinc, and steel/aluminium

NOTE!

A CMT reference book is available complete with typical applications; see
ISBN 978-3-8111-6879-4.

30

System components

(1)

(2)

(3)

(4)

General The power sources can be operated with various system components and options. This

makes it possible to optimise procedures and to simplify machine handling and opera­tion, as necessitated by the particular field of application in which the power source is to
be used.

EN-US

Overview

(1) Trolley
(2) Power source VW AG/VAS 821

001/MIG270i

(3) Power source VW AG/VAS 821

001/MIG220

(4) Gas cylinder holder

also:

- Welding torch

- Grounding cable and electrode cable

31

32

Operating controls, connections and

mechanical components

33

34

Control Panel

(1) (2) (3) (4) (5) (6)

(7)

(10)

(8)

(9)

(17)

(16)

(15)
(14)

(13)

(12)

(11)

General Welding parameters can be easily changed and selected using the adjusting dial.

The parameters are shown on the display while welding is in progress.

The synergic function ensures that other welding parameters are also adjusted whenever
an individual parameter is changed.

NOTE!

As a result of firmware updates, you may find that your device has certain func­tions that are not described in these operating instructions, or vice versa.

Certain illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.

EN-US

Safety

Danger due to incorrect operation.

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

▶
▶

Control panel

WARNING!

Do not use the functions described here until you have fully read and understood the
Operating Instructions.
Do not use the functions described here until you have fully read and understood all
of the Operating Instructions of the system components, especially the safety rules.

35

No. Function

(1) Process control parameter indicator

For the LSC and PMC welding processes

Penetration stabilizer indicator

Lights up if the penetration stabilizer is active

Arc length stabilizer indicator

Lights up when the arc length stabilizer is active

(2) Left parameter selection

The corresponding indicator lights up when a parameter is selected.
The following parameters can be selected by pressing the button:

Material thickness *

In mm or inches

Welding current *

In A
Before the start of welding, the machine automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.

Wire speed *

In m/min or ipm

Special function

Any parameter can be assigned to this
The function can be selected if a parameter has been saved.

36

Penetration stabilizer

Arc length stabilizer

The "Penetration stabilizer" and "Arc length stabilizer" process control paramet­ers can only be selected when the LSC/PMC welding process is used.
The currently adjustable parameter is marked with an arrow.
* Synergic parameter When a synergic parameter is changed, the synergic func­tion automatically changes all other synergic parameters to match.

(3) Display

For displaying values

(4) Hold/Intermediate arc indicator

Hold indicator

The indicator lights up at the end of each welding operation and the actual values
for the welding current, welding voltage and wire speed, etc. are automatically
shown on the display.

EN-US

Intermediate arc indicator

The indicator lights up when a spatter-prone intermediate arc occurs between the
dip transfer arc and the spray arc.

(5) Right parameter selection

The corresponding indicator lights up when a parameter is selected.
The following parameters can be selected by pressing the button:

Arc length correction

For correcting the arc length

Welding voltage *

In V
Before the start of welding, the machine automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.

Pulse/dynamic correction

37

The function varies according to the welding process being used. A description of
the various functions can be found in the Welding chapter under the correspond­ing welding process.

Special function

Any parameter can be assigned to this
The function can be selected if a parameter has been saved.
* Synergic parameter
When a synergic parameter is changed, the synergic function automatically
changes all other synergic parameters to match.

(6) Indicators

SFI indicator

Lights up when SFI (Spatter Free Ignition) is active

SynchroPulse indicator

Lights up when SynchroPulse is active

VRD indicator

Lights up when the voltage reduction device (VRD) is active

(7) EasyJob buttons

For saving, retrieving and deleting EasyJobs
The LED on the corresponding button lights up when an EasyJob is selected.

(8) Right adjusting dial with turn/press function

For setting the arc length correction, welding voltage, pulse/dynamic correction
and F2 parameters
Turn the adjusting dial to:
change values, select parameters (in the Setup menu and when selecting the
filler metal)
Press the adjusting dial to:
confirm a menu selection, apply values

(9) Welding process selection

The corresponding LED lights up when a welding process is selected.
The following welding processes can be selected by pressing the button:

38

- PULS SYNERGIC (MIG/MAG pulse synergic welding)

- SYNERGIC (MIG/MAG standard synergic welding)

-

- LSC/PMC (LSC = Low Spatter Control, PMC = Pulse Multi Control)

- STICK/TIG (MMA welding/TIG welding)

- CMT / SP (CMT welding / special programs)

(10) USB port

For updating the software using a USB Ethernet adapter

(11) Mode selection

The corresponding LED lights up when a mode is selected.
The following modes can be selected by pressing the button:

-

-

-

-

- MODE (Special modes depending on the function package)

(12) Gas-test button

For setting the required gas flow rate on the gas pressure regulator.
After pressing this button, gas flows for 30 seconds. Press the button again to
stop the gas flow prematurely.

MANUAL (MIG/MAG standard manual welding)

Depending on which function package is enabled

2T (2-step mode)

4T (4-step mode)

S4T (Special 4-step mode)

S2T (Special 2-step mode)

EN-US

(13) Wire threading button

To thread the wire electrode into the torch hosepack with no accompanying flow
of gas or current

(14) Left adjusting dial with turn/press function

- For setting the sheet thickness, welding current, wire speed, F1, penetration
stabilizer and arc length stabilizer parameters

- For displaying help texts

Turn the adjusting dial to:
select parameters, change values, display long help texts
Press the adjusting dial to:
confirm a menu selection, apply values, call up help texts for parameters

(15) Favourites button

Individual parameters or parent folders can be assigned to it

(16) Filler metal info button

For showing the currently set filler metal

(17) Filler metal selection button

For selecting the filler metal

39

Displaying plain

1

2

text for paramet­ers

The left adjusting dial can be used to display the corresponding plain text for each para­meter abbreviation shown on the display.

Example:

Parameter or entry from the Setup menu has been selected using the right

adjusting dial; the LED on the right adjusting dial lights up.

Press the left adjusting dial

1

The plain text for the parameter is displayed; the LED on the left adjusting dial lights up.

