Welding Equipment Operations Reference Guide

/ Battery Charging Systems / Welding Technology / Solar Electronics
MIG Welding Equipment

Operations Reference Guide
Fronius USA
Office: 1-877-376-6487 www.fronius-usa.com
13 SEP 12
General Information
Use and Operation
Table of Contents Initial Set-up and Turn-on page 35
Quick Reference Sheet, TPS page 36
Conversion Charts page 1 Weld Correction Value page 41
Front Panel, TPS page 42
3d-Drawing page 2 Front Panel, CMT page 45
Quick Reference Sheet, TsT page 55
Weld System Front Panel, TsT page 57
Component Layout page 3
Configurations page 4 Processes
Synergic Lines page 48
Power Source Jobs page 49
Models page 7 Resistance Test page 50
Nameplate page 9 Push-Pull Alignment page 51
Technical Specifications page 10 Cooler Verification page 53
Connections and Controls page 11 Output Tests page 54
Wire Feeder Consumables

Models page 15 Drive Rolls page 61
Motor-plate page 17 Liners page 62
Connections and Controls page 18 Contact Tips page 63
Torch Breakdown page 64
Welding Torch page 22 Changing a Liner page 67
Part Numbers page 69
Cooler page 23
Interface
Weld Process Models page 76
Overview page 24 General Information page 77
MIG, short circuit page 26 Inputs/Outputs page 78
MIG, pulse page 27 Signal Interaction page 82
Gas Characteristics page 28
Torch Movement and Position page 32 Fronius Xplorer page 85
13 SEP 12
Discontinuity page 33
Basic Troubleshooting page 87
General Information Inch/min Mm/sec Cm/min Meters Feet

Conversion Charts 5 2.12 12.70 0.25 0.8
10 4.23 25.40 0.50. 1.6
15 6.35 38.10 0.75 2.5
Fraction* Decimal* Millimeters Wire Guage** Ft3/hour L/min
20 8.47 50.80 1.00 3.1
5 2.36
2/64 .030 0.8 20 25 10.58 63.50 1.25 4.1
10 4.72
30 12.70 76.20 1.50 4.9
--- .035 0.9 19 15 7.08
35 14.82 88.90 1.75 5.7
20 9.44
--- .040 1.0 18 40 16.93 101.60 2.0 6.6
25 11.80
45 19.05 114.30 2.5 8.2
3/64 .045 1.2 17 30 14.16
50 21.17 127.00 3.0 9.8
35 16.52
--- .052 1.4 16 3.5 11.5
40 18.88 55 23.28 139.70
1/16 .062 1.6 14 45 21.24 60 25.40 152.40 4.0 13.1
--- .071 1.8 13 50 23.60 65 27.51 165.10 4.5 14.8

55 25.95 70 29.63 177.80 5.0 16.4
5/64 .078 2.0 12
60 28.31 75 31.75 190.50 10 32.8
3/32 .094 2.4 11
65 30.67 80 33.86 203.2 15 49.2
7/64 .109 2.8 9 70 33.03 85 35.98 215.90 20 65.6
¼ .250 6.4 2 75 35.39 90 38.10 228.60 25 82.0
1/2 .500 12.7 - 80 37.75 95 40.21 241.30 30 98.4

85 40.11 100 42.33 254.00 35 114.8
3/4 .750 19.1 -
90 42.47 105 44.45 266.70 40 131.2
1 1.00 25.4 -
95 44.83 110 46.56 279.40 45 147.6
100 47.19 115 48.68 292.10 50 164
Conversion Factors
105 49.55 120 50.80 304.80 55 180.4
Inch/min to Mm/sec x 0.4233
110 51.91 125 52.91 317.50 60 196.8
Inch/min to Cm/min x 2.54
Mm/sec to Inch/min x 2.3622 115 54.27 130 55.03 330.20 65 213.3
Cm/min to Inch/min x 0.3937 120 56.63 135 57.15 342.90 70 229.6
Ft3/hour to L/min x 0.4719 125 58.99 140 59.26 355.60 75 246.0
L/min to Ft3/hour x 2.1189 130 61.35 145 61.38 368.30
Meter to Feet x 3.2808
13 SEP 12
135 63.71 150 63.50 381.00

Feet to Meter X 0.3048
-1-
-2-
Components consist of
Weld System -1- Power Source
-2- Wire Feeder
-3- Torch
Component Layout -4- Work Surface/Fixture
-5- Main Power (230 or 460V AC⁄
-6- Front Panel
-7- Gas Tank
-8- Remote Control Unit (RCU⁄
5 6 -9- Robot Interface
-10-
10- Cooler
-11-
11- PC Interface Tool
8
B 11 Connections consist of
D -A- Ground Connection
D -B- Main Power (230 or 460V AC⁄
-C- Gas
-D- LocalNet
-E- Motor Voltage (55V DC⁄
D D -F- Main Current
-G- Pump Voltage (230 or 400V AC⁄
E -H- Data Lines (non LocalNet⁄
F -I- Coolant Out
9 D -J- Coolant In
1
F
A
C
3
2
J
G
D
H
Component Management
4 Controlled by LocalNet (Fronius communication

C protocol⁄.
I Plug and play configuration
10 7
J Provides both operating power and
communication to peripheral components.
13 SEP 12
-3-
Weld System
Configurations
Data
Control Voltages
Welding Current
Shielding Gas
Control Voltages
Welding Current
Coolant Lines
Wire
Data
Coolant Lines
Power-
Power-Source Mounted Wire Feeder
The wire feeder can be mounted directly on top of the welding power
source. This configuration can be applied with either robotic or manual
systems. This configuration allows for the following features.
The connections between the wire feeder to the power source, shielding
gas and coolant are made through the Interconnecting Hose Pack .
The connections between the wire feeder and welder can vary in
length. This allows the operator to relocate the wire feeder if
needed.
Length of the torch and the interconnecting hose pack must be
taken into consideration when determining if the system should be
a push or push/pull orientation.
13 SEP 12
-4-
Weld System
Configurations
Data Data
Control Voltages Control Voltages
Welding Current Welding Current
Shielding Gas
Wire
Coolant Lines Coolant Lines
Remote Mounted Wire Feeder

The wire feeder is placed between the welder and the torch location. This placement may or may not be permanent.
This configuration allow for:
Varying distances between the power source and wire feeder.
Enables the wire feeder to torch end distances to be reduced which can reduce the need for a push/pull system.
The wire feeder can be kept within a restricted area while the welder is easily accessible for parameter
monitoring and changes.
13 SEP 12
-5-
Weld System
Configurations
Data Data
Control Voltages Control Voltages
Welding Current Welding Current
Shielding Gas
Wire
Coolant Lines Coolant Lines
Robot Mounted Wire Feeder

The wire feeder can be mounted directly to the robot arm or automated system. This type of configuration has no built
in mechanism for manually starting the torch and is intended only for robotic/automated applications.
Interconnecting hose packs can vary in length. The length must be accommodate for the distance between the
power source and feeder but also for the motion of the robot.
This configuration allows for the wire feeder to be kept within a restricted area while the power source is left
accessible area for monitoring and adjusting parameters.
13 SEP 12
-6-
Power Source
Models
TPS 2700
270-amp pulse machine with a built in wire feeder. Multi-voltage model is available
Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc
range.
Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
Power source is lightweight, easily updateable, and expanded through a plug and play interface.
Trans Synergic (TS) 3200/4000/5000

Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
range.
Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal,
gas types, and wire diameters
Power source is equally suited to robotic, automated, and manual tasks based on application
demands.
Trans-Pulse Synergic (TPS) 3200/4000/5000

Three amp ranges available (320, 400, and 500⁄. Multi-voltage model is available
Welder is capable of pulse welding pre-loaded with pulse-designed synergic lines
range.
Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of
filler metal, gas types, and wire diameters
13 SEP 12
Power source is lightweight, easily updateable, and expanded through a plug and -7-
play interface.
Power Source
Models
Trans-Steel (TsT) 3500 Compact
350-amp pulse machine with a built in wire feeder. Multi-voltage model is NOT available
range.
Welder comes pre-loaded with multiple standard synergic lines over a large variety of filler metal,
Power source is lightweight, easily updateable, and expanded through a plug and play interface.
Trans-Steel (TsT) 3500/5000 Manual

Two amp ranges available (350 and 500⁄. Multi-voltage model available.
Welder is designed specifically for steel welding, offering a large variety of options at a low price.
range.
Trans-Steel (TsT) 3500/5000 Robotic

Two amp ranges available (350 and 500⁄. Multi-voltage model available.
Welder is designed specifically for steel welding, offering a large variety of options at a low price.
range.
13 SEP 12

Designed with robotic or automated welding in mind. -8-
Power Source
Name Plate
The identification portion of the label will give a detailed
description of the welder, the full part number, and a unique
serial number.
Using the format below, the serial number can be used to

determine the approximate age of the welding power supply.
This technique can be used to age any Fronius product with an
8-digit serial number.
23080753
23 – subtract “11” to get the year of manufacture
08 – this is the week of manufacture (1 – 52)
0753 – this is the item number for the day of manufacture.
The name plate is found on the top of the

machine just underneath the carrying handle.
This label includes identification, technical, The middle portion of the label include technical that includes
upgrade, and duty-cycle information about the duty cycle, amp drops, input and output voltage ranges, and
13 SEP 12
welding power supply. maximum outputs.

-9-
Power Source
Tech Specs
TPS 2700 MV TPS 3200 MV TS/TPS 4000 MV TS/TPS 5000 MV CMT-A 4000 MV
3 x 240 200 – 240 V 200 – 240 V 200 – 240 V 200 – 240 V 200 – 240 V
Mains Voltage Range
3 x 460 380 – 460 V 380 – 460 V 380 – 460 V 380 – 460 V 380 – 460 V
Mains Tolerance +/-10% +/-10% +/- 10% +/- 10% +/- 10%
Mains Frequency 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz
3 x 460 25 A 35 A 63 A 63 A 63 A
Fuse Protection, slow-blow
3 x 240 16 A 35 A 35 A 35 A 35 A
Primary Continuous Current (100% dc) 6.4 – 14.2 A 10.6 – 31.2 A 15.3 – 34.4 A 10.1 – 36.1 A n/a
Primary Continuous Power (100% dc) 4.6 – 10.7 KVA 8.7 – 11.5 kVA 10.6 – 12.4 kVA 12.4 – 13.9 kVA 13.0 – 16.0 kVA
Electrical Efficiency 88 – 91% 90 – 91% 88 – 91% 88 – 91% n/a
MIG 3 – 270 A 3 – 320 A 3 – 400 A 3 – 500 A 3 – 400 A
Welding Current Range Stick 10 – 270 A 10 – 320 A 10 – 400 A 10 – 500 A 10 – 400 A
TIG 3 – 270 A 3 – 320 A 3 – 400 A 3 – 500 A n/a
MIG 14.2 – 27.5 V 14.2 – 30.0 V 14.2 – 34.0 V 14.2 – 30.0 V 14.2 – 34.0 V
Welding Voltage Range Stick 20.4 – 30.8 V 20.4 – 32.8 V 20.4 – 36.0 V 20.4 – 40.0 V 20.4 – 36.0 V
TIG 10.1 – 20.8 V 10.1 – 22.8 V 10.1 – 26.0 V 10.1 – 30.0 V n/a
Max Welding Voltage 34.6 V 49.1 – 63.1 V 48 V 49.2 V n/a
Open Circuit Voltage 50 V 64 – 67 V 68 – 78 V 68 – 78 V 90 V
60% @ 270 A 89% @ 320 A 75% @ 400 A 75% @ 500 A 85% @ 400 A
Duty Cycle 77º F (25º C)
100% @ 210 A 100% @ 304 A 100% @ 365 A 100% @ 450 A 100% @ 380 A
40% @ 320 A 40% @ 400 A 40% @ 500 A 40% @ 400 A
60% @ 270 A
Duty Cycle 104º F (40º C) 60% @ 260 A 60% @ 365 A 60% @ 450 A 60% @ 350 A
100% @ 170 A
100% @ 220 A 100% @ 320 A 100% @ 340 A 100% @ 290 A
13 SEP 12
- 10 -
Power Source
Connections – TPS 3200/4000/5000
LocalNet Connection
Front Panel
This connection is for the
The front panel allows the welder to LocalNet connection to the wire-
control the power source s welding feeder and/or interface device.
characteristics.
(-⁄ Current Socket Connection Blanking Cover(s⁄

The connection depends on the These connections are for
operating mode of the power source optional upgrades to the power
Welding: Connect the
MIG Welding source.
welding ground to this socket.
TIG Welding
current connection on the torch
to this socket.
STICK Welding Mains Connection
electrode cable to this socket This connection is for the 3-
(depending on the type of phase input power.
electrode being used⁄.
Current Connection
Power Switch (+⁄ Current Socket Connection
(optional⁄
This switch turns the power source on The connection depends on the operating mode of the power source
(1⁄ and off (0⁄. This connection is reserved for
Welding: Connect the current connection of the interconnection
MIG Welding an optional current socket
hose pack to this socket.
13 SEP 12
Welding: Connect the welding ground to this socket.

