Fronius TPS Operating Instructions

TransSynergic 4000 / 5000
TransPuls Synergic 2700

TransPuls Synergic 3200 / 4000 / 5000
Operating Instructions
TIME 5000 Digital GB
Spare Parts List
MIG/MAG power source
42,0426,0001,EN 012005
Dear Reader
Introduction Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
ud_fr_st_et_00493 012004
Safety rules
DANGER!
“DANGER!” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.
WARNING!
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.
CAUTION!
“CAUTION!” indicates a potentially hazardous situation which, if not avo-
ided, may result in minor or moderate injury. It may also be used to alert
alert against unsafe practices that may cause property damage.
NOTE! “NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.
Important! “Important!” indicates practical hints and other useful special-information. It

is no signal word for a harmful or dangerous situation.
Whenever you see any of the symbols shown above, you must pay even
closer attention to the contents of the manual!
General remarks This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/operator,
- efficient working with the equipment.
All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.
The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must be
kept on hand, and of course observed in practice.
All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged
I ud_fr_st_sv_00467 012005
General remarks - must not be removed
(continued) - must not be covered, pasted or painted over
For information about where the safety instructions and danger warnings are
located on the machine, please see the section of your machine’s instruction
manual headed “General remarks”.
Any malfunctions which might impair machine safety must be eliminated

immediately - meaning before the equipment is next switched on.
It’s your safety that’s at stake!
Utilisation for The machine may only be used for jobs as defined by the “Intended
intended purpose purpose”.
only
The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall not
be liable for any damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.
The appliance must never be used for the following:

- Thawing pipes
- Charging batteries/accumulators
- Starting engines
The machine is designed to be used in industrial and workshop

environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.
Likewise the manufacturer will accept no liability for defective or faulty work
results.
Ambient Operation or storage of the power source outside the stipulated range is
conditions deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.
Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)
Relative atmospheric 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.
Elevation above sea level: Up to 2000 m (6500 ft)
ud_fr_st_sv_00467 012005 II
Obligations of The owner/operator undertakes to ensure that the only persons allowed to
owner/operator work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood the sections on “safety rules” and the “war-
nings“ contained in this manual, and have confirmed as much with their
signatures
- be trained in such a way that meets with the requirements of the work
results
Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.
Obligations of Before starting work, all persons to be entrusted with carrying out work with
personnel (or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.
Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.
Protection for When welding, you are exposed to many different hazards such as:
yourself and - flying sparks and hot metal particles
other persons - arc radiation which could damage your eyes and skin
- harmful electromagnetic fields which may put the lives of cardiac pace-
maker users at risk
- electrical hazards from mains and welding current
- increased exposure to noise
- noxious welding fumes and gases.
Anybody working on the workpiece during welding must wear suitable pro-
tective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups
III ud_fr_st_sv_00467 012005

Protection for “Protective clothing” also includes:
yourself and - protecting your eyes and face from UV rays, heat and flying sparks with
other persons an appropriate safety shield containing appropriate regulation filter glass
(continued) - wearing a pair of appropriate regulation goggles (with sideguards) behind
the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insula-
ting, heat-proof)
To lessen your exposure to noise and to protect your hearing against injury,
wear ear-protectors!
Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.
Hazards from The fumes given off during welding contain gases and vapors that are
noxious gases harmful to health.
and vapours
Welding fumes contain substances which may cause birth defects and
cancers.
Keep your head away from discharges of welding fumes and gases.
Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable means.
Ensure a sufficient supply of fresh air.
Where insufficient ventilation is available, use a respirator mask with an

independent air supply.
If you are not sure whether your fume-extraction system is sufficiently power-
ful, compare the measured pollutant emission values with the permitted
threshold limit values.
The harmfulness of the welding fumes will depend on e.g. the following
components:
- the metals used in and for the workpiece
- the electrodes
- coatings
- cleaning and degreasing agents and the like
For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.
Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.
ud_fr_st_sv_00467 012005 IV
Hazards from Flying sparks can cause fires and explosions!
flying sparks
Never perform welding anywhere near combustible materials.
Combustible materials must be at least 11 meters (35 feet) away from the
arc, or else must be covered over with approved coverings.
Have a suitable, approved fire extinguisher at the ready.
Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that there
is no risk of injury or fire.
Do not perform welding in locations that are at risk from fire and/or explosion,
or in enclosed tanks, barrels or pipes, unless these latter have been
prepared for welding in accordance with the relevant national and
international standards.
Welding must NEVER be performed on containers that have had gases,