To display extended plain texts, turn the left adjusting dial

2

The plain text is moved across the display.

To make another selection, turn the right adjusting dial

3

40

F1/F2 special function parameters, Favourites but-

I-S [%] 150

~ 3 sec.

2

2

~ 3 sec.

1

I-S [%] 0.0

1

1

~ 3 sec.

ton

F1 and F2 special
function paramet­ers

Setting F1 and F2 special function parameters

Example: the selected parameter I-S is assigned to F1

Select the desired parameter in the Setup menu

1

Further information on the Setup menu can be found from page 89

To assign the selected parameter to F1 or F2, press the parameter selection button

2

for approx. 3 seconds:
F1 ... left parameter selection
F2 ... right parameter selection

EN-US

F1/F2 flashes while the parameter selection button is pressed.

As soon as the parameter is saved, the indicator for the corresponding special function
parameter lights up.
F1 (for example) and a tick is shown next to the parameter:

The selected parameter is now stored under F1.

If a parameter cannot be assigned to the F1 or F2 special function parameters, after
approx. 5 seconds F1 (for example) and X is displayed:

This deletes an existing stored parameter.

Retrieving F1 and F2 special function parameters

41

Press the parameter selection button until F1 or F2 lights up:

150 0.0

2 2

> 5 sec.

1

1

> 5 sec.

~ 3 sec.

1

2

1

F1 ... left parameter selection
F2 ... right parameter selection

The stored parameter is shown first, then the currently set value of the parameter.

Change the value of the parameter by turning the adjusting dial:

2

F1 ... left adjusting dial
F2 ... right adjusting dial

Deleting F1 and F2 special function parameters

The Favourites
button

Press the parameter selection button for at least 5 seconds:

1

F1 ... left parameter selection
F2 ... right parameter selection

The stored parameter is deleted, F1 (for example) and X is shown on the display:

The F1 and F2 special function parameters can also be set in the Setup menu (page

112).

Assigning the Favourites button

Individual parameters or parent folders from the Setup menu can be assigned to the
Favourites button. These parameters or parent folders can then be called up directly
using the control panel.

Example: The selected SynchroPulse folder is assigned to the Favourites button

42

Select the desired parameter or the desired parent folder in the Setup menu

< 3 sec.

1

> 5 sec.

1

1

Further information on the Setup menu can be found from page 89

To assign the selected parameter or folder to the Favourites button, press the

2

Favourites button for approx. 3 seconds

Next to the parameter or folder and a tick are shown:

The selected parameter or folder is now assigned to the Favourites button.

Retrieving favourites

Parameters or folders stored under the Favourites button can be retrieved in any setting,
except for when the Setup menu is active.
Ongoing selection processes or called up jobs are cancelled when favourites are
retrieved.

EN-US

Briefly press the "Favourites" button (< 3 seconds)

1

The LED on the Favourites button lights up and the stored parameter or folder is shown
on the display.

To end retrieval of the favourite, briefly press the Favourites button again (< 3

2

seconds)

The LED on the Favourites button goes out and the display switches to the welding para­meters.

Deleting favourites

Press the Favourites button for at least 5 seconds:

1

The stored parameter or folder is deleted and and X are shown on the display:

43

The Favourites button can also be assigned in the Setup menu (page 113).

44

Connections, Switches, and Mechanical Compon-

(1)

(2)

(3)

(4)

(5)

(11)

(6)

(7)

(10)

(8)

(9)

ents

Connections,
switches and
mechanical com­ponents

Front

EN-US

No. Function

(1) Control panel with display

for operating the power source

(2) (+) current socket with bayonet

latch

(3) Blanking cover

reserved for the TMC connection
socket of the TIG option

(4) Welding torch connection

for connecting the welding torch

(5) (-) current socket with bayonet

latch

used to connect the grounding
cable during MIG/MAG welding

Rear

No. Function

(6) MIG/MAG shielding gas connec-

tion socket

(7) Blanking cover/TIG shielding

gas connection socket (option)

(8) Blanking cover/Ethernet con-

nection socket (option)

(9) Blanking cover/SpeedNet Con-

nector connection socket
(option)/external sensor (option)

(10) Mains cable with strain relief

device

(11) Mains switch

for switching the power source on
and off

45

(13)

(12)

Side view

No. Function

(12) Wirespool holder with brake

for holding standard wirespools
weighing up to 19 kg (41.89 lb.)
and with a max. diameter of 300
mm (11.81 in)

(13) 4 roller drive

46

Installation and Startup

47

48

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

MIG/MAG gas­cooled welding

Manual CMT
welding

TIG DC welding - Power source

- Power source

- Grounding (earthing) cable

- MIG/MAG welding torch, gas-cooled

- Shielding gas supply

- Wire electrode

- Power source

- Standard, Pulse and CMT welding packages enabled on the power source

- Grounding cable

- PullMig CMT welding torch incl. CMT drive unit and CMT wire buffer

- OPT/i PushPull

- CMT interconnecting hosepack

- Wire electrode

- Gas connection (shielding gas supply)

- Grounding (earthing) cable

- TIG gas-valve torch

- Gas connection (shielding gas supply)

- Filler metal (depending on the application)

MMA welding - Power source

- Grounding (earthing) cable

- Electrode holder with welding cable

- Rod electrodes

49

Before installation and initial operation

Safety

Danger due to incorrect operation.

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

▶
▶

Intended Use The power source is only intended for MIG/MAG, MMA and TIG welding. Any other use

is deemed to be "not in accordance with the intended purpose." The manufacturer shall
not be liable for any damage resulting from such improper use.

Intended use also means:

- Following all instructions in the Operating Instructions

- Carrying out all the specified inspection and maintenance work

Setup regulations The device has been tested according to degree of protection IP23. This means:

- Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)

- Protection against spraywater at any angle up to 60° from the vertical

WARNING!

Do not use the functions described here until you have fully read and understood the
Operating Instructions.
Do not use the functions described here until you have fully read and understood all
of the Operating Instructions of the system components, especially the safety rules.

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

WARNING!

Toppling or falling devices can be deadly.

Set up devices, upright brackets and trolleys so that they are stable on a flat and

▶

solid surface.