TIG Welding
Welding: Connect the electrode cable to this socket (depending
STICK Welding
on type of electrode being used⁄. - 11 -
Power Source
Connections – TPS 2700
Carrying Strap
Power Switch
Front Panel
Blanking Cover(s⁄
LocalNet Connection
Ground Connection (optional⁄
Current Connection
Gas Connection (bottle⁄

13 SEP 12
Mains Connection
- 12 -
Current Connection (torch⁄ Ground Connection Trigger Connection (torch⁄
Power Source
Connections – TsT 3500/5000
Front Panel
Optional Add-
Add-ons
Ground Connection
Mains Connection
13 SEP 12
Current Connection LocalNet Connection

Power Switch
- 13 -
Power Source
Connections – TsT Compact
Front Panel Gas Purch / Wire
Feed Switch
Ground
Connection
Mains
Connection
Current
Connection
Torch Gas
Connection
13 SEP 12
Connector
LocalNet Power
Connection Switch - 14 -
Wire Feeder
Models
VR 1500
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
A push/pull torch requires an additional, internally installed kit.
VR 1550
This wire feeder is designed specifically for robotic or automated applications.
Using this wire feeder for manual welding is not feasible without special
modifications
This feeder can be used for CMT and/or push/pull applications using a series of
specially designed kits.
VR 4000
This wire feeder is designed specifically for manual applications.
This device has the trigger connections required for manual torches to operate.
A removable wire-spool holder is mounted to the rear of the feeder.
Robotic/automated connections and controls can easily be added to this wire feeder
VR 7000 CMT
This wire feeder was developed specifically for the Cold Metal Transfer (CMT⁄ process.
The feeder is equally suited to both manual and robotic/automated needs.
A wire spool holder is integrated to the feeder allowing for both spool and drum use.
13 SEP 12
This feeder is designed to operate with either a push or a push/pull torch. - 15 -

Wire Feeder
Models
VR 1500 PAP
This wire feeder is designed specifically for robotic through-the-arm applications.
The size and weight was kept as small as possible, keeping only the mandatory components
in the feeder itself and moving the remainder to the welder.
Using this wire feeder for manual welding is not possible.
VR 5000 Manual
Newly developed wire feeder designed specifically for the TransSteel Welding System.
Built with highly reliable, impact resistant materials. This provides reasonable protection
from dragging, dropping and hanging.
Multiple control options to handle both manual and synergic welding needs
Incredibly precise feed system allowing for perfect wire feed
Specialized current connection with data lines integrated to the connection simplifies setup
and keeps wiring to a minimum.
VR 5000 ROB
Newly developed wire feeder specifically designed for the robotic TransSteel Welding
system.
Designed to have the smallest profile of any Fronius wire feeder while maintaining a high
standard of durability and reliability.
Multiple versions available based on the robot type and design (PAP, standard, etc.⁄ with a
13 SEP 12
large range of options and fixtures to choose from.

- 16 -
Wire Feeder
Motor Plate
Tension Knobs
Drive Rolls (top⁄
Wire Guide Insert (steel or synthetic⁄
Main Drive Roll
Drive Rolls (bottom⁄
Torch Connectors
Fronius Connector (F++⁄ Fronius System Connector (FSC⁄ Euro Connector (E⁄ Tweeco Connector (T⁄
13 SEP 12
- 17 -
Wire Feeder
Connections & Controls – VR 1500
Current/Gas Connection (torch⁄ Gas Purge Button
Current Connection (welder⁄
Gas Connection (bottle⁄ Wire Inch Button

LocalNet Connection (spare⁄
Coolant Feed - hot (torch⁄ Robacta Connection (torch⁄
Coolant Feed - cold (torch⁄
Coolant Feed - hot (welder⁄
LocalNet Connection (welder⁄

13 SEP 12
Coolant Feed - cold (welder⁄ - 18 -

Wire Feeder
Connections & Controls – VR 7000
LHSB Connection (welder⁄
Spool Holder Gas Purge (up⁄ / Wire Feed (down⁄ switch
Coolant Feed - hot (welder⁄
Coolant Feed - cold (welder⁄
Motor-
Motor-plate
Power Control (WFS, Current, etc.⁄

Arc Length Control
Buffer Connection (torch⁄

LHSB Connection (torch⁄
Robacta Connection (torch⁄

LocalNet Connection (spare⁄
Current/Gas Connection (torch⁄ Trigger Connection (torch⁄

13 SEP 12
Coolant Feed - cold (torch⁄ Coolant Feed - hot (torch⁄ - 19 -

Wire Feeder
Connections & Controls – VR 5000 Rob
- PAP System Only -
- Standard System Only -
Current/Gas Connection (torch⁄ Wire Inlet (drum or spool⁄
LocalNet Connection (welder ⁄

Standard System Only -

PAP System Only -
Motor-
Motor-plate
13 SEP 12
Wire Inch Button - 20 -

Wire Feeder
Connections & Controls – VR 5000 Manual
Handle Current Connection (welder⁄

Spool Window Spool Holder Synergic Selection
-Synergic version only -
Weld Control
Panel
Motor-
Motor-plate
Current/Gas Connection (torch⁄ Coolant Feed - cold (welder⁄
LocalNet Connection (welder⁄ - optional add on -
Coolant Feed - hot (torch⁄

13 SEP 12
- optional add on - Coolant Feed - hot (welder⁄ -

Coolant Feed - cold (torch⁄
optional add on - - 21 -
- optional add on -
Welding Torch
Models
Manual Torches Robotic Torches

Trigger to start/stop the arc. Robotic/Automated control of the arc
Water-cooled or Air-cooled Water-cooled or Air-cooled
Several control options No parameter control options.
None Wire feed and gas control
Up/Down (U/D⁄ Only on drive-based torches.
Jobmaster (JM⁄ Several wire feeder connections
Several wire feeder connections Fronius (F/F++⁄
Fronius (F/F++⁄ Fronius System Connector (FSC⁄
Fronius System Connector (FSC⁄ Euro (E⁄
Euro (E⁄ Tweeko (Z⁄
Tweeko (Z⁄ Will have Robacta in the description
BAAN/Price-
BAAN/Price-book Description Examples
AL 4000 G/E/UD/4.5m/14.5ft - AL 4000 (torch type-manual⁄ G (gas-cooled⁄ E (Euro connector⁄ UD (up/down control⁄
Robacta Drive Ext. W/F++/1.75m/5.7ft - Robacta Drive Ext (torch type-robotic⁄ W (water-cooled⁄ F++ (Fronius connector⁄
PullMig CMT W/F/6m/19.7ft - PullMig CMT (torch type-manual⁄ W (water-cooled⁄ F (Fronius connector⁄
13 SEP 12
- 22 -
Cooler
Models
Cooling Units
Standard Features
Integrated system linked directly to power source for power and control.
Fuse protection against potential over-voltage damage.
Flow sensor to verify proper coolant movement.
Variable flow measurements to account for lengthy hose-packs.
FK 4000 / FK 5000
Standard water cooler for most MIG and TIG packages
Internal reservoir that allows for a completely closed system.
FK 9000
High volume water cooler for specialized system that require a larger
coolant capability.
Two separate units with integral components divided between them.
13 SEP 12
- 23 -
Weld Process
Overview
Shielded Metal Arc Welding (SMAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a covered metal electrode and the workpiece(s).
Shielding is obtained from decomposition of the electrode covering. Pressure is not used, and filler metal is obtained from the electrode.
– Stick Welding
– Performed with a basic constant current (CC) power source that is equipped with an electrode holder and a ground clamp
– Manual
Gas Tungsten Arc Welding (GTAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a tungsten electrode (non-consumable) and the
workpiece(s). Shielding is obtained from a gas. Pressure may or may not be used, and filler may or may not be used.
– TIG welding
– Performed with a constant current (CC) power source equipped with a GTA welding torch that supplies current through a tungsten electrode
and ground clamp
– GTAW requires an inert gas such as Argon (most commonly used) or Helium (or a mixture of the two) to support the arc
– Manual, Mechanized, and Automated
Gas Metal Arc Welding (GWAW)
An arc welding process that produces coalescence of metals by heating them with an arc between a continuous filler metal electrode and the
workpiece(s). Shielding is obtained entirely from an externally supplied gas.
– MIG/MAG welding
– Performed with a constant voltage (CV) power supply equipped with a wire feeder to supply welding wire through a GMA welding torch to the
13 SEP 12
workpiece(s) and with a ground clamp to complete the electrical circuit

– Semi–auto process (manual), Mechanized, and Automated - 24 -
- 24 -
Weld Process
Overview
Synergic Welding
– Computer control of the welding arc based on a single user-defined characteristic (wire-
feed speed, material thickness, amps, etc.)
VOLTAGE
– Changing the wire-feed speed will automatically adjust the voltage necessary for the
filler metal and gas being used. This is done through the use of a digital signal
processor and a synergic line
– Provides an extremely high level of repeatability and precision
– The synergic line can be modified slightly to account for environmental differences
between laboratory testing and production
WIRE-FEED SPEED (current)

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

the most ‘ideal’ values for a specific filler metal, wire diameter, shielding gas, and
operating mode
– This line is created through a complex set of measurements taken while welding with
the specified settings
– A standard line can be chosen/programmed in a matter of seconds with the simple
selection of a few base parameters
TransSynergic and TransPulseSynergic
– Standard MIG power sources available from Fronius