fuels, mineral oils etc. stored in them. Even small traces of these substances
left in the containers are a major explosion hazard.
Hazards from An electric shock can be fatal. Every electric shock is hazardous to life.
mains and weld-
ing current Do not touch any live parts, either inside or outside the machine.
In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.
Always place the wirefeeder on an adequately insulated floor or base, or else

use a suitable insulating wirefeeder holder.
Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/frame
potential. The base or cover must completely cover the entire area between
your body and the ground/frame potential.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.
Do not loop any cables or other leads around your body or any part of your
body.
Never immerse the welding electrode (rod electrode, tungsten electrode,

welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.
Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.
Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.
Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.
V ud_fr_st_sv_00467 012005
Hazards from If the machine is run on a mains network without a PE conductor and
mains and weld- plugged into a power outlet socket without a protective-conductor contact,
ing current this counts as gross negligence and the manufacturer shall not be liable for
(continued) any resulting damage.
Wherever necessary, use suitable measures to ensure that the workpiece is

sufficiently grounded (earthed).
Switch off any appliances that are not in use.
When working at great heights, wear a safety harness.
Before doing any work on the machine, switch it off and unplug it from the
mains.
Put up a clearly legible and easy-to-understand warning sign to stop anybody

inadvertently plugging the machine back into the mains and switching it back
on again.
After opening up the machine:

- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.
If work needs to be performed on any live parts, there must be a second

person on hand to immediately switch off the machine at the main switch in
an emergency.
Stray welding If the following instructions are ignored, stray welding currents may occur.
currents These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment
Ensure that the workpiece clamp is tightly connected to the workpiece.
Attach the workpiece clamp as close as possible to the area to be welded.
On electrically conductive floors, the machine must be set up in such a way

that it is sufficiently insulated from the floor.
When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/welding
tongs is also current carrying. Please ensure that there is sufficient insula-
ting storage for the unused welding torch/tongs.
ud_fr_st_sv_00467 012005 VI
EMC and EMI It is the responsibility of the owner/operator to ensure that no electromagnetic
Precautions interference is caused to electrical and electronic equipment.
If electromagnetic interference is found to be occurring, the owner/operator is

obliged to take all necessary measures to prevent this interference.
Examine and evaluate any possible electromagnetic problems that may

occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices
Ancillary measures for preventing EMC problems:
a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the mains
connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).
b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.
c) Equipotential bonding
d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.
e) Shielding, where necessary

- Shield other equipment in the vicinity
- Shield the entire welding installation.
Electromagnetic fields may cause as yet unknown damage to health.

- Effects on the health of persons in the vicinity, e.g. users of heart pace-
makers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/body
of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not loop
around body or or any part of body
Particular danger Keep your hands, hair, clothing and tools well away from all moving parts,
spots e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires
Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.0
Covers and sideguards may only be opened or removed for as long as is

absolutely necessary to carry out maintenance and repair work.
VII ud_fr_st_sv_00467 012005

Particular danger While the machine is in use:
spots - ensure that all the covers are closed and that all the sideguards are
(continued) properly mounted ...
- ... and that all covers and sideguards are kept closed.
When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...). For this
reason, when feeder-inching etc., always hold the torch so that it is pointing
away from your body (machines with wirefeeder).
Do not touch the workpiece during and after welding - risk of injury from
burning!
Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.
Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.
Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.
Risk of scalding from accidental discharge of hot coolant. Before unplugging

the connectors for coolant forward flow and return flow, switch off the cooling
unit.
Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.
When hoisting the machines by crane, only use suitable manufacturer-

supplied lifting devices.
- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).
When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).
If a machine is fitted with a carrying strap or carrying handle, remember that

this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.
Danger of colourless and odourless inert gas escaping unnoticed, when

using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.
ud_fr_st_sv_00467 012005 VIII

Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are
shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall
cylinders welding outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from excessive

heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).
Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).
Never hang a welding torch on a shielding-gas cylinder.
Never touch a shielding-gas cylinder with a welding electrode.
Explosion hazard - never perform welding on a pressurized shielding-gas

cylinder.
Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories that
are in good condition.
When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.
Close the shielding-gas cylinder valve when no welding is being carried out.
When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.
Observe the manufacturer’s instructions and all relevant national and

international rules applying to shielding-gas cylinders and accessories.
Safety precauti- A machine that topples over can easily kill someone! For this reason, always
ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly.
lation site and - An angle of inclination of up to 10° is permissible.
when being
transported
Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.
By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.
The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.
When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.
When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportation
and carriage.
IX ud_fr_st_sv_00467 012005
Safety precauti- Before transportation, completely drain any coolant and dismantle the follo-
ons at the instal- wing components:
lation site and - Wire feed
when being - Wire wound coil
transported - Gas bottle
(continued)
Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by trained service per-
sonnel before commissioning.
Safety precau- Only operate the machine if all of its protective features are fully functional. If
tions in normal any of the protective features are not fully functional, this endangers:
operation - the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.
Any safety features that are not fully functional must be put right before you
switch on the machine.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered by

your doing so.
- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frost-
proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
- Only use suitable original coolant of the manufacturer.
- Do not mix original coolant of the manufacturer with other coolants.
- If any damage occurs in cases where other coolants have been used, the
manufacturer shall not be liable for any such damage, and all warranty
claims shall be null and void.
- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
- Before starting welding - while the machine is still cool - check the
coolant level.
Preventive and With parts sourced from other suppliers, there is no certainty that these parts
corrective main- will have been designed and manufactured to cope with the stressing and
tenance safety requirements that will be made of them. Use only original spares and
wearing parts (this also applies to standard parts).
Do not make any alterations, installations or modifications to the machine

without getting permission from the manufacturer first.
Replace immediately any components that are not in perfect condition.
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Preventive and When ordering spare parts, please state the exact designation and the
corrective main- relevant part number, as given in the spare parts list. Please also quote the
tenance serial number of your machine.
(continued)
Safety inspection The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.
The manufacturer also recommend the same (12-month) interval for regular
calibration of power sources.
A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations
- after any modifications or installations of additional components
- following repairs, care and maintenance
- at least every twelve months.
Observe the relevant national and international standards and directives in

connection with the safety inspection.
More detailed information on safety inspections and calibration is available

from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste!