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 directly into the system.

Mains connection - The devices are designed for the mains voltage specified on the rating plate.

- Devices with a nominal voltage of 3 x 575 V must be operated on three-phase sys­tems with earthed star point.

- If your version of the appliance does not come with mains cables and mains plugs
ready-fitted, these must be fitted by a qualified person in accordance with national
standards.

- The fuse protection for the mains lead is indicated in the technical data.

50

CAUTION!

Generator­Powered Opera­tion

An inadequately dimensioned electrical installation can cause serious damage.

The mains lead and its fuse protection must be dimensioned to suit the local power

▶

supply.
The technical data shown on the rating plate applies.

The power source is generator-compatible.

The maximum apparent power S

of the power source must be known in order to

1max

select the correct generator output.
The maximum apparent power S

Three-phase devices: S

Single-phase devices: S

I

and U1 according to the device rating plate and technical data

1max

1max

1max

= I

= I

The generator apparent power S

of the power source is calculated as follows:

1max

x U1 x √3

1max

x U

1max

GEN

1

needed is calculated using the following rule of

thumb:

S

GEN

= S

1max

x 1.35

EN-US

Information on
system compon­ents

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

IMPORTANT! The generator apparent power S
apparent power S

of the power source!

1max

must not be less than the maximum

GEN

When single phase devices are being operated with a 3-phase generator, note that the
stated apparent power of the generator is often just the total that can be present across
all three phases of the generator. If necessary, obtain further information about the
single-phase power of the generator from the generator manufacturer.

NOTE!

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

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

The steps and activities described below include references to various system compon­ents, including:

- Trolley

- Welding torch

- etc.

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

51

Connecting the Mains Cable

Safety

Danger from work that is not carried out properly.

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

▶
▶

Danger from improperly prepared mains cable.

Short circuits and damage to property may result.

▶

General A mains cable that is suitable for the connection voltage must be connected to the MV

power source before commissioning.
A strain-relief device for cables with an outer diameter of 14 - 18.5 mm is fitted to the MV
power source.

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

WARNING!

The work described below may only be performed by trained specialist personnel.
Follow national standards and guidelines.

CAUTION!

Fit ferrules to all phase conductors and the ground conductor of the stripped mains
cable.

Stipulated mains
cables

Connecting the
mains cable ­general

Mains voltage Cable cross-section

USA / Canada * Europe
3 x 200 V

3 x 230 V
3 x 380 V

3 x 400 V
3 x 460 V

* Cable type for USA / Canada: Extra-hard usage

AWG = American wire gauge

CAUTION!

Risk of injury and damage from short circuits.

Short circuits can occur between the phase conductors or between the phase conductors
and the ground conductor unless ferrules are used.

Strip the insulation of the mains cable and fit ferrules to all phase conductors, as well

▶

as the ground conductor.

AWG 12 4G 2.5 mm²

AWG 14 4G 2.5 mm²

52

NOTE!

Mains cables must be connected to devices in compliance with national standards
and guidelines and the work must be carried out by suitably qualified personnel!

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

than the phase conductors.

EN-US

1

6 x TX25

3

2

5 x TX25

4

Tightening torque = 1.2 Nm

IMPORTANT! When connecting the cable to the switch, ensure:

- To route the conductors near to the switch

- Not to make the conductors unnecessarily long

- To fit the protective hose supplied over the cable and insert the covered cable into
the strain-relief device if cable diameters are small

53

5

6

Tightening torque = 1.2 Nm

7

5 x TX25, tightening torque = 3 Nm

Tightening torque = 1.2 Nm

8

6 x TX25, tightening torque = 3 Nm

54

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 the power source is described with reference to a manual gas-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.

Connecting the
gas cylinder

WARNING!

There is a high risk of very serious injury and damage if a gas cylinder falls over.

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

▶

Observe the safety rules of the gas cylinder manufacturer

▶

Place the gas cylinder on a solid, level

1

surface in such a way that it remains
stable

Secure the gas cylinder to prevent it

2

from toppling over (but not around the
neck of the cylinder)

Take the protective cap off the gas cyl-

3

inder
Briefly open the gas cylinder valve to

4

remove any dust or dirt
Inspect the seal on the gas pressure

5

regulator
Screw the pressure regulator onto the

6

gas cylinder and tighten it
Connect the pressure regulator to the

Connecting the gas hose

7

shielding gas connection on the power
source using the gas hose

55

Establishing a

2

2

3

4

ground earth
connection

Connecting the grounding cable

Plug the grounding cable into the (-)

1

current socket
Lock the grounding cable in place

2

Use the other end of the grounding

3

cable to establish a connection to the
workpiece

Connecting the
welding torch

Before connecting the welding torch, check that all cables, lines and hosepacks are

1

undamaged and properly insulated.

Open the wire-feed unit cover

2

3

56

Inserting/repla­cing feed rollers

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

NOTE!

Only use feed rollers that are suitable for the wire electrode.

An overview of the feed rollers available and their possible areas of use can be found in
the spare parts lists.

CAUTION!

Risk of injury if the feed roller holders fly upwards.

When unlocking the lever, keep fingers away from the area to the left and right of the

▶

lever.

1 2

EN-US

3 4

57

Inserting the
wirespool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

While inserting the wirespool, hold the end of the wire electrode firmly to avoid injur-

▶

ies caused by the wire springing back.

CAUTION!

Risk of injury from falling wirespool.

Make sure that the wirespool is fitted securely to the wirespool holder.

▶

CAUTION!

Risk of injury and impaired performance if the wirespool topples over because the
locking ring has been placed the wrong way round.

Always position the locking ring as shown in the diagram on the left.

▶

1

58

Inserting the bas­ket-type spool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

While inserting the basket-type spool, hold the end of the wire electrode firmly to

▶

avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling basket-type spool.

Make sure that the basket-type spool and basket-type spool adapter are fitted

▶

securely to the wirespool holder.

NOTE!

When working with basket-type spools, only use the basket-type spool adapter
included in the scope of supply.

CAUTION!

Risk of injury from falling basket-type spool.