– Both have the ability to do standard (conventional “2 dial”) welding and synergic welding
(one dial)
– The TransPulse Synergic power source has the added ability to perform pulse-synergic
13 SEP 12
welding
- 25 -
Weld Process
MIG – Short Circuit Transfer
Short Circuit Transfer
This is a transfer mode where the electrode wire touches the work piece “snubbing out” the arc and the heat from electrical resistance violently pinches
off and deposits the molten wire electrode into the weld pool. - The wire heats up forming a ball of metal at the end of the wire which is then reintroduced
into the molten weld pool where it shorts the circuit, then gets pinched off and deposited into the weld pool. The cycle then repeats itself.
– Disadvantages include: Limited wire feed speed and therefore lower deposition rates - Cold lapping/lack of fusion is also more likely to occur
(proper technique is needed to avoid cold lapping/lack of fusion) – Moderate amount of spatter (dependent on environmental factors and
parameters).
– Advantages Include: Low heat input - All positions – Gap bridging - Capable Process for thick and thin materials
Globular Transfer:
This is an uncontrolled spray transfer mode. When CO2 or Argon-CO2 is used, a molten ball tends to form on the end of the electrode and may grow in
size until its diameter is greater than the diameter of the electrode. These droplets, larger in size, may cause short circuits and this mode is known as
“globular transfer.” This method of transfer produces a large amount of spatter and higher heat input when compared to the short circuit transfer mode.
– Disadvantages include: High level of spatter and arc instability

– Advantages: Can use 100% CO2 , an inexpensive gas - Has good penetration on thick metals
Spray Transfer:
This is a high heat input transfer mode where the shielding gas is an Argon rich (Argon-Oxygen - 8% Oxygen maximum) or (Argon-CO2 -18% CO2
maximum) mixture. The droplets being sprayed across the arc are very fine and never short circuit the arc therefore propelling small molten droplets of
the electrode across an open arc to the workpiece(s).
– Disadvantages include: High heat input - Limited range of welding positions - Higher percentages of argon required thus increasing gas cost
13 SEP 12
– Advantages include: High deposition rates - Good penetration - Good weld appearance with little to no spatter
- 26 -
Weld Process
MIG – Pulsed Current Welding (Pulse)
Pulse Welding (GMAW-P):
This is a GMAW process variation in which the welding current is pulsed resulting in a lower heat input for a given set of welding parameters when
compared to conventional GMAW.
– Disadvantages include: Special power source required to support pulsing current - Higher argon percentages required to support arc –
diameter of spatter balls typically larger than conventional GMAW spatter ball size
– Advantages include: High deposition rates - Lower heat inputs - Viable solution to many welding situations - Less spatter when compared to
conventional GMAW – Good weld appearance
Note Concerning Synergic Welding:
Synergic is a term used to describe “single dial” manipulation of multiple welding parameters at the same time.
– Disadvantages include: Specific power source designed to allow single dial manipulation of multiple welding parameters at the same time
– Advantages include: Reduced parameter development time due to the ability to change multiple parameters with a single dial turn (current and
voltage with single dial)
13 SEP 12
- 27 -
Weld Process
Gas Characteristics
INERT GASES INERT MIXED GASES

Argon
Ionizes easily, deep fusion penetration, finger-shaped, low cost to manufacture (filtered out of ambient air⁄.
Helium
Difficult to ionize; high heat conductivity; deep, wide penetration; fluid weld pool; good wetting; more expensive
than argon (filtered out of natural gas⁄
Argon-Helium Mix
The advantages/disadvantage of each gas increases and decreases in relation to the proportion within the mix.
ACTIVE GASES ACTIVE MIXED GASES

CO2
Reacts with the material, deeper reduced-pore fusion penetration, tends towards spattering, cheap to manufacture
Argon CO2
Combines advantages of its components, the most used gas combination for unalloyed steel and chrome-nickel
Argon Oxygen
Arc more stable, reduced surface tension of weld pool, pore-sensitive, Oxygen 8% maximum
13 SEP 12
- 28 -
Weld Process
Overview of Active Mixed Gas
CO2 Ar/CO2 Ar/O2

Fusion Penetration
Horizontal Very Good Good Good
Very Good More CO2 = better fusion Critical

Positional Welding penetration
Normal
Pores Very Little Pore-sensitive
More CO2 = fewer pores
Arc Stability Poor, except KL Good Very Good
Spatter Level High Medium Low
Fusion Penetration Profile

13 SEP 12
- 29 -
Weld Process
Impact of CO2 on the Arc
5% CO2 18% CO2

• Narrow arc range • Wider arc range
• Deeper, narrower fusion • Wider fusion penetration
penetration
• Little pore creation
• Pore creation possible
The proportion of CO2 in the gas is mainly responsible for the shape of the arc and the resulting behavior of it (fusion
penetration, pore creation, etc.).
13 SEP 12
- 30 -
Weld Process
Fronius Options
Gas Flow
Typically, the weld system opens and closes the gas
• The flow rate of the shielding gas is a critical aspect of valve. If flow monitoring is desired within the system, the
the welding process. Too high OR too low will have a following options are available.
serious impact on weld results.
• Rule of thumb for the flow rate: 10 – 12 times the

diameter in l/min of flow
- 1.2mm x 10 = 12 l/min
- 1 l/min = 2.1 CFH
Gas Pressure Sensor (4,100,343)
- 12 l/min x 2.1 = 25 CFH
Manually set gas valve that reports a gas error to the weld
system when flow is too low. Only errors out for low flow
and doesn’t report specific flow information.
• Helium and Hydrogen require about 50% more flow
than other gases due to their lighter weights.
Correct flow rate Excessive flow rate
Digital Gas Sensor (4,100,374)

The specific gas flow is set, regulated, and monitored
using this device. Not only is a low or high flow rate
detected, but the system also reports back specific gas
flow data.
13 SEP 12
- 31 -
Weld Process
Torch Movement and Handling
Neutral Travel Angle
Arc heats and transmits it s total power into the weld pool
Stable, quiet arc
Fusion penetration is MEDIUM
Weld Width is MEDIUM
Push Travel Angle
Arc heats and transmits it s total power into the weld pool
Stable, quiet arc
Fusion penetration is SHALLOW
Weld Width is WIDE
Drag Travel Angle
Arc partially heats the base material and the weld pool
Not a particularly quiet arc
Fusion penetration is DEEP
Weld Width is NARROW
13 SEP 12
- 32 -
Weld Process
Discontinuity Insufficient Throat
The weld bead is too shallow
Excessive Reinforcement Possible Cause(s⁄

Weld bead reinforcement is too high and lumpy
Combination of travel speed too fast and
current too low
Possible Cause(s⁄
Improper placement of weld beads when
Travel speed too slow
doing multiple passes
Weld current too low
Improper travel angle
Insufficient Leg (undersized weld⁄
Leg size too small
Undercut Possible Cause(s⁄

Cutting away at the toe(s⁄ Using the wrong work angle
Possible Cause(s⁄ Insufficient wire feed speed for travel speed
Amperage too high
Arc length too long (voltage too high⁄
Improper work angle
Lack of Fusion
Weld not fused completely
Insufficient Penetration Possible Cause(s⁄

Not penetrated at root or between passes
Amperage too low
Possible Cause(s⁄ Travel speed too high
Amperage too low Improper work/travel angle
Travel speeds too fast Improper weave parameters
Too large or wrong electrode
13 SEP 12
Improper travel angle

- 33 -
Weld Process
Discontinuity Porosity
Pinholes
Overlap / Weld Bead Rollover Possible Cause(s⁄

Weld metal cold and lapped at toe or root Dirty, painted, or galvanized base metal
Arc length too long
Possible Cause(s⁄
Moisture in weld
Amperage too high
Insufficient shielding gas coverage
Travel speed too slow
Electrode too large
Cracking
Cracks in the weld and/or base metal
Slag Inclusions Possible Cause(s⁄

Slag trapped in weld Using the wrong electrode
Possible Cause(s⁄ Using excessively high amperage
Improper manipulation of covered electrode Underfill or improper crater geometry (crater

cracking⁄
Improper cleaning and/or slag removal between
passes Moisture in low hydrogen processes
Excessive Spatter
Possible Cause(s⁄
Amperage too high
Electrode angle too extreme
Arc length too short/long
13 SEP 12
Process driven
- 34 -
Use and Operation Step 6: If using a cooler, verify cooler is turned on and set
Initial Set-up and Turn On properly (C-C and C-T⁄.
Step 7: Select proper synergic-line for the application to be

Step 1: Connect main power, gas and wire done.
to the welder/wire feeder. If equipped with
one, fill the cooler with Fronius Coolant.
Step 8: If using jobs, set and edit them as needed. If
not, select all other needed weld parameters.
Step 2: Connect or clamp the ground
connection to the fixture or work piece.
Step 9: Start welding
Plug the other end into the welder ground
connection.
Notes
Step 3: Turn the welder on. Almost If you encounter an error code
immediately, you will hear a click from the or weld problems, attempt to
wire feeder. Within a minute, the display perform a basic check-out.
should come on. Note any failure points before
calling support.
Step 4: Load the consumables into the wire feeder and torch as When calling support, please
necessary. Store extras in a safe place for later use. have the following information
available:
Step 5: Perform a resistance test. - Welder serial number

- Welder firmware/database
Step 5: If using a non-CMT push-pull gun, perform a PPU - Error Codes (if any⁄
alignment - Filler metal type,
13 SEP 12
diameter, and gas.

- 35 -
- 36 -
- 37 -
- 38 -
- 39 -
- 40 -
Use and Operation

MIG Correction Values
Correction Value 1 Correction Value 2

+30 = longer arc length → more voltage +5 = More inductance → Lower peak current, soft arc
Standard Synergic 0 = Standard arc length 0 = Standard inductance
-30 = Shorter arc length → Less voltage -5 = Less inductance → Higher peak current, hard arc
+30 = longer arc length → more voltage +5 = Wider arc → Higher pulse force
Pulse Synergic 0 = Standard arc length 0 = Standard width
-30 = Shorter arc length → Less voltage -5 = Narrower arc → Lower pulse force
+30 = Lower droplet detach freq → more voltage +5 = Less SC2 Current → Colder melt pool
Standard CMT
0 = Standard Plasma WFS 0 = Standard SC2 Current
(Steel)
-30 = Higher droplet detach freq → Less voltage -5 = More SC2 Current → Hotter melt pool
+30 = Slower Burn WFS → more voltage +5 = Increased arc length at ignition
Standard CMT
(Aluminum and 0 = Standard Burn WFS 0 = No increased arc length at ignition
Stainless)
-30 = Faster Burn WFS → Less voltage -5 = No impact
+30 = longer arc length → more voltage +5 = More energy → Drop falls with more pressure
CMT Pulse
0 = Standard arc length 0 = Standard energy
(Steel)
-30 = Shorter arc length → Less voltage -5 = Less energy → Drop falls with less pressure
+30 = Slower Pulse WFS → more voltage +5 = More energy → Drop falls with more pressure
CMT Pulse
(Aluminum and 0 = Standard Pulse WFS 0 = Standard energy
Stainless)
-30 = Faster Pulse WFS → Less voltage -5 = Less energy → Drop falls with less pressure
13 SEP 12
- 41 -
Use and Operation

Front Panel – Controls (TPS)
Parameter Selection Button
Keylock Switch (optional⁄ Parameter Selection Button Used to determine what welding parameter
Used to lock and unlock the front panel control, Used to determine what welding parameter will be will be displayed on the SECOND 3-digit
limiting access to who can change welding settings. displayed on the first 3 digit display (sheet thickness, display (arc-length correction, dynamic,
welding current, wire-feed speed, or drive current⁄. welding voltage, or job number⁄
Inch Forward Button