To comply with the European Directive 2002/96/EC 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 our agent, or find out about the approved collec-
tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
Safety markings Equipment with CE-markings fulfils the basic requirements of the Low-
Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .
Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.
Data security The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.
XI ud_fr_st_sv_00467 012005
Copyright Copyright to this instruction manual remains the property of the
manufacturer.
The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the in-
struction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.
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Table of contents
General remarks ........................................................................................................................................... 5
Machine concept ...................................................................................................................................... 5
Functional principle .................................................................................................................................. 5
Areas of utilisation .................................................................................................................................... 5
Warning notices affixed to the machine ................................................................................................... 6
Special versions ............................................................................................................................................ 7
General remarks ...................................................................................................................................... 7
Alu-Edition ................................................................................................................................................ 7
CrNi-Edition .............................................................................................................................................. 7
CMT Variants ........................................................................................................................................... 7
TIME 5000 Digital ..................................................................................................................................... 8
System components ...................................................................................................................................... 9
General remarks ...................................................................................................................................... 9
Overview .................................................................................................................................................. 9
Descriptions of the control panels ............................................................................................................... 10
General remarks .................................................................................................................................... 10
Standard control panel ........................................................................................................................... 10
“Comfort” control panel .......................................................................................................................... 14
“US” control panel .................................................................................................................................. 18
TIME 5000 Digital control panel ............................................................................................................. 22
“Remote” operating panel ...................................................................................................................... 27
“CMT” control panel ............................................................................................................................... 28
Connections - switches - mechanical components ..................................................................................... 29
TPS 2700 power source ......................................................................................................................... 29
TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources ...................................................................... 30
Minimum equipment needed for welding ..................................................................................................... 31
General remarks .................................................................................................................................... 31
MIG/MAG welding .................................................................................................................................. 31
TIG-DC welding...................................................................................................................................... 31
Rod electrode (MMA) welding ................................................................................................................ 31
Before commissioning ................................................................................................................................. 32
General remarks .................................................................................................................................... 32
Utilisation for intended purpose only ...................................................................................................... 32
Machine set-up regulations .................................................................................................................... 32
Mains connection ................................................................................................................................... 32
Connecting up the mains cable on US power sources ................................................................................ 33
General remarks .................................................................................................................................... 33
Stipulated mains cables and strain relief devices ................................................................................... 33
Safety ..................................................................................................................................................... 33
Connecting up the mains cable .............................................................................................................. 33
Exchanging the strain relief device ........................................................................................................ 34
Commissioning ........................................................................................................................................... 36
General remarks .................................................................................................................................... 36
Remarks on the cooling unit ................................................................................................................... 36
Overview ................................................................................................................................................ 36
Installation of the system components ........................................................................................................ 37
Installation of the system components (overview) .................................................................................. 37
Fixing strain relief device in place and connecting interconnecting hosepack ............................................ 38
Fixing the strain relief device in place .................................................................................................... 38
Connecting interconnecting hosepack ................................................................................................... 39
Connecting gas cylinder and making an earth connection .......................................................................... 40
Connecting up the gas cylinder .............................................................................................................. 40
Making an earth connection ................................................................................................................... 40
1
Fitting the welding torch and putting the cooling unit into service ................................................................ 41
Fitting the welding torch ......................................................................................................................... 41
Putting the cooling unit into service ........................................................................................................ 41
MIG/MAG operating modes ........................................................................................................................ 42
General remarks .................................................................................................................................... 42
Symbols and abbreviations .................................................................................................................... 42
2-step mode ........................................................................................................................................... 43
4-step mode ........................................................................................................................................... 43
Special 4-step mode (aluminium welding start-up) ................................................................................ 44
Spot welding ........................................................................................................................................... 44
MIG/MAG welding ....................................................................................................................................... 45
MIG/MAG welding .................................................................................................................................. 45
Ignition time-out function ........................................................................................................................ 46
Arc break watchdog function .................................................................................................................. 47
Standard manual welding ....................................................................................................................... 47
“Spatter-free ignition” option ................................................................................................................... 48
SynchroPuls option ................................................................................................................................ 49
Special 2-step mode for robot interface ................................................................................................. 50
TIG welding ................................................................................................................................................. 52
General remarks .................................................................................................................................... 52
Preparations ........................................................................................................................................... 52
TIG welding ............................................................................................................................................ 52
Igniting the arc ........................................................................................................................................ 53
Finishing welding .................................................................................................................................... 53
TIG-Comfort-Stop option ........................................................................................................................ 54
TIG welding with TIG Comfort Stop ........................................................................................................ 56
CSS parameter ...................................................................................................................................... 56
Rod electrode (MMA) welding ..................................................................................................................... 57
General remarks .................................................................................................................................... 57
Preparations ........................................................................................................................................... 57
Hot-Start function ................................................................................................................................... 58
Anti-stick function ................................................................................................................................... 58
Job mode .................................................................................................................................................... 59
General remarks .................................................................................................................................... 59
Creating a job ......................................................................................................................................... 59
Copying/overwriting a job ....................................................................................................................... 60
Deleting a job ......................................................................................................................................... 61
Retrieving a job ...................................................................................................................................... 61
Job correction .............................................................................................................................................. 62
General remarks .................................................................................................................................... 62
Accessing the job correction menu ........................................................................................................ 62
Changing a parameter ........................................................................................................................... 62
Exiting the job correction menu .............................................................................................................. 63
Available parameters ............................................................................................................................. 63
Permanently settable parameters .......................................................................................................... 63
Parameters that can be corrected at a later time ................................................................................... 66
Shielding gas set-up menu .......................................................................................................................... 68
General remarks .................................................................................................................................... 68
Standard control panel: Accessing ......................................................................................................... 68
“Comfort” / “US” control panel: Accessing .............................................................................................. 68
Gas test parameters .............................................................................................................................. 69
Set-up menu: Level 1 .................................................................................................................................. 70
General remarks .................................................................................................................................... 70
Standard control panel: Accessing ......................................................................................................... 70
Standard control panel: Parameters ....................................................................................................... 70
“Comfort” / “US” control panel: Accessing .............................................................................................. 70
“Comfort” / “US” control panel: Parameters ........................................................................................... 72
2
Process parameters .................................................................................................................................... 73
MIG/MAG standard synergic/pulse synergic welding ............................................................................. 73
TIG welding ............................................................................................................................................ 75
Operating-mode parameters ....................................................................................................................... 76
Special 2-step mode for robot interface ................................................................................................. 76
Special 4-step mode (aluminium welding start-up) ................................................................................ 77
Spot welding ........................................................................................................................................... 77
Set-up menu: Level 2 .................................................................................................................................. 78
General remarks .................................................................................................................................... 78
Standard control panel ........................................................................................................................... 78
“Comfort” / “US” control panel ................................................................................................................ 78
Parameters 2nd ........................................................................................................................................... 80
MIG/MAG standard synergic/pulse synergic welding ............................................................................. 80
Operating power sources in parallel ....................................................................................................... 82
TimeTwin Digital process ....................................................................................................................... 83
TIG welding ............................................................................................................................................ 83
Push-pull unit .............................................................................................................................................. 87
General remarks .................................................................................................................................... 87
Calibrating the push-pull unit .................................................................................................................. 87
Service codes for push-pull calibration ....................................................................................................... 90
Safety ..................................................................................................................................................... 90
Error codes shown when the drive units are engaged (“engaged” calibration) ...................................... 90
Error codes shown when the drive units are engaged (“engaged” calibration) ...................................... 91
Measuring the welding circuit resistance “r” ................................................................................................ 93
General remarks .................................................................................................................................... 93
Measuring the welding circuit resistance “r” ........................................................................................... 93
Indicating the welding circuit inductivity L .................................................................................................... 95
Indicating the welding circuit inductivity L ............................................................................................... 95
Correct arrangement of the hosepack ................................................................................................... 95
Troubleshooting ........................................................................................................................................... 96
General remarks .................................................................................................................................... 96
Displayed service codes ........................................................................................................................ 96
Power source - troubleshooting ........................................................................................................... 102
Care, maintenance and disposal ............................................................................................................... 105
General remarks .................................................................................................................................. 105
Every start-up ....................................................................................................................................... 105
Every 2 months .................................................................................................................................... 105
Every 6 months .................................................................................................................................... 105
Disposal ............................................................................................................................................... 105
Technical data ........................................................................................................................................... 106
Special voltages ................................................................................................................................... 106
TPS 2700 ............................................................................................................................................. 106
TPS 2700 MV ....................................................................................................................................... 107
TPS 3200 ............................................................................................................................................. 108
TPS 3200 MV ....................................................................................................................................... 109
TS/TPS 4000 ........................................................................................................................................ 110
TS/TPS 4000 MV .................................................................................................................................. 111
TS/TPS 5000 ........................................................................................................................................ 112
TS/TPS 5000 MV .................................................................................................................................. 113
Technical data - US power source ........................................................................................................ 113
Technical data Alu-Edition, CrNi-Edition and CMT variants ................................................................... 113
TIME 5000 Digital .................................................................................................................................. 114
Welding program databases ...................................................................................................................... 115
Explanation of symbols ......................................................................................................................... 115
3
Terms and abbreviations used ................................................................................................................... 116
General remarks ................................................................................................................................... 116
Terms and abbreviations ....................................................................................................................... 116
Spare parts lists
Fronius Worldwide
4
General remarks
Machine concept The TransSynergic (TS) 4000 and TS