Place the basket-type spool on the adapter provided in such a way that the bars on

▶

the spool are inside the adapter guideways.

EN-US

CAUTION!

Risk of injury and impaired performance if the basket-type spool topples over
because the locking ring has been placed the wrong way round.

Always position the locking ring as shown in the diagram on the left.

▶

59

1 2

Feeding in the
wire electrode

CAUTION!

Risk of injury from springiness of spooled wire electrode.

When inserting the wire electrode into the 4-roller drive, hold the end of the wire

▶

electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of damage to the welding torch from sharp end of wire electrode.

Deburr the end of the wire electrode well before feeding in.

▶

Arrange the welding torch hosepack in as straight a line as possible.

1 2

60

CAUTION!

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

Keep the welding torch away from the face and body when pressing the torch trigger

▶

or feeder inching button.
Do not point the welding torch at people

▶

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

▶

ded) parts (e.g. the housing, etc.) when pressing the torch trigger

1

2

4

5

3

5

1

1

2

3

EN-US

6

Setting the con­tact pressure

NOTE!

Set the contact pressure in such a way that the wire electrode is not deformed but
nevertheless ensures proper wirefeed.

1

Contact pressure standard values for
U-slot rollers

Steel:
4 - 5

CrNi
4 - 5

Tubular cored electrodes
2 - 3

61

Adjusting the

4

3

STOP

6

7

5

1

2

2

1

2

1

4

STOP

OK

3

brake

NOTE!

After releasing the torch trigger the wirespool should stop unreeling.

Adjust brake if necessary.

1

3

2

Design of the
Brake

62

WARNING!

Danger from incorrect installation.

Serious personal injury and damage to
property may result.

Do not dismantle the brake.

▶

Maintenance and servicing of brakes

▶

is to be carried out by trained, quali­fied personnel only.

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

Performing R/L
alignment

IMPORTANT! For optimum welding results, the manufacturer recommends performing

an R/L alignment when starting the device for the first time and when any changes are
made to the welding system.

EN-US

63

64

Welding Mode

65

66

MIG/MAG Operating Modes

S

E

EN-US

General

Symbols and
their explana­tions

WARNING!

Danger from incorrect operation.

Possible serious injury and damage to property.

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

▶

stood these Operating Instructions.
Do not use the functions described here until you have fully read and understood all

▶

of the Operating Instructions for the system components, in particular the safety
rules!

See the Setup menu for information on settings, setting range and units of measurement
for the available parameters.

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

GPr

Gas pre-flow

I-S

Starting-current phase: the base material is heated up rapidly, despite the high thermal
dissipation that occurs at the start of welding

t-S

Starting current time

Start arc length correction

SL1

Slope 1: the starting current is steadily lowered until it reaches the welding current

I

Welding-current phase: uniform thermal input into the base material, whose temperature
is raised by the advancing heat

I-E

Final current phase: to prevent any local overheating of the base material due to heat
build-up towards the end of welding. This eliminates any risk of weld seam drop-through.

t-E

Final current time

End arc length correction

67

SL2

t

I

+

I

GPr GPo

t

I

+

I

GPr GPo

+

I

t

I

GPr GPo

I-E

SL1t-S

I-S

SL2

+ +

S

E

t-E

I

I-S

I-E

+

I

S

E

GPr GPoSL1 SL2

t

t-S t-E

Slope 2: the welding current is steadily lowered until it reaches the final current

GPo

Gas post-flow

A detailed explanation of the parameters can be found in the section headed "Process
parameters"

2-step mode

4-step mode

Special 4-step
mode

"2-step mode" is suitable for

- Tacking work

- Short weld seams

- Automated and robot welding

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

"Special 4-step mode" is particularly suit­able for welding aluminium materials. The
special slope of the welding current curve
takes account of the high thermal conduct­ivity of aluminium.

Special 2-step
mode

68

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

MIG/MAG and CMT welding

1

2

EN-US

Safety

MIG/MAG and
CMT welding –
overview

WARNING!

Danger due to incorrect operation.

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

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

▶

Operating Instructions.
Do not use the functions described here until you have fully read and understood all

▶

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

WARNING!

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.

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.

The "MIG/MAG and CMT welding" section comprises the following steps:

- Switching on the power source

- Selecting the welding process and operating mode

- Retrieving the currently set filler metal

- Selecting the filler metal

- Setting the welding parameters

- Setting the shielding gas flow rate

- MIG/MAG or CMT welding

Switching on the
power source

Setting the weld­ing process and
operating mode

Connect the mains cable

1

Move the mains switch to the "I" position

2

IMPORTANT! For optimum welding results, the manufacturer recommends performing

an R/L alignment when starting the device for the first time and when any changes are
made to the welding system.

Press the "Welding process" button until the LED for the desired welding process

1

lights up
Press the "Mode" button until the LED for the desired operating mode lights up

2

69

Retrieving the

1

42

-

5

/

1

2

3

...

...

currently set filler
metal

Press the "Filler metal info" button

1

The LED on the button lights up and the currently set filler metal is shown on the display:

Turn the right adjusting dial

2

The currently set wire diameter is shown on the display:

Turn the right adjusting dial

3

Selecting the
filler metal

The currently set shielding gas is shown on the display:

Turn the right adjusting dial

4

The currently set characteristic is shown on the display:

Press the "Filler metal info" button

5

The currently set welding parameter values are shown on the display.

70

Press the "Filler metal selection" button

1

The LED on the button lights up and "filler metal?" is shown on the display:

Press the right adjusting dial

2

The first available filler metal is displayed:

Select the desired filler metal by turning the right adjusting dial

3

Press the right adjusting dial

4

"diameter?" is shown on the display: *

Press the right adjusting dial

5

The first available wire diameter is displayed:

Select the desired wire diameter by turning the right adjusting dial

6

Press the right adjusting dial

7

EN-US

"gas?" is shown on the display: *

Press the right adjusting dial

8

The first available shielding gas is displayed:

Select the desired shielding gas by turning the right adjusting dial

9

Press the right adjusting dial

10

If available, the first available characteristic is displayed: *

Select the desired characteristic by turning the right adjusting dial

11

Press the right adjusting dial

12

A prompt to apply the new filler metal is displayed: *

Press the right adjusting dial

13

The set filler metal is saved.