Used to inch the filler wire
forward through the torch Adjustment Dial
without gas or current flow. Used to change the
value of a parameter
or setting.
Purge Button
Used to test the gas flow.
One press will allow gas
flow for 30s, a second Mode Selection
press will stop the flow. Buttons (up/down⁄
Used to change the
welding process of the
power source.
Store Button
Used in conjunction with
other buttons to get into
various other menu s. Can
also be used to exit any
menu.
Trigger Selection Buttons

(up/down⁄
Diameter Selection Button Material Selection Buttons (up/down⁄
13 SEP 12
Used to changed the type of trigger

Used to select the diameter of the filler metal to be Used to select the shielding gas and filler metal to setting for the welding torch.
used during the welding process. be used during the welding process. - 42 -
Use and Operation

Hold Indicator
Front Panel – Indicators (TPS)
When lit, the last welding values are
shown on the 3-digit displays. Only 3-Segment Display
Wire Feeder Current Indicator lights after a weld has completed.
Parameter Adjustment Indicator When lit, the second 3-digit display is
active and adjustable when
When lit, the wire-feeder motor current is When lit, the first 3-digit display is active and applicable.
shown on the first 3-digit display. adjustable when applicable.
Torch Motor Current Indicator Parameter Adjustment Indicator

(if equipped⁄ When lit, the parameter being looked at
When lit, the torch motor current is can be adjusted to a new value.
shown on the first 3-digit display.
3-Segment Display
When lit, the first 3-digit display is active
and adjustable when applicable. Coolant Flow (if equipped⁄
When lit and equipped with a digital flow
meter the 3-segment display will show
Power Indicators Temperature the coolant flow.
When lit, the first 3-digit display shows one of several power Indicator
values depending on the power source mode.
When lit, the internal
Thickness: When lit, the first 3-digit display will
Sheet Thickness temperature for the
show the sheet thickness of the material to be power source is too Welding Voltage Parameter Adjustment Indicator
welded to. This value is adjustable in any synergic high. Indicator
mode. When lit, the second 3-digit display is
When lit, the second 3- active and adjustable when applicable.
digit display will show
Arc Length
Current: When lit, the first 3-digit display will
Welding Current the voltage that will be
show the welding current that will be welded with. Correction welded with. This value
This value is adjustable in any synergic mode. Indicator is adjustable. Job Number Indicator
When lit, the second 3- When lit, the second 3-digit display
digit display shows the shows the number of the job being used.
Speed: When lit, the first 3-digit display
Wire Feed Speed
current arc length Dynamic/Droplet
will show the wire feed speed that will be welded
correction. This value
with. This value is adjustable in any synergic mode..
is adjustable.
Correction Indicator
When lit, the second 3-
Pulse: The three values are linked to each other. digit display will show
Synergic & Pulse
As you change one, the other two will adjust automatically. either the dynamic
correction (synergic⁄ or
13 SEP 12
Standard: Only current and wire feed are available as

Standard the droplet-detachment
selections. Wire feed speed is the ONLY parameter that can (pulse⁄.
be adjusted. - 43 -
Use and Operation

Front Panel – Indicators (TPS)
Globular Transfer Arc Indicator
When lit, conditions are correct for the
power source to weld between short
circuit and spray arcs.
Wire Diameter Indicator

When lit, this will indicate which wire
diameter is selected to weld with.
Wire Diameter Special Indicator

When lit, this indicates that a size other
than the normal ones are selected to Mode Indicators
weld with. These indicators determine which welding mode the power
source is in for welding.
Pulse Synergic: This will set the power source
Filler Metal/Gas Indicator for welding in pulse MIG welding using stored
Trigger Indicators
When lit, this indicates the shielding gas and synergic line.
filler metal combination used during the These indicators determine how the torch trigger reacts
Synergic: This will set the power source for
welding process. during the welding process.
conventional MIG welding using a stored
Conventional: Press and hold torch trigger to start
Conventional synergic line.
arc. Release trigger to stop.
Standard: This will set the power source for
Filler Metal/Gas Special Indicator Trigger Lock ( 2-step⁄⁄: Press and release torch conventional MIG welding using NO synergic
trigger to start arc. Press (and release⁄ trigger to line.
When lit, this indicated that a special filler stop arc.
metal/gas combination has been selected. JOB: This will set the power source for welding
These two lines generally vary based on the Special 44--Step: Press and hold torch trigger to begin based on the JOB previously set up (there will
synergic data loaded into the power source. welding at Current start value. Release trigger to be a second indicator showing the saved
move to normal welding current. Press and hold mode for the JOB⁄.
trigger to move to ending current value. Finally,
TIG: This will set the power source for TIG
release torch trigger to stop the arc.
welding (assuming optional components are
Mode: Press and release torch trigger to start
Spot Mode installed⁄.
the weld, it will run until the time runs out and then
Stick: This will set the power source for Stick
stop automatically. You can abort the weld by
13 SEP 12
(CV⁄ welding.
pressing and releasing the torch trigger a second
time. - 44 -
Use and Operation

Front Panel – Controls (CMT) Parameter Selection Button
Used to determine what welding parameter will be
displayed on the RIGHT 3-digit display (arc-length
Keylock Switch (if equipped⁄ Parameter Selection Button correction, dynamic, welding voltage, or job
Used to lock and unlock the front panel control, Used to determine what welding parameter will be number⁄
limiting access to who can change welding settings. displayed on the LEFT 3 digit display (sheet
thickness, welding current, wire-feed speed, or drive
current⁄.
Inch Forward Button

Used to inch the filler wire
forward through the torch Adjustment Dial
without gas or current flow. Used to change the
value of a parameter or
setting.
Purge Button
Used to test the gas flow.
One press will allow gas
flow for 30s, a second
Mode Selection
press will stop the flow. Buttons (up/down⁄
Used to change the
welding process of the
power source.
Store Button
Used in conjunction with
other buttons to get into
various other menu s. Can
also be used to exit any
menu.
Diameter Selection Button Material Selection Buttons (up/down⁄ Trigger Selection Buttons (up/down⁄
13 SEP 12
Used to select the diameter of the filler metal to be Used to select the shielding gas and filler metal to Used to changed the type of trigger setting for the
used during the welding process. be used during the welding process. welding torch.
- 45 -
Use and Operation

Hold Indicator
Front Panel – Indicators (CMT)
When lit, the last welding values are
shown on the 3-digit displays. Only 3-Segment Display
Wire Feeder Current Indicator lights after a weld has completed.
Parameter Adjustment Indicator When lit, the right 3-digit display is
active and adjustable when
When lit, the wire-feeder motor current is When lit, the left3-digit display is active and applicable.
shown on the first 3-digit display. adjustable when applicable.
Torch Motor Current Indicator Parameter Adjustment Indicator

(if equipped⁄ When lit, the parameter being looked at
When lit, the torch motor current is can be adjusted to a new value.
shown on the first 3-digit display.
3-Segment Display
When lit, the first 3-digit display is active
and adjustable when applicable. Coolant Flow (if equipped⁄
When lit and equipped with a digital flow
meter the 3-segment display will show
Power Indicators Temperature the coolant flow.
When lit, the first 3-digit display shows one of several power Indicator
values depending on the power source mode.
When lit, the internal
Thickness: When lit, the first 3-digit display will
Sheet Thickness temperature for the
show the sheet thickness of the material to be power source is too Welding Voltage Parameter Adjustment Indicator
welded to. This value is adjustable in any synergic high. Indicator
mode. When lit, the second 3-digit display is
When lit, the second 3- active and adjustable when applicable.
digit display will show
Arc Length
Current: When lit, the first 3-digit display will
Welding Current the voltage that will be
show the welding current that will be welded with. Correction welded with. This value
This value is adjustable in any synergic mode. Indicator is adjustable. Job Number Indicator
When lit, the second 3- When lit, the second 3-digit display
digit display shows the shows the number of the job being used.
Speed: When lit, the first 3-digit display
Wire Feed Speed
current arc length Dynamic/Droplet
will show the wire feed speed that will be welded
correction. This value
with. This value is adjustable in any mode.
is adjustable.
Correction Indicator
When lit, the second 3-
Pulse: The three values are linked to each other. digit display will show
Synergic & Pulse
As you change one, the other two will adjust automatically. either the dynamic
correction (synergic⁄ or
13 SEP 12
Standard: Only current and wire feed are available as

Standard the droplet-detachment
selections. Wire feed speed is the ONLY parameter that can (pulse⁄.
be adjusted. - 46 -
Use and Operation

Front Panel – Indicators (CMT)
CMT-
CMT-Pulse Indicator
This will light when a CMT-Pulse
synergic line has been selected.
Wire Diameter Indicator

When lit, this will indicate which wire
diameter is selected to weld with.
Wire Diameter Special Indicator

When lit, this indicates that a size other
than the normal ones are selected to
weld with. Mode Indicators
These indicators determine which welding mode the power
source is in for welding.
Filler Metal/Gas Indicator
Trigger Indicators Pulse Synergic: This will set the power source
When lit, this indicates the shielding gas and for welding in pulse MIG welding using stored
filler metal combination used during the These indicators determine how the torch trigger reacts synergic line.
welding process. during the welding process.
Synergic: This will set the power source for
Conventional: Press and hold torch trigger to start
Conventional conventional MIG welding using a stored
arc. Release trigger to stop. synergic line.
Filler Metal/Gas Special Indicator Trigger Lock ( 2-step⁄⁄: Press and release torch CMT / CMT Pulse: This mode will set the
trigger to start arc. Press (and release⁄ trigger to power source for CMT and CMT Pulse using
When lit, this indicated that a special filler
stop arc. selected synergic lines.
metal/gas combination has been selected.
These two lines generally vary based on the Special 44--Step: Press and hold torch trigger to begin STANDARD: This will set the power source for
synergic data loaded into the power source. welding at Current start value. Release trigger to conventional MIG welding using NO synergic
move to normal welding current. Press and hold lines.
trigger to move to ending current value. Finally,
release torch trigger to stop the arc. JOB: This will set the power source for welding
based on the JOB previously set up (there will
Mode: Press and release torch trigger to start
Spot Mode be a second indicator showing the saved
the weld, it will run until the time runs out and then mode for the JOB⁄.
13 SEP 12
stop automatically. You can abort the weld by

pressing and releasing the torch trigger a second Stick: This will set the power source for Stick
(CV⁄ welding.
time. - 47 -
Processes Checking Software

Use and Operation
Select a Synergic Line
1/3 2
1: Press and hold the STORE button and then press
Step 1
2 3 4 the MATERIAL SELECTION button. Release
1 both buttons. One of four numbers will appear.

UST Firmware: 4.25.016 (sample number⁄
Welding Database: 03.0139 (sample number⁄
SR41 Firmware: A2.02.02 (sample number⁄
1: Choose the desired filler metal wire diameter
Step 1 Arc Hours: 00131.1 (sample number⁄
2: Choose the desired shield gas/filler metal
Step 2 Synergic Line: r0209 (sample number⁄
combination.
The machine may enter any of the four codes above,
3: Choose the desired trigger type.
Step 3 but will cycle through in the same order.
4: Choose the desired welding mode.
Step 4 2: Use the MATERIAL SELECTION buttons to cycle
Step 2
through the software codes.
3: Press and release the STORE button to return to
Step 3
the main welding screen.
13 SEP 12
- 48 -
Processes
Job Programing and Editing
Program a Job Editing a Job
2/4 1
2/4
1/3/5/
6
1/6 3
1: Choose the desired synergic line.