5000, TransPuls Synergic (TPS) 2700,
TPS 3200, TPS 4000 and TPS 5000
power sources are completely digitised,
VR
70
microprocessor controlled inverter power
00
sources.
The modular design and potential for

system add-ons ensure a high degree of
flexibility. The machines can be adapted to
any specific situation.
All machines except TS 4000/5000 have

multi-processer capability:
- MIG/MAG welding
- TIG welding with touch-down ignition
- Rod electrode (MMA) welding
Fig.1 The TS 4000 / 5000, TPS 3200 / 4000 /
5000 and TPS 2700 welding machines
Functional prin- The central control and regulation unit of the power sources is coupled with a digital
ciple signal processor. The central control and regulation unit and signal processor control the
entire welding process.
During the welding process, the actual data is measured continuously and the machine
responds immediately to any changes. The control algorithms developed by the manuf-
acturer ensure that the specified target status is maintained.
This results in:

- a precise welding process,
- exact reproducibility of all results
- excellent welding properties.
Areas of utilisati- The machines are used in workshops and industry: manual and automated applications
on with classical steel, galvanised sheets, chrome/nickel and aluminium.
The integral 4-roller drive, high performance and low weight of the TPS 2700 power
source make it the ideal choice for portable applications on building sites or in repair
workshops.
The TS 4000/5000 and TPS 3200/4000/5000 power sources are designed for:
- automobile and component supply industry,
- equipment construction,
- chemical plant construction,
- machine and tracked vehicle manufacturing,
- shipyards, etc.
5
Warning notices US power sources come with extra warning labels affixed