* The previous item can be called up by turning the right adjusting wheel and

selecting "back".

71

Setting the weld-

22.8 5O.O

1

2

3

4

ing parameters

Press the button until the desired welding parameter lights up

1

Material thickness

Welding current

Wire speed

Setting the
shielding gas
flow rate

Special function

Turn the left adjusting dial to change the value of the welding parameter

2

3

Turn the right adjusting dial to change the value of the welding parameter

4

The amended parameter values are applied immediately.
If one of the wire speed, material thickness, welding current or welding voltage paramet­ers are changed during synergic welding, the remaining parameters are immediately
altered accordingly.

Open the gas cylinder valve

1

Press the gas test button

2

Shielding gas flows out

Turn the adjusting screw on the underside of the pressure regulator until the pres-

3

sure gauge shows the required shielding gas flow rate
Press the gas test button

4

The flow of gas stops.

72

MIG/MAG or CMT
welding

CAUTION!

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

When pressing the torch trigger:

keep the torch away from your face and body

▶

do not point the welding torch at people

▶

make sure that the wire electrode does not touch any electrically conducting or

▶

earthed (grounded) parts, such as the housing, etc.

Press the torch trigger and start welding

1

Whenever welding ends, the actual values for the welding current, welding voltage and
wire speed are stored, and HOLD appears on the display.

NOTE!

It is not always possible to change parameters that have been set on a system
component control panel (e.g. remote control) on the power source control panel.

EN-US

73

MIG/MAG and CMT welding parameters

Welding paramet­ers for MIG/MAG
pulse synergic
welding, for CMT
welding and PMC
welding

The following welding parameters can be set and displayed for MIG/MAG pulse synergic
welding, CMT welding and PMC welding:

using the left adjusting dial:

Material thickness

Setting range: 0.1 - 30.0 mm 2) / 0.004 - 1.18 in.

Welding current

in A

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

Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.

1)

2)

1)

Wire speed

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Penetration stabilizer4) (see page 95)

Setting range: 0 - 10 m/min / 0 - 393.7 ipm
Factory setting: 0

Arc length stabilizer4) (see page 97)

1)

2)

74

Setting range: 0 - 5
Factory setting: 0

using the right adjusting dial:

Arc length correction

for correcting the arc length;

Setting range: -10 - +10
Factory setting: 0

- .... shorter arc length

0 ... neutral arc length
+ ... longer arc length

EN-US

Welding voltage

1)

in V

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

Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction

for correcting the pulsing energy of a pulsed arc

Setting range: -10 - +10
Factory setting: 0

- ... lower droplet detachment force

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

Welding paramet­ers for MIG/MAG
standard syner­gic welding and
LSC welding

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

The following welding parameters can be set and displayed for MIG/MAG standard syn­ergic welding and LSC welding:

using the left adjusting dial:

Material thickness

1)

75

Setting range: 0.1 - 30.0 mm 2) / 0.004 - 1.18 in.

2)

Welding current

1)

in A

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

Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.

Wire speed

1)

for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

2)

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Penetration stabilizer4) (see page 95)

Setting range: 0 - 10 m/min / 0 - 393.7 ipm
Factory setting: 0

using the right adjusting dial:

Arc length stabilizer4) (see page 97)

Setting range: 0 - 2
Factory setting: 0

Arc length correction

for correcting the arc length, which is pre-set by the characteristic or the synergic pro­gram

Setting range: -10 - +10
Factory setting: 0

76

- .... shorter arc length

0 ... neutral arc length
+ ... longer arc length

EN-US

Welding voltage

1)

in V

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

Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.

Pulse/dynamic correction

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

Setting range: -10 - +10
Factory setting: 0

- ... harder and more stable arc

0 ... neutral arc
+ ... soft and low-spatter arc

Welding paramet­ers for MIG/MAG
standard manual
welding

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

The following welding parameters can be set and displayed for MIG/MAG standard
manual welding:

using the left adjusting dial:

Wire speed

1)

for setting a harder, more stable arc

Setting range: 0.5 - 25 m/min 2) / 20 - 980 ipm.

2)

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

77

using the right adjusting dial:

Welding voltage

1)

in V

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

Pulse/dynamic correction

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

Setting range: 0 - 10
Factory setting: 0

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

Special function

any parameter can be assigned to this (see page 41)

The function can be selected if a parameter has been saved.

Explanation of
footnotes

1) Synergic parameter

When a synergic parameter is changed, the synergic function automatically
changes all other synergic parameters to match.

The actual setting range depends on the power source and wirefeeder used and
on the welding program selected.

2) The actual setting range depends on the welding program selected.

3) The maximum value depends on the wirefeeder used.

4) Only in the LSC and PMC welding processes

78

EasyJob mode

1

~ 3 sec.

2

< 3 sec.

3

> 5 sec.

General The 5 EasyJob buttons enable up to 5 operating points to be saved quickly.

The current welding settings are saved.

EasyJob mode

Storing EasyJob operating points

EN-US

To store the current welding settings, press one of the EasyJob buttons for approx. 3

1

seconds.

"Job", the button number and a tick are shown on the display and the EasyJob but­ton LED lights up, e.g.:

The settings have now been stored.

IMPORTANT! If an operating point has already been saved under an EasyJob but­ton it will be overwritten without any prior warning.

Retrieving EasyJob operating points

To retrieve a saved EasyJob operating point, press the corresponding EasyJob but-

2

ton briefly (< 3 seconds).

The EasyJob button LED lights up and the saved values are shown on the display.

If no values are displayed after pressing an EasyJob button, an operating point is not
stored under this EasyJob button.

Deleting EasyJob operating points

To delete an EasyJob operating point, press the relevant EasyJob button for approx.

3

5 seconds.

After approx. 3 seconds the saved operating point will be overwritten with the current
settings and "Job", the button number and a tick are shown on the display.
After a total of approx. 5 seconds the EasyJob button LED goes out and "Job", the

button number and an X are shown on the display, e.g.:
The EasyJob operating point has been deleted.