Step 1 1: Press and hold the STORE button and then press
Step 1
the 1st PARAMETER SELECTION button. The
2: Dial in the desired power rating if known, if unknown
Step 2
display should change to Job 0 .
this step may be skipped.
2: Dial in the number of the job you wish to modify.
Step 2
3: Press and release the STORE button. The first 3-
Step 3
digit display should change to nPG and the second 3: Use the up/down arrows to cycle through the
Step 3
should have a number on it. This is the first available parameters until you find the one you wish
available job number. edit.
4: Select the desired job number (note: if a job is
Step 4 4: Dial in the new value (note the starting value since
Step 4
already saved, the first display will change to PrG . there is no way to undo a change⁄.
5: Press and hold the STORE button until the first
Step 5 5: Repeat steps 3 and 4 until all parameters have been
Step 5
display changes from Pro to PrG . Release the changed.
STORE button once this happens.
Step 6
13 SEP 12

Step 6 the main screen.
the main screen. - 49 -
Processes
Step 6: Use the process select up arrow to cycle through
Resistance Test the parameters until r appears in the display.
Step 7: Ensure that no one is touching any part of the
welding circuit.
Step 8: Press the wire feed button (C⁄ on the front panel,
the trigger on the torch, or the arc-on command
through the robot to activate the test.
C Step 9: Display value should change to a new number.

Repeat this process three times.
Step 10: Press the Store button (A⁄ twice to return to main
menu.
A B
Step 1: Remove gas nozzle from torch and retract wire so Error Codes
that no wire inside the tip. r E30 There is an open measurement in the welding
Step 2: Firmly touch the contact tip as close to the welding circuit
point as possible. If the work-piece is not r E31 Calibration procedure was interrupted by a
available, use a bare part of the fixture instead. repeated pressing of the start button (wire feed,
Step 3: On the front panel, press the store button (A⁄ and torch trigger, etc.⁄ before test is finished.
the process select up arrow (B⁄ at the same time. r E32 Measured value is too low (.5 m ⁄ or too high (30
Once the display changes, release both buttons. m ⁄.
Step 4: Use the process select up arrow (B⁄ to cycle r E33 Poor contact between the contact tip and the
through the parameters until 2nd appears on the work-piece.
display.
r E34 Poor contact between the contact tip and the
Step 5: On the front panel, press the store button (A⁄ and work-piece.
13 SEP 12
the process select up arrow (B⁄ at the same time.

Once the display changes, release both buttons. - 50 -
Processes
Step 6: Press the torch trigger or the wire feed button (D⁄
Push Pull Alignment on the front panel. The display should change to
St.1 .
Step 7: Open all drive rolls on the wire feeder and torch.
Step 8: Press the torch trigger or the wire feed button (D⁄
C again. The display should change to St. 1 run
and the drive rolls in the torch and gun should
both run.
D Step 9: When the test is finished, the display will read St.
2 . Ensure there is wire loaded and close the
drive rolls on the wire feeder and torch.
A B Step 10: Press the torch trigger or wire feed button (D⁄ on
the front panel. Depending on the PPU number,
the display with either immediately change to
Step 1: On the front panel, press the Store button (A⁄ and PPU # or run both sets of drive rolls (and wire⁄.
the Process Select up arrow (B⁄ at the same time. Once finished, it will then display PPU # .
Once the display changes, release both buttons.
Step 2: Use the Process Select up arrow (B⁄ to cycle menu.
through the parameters until 2nd appears on the
display. Step 12: Once finished, press the Store button (A⁄ twice,
cut off the excess wire and dispose of it.
Step 3: On the front panel, press the Store button (A⁄ and
the Process Select up arrow (B⁄ at the same time.
Note: when using a standard torch with a CMT wire
Step 4: Use the process select up arrow (B⁄ to cycle feeder, select PPU 0 and press the wire feed button. You
through the parameters until PPU appears in the can then set up the torch as normal.
display.
13 SEP 12
Step 5:
5 Use the red selection knob (C⁄ to select the PPU
number that corresponds to the torch being used. - 51 -
Processes
PPU Error Codes
PPU - Additional Information
Err Eto Incorrect measurement during PPU alignment
PPU Number for Push Pull Torch
St1 E1 No feedback from wire-feeder motor at min speed
St1 E2 No feedback from wire-feeder motor at max speed
PPU 2 Fronius KD Drive push-pull
PPU 3 Fronius Robacta Drive, master (3.5m or more⁄
St1 E4 No feedback from torch motor at min speed
PPU 4 Fronius Robacta Drive, slave (less than 3.5m⁄
St1 E5 No feedback from wire-feeder motor at max speed
PPU 5 Fronius PullMig, with potentiometer
St1 E6 No feedback from torch motor at max speed
PPU 6 Fronius PullMig, without potentiometer
St1 E16 PPU alignment interrupted by torch trigger press
PPU 16 MK Cobra Gold
St2 E7 PPU open drive roll has not been accomplished
PPU 26 MK Python
PPU 28 Fronius CMT PullMIG, with potentiometer
St2 E9 No feedback from torch motor at min speed
PPU 29 Fronius CMT PullMIG, without potentiometer
St2 E10 Wire-feeder motor current out of range at min speed
PPU 50 Fronius PT Drive, .030 aluminum
St2 E11 Torch motor current out of range at min speed
St2 E12 No speed value from wire-feeder at max speed
St2 E13 No speed value from torch motor at max speed
PPU 53 Fronius PT Drive, 1/16 aluminum
St2 E14 Wire-feeder motor current out of range at min speed
PPU 59 Fronius PT Drive, .040 steel
St2 E15 Torch motor current out of range at max speed
St2 E16 PPU alignment interrupted by torch trigger press
13 SEP 12

- 52 -
Processes Step 5: Use the red selection knob (C⁄ to select from one
Functional Tests of three options
Cooler Verification ON Turns the cooler on as soon as the welder

powers up.
OFF Turns the cooler off and disables flow-
monitoring
C Auto Turns the cooler on during welding and for 2
minutes after welding stops.
Step 6: Use the process select up arrow (B⁄ to cycle
D through parameters until C-T appears in the
display.
Step 7: Use red selection knob (C⁄ to select the amount of
time before flow sensor shuts the welding process
A B down. If unsure, set to ten.
Step 1: On the front panel, press the Store button (A⁄ and display.
the Process Select up arrow (B⁄ at the same time.
Step 2: Use the Process Select up arrow (B⁄ to cycle
through the parameters until 2nd appears on the
display.
Step 3: On the front panel, press the Store button (A⁄ and
the Process Select up arrow (B⁄ at the same time. Note: the flow switch will only shut the system down after
Once the display changes, release both buttons. the first weld has been done. When initially turned on, the
flow sensor is ignored.
Step 4: Use the process select up arrow (B⁄ to cycle
through the parameters until C-C appears in the
13 SEP 12
display.
- 53 -
Processes
Functional Tests
Motor Draw Test Output Voltage Test
B
D E
A B A
C
C
Step 1: Press the Parameter Selection button (A⁄ until the Step 1: Press the Parameter Selection button (A⁄ until the
main motor indicator (B⁄ is lit. voltage indicator (B⁄ is lit.
Step 2: First test the motor without load by opening up the Step 2: Disconnect the ground connection from the front of
drive rolls on the wire feeder the power supply.
Step 3: Press the Wire Feed button (C⁄ and check the left Step 3: Press the process select button (C⁄ until the Stick
most display (D⁄. It should be ~.7 amps (+/- 1 indicator (D⁄ lights up.
amp⁄.
Step 4: The right most display (E⁄ should indicate 40V
Step 4: Check the motor under load by closing the drive within one minute.
rolls on the wire feeder
Step 5: Press the process select button (C⁄ until the
Step 5: Press the Wire Feed button (C⁄ and check the left process changes to something other than TIG or
13 SEP 12
most display (D⁄. It should be ~1.0 amps. (+/- Stick.

- 54 -
20%⁄
Use and Operation

TsT Parameter Reference (MIG)
13 SEP 12
- 55 -
Use and Operation

TsT Parameter Reference (Stick)
13 SEP 12
- 56 -
3-digit Display (Voltage⁄

Use and Operation This value will display the voltage
dialed into the machine.
Front Panel – (TsT - Manual)
Hold Indicator
This indicator will light up after a weld has been completed and the Inductance Controls and Indicators
3-digit displays will show the last values used during welding. When
This is used to control and display the
welding starts up again or the values are changed, this indicator will
inductance for the welding machine.
go out.
The buttons increase and
decreased the inductance
3-digit Display (Amperage⁄ to the desired value.
This value will increase as the wire
feed speed increases
The value is then
displayed as a
representation with one
bar being the minimum
value and 7 bars being
Control Knob (Wire Feed Speed⁄
the maximum.
This control will vary the wire feed
speed the machine is set for. The
value corresponds with the
numbers around the dial and will
Control Knob (Voltage⁄
increase or decrease the current
value displayed on the 3-digit This control will vary the voltage
display. . the machine is set for and will
directly change the value
displayed on the 3-digit display.
Trigger Control and Indicators

The button switches between the two trigger options, 2-step (2T⁄ and
Process Control and Indicators
4-step (4T⁄.
The button switches between the
2-step: Press and hold torch trigger to start the arc. Release trigger
machines processes.
to stop the arc.
13 SEP 12
The indicator displays the process the

4-step: Press and release trigger to start the arc, press and release - 57 -
machine is currently set up for.
trigger to stop the arc.
Use and Operation Hold Indicator

This indicator will light up after a weld has been
Front Panel – (TsT - Synergic) completed and the 3-digit displays will show the last
values used during welding. When welding starts up
again or the values are changed, this indicator will go out.
Weld Power Controls and Indicators

These controls and indicators are used to Weld Adjustment Controls and Indicators
display and change the weld power values.
These controls and indicators are used to
display and change the weld adjustment
The three segment display will show values.
the value of the power indicator lit
below. The three segment display will show
the value of the adjustment indicator
The button control switches between lit below.
the three power values.
The button control switches between
Material Thickness: The display will the three adjustment values.
show the sheet thickness of the
material to be welded to. This value Arc Length Correction: The display
is adjustable in synergic mode only. will show the current arc length
correction set into the machine.
Welding Current: The display will Note that this value is NOT available
show the value of the welding in manual mode.
current that will be welded with. This
value is adjustable in any process. Welding Voltage: The display will
show the welding voltage currently
Wire-
Wire-Feed Speed: The display will set in the machine. Note that this is
show the value of the feed speed only adjustable in manual mode.
that will be welded with.
Dynamic Correction: The display will
Control Knob (power⁄: This will show the value of the current
control the value on the 3-digit dynamic set in the machine.
display.
Globular Transfer Mode Control Knob (adjustment⁄: This will
control the value on the 3-digit
Please note that the three power values This indicator will light when the
display.
(material thickness, welding current, and wire- settings on the synergic line will result
in globular arc.
13 SEP 12
feed speed⁄ are linked to one another in

synergic mode.
- 58 -
Operating Point Save/Selection Buttons

Use and Operation These buttons are used to save and recall weld
settings stored in memory by the user.
Front Panel – (TsT - Synergic)
Trigger Control and Indicators

The button switches between the
three trigger options, 2-step (2T⁄, Process Control and Indicators
4-step (4T⁄, and special 4-step
(S4T⁄ The button switches between the
machines processes.
2-step: Press and hold torch
trigger to start the arc. Release Manual Mode: Welding will occur
trigger to stop the arc. using with no link between wire-
feed speed and voltage.
4-step: Press and release trigger
to start the arc, press and release Synergic Mode: Welding will occur
trigger to stop the arc. using one of several synergic lines
that establishes a link between
Special 4-
4-step: Press and hold the current, wire-feed speed, and
trigger to begin welding at the voltage.
starting value, release trigger to
change to normal power value, Stick Mode: This mode is for
press and hold for ending power welding using the MMA process.
value, and finally release trigger to
stop the weld.
Filler Metal Selection and Wire Diameter Selection and Shield Gas Selection and
Indicator Indicator Indicator
The button is used to cycle The button is used to cycle The button is used to cycle
through the different filler metal through the different wire through the different shielding gas
types available. The finals SP diameters available. The finals types available. The finals SP
13 SEP 12
selection is designed for SP selection is designed for selection is designed for

customized synergic selections. customized synergic selections. customized synergic selections. - 60 -
Consumables Please note that drive rolls are wire diameter specific and the wires
Drive Rolls mentioned above are suggestions based on past experience.
Standard T Rolls Standard H Rolls Knurled K Rolls

Tension ~ 2 Tension ~ 1.5 to 2 Tension ~ 2 to 3
Standard drive rolls for steel and stainless wire Standard drive rolls for aluminum and CuSi wire Ridged drive rolls for flux and solid-cored wire.
when working through single shift operations. when working through single shift operations. One style for single or multiple shift operations.
Three points of contact on the wire (red dots⁄ Two points of contact on the wire (red dots⁄ Four points of contact on the wire (red dots⁄
Professional U Rolls Professional H Rolls Synthetic Rolls

Tension ~ 2.5 to 3 Tension ~ 1.5 to 2 Tension ~ 3
Heavy duty drive rolls for steel and stainless wire Heavy duty drive rolls for aluminum and CuSi Specialized drive rolls for soft aluminum or
when working through multiple shift operations. wire when working through multiple shift special care wire. Tend to wear out quickly
These are designed to last much longer than the operations. These are designed to last much and must be replaced regularly.
standard rolls. longer than the standard rolls.
Total point of contact on the wire (red dots⁄
13 SEP 12
Four points of contact on the wire (red dots⁄ Two points of contact on the wire (red dots⁄
- 61 -
Consumables
Liners
Teflon
Teflon is a specialty liner that is used when precise wire feed is needed or
for high heat applications that would typically melt graphite liners.
Graphite
Graphite liners are used for aluminum and other wires that are susceptible
to marring or damage from the liner.
Graphite - Combi
Combi liners are graphite liners with a brass end. The brass is used in the
contact tip end for withstanding higher heat applications with malleable
wire.
Bare Steel
Standard for steel and metal core/flux core wires with a water-cooled torch.
Insulated Steel
This is the standard steel liner for gas cooled, steel applications.
13 SEP 12
- 62 -
Consumables 2 1
Contact Tips
3
Quality (standard or high⁄ 2 Bore Size (none, Center-Bore⁄ 3 Wire Size (see below⁄
This trait refers to the tolerance of This trait refers to how the inner The wire size refers to the diameter
the wire diameter the tip is designed linger fits into the contact tip. This of the wire the tip is designed for.
for. Standard quality tips have a is critical with Aluminum wire This size can be either standard
much looser tolerance than High especially. (US⁄ or metric (EU⁄. Basic sizes
Quality tips. High Quality tips wear used in the US are
at a slower rate than Standard None:
None There is no center bore,
quality tips. the contact tip end is cone Fraction Standard Metric
shaped to guide the wire through
--- .035 .9
the tip.
3/64 .045 1.2
1/16 .062 1.6
Center Bore (CB⁄: The contact tip
1 Thread Size (M6, M8, and M10⁄ is squared off internally (see
This trait refers to the size of the figure 2⁄ and will come in one of
threads the contact tip will screw two sizes (4.1mm or 4.8mm⁄
into. M8 and M10 are typical sizes depending on the size of the
for most MIG applications. inner liner.
CB tips are required for aluminum
welding. This type of tip allows Figure 2: no bore versus center-bore
the liner to be exactly centered in
the tip.
13 SEP 12
- 63 -
Consumables
Fixing Nozzle Contact
Torch Breakdown – No Drive Sleeve Stock Tip
Insulating Spatter Gas

Ring Guard Nozzle
(if used⁄
Guide Nozzle Clamping

(if used⁄ Lock
Clamping
Nut
Steel Liner
Combi Liner
13 SEP 12
Teflon Liner
- 64 -
Consumables
Torch Breakdown – Whip Drive Fixing Nozzle Contact
Sleeve Stock Tip

Ring Guard Nozzle
2-piece (if used⁄
Drive Roll
Guide Nozzle Clamping 1-piece
(if used⁄ Lock Drive Roll
Guide or
Nozzle
Clamping
Nut
1-piece Drive
Roll (keyed⁄
2-piece Drive
Roll (keyed⁄
Ceramic Insert/Liner Brass Insert/Liner

Steel Liner
Combi Insert/Liner Steel Insert/Liner
Graphite Liner
Teflon Insert/Liner
13 SEP 12
Teflon Liner
- 65 -
Consumables
Torch Breakdown - CMT Fixing Nozzle Contact
Sleeve Stock Tip
Teflon Insert/Liner

Ring Guard Nozzle
(if used⁄
Guide Nozzle Clamping 1-piece

(if used⁄ Lock Drive Roll
Clamping
Nut
1-piece Drive
Roll (keyed⁄
Ceramic Insert/Liner Brass Insert/Liner

Steel Liner
Combi Insert/Liner Steel Insert/Liner
Graphite Liner
Teflon Insert/Liner
13 SEP 12
Teflon Liner - 66 -
Consumables
Liner Installation Procedure
Graphite/Teflon Liner Tools
1 - Whips should be laid out straight prior to installation

2 - Be sure liner is fully inserted in the whip and remove all of the free play.
3 - Cut liner flush with the diffuser and remove any burrs present after cutting.
4 - Contact tip should apply pressure against the inner liner as it is threaded into the diffuser.
2. 3.
1.
13 SEP 12
- 67 -
Consumables
Liner Installation Procedure
Feeder End of Torch
Fully insert inner liner Cut liner flush Install clamp nut install wire guide
13 SEP 12
- 68 -
Consumables
TS/TPS/KD Flux-cored (K-groove)
Feeder and Cooler
42,0001,0404 Feeder Roll, .045 (1.2)
42,0001,0352 Feeder Roll, 1/16 (1.6)
TS/TPS/KD Standard – Steel (T-groove)
42,0001,1732 Pressure Roll, smooth TsT Standard – Steel (U-groove)
42,0001,3275 Feeder Roll, .035 (.9) 44,0001,1406 Feeder Roll, .035 (.9)
42,0001,1361 Feeder Roll, .045 (1.2) 44,0001,1407 Feeder Roll, .045 (1.2)
42,0001,1362 Feeder Roll, 1/16 (1.6) 44,0001,1408 Feeder Roll, 1/16 (1.6)
TS/TPS/KD Heavy – Steel (U-groove) TsT Flux-cored (R-groove)

44,0001,1376 Feeder Roll, .035 (.9) 44,0001,1431 Feeder Roll, .045 (1.2)
44,0001,1379 Feeder Roll, .052 (1.4) 44,0001,1433 Feeder Roll, 1/16 (1.6)
44,0001,1323 Feeder Roll, 1/16 (1.6)
TS/TPS/KD Misc Wire Feeder Consumables
TS/TPS/KD Standard – Aluminum (H-groove) 42,0100,0333 Wire Guide Insert, synthetic, .035 - .045
42,0001,1613 Feeder Roll, .035 (.9) 42,0100,0334 Wire Guide Insert, synthetic, .052+
42,0001,0385 Feeder Roll, .045 (1.2) 42,0001,3481 Wire Guide Insert, steel
42,0001,3053 Feeder Roll, .052 (1.4) 44,0001,1203 Main Drive Roll
42,0001,0386 Feeder Roll, 1/16 (1.6)
Cooler Consumables
TS/TPS/KD Heavy Aluminum (H-groove) 40,0009,0046 Coolant, standard, -10° outside
13 SEP 12
44,0001,1185 Feeder Roll, .045 (1.2) 40,0009,0079 Coolant, pipe, up to -50° outside
44,0001,1209 Feeder Roll, 1/16 (1.6) 40,0009,0084 Coolant, indoor - 69 -

Consumables
Manual Torch-body Consumables
AL 4000 / AW 5000 AL 5000

42,0100,1018 Insulating Ring, AL 4000 1 42,0100,1205 Insulating Ring, AL 5000
1
42,0100,1016 Insulating Ring, AW 5000
2 42,0100,0312 Insulating Sleeve
2 42,0001,2970 Fixing Sleeve
3 42,0001,5912 Nozzle Stock, M10
3 42,0001,5122 Nozzle Stock, M10
42,0001,3277 Contact Tip, standard, .035 (.9)
4 42,0100,1007 Spatter Guard 42,0001,1578 Contact Tip, standard, .045 (1.2)
4
42,0001,1930 Contact Tip, standard, .056 (1.4)
42,0001,3277 Contact Tip, standard, .035 (.9) 42,0001,1579 Contact Tip, standard, 1/16 (1.6)
5
42,0001,1930 Contact Tip, standard, .056 (1.4) 42,0001,5405 Contact Tip, center-bore (CB), .035 (.9)
42,0001,1579 Contact Tip, standard, 1/16 (1.6) 42,0001,3592 Contact Tip, center-bore (CB), .045 (1.2)
4
42,0001,5059 Contact Tip, center-bore (CB), .056 (1.4)
42,0001,5405 Contact Tip, center-bore (CB), .035 (.9) 42,0001,5060 Contact Tip, center-bore (CB), 1/16 (1.6)
5
42,0001,5059 Contact Tip, center-bore (CB), .056 (1.4) 5 42,0001,5652 Gas Nozzle, standard
42,0001,5060 Contact Tip, center-bore (CB), 1/16 (1.6)
6 42,0001,5128 Gas Nozzle, standard
d1 d2 d3 L d1 d2 d3 L
13 SEP 12
..669” (17mm) .984” (25mm) n/a 3.110” (79mm) .709” (18mm) 1.063” (27mm) n/a 3.031” (77mm)
- 70 -
Consumables
Manual Torch-body Consumables
AL 3000 / AW 4000 MTG 5300 S

42,0100,1014 Insulating Ring, AL 3000 1 42,0100,1205 Insulating Ring, MTG 5300
1
42,0100,1010 Insulating Ring, AW 4000
2 42,0100,0312 Nozzle Stock, M8
2 42,0001,2930 Fixing Sleeve
42,0001,3889 Contact Tip, sharp, .035 (.9)
3 42,0001,5084 Nozzle Stock, M8 42,0001,3891 Contact Tip, sharp, .045 (1.2)
3
42,0001,3892 Contact Tip, sharp, .056 (1.4)
42,0001,3082 Contact Tip, standard, .035 (.9) 42,0001,3893 Contact Tip, sharp, 1/16 (1.6)
4
42,0001,3653 Contact Tip, center-bore (CB), .035 (.9)
4
42,0001,3485 Contact Tip, center-bore (CB), 1/16 (1.6)
d1 d2 d3 L d1 d2 d3 L
13 SEP 12
.679” (13mm) .984” (22mm) .669” (17mm) 2.637” (67mm) .709” (18mm) 1.063” (27mm) n/a 3.465” (88mm)
- 71 -
Consumables
Robotic Torch-body Consumables
MTG 4000 Robacta 5000

1 44,0350,2616 Gas Nozzle Holder, twist-lock 1 42,0001,2970 Fixing Sleeve
2 42,0100,0510 Insulating Ring, MTG 4000 2 42,0100,1016 Insulating Ring, Robacta 5000
3 42,0001,5528 Nozzle Stock, M10 3 42,0001,5122 Nozzle Stock, M10
42,0001,3277 Contact Tip, standard, .035 (.9) 4 42,0100,1007 Spatter Guard
4 42,0001,3277 Contact Tip, standard, .035 (.9)
42,0001,1579 Contact Tip, standard, 1/16 (1.6) 5
42,0001,5405 Contact Tip, center-bore (CB), .035 (.9) 42,0001,1579 Contact Tip, standard, 1/16 (1.6)
4 42,0001,5405 Contact Tip, center-bore (CB), .035 (.9)
42,0001,5060 Contact Tip, center-bore (CB), 1/16 (1.6) 5
5 42,0001,5532 Gas Nozzle, standard 42,0001,5060 Contact Tip, center-bore (CB), 1/16 (1.6)
d1 D2 d3 L d1 d2 d3 L
13 SEP 12
.669” (17mm) 1.063” (27mm) .827” (21mm) 2.874” (73mm) .669” (17mm) .984” (25mm) .787” (20mm) 3.110” (79mm)
- 72 -
Consumables
Torch Drive Consumables PullMig
1 42,0001,6210 Wire Inlet Guide, PullMig
42,0100,1114 Intake Nozzle, .045 (1.2)
2
42,0100,1121 Intake Nozzle, 1/16 (1.6)
42,0001,0456 Pressure Roll, .035 - .045 (.9 – 1.2)
3
42,0001,0457 Pressure Roll, 1/16 (1.6)
42,0001,0452 Driver Roll, .035 - .045 (.9 – 1.2)
4
42,0001,0453 Driver Roll, 1/16 (1.6)
42,0100,1003 Guide Nozzle, .045 (1.2)
5
42,0100,1008 Guide Nozzle, 1/16 (1.6)
44,0350,1788 Torch Body Insert, combi, .045 (1.2)
6
44,0350,1798 Torch Body Insert, combi, 1/16 (1.6)
44,0350,1806 Torch-body Insert, ceramic, .045 (1.2)
7
44,0350,1838 Torch-body Insert, ceramic, 1/16 (1.2)
Pre-cut Liners, F++

Inner Liner, bulk (ordered by the meter)
42,0300,0343 Inner Liner, graphite, 1/16 (1.6), 19.7ft (6m)
40,0002,0002 Inner Liner, steel, .045 (1.2)
40,0002,0004 Inner Liner, steel, 1/16 (1.6)
40,0001,0074 Inner Liner, graphite, .045 (1.2)
40,0001,0054 Inner Liner, graphite, 1/16 (1.6)
40,0001,0415 Inner Liner, teflon, .045 (1.2)
40,0001,0416 Inner Liner, teflon, 1/16 (1.6)
13 SEP 12
- 73 -
Consumables
Torch Drive Consumables Robacta Drive
42,0100,1003 Guide Nozzle, .045 (1.2)
1
42,0100,1008 Guide Nozzle, 1/16 (1.6)
42,0403,0143 Pressure Roll, .035 (.9)
42,0403,0147 Pressure Roll, .045 (1.2)
2
42,0403,0149 Pressure Roll, .056 (1.4)
42,0403,0151 Pressure Roll, 1/16 (1.6)
42,0403,0144 Driver Roll, slot, .035 (.9)
42,0403,0148 Driver Roll, slot, .045 (1.2)
3
42,0403,0150 Driver Roll, slot, .056 (1.4)
42,0403,0152 Driver Roll, slot, 1/16 (1.6)
4 42,0400,1024 Clamping Nut, threaded
5 42,0001,5412 Clamping Piece
6
7
Basic Kit
Inner Liner, bulk (ordered by the meter) 44,0350,2006 Basic Kit, .035 (.9)
40,0002,0002 Inner Liner, steel, .045 (1.2) 44,0350,2008 Basic Kit, .045 (1.2)
40,0002,0004 Inner Liner, steel, 1/16 (1.6) 44,0350,2009 Basic Kit, 1/16 (1.6)
40,0001,0074 Inner Liner, graphite, .045 (1.2) Basic kits include items 1-6 and graphite liner.

13 SEP 12

- 74 -
Consumables
Torch Drive Consumables CMT Robacta - PullMig
42,0100,1003 Guide Nozzle, .045 (1.2)
1
42,0100,1008 Guide Nozzle, 1/16 (1.6)
42,0001,5774 Pressure Roll, .035 (.9)
2 42,0001,5735 Pressure Roll, .045 (1.2)
42,0001,5736 Pressure Roll, 1/16 (1.6)
42,0001,5772 Driver Roll, slot, .035 (.9)
3 42,0001,5730 Driver Roll, slot, .045 (1.2)
42,0001,5729 Driver Roll, slot, 1/16 (1.6)
4 42,0400,1024 Clamping Nut, threaded
5 42,0001,5412 Clamping Piece
44,0350,2444 Wire Buffer Insert, .045 (1.2)
6
42,0404,1012 Wire Buffer Insert, 1/16 (1.6)
7
8
Inner Liner, bulk (ordered by the meter)

Basic Kit
40,0002,0002 Inner Liner, steel, .045 (1.2)
44,0350,2399 Basic Kit, aluminum, .035 (.9)
40,0002,0004 Inner Liner, steel, 1/16 (1.6)
44,0350,2383 Basic Kit, aluminum, .045 (1.2)
40,0001,0074 Inner Liner, graphite, .045 (1.2)
44,0350,2384 Basic Kit, aluminum, 1/16 (1.6)
44,0350,2401 Basic Kit, steel, .035 (.9)
44,0350,2391 Basic Kit, steel, .045 (1.2)
Basic kits include items 1-6 and graphite liner.
13 SEP 12
- 75 -
Interface
Models
Discrete I/O (Rob 3000, 4000, 5000, 5000 OC)

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

Each interface signal is converted to a fieldbus protocol and digitally transferred
between the welding power supply and the robot/automation controller
A single bit is used for on/off based interface signals
Multiple bits are put together to form a binary value for variable signals.
No modification or changes are possible with the signal set.
Ethernet (Ethernet IP, WeldCOm)

Each interface signal is converted to a TCP/IP protocol and digitally transferred between the
weldign power supply and the automation controller.
A single bit is used for on/off based interface signals
Multiple bits are put together for form a binary value for variable signals.
The bit-map can be changed (though time-consuming and expensive⁄
Offers the most versatile and capable of all interfaces.
13 SEP 12
- 76 -
Interface
General Information
• Provide communication between the welding system and an automated controller (PLC, robot,
automation, etc.).
• Connects to the power source through LocalNet
Power source is a slave to the controller.
STOP is displayed on the power source until the Robot Ready and the Source Error Reset signal is
initialized.
An additional LocalNet connect is provided that connects directly to the ROB 5000.
If no LocalNet connection is available, a passive distributor (4,100,261⁄ may be used.
• Power source functions are controlled through the use of analog command values
0-10 VDC (or binary equivalent⁄ for welding power and arc length correction.
Welding programs may be selected on the by the robot/PLC, the power source control panel, or through an
RCU.
• Digital inputs/outputs are galvanically separated (ROB series only):

From one another,
From the LocalNet and the welding potential.
For a maximum voltage difference of 100 V.
13 SEP 12
- 77 -
Interface
Major Signals
Major Digital Inputs (Robot to the Power Source)
Robot Ready: This signal indicated that the robot is communicating, functioning, and ready to weld. This is one of two
signals REQUIRED for any sort of operation or adjustment of the welding system. Without this signal, the power
supply will continuously display “STOP” on the front panel display and send an error code to the robot.
Source Error Reset: This signal is designed to clear any error state the welder is currently in. For proper use, this signal
should be toggled on and then off again. So long as the error is no longer valid, the error will clear and a normal
display will appear on the front panel. Otherwise an error code will be displayed (such as the “STOP” error code).
Arc On: This signal will start the welding process, beginning with pre-welding (gas pre-flow, hot start) and then
automatically moving to the welding process. Once this signal goes low, the post welding process (crater fill and gas
post-flow) will then start automatically.
Welding Mode: This is a combination of three signals joined together to form a single binary number. Each number
corresponds to a specific mode the welding power source can be set to. Some of the major modes are…
Mode 2 - Job: When the welder is in this mode, the welding characteristics are controlled by a schedule
number (0-99) that will link to a set of welding parameters stored on the welding power source. This
mode allows for the maximum capability of the welding process as all activated parameters are usuable.
Mode 3 – Set Up: When the welder is in this mode, the front panel is fully functional and anything can be
programmed in. If welding occurs while the welder is set to this mode, the weld will be based on
whatever is currently programmed into the power source.
Job Number: This is a combination of several bits joined together to form a binary number between 0 and 99. When the
welder is in job mode, this set of bits tells the welder which schedule specifically to use.
13 SEP 12
- 78 -
Interface
Major Signals
Major Digital Inputs (Robot to the Power Source)
Gas Test: This signal is used to purge gas from the robot controller or through the robot pendant. This can be used as a gas
pre-flow and/or post flow as necessary.
Wire Inching/Retracting: These signals are used to move the wire forward and backward from the robot controller or
through the robot pendant without gas or current flow.
Weld Simulation: When this signal is turned on, the power source will go through the welding process and respond with/to
all the proper inputs/outputs WITHOUT feeding wire, moving gas, or current flow.
Major Analog Inputs (Robot to the Power Source)
Welding Power: This combination of bits will form an analog value that will measure the welders wire feed speed (or current⁄
between 0% and 100% (with 0 being the lowest welding value and 100% being the maximum⁄. This input is only used
when welding in synergic, pulse synergic, or manual mode WITHOUT the use of the Job mode. This can be used
during JOB mode, but the job settings will limit how much it can be adjusted up or down.
Arc Length Correction: This combination of bits will form an alalog value that will measure the welders arc length correction
value between -30 and +30. This value is controllable in any mode though job settings will limit how much this value
can be adjusted.
Pulse or Dynamic Correction: This combination of bits will form an alalog value that will measure the welders arc length
correction value between -5 and +5. This value is controllable in any mode though job settings will limit how
much this value can be adjusted.
13 SEP 12
- 79 -
Interface
Major Signals
Major Digital Outputs (Power Source to the Robot)
Power Source Ready: This signal is sent to the robot when the power source has established successful communication
AND there are no errors that will interfere with the function of the welder. Note this signal will not be active is a STOP
or E-STOP is displayed on the power source for any reason⁄.
Arc Stable: This signal is sent to the robot once an arc has been started AND that arc is within acceptable parameters as
determined by the welding power source.
Process Active: This signal will go high once the welding process has started (after an Arc On signal⁄ beginning with the
gas pre-flow if set by the welder (note this signal will not go high is the gas is controlled by the robot instead⁄.
13 SEP 12
- 80 -
Interface
Major Signals
Bit 0 (X2:6⁄ Bit 1 (X8:1⁄ Bit 2 (X8:2⁄ Dec Hex

Standard Mode LOW LOW LOW 0 0
Pulse-Synergic Mode HIGH LOW LOW 1 1
Job Mode LOW HIGH LOW 2 2
Parameter Selection (internal mode⁄ HIGH HIGH LOW 3 3
Manual HIGH HIGH LOW 4 4
CC/CV HIGH LOW HIGH 5 5
TIG LOW HIGH HIGH 6 6
CMT/Special Process HIGH HIGH HIGH 7 7
Standard Mode: This allows the power source to weld using the synergic mode.
Pulse-Synergic Mode: This allows the power source to weld using the pulse-synergic mode.
Job Mode: This allows the power source to weld in job mode using one or more jobs specified by the robot.
Parameter Selection: Set-up mode for operator to make weld changes. Use caution when in this mode.
Manual Mode: This allows the power source to be controlled using analog inputs. There are NO job/program options.
CC/CV Mode: This allows the power source to be operated in a constant current or constant voltage mode.
TIG Mode: This allows the power source to be operated in TIG mode.
13 SEP 12
CMT/Special Process: This allows the power source to weld using CMT or a special process.
- 81 -
Interface
• Regardless of the mode, the welder must see
Signal Interaction – Job Mode the Robot Ready and Source Error Reset
signals before it will allow any sort of welding or
selections to occur:
• When using this mode, the welder controls the

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

process active signal.
• This mode allows for the most customization of

the weld and ensures that the timing between
weld factors are smooth, efficient, and quick.
• Adjust the weld parameters is typically done

from the welder or a separate pendant. This is
not true of every interface, however.
• NOTE: The points above are intended as a

general guide. Exceptions can be made as the
13 SEP 12
application requires.
- 82 -
Interface
• Regardless of the mode, the welder must see
Signal Interaction – Program Mode the Robot Ready and Source Error Reset
signals before it will allow any sort of welding or
selections to occur:
• When using this mode, the robot controls all of

the weld and gas parameters it is capable of
and the travel speed. The welder is only
responsible for creating and controlling the arc.
• Robot movement usually based off of the

process active signal.
• This mode will only have weld parameter

adjustments based on the capability of the
robot interface and almost never as completely
as job mode
• Usually the robot will need to be scaled based

on the synergic line being used. If multiple
lines are being used a separate scale file may
be required.
• NOTE: The points above are intended as a

13 SEP 12
general guide. Exceptions can be made as the

application requires.
- 83 -
Fronius Xplorer
General Info
The machine specific screen is made up of several

different tabs. The core software includes the Overview
and Panel tabs. Additional tabs are activated based on
The main entry screen gives an overview of the entire software and hardware additions to the Weld system.
welding network the software is connected to.
Overview:
Overview: Details the hardware attached to each system
This screen can be divided into an unlimited number of through LocalNet and allows configuration changes.
customized locations that can represent factories,
departments, sub-departments, cells, and even individual Panel:
Panel: Simulates the front panel of the machine. Will
welding machines. NOT allow unsafe actions to be activated (wire feed⁄.
A total machine listing is also given that will detail how Jobs (extra⁄: Allows jobs to be viewed and edited both
many machines are ready , in an error state , have a online and offline. When offline, the jobs will be updated
warning , or offline . These listings can be clicked on when the machine is back online.
for a list of specific welders in each category. Docu (extra⁄: Displays weld data once a weld has been
Finally, a quick list is available on the side that will display completed.
recently viewed machines and some basic information Logbook (extra⁄: Displays changes and errors that occurs
including status, name, IP address, and current
13 SEP 12
with the machine.

connection.
- 84 -
Fronius Xplorer The Options button opens up a

Overview Tab submenu that has several useful
functions including the Show
connection data and Machine
Configuration selections.
By using these buttons, Weld Jobs

can be saved to a computer (Backup⁄
or loaded from one (Restore⁄.
As long as the synergic lines exist in
the database loaded into the Show connection data shows
machine, any Weld Job set can be the IP and connection interface for
used. any Ethernet card connected to
LocalNet. This option also allows
These job sets are NOT compatible
for these settings to be changed as
with other Backup/Restore tools.
needed.
This display shows everything that is

currently connected through
The license button is used to see which
LocalNet. Machine Configuration outputs a
software options are loaded into the
text file that includes all equipment
In addition, hardware, firmware, and machine. Unlocked options are displayed
connected through LocalNet. Serial
database information will be as green locks while locked ones are red
numbers, firmware, and hardware
displayed for each piece of locks. New ones can be loaded in using
versions are also saved.
13 SEP 12
equipment that is selected (yellow bar the Enter new software code button.
indicated selection⁄. - 85 -
Fronius Xplorer
Job and Docu Tab
The Docu tab allows you to monitor the
weld parameters of one or more welders
AFTER they have completed a weld.
The parameters can be customized
The Job tab give a quick view of jobs based on the user desires by right
loaded into the welder, the weld clicking on the data screen.
parameters for these jobs, and any Previous data can be viewed by opening
changes that have been made recently. up older files. Each days welding is
Group and job names can be changed to stored for future viewing and/or
reflect the application and/or production importing.
floor.
The Options button opens up a
submenu that has several useful
functions including the Set
A job can be copied to one or more consumption figures and the
other locations and than customized to Country settings selections.
suit the needs of the application.
The Set consumption figures
When a change is made, there is an allows you to set the costs of your
option to either accept the change or wire, gas and energy as well as
undo the change. specify the travel speeds used during
the welding process.
Finally, a history of job changes is kept The Country settings changes
that can not only be reviewed but also the unit of measurement between metric
loaded from should the need arise. and imperial depending on the needs of the
plant.
13 SEP 12
- 86 -
Troubleshooting
Weld System
• Many factors can effect weld quality and many times the poor quality will come from wear parts rather than weld
settings. However in some cases the weld quality can be effected by the weld settings. This would be the case if the
settings have been adjusted from settings that were known to work for specific process. Also a change in base
materials or parts can make the predetermined settings no longer the best viable settings to produce quality welds.
• When trouble shooting weld quality it is very important to go through a number of checks prior to designating a
certain cause to the problem.
• These checks include:

Consumables
Loose Connections
Settings that differ from pre determined settings
Torch Quality
Torch Itself internal/externally or liner itself
Wire Drive unit
Damaged or loose connections
Damage to drive motor or drive rolls
Firmware
Hose Pack
Damage to any connections, hoses or cabling included in the hose pack
Power Source
Internal Hardware or Firmware
13 SEP 12
- 87 -
Troubleshooting
Welder Error Codes
DSP xxx
Error with the Digital Signal Processor – Reload firmware/database or replace UST
EFD xxx
Error with the wire feed system, refer to wire feeder error codes for more details
Err 049, 051, and 052

Error detected in mains power input (phase missing or voltage too low/high). Check mains and then replace NT 24
Err 050
Intermediate circuit imbalance. Further troubleshooting needed
Err IP
Primary transformer over-current detected. Check the secondary power module and the BPS board.
Err PE
Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points.
No H2O
Error with the coolant system, check cooler for operation and system for good flow.
No Prg
Synergic line selected doesn’t exist. Verify synergic line settings, reprogram UST, or replace UST.
STOP
Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot.
Tsx xxx and Tpx xxx

Internal temperature errors on the secondary or primary side. Check for duty cycle and proper air flow.
13 SEP 12
- 88 -
Troubleshooting
Torches
Error Codes
- Few error codes refer directly to a problem with the torch. However, a large
number of them can indirectly be caused by the torch or the torch position.
Physical Clues
- The torch neck needs to be inspected for excessive wear or damage
caused by the welding process. As needed, it should be cleaned of build-
up spatter and other contaminates.
- Consumables should be checked regularly and cleaned/changed as
needed. Consumables include
Gas Nozzle: free of spatter build-up and excessive conal damage.
Torch Tip: free spatter build-up and excessive wire wear.
Spatter Guard: gas holes free of blockage and excessive part
damage
Nozzle Stock: gas holes free of blockage, excessive spatter build-
up, and stripped threads.
- Ensure pressure and drive rolls (if equipped⁄ are clean and not excessively
worn or damaged.
Electronics/Settings
- Some problems with the torch can be addressed by 1st level welding
13 SEP 12
settings in the power source.

- 89 -
Troubleshooting
Wire Feeder Error Codes
EFD 1.x through 7.x
These are all internal logic errors and require a software update or SR board change
EFD 7.1
Configuration Memory (config mem) error
EFD 8.x
Main motor or push pull motor current errors
EFD 9.x
Main motor voltage errors
EFD 10.x
Internal logic errors between the SR-xx and the PM-xx board
EFD 11.x
Main motor and push pull motor alignment errors
EFD 12.x
Main motor and push pull motor movement errors (not to be confused with encoder errors)
EFD 15.x
Wire buffer errors (CMT, only active when welding)
EFD 30.x
Local High Speed Bus (LHSB) communication error
13 SEP 12
EFD 31.x
Encoder feedback errors. - 90 -

Welding Equipment Operations Reference Guide

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

Welding Equipment Operations Reference Guide

Hochgeladen von

Copyright:

Verfügbare Formate

/ Battery Charging Systems / Welding Technology / Solar Electronics

MIG Welding Equipment

Wire Feeder Consumables

General Information Inch/min Mm/sec Cm/min Meters Feet

--- .071 1.8 13 50 23.60 65 27.51 165.10 4.5 14.8

1/2 .500 12.7 - 80 37.75 95 40.21 241.30 30 98.4

135 63.71 150 63.50 381.00

4 Controlled by LocalNet (Fronius communication

Control Voltages Control Voltages

Welding Current Welding Current

Coolant Lines Coolant Lines

Remote Mounted Wire Feeder

Control Voltages Control Voltages

Welding Current Welding Current

Coolant Lines Coolant Lines

Robot Mounted Wire Feeder

Trans Synergic (TS) 3200/4000/5000

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

Trans-Steel (TsT) 3500/5000 Manual

Trans-Steel (TsT) 3500/5000 Robotic

gas types, and wire diameters

Using the format below, the serial number can be used to

The name plate is found on the top of the

welding power supply. maximum outputs.

(-⁄ Current Socket Connection Blanking Cover(s⁄

Welding: Connect the welding ground to this socket.

Ground Connection (optional⁄

Gas Connection (bottle⁄

Current Connection LocalNet Connection

This feeder is designed to operate with either a push or a push/pull torch. - 15 -

large range of options and fixtures to choose from.

Drive Rolls (top⁄

Wire Guide Insert (steel or synthetic⁄

Main Drive Roll

Drive Rolls (bottom⁄

Current Connection (welder⁄

Gas Connection (bottle⁄ Wire Inch Button

Coolant Feed - hot (torch⁄ Robacta Connection (torch⁄

Coolant Feed - cold (torch⁄

Coolant Feed - hot (welder⁄

LocalNet Connection (welder⁄

Coolant Feed - cold (welder⁄ - 18 -

Current Connection (welder⁄

LocalNet Connection (welder⁄

Coolant Feed - hot (welder⁄

Gas Connection (bottle⁄

Coolant Feed - cold (welder⁄

Power Control (WFS, Current, etc.⁄

Buffer Connection (torch⁄

Robacta Connection (torch⁄

Current/Gas Connection (torch⁄ Trigger Connection (torch⁄

Coolant Feed - cold (torch⁄ Coolant Feed - hot (torch⁄ - 19 -

Current/Gas Connection (torch⁄ Wire Inlet (drum or spool⁄

LocalNet Connection (welder ⁄

LocalNet Connection (welder⁄

Wire Inch Button - 20 -

Handle Current Connection (welder⁄

Gas Connection (bottle⁄

Coolant Feed - hot (torch⁄

- optional add on - Coolant Feed - hot (welder⁄ -

Manual Torches Robotic Torches

Gas Tungsten Arc Welding (GTAW)

Gas Metal Arc Welding (GWAW)