79

Spot welding

Spot welding Spot welding can be carried out in the following welding processes:

PULSE SYNERGIC | SYNERGIC | MANUAL | LSC/PMC | SP (CMT)

Select the desired welding process by pressing the "Welding process" button

1

Select the MODE by pressing the "Mode" button

2

"Spot" appears briefly on the display.

Setup menu / Process parameters / Spot welding

3

Press the right adjusting dial

4

The SPt (spot welding time) parameter is shown.

Enter the desired value for the spot welding time: press and turn the right adjusting

5

dial

Setting range: 0.1 - 10.0 s
Factory setting: 1.0 s

Confirm the value by pressing the right adjusting dial

6

NOTE!

4-step mode is assigned as standard for spot welding.

Press the torch trigger - Spot welding process runs until the end of the spot welding time

- Press again to stop the spot welding time prematurely
The spot welding setting can be changed to 2-step in the Setup menu under Set-

▶

tings / System / SPm
(more information on 2-step and 4-step mode for spot welding starts on page 116)

Select the filler metal, wire diameter and shielding gas

7

Open the gas cylinder valve

8

Set the shielding gas flow rate

9

CAUTION!

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

When pressing 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 earthed parts

▶

(e.g. housing, etc.)

80

Spot welding

10

Procedure for producing a welding spot:

Hold the welding torch vertical

1

Press and release the torch trigger

2

Keep the torch in the same position

3

Wait for the gas post-flow time

4

Lift the torch off the workpiece

5

NOTE!

Pre-set start of welding and end of welding parameters are also active for spot
welding.

A start of welding / end of welding action for spot welding can be stored in the Setup

▶

menu under Process parameters / Start/End.
If the final current time is active, the end of welding is not after the pre-set spot weld-

▶

ing time, but only once the pre-set slope and final current times have ended.

EN-US

81

TIG welding

Safety

Preparations

WARNING!

Danger due to incorrect operation.

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

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

▶

Operating Instructions.
Do not use the functions described here until you have fully read and understood all

▶

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

WARNING!

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.

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.

Move the mains switch to the "O" position

1

Disconnect the mains plug

2

Remove the MIG/MAG welding torch

3

Disconnect the grounding (earthing) cable from the (-) current socket

4

Plug the grounding (earthing) cable into the 2nd (+) current socket and twist to fasten

5

it
Use the other end of the grounding (earthing) cable to establish a connection to the

6

workpiece
Plug the bayonet current plug on the TIG gas-valve torch into the (-) current socket

7

and twist it clockwise to fasten it
Screw the pressure regulator onto the (argon) gas cylinder and tighten it

8

Connect the gas hose of the TIG gas-valve torch to the pressure regulator

9

Plug in the mains plug

10

TIG welding

82

CAUTION!

Risk of injury and damage from electric shock.

As soon as the mains switch is in the "I" position, the tungsten electrode of the welding
torch is live.

Make sure that the tungsten electrode does not touch any persons or electrically

▶

conductive or earthed parts (e.g. housing, etc.)

Move the mains switch to the "I" position

1

IMPORTANT! For optimum welding results, the manufacturer recommends performing

an R/L alignment when starting the device for the first time and when any changes are
made to the welding system.

2

Press the "Welding process" button until the LED for the STICK/TIG welding process

3

2

lights up and "TIG" is shown on the display.

After a short time, the currently set welding current is shown on the display. The welding
current indicator lights up.

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

EN-US

NOTE!

Parameters that have been set on a system component control panel (e.g. wire
feed unit or remote control) might not be able to be changed on the power source
control panel.

To change the welding current, turn the left adjusting dial

3

The altered welding current is applied immediately.

Adjust the process parameters accordingly to make user- or application-specific set-

4

tings on the welding system
Open the gas stop valve on the TIG gas-valve torch

5

Set the desired shielding gas flow rate on the pressure regulator

6

Start welding (ignite the arc)

7

83

Igniting the arc The welding arc is ignited by touching the workpiece with the tungsten electrode.

1 2 3 4

+

Place the gas nozzle on the ignition location so that there is a gap of 2-3 mm (0.08 -

1

0.12 in.) between the tip of the tungsten electrode and the workpiece
Gradually tilt the welding torch up until the tungsten electrode touches the workpiece

2

Raise the torch and tilt it into the normal position - the arc now ignites

3

Carry out welding

4

Finishing welding

Lift the TIG gas-valve torch away from the workpiece until the arc goes out.

1

IMPORTANT! To protect the tungsten electrode, ensure that the shielding gas at the

end of welding flows for long enough to allow the tungsten electrode to cool suffi­ciently.

Close the gas stop valve on the TIG gas-valve torch

2

84

Manual Metal Arc Welding

EN-US

Safety

Preparations

WARNING!

Danger due to incorrect operation.

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

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

▶

Operating Instructions.
Do not use the functions described here until you have fully read and understood all

▶

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

WARNING!

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.

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.

Move the mains switch to the "O" position

1

Disconnect the mains plug

2

Remove the MIG/MAG welding torch

3

MMA welding

NOTE!

Check the rod electrode packaging or labelling to determine whether the rod
electrodes are for positive pole or negative pole welding.

Plug the grounding (earthing) cable into either the (-) or the (+) current socket

4

depending on the type of electrode, and twist to fasten it
Use the other end of the grounding (earthing) cable to establish a connection to the

5

workpiece
Plug the bayonet current plug of the electrode holder cable into the free current

6

socket with the opposite polarity, according to the type of electrode, and twist it
clockwise to latch it in place

Plug in the mains plug

7

CAUTION!

Risk of injury and damage from electric shock.

As soon as the mains switch is in the "I" position, the rod electrode in the electrode
holder is live.

Make sure that the rod electrode does not touch any persons or electrically conduct-

▶

ive or earthed parts (e.g. housing, etc.)

Move the mains switch to the "I" position

1

85

IMPORTANT! For optimum welding results, the manufacturer recommends performing

STICK

2

175 20

43

an R/L alignment when starting the device for the first time and when any changes are
made to the welding system.

Press the "Welding process" button until the LED for the STICK/TIG welding process

2

lights up and "STICK" is shown on the display.

After a short time, the currently set welding current and the currently set dynamic are
shown on the display. The welding current and dynamic indicators light up.

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

NOTE!

Parameters that have been set on a system component control panel (e.g. wire
feed unit or remote control) might not be able to be changed on the power source
control panel.

To change the welding current, turn the left adjusting dial

3

If required, turn the right adjusting dial to change the dynamic

4

The amended values are applied immediately.

Adjust the process parameters accordingly to make user- or application-specific set-

5

tings on the welding system
Start welding

6

86

Welding paramet­ers for manual
metal arc welding

The following welding parameters can be set and displayed for manual metal arc weld­ing:

using the left adjusting dial:

EN-US

Main current

1)

in A

Setting range: depends on the power source available

Before the start of welding, the machine automatically displays a standard value based
on the programmed parameters. The actual value is displayed during welding.

using the right adjusting dial:

Arc-force dynamic

to influence the short-circuiting dynamic at the instant of droplet transfer

Setting range: 0 - 100
Factory setting: 20

0 ... soft and low-spatter arc
100 ... harder and more stable arc

87

88

Setup Settings

89

90

Setup menu - overview

1

1

Entering/exiting
the Setup menu

To enter the Setup menu, press the "Welding process" and "Mode" buttons at the

1

same time

"Process parameters" is shown on the display.

To exit the Setup menu, press the "Welding process" and "Mode" buttons at the

2

same time

EN-US

91

Setup menu ­overview

Process param.

Start/End

3)

1)

Display System back

Settings

Gas-setup

Process c.

4)

Spot welding

Components

STICK

TIG

5)

6)

7)

SynchroPulse

Process Mix

8)

R/L-check / align-

ment

Unit 9) xx

Standard

UIBS

DRSL.

F1/F2 Param

Favourite

11)

13)

14)

10)

xx

12)

15)

< back System data < back

< back

FAC

16)

17)

CLS [s]

Web-PWreset

Information

SPm

19)

20)

iJob xx

18)

Language xx

2)

... Turn the right adjusting dial

... Press the right adjusting dial

Press the left adjusting dial:

...

The parameter is shown in plain text

Turn the left adjusting dial:

...

To read long plain texts for parameters; the plain text for the parameter is moved to the
left on the display

1) Process parameters

2) Language abbreviation

3) Start/end of welding

4) Process control

5) Component monitoring

6) Electrode setup

7) TIG setup

8) Process Mix

9) Units

10) metric/imperial

11) Standards

12) CEN/AWS

13) Display brightness

14) Display replaced char­acteristics

15) Activate F1/F2 para­meter

16) Duration of interior
lighting

17) Restore factory set­tings

18) Reset password for the
website

19) Mode Setup – Special
display for JobMaster

20) 2-step/4-step spot
welding

92

Process parameters

EN-US

Process paramet­ers for start of
welding/end of
welding

The following process parameters can be set and displayed for the start and end of weld­ing:

I-S
Starting current

For setting the starting current for MIG/MAG welding (e.g. aluminium welding start-up)

Setting range: 0 - 200% (of welding current)
Factory setting: 135%

AlS
Start arc length correction

For correcting the arc length at the start of welding

Setting range: -10 - +10% (of welding voltage)
Factory setting: 0

- .... shorter arc length

0 ... neutral arc length
+ ... longer arc length

t-S
Starting current time

For setting the length of time the starting current is to be active 

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SL1
Slope 1

For setting the time during which the starting current is decreased or increased to the
welding current

Setting range: 0 - 9.9 s
Factory setting: 1 s

SL2
Slope 2

For setting the time during which the welding current is decreased or increased to the
final current.

Setting range: 0 - 9.9 s
Factory setting: 1 s

I-E
Final current

For setting the final current so that
a) heat build-up towards the end of welding is prevented and
b) the end-crater can be filled when welding aluminium

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

AlE
End arc length correction

For correcting the arc length at the end of welding

93

Setting range: -10 - +10% (of welding voltage)
Factory setting: 0

- .... shorter arc length

0 ... neutral arc length
+ ... longer arc length

t-E
Final current time

For setting the length of time for which the final current is to be active

Setting range: off / 0.1 - 10.0 s
Factory setting: off

SFI

to activate/deactivate the SFI function (Spatter Free Ignition of the arc)

Setting range: off / on
Factory setting: off

SFI-HS
SFI HotStart

For setting a HotStart time in conjunction with SFI ignition

During SFI ignition, a spray arc phase occurs within the set HotStart time. This increases
the heat input irrespective of the mode, thus ensuring deeper penetration right from the
very start of welding.

Setting range: off / 0.01 - 2.00 s
Factory setting: off

W-r
Wire retract

For setting the wire withdrawal value (= composite value based on backward movement
of wire and a time).
The wire withdrawal depends on the features of the welding torch.

Setting range: 0.0 - 10.0
Factory setting: 0.0

IgC
Ignition current (manual mode)

For setting the ignition current for MIG/MAG standard manual welding

Setting range: 100 - 450 A
Factory setting: 450

W-r (man.)
Wire retract (manual mode)

For setting the wire withdrawal value (= composite value based on backward movement
of wire and a time) for MIG/MAG standard manual welding.
The wire withdrawal depends on the features of the welding torch.

Process paramet­ers for Gas-Setup

94

Setting range: 0.0 - 10.0
Factory setting: 0.0

The following process parameters can be set and displayed for Gas-Setup:

GPr
Gas pre-flow

For setting the gas flow time before the arc is ignited

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

GPo
Gas post-flow

For setting the gas flow time after the arc has gone out

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

GCV
Gas set value

For specifying the gas set value in l/min

GCF
Gas factor

For setting the gas correction factor

Setting range: aut, 0.90 - 20.0
Factory setting: aut

EN-US

Process paramet­ers for process
control

Penetration sta­bilizer

The following process parameters can be set and displayed for the process control:

- PSt - penetration stabilizer

- AlSt - arc length stabilizer

Penetration stabilizer and arc length stabilizer can also be set in combination with one
another.

The penetration stabilizer is used to set the max. permitted change in the wire speed to
ensure that the welding current and hence the penetration is kept stable or constant with
variable stick out.

The penetration stabilizer parameter is only available when the WP PMC (Welding Pro­cess Pulse Multi Control) or WP LSC (Welding Process Low Spatter Control) option has
been enabled on the power source.

0 - 10.0 m/min (ipm)
Factory setting: 0 m/min

0
The penetration stabilizer is not activated.
The wire speed remains constant.

0.1 - 10.0
The penetration stabilizer is activated.
The welding current remains constant.

95

Application examples

I [A]

v

D

[m/min]

1

2

1

2

h

s

1

s

2

x

1

x

2

t [s]

s

1

< s

2 x1

> x

2

I [A]

v

D

[m/min]

1

2

1

2

h

s

1

s

2

x

1

x

2

t [s]

s

1

< s

2 x1

= x

2

Penetration stabilizer = 0 m/min (not activated)

Penetration stabilizer = 0 m/min (not activated)

Changing the contact tube distance (h) alters the resistance in the welding circuit due to
the longer stick out (s2).

The constant voltage control for constant arc length causes a reduction in the mean cur­rent value and hence a smaller penetration (x2).

Penetration stabilizer = n m/min (activated)

Penetration stabilizer = n m/min (activated)

Specifying a value for the penetration stabilizer ensures a constant arc length without
large current variations if the stick out is changed (s1 ==> s2).

The penetration (x1, x2) remains virtually unchanged and stable.

Penetration stabilizer = 0.5 m/min (activated)

96

I [A]

v

D

[m/min]

1

3

1 2

3

h

s

1

s

3

x

1

x

3

t [s]

s

1

< s

3 x1

> x

3

2

0,5 m/min

Penetration stabilizer = 0.5 m/min (activated)

1

2

3

To minimise the change in welding current if the stick out is changed (s1 ==> s3), the wire
speed is increased or reduced by 0.5 m/min.

In the example shown, the stabilising effect is obtained without a change in current up to
the set value of 0.5 m/min (Position 2).

I ... Welding current vD ... Wire speed

EN-US

Arc length stabil­izer

Arc length stabilizer

The arc length stabilizer forces short arcs, advantageous for welding, via a short-circuit
current control and keeps them stable even with a variable stick out or external interfer­ence.

The arc length stabilizer welding parameter is only available if the WP PMC (Welding
Process Pulse Multi Control) option has been enabled on the power source.

0.0 - 5.0 (effect of stabilizer)
Factory setting: 0.0

0.0
The arc length stabilizer is deactivated.

0.1 - 5.0
The arc length stabilizer is activated.
The arc length is decreased until short circuits start to occur.

Application examples

Arc length stabilizer = 0 / 0.5 / 2.0

Arc length stabilizer = 0

Arc length stabilizer = 0.5

Arc length stabilizer = 2

97

I [A]

v

D

[m/min]

U [V]

t [s]

L

1

> L2 > L

3

1

2

3

1

2

3

I

v

D

U

L

1

L

2

L

3

*

*

*

Arc length stabilizer = 0 / 0.5 / 2.0

L1 = L

2

L

1

L

2

*

*

*

L

1

L

2

L1 = L

2

Activating the arc length stabilizer reduces the arc length until short circuits start to occur.
The frequency of the short circuits is controlled and kept stable.

Increasing the arc length stabilizer causes a further shortening of the arc length (L1 ==>
L2 ==> L3). The advantages of a short, stable and controlled arc can be used more
effectively.

Arc length stabilizer with change of weld seam profile and position

Arc length stabilizer not activated

A change of weld seam profile or welding
position can negatively affect the welding
result

Arc length stabilizer activated

Since the number and duration of the short
circuits is controlled, the properties of the
arc stay the same if the weld seam profile
or welding position is changed.

I ... Welding current vD ... Wire speed U ... Welding voltage
* ... Number of short circuits

98

Combination of

Δs

I [A]

v

D

[m/min]

U [V]

t [s]

1

2

1

2

I

v

D

U

*

*

*

*

Δs

I [A]

v

D

[m/min]

U [V]

t [s]

1

2

1

2

I

v

D

U

*

*

*

*

penetration sta­bilizer and arc
length stabilizer

Example: Stick out change

EN-US

Arc length stabilizer without penetration stabilizer

The advantages of a short arc are main­tained even if the stick out is changed,
since the short-circuit properties stay the
same.

Arc length stabiliser with penetration stabilizer

If the stick out is changed with the penet­ration stabilizer activated, the penetration
also stays the same.
The short circuit behaviour is controlled by
the arc length stabilizer.

I ... Welding current vD ... Wire speed U ... Welding voltage
* ... Number of short circuits Δs ... Stick out change

99

Process paramet­ers for spot weld­ing

SPt
Spot welding time

0.1 - 10.0 s
Factory setting: 1.0 s

Process paramet­ers for monitor­ing and compon­ents

The following process parameters can be set and displayed for the system components
of a welding system:

C-C
Cooling unit mode

To determine whether a cooling unit is to be switched on or off, or operated automatically

Setting range: eco / auto / on / off (depending on the cooling unit)
Factory setting: auto

C-t
Delay time flow sensor

For setting the time from when the flow sensor responds until a warning message is out­put

Setting range: 5 - 25 s
Factory setting: 10 s

CFU
Cooler flow warning limit

Setting range: off / 0.75 - 0.95 l/min
Factory setting: off

Fdi
Feeder inching speed

in m/min (ipm)
For setting the wire speed at which the wire electrode is threaded into the torch hosep­ack

100

Setting range:
min. - max. (depending on the wire speed)
Factory setting: 10.0 m/min

ito
Ignition time-out

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

Setting range: off / 5 - 100 mm (0.2 - 3.94 in.)
Factory setting: off

The ignition time-out process parameter is a safety function. The length of wire that is fed
before the safety cut-out trips may differ from the pre-set wire length, particularly when
the wire is being fed at fast wire speeds.

How it works:
Once the torch trigger is pressed, gas pre-flow begins immediately. Wirefeeding then
begins, followed by ignition. If no current starts flowing before the specified length of wire
has been fed, the power source cuts out automatically.
To try again, press the torch trigger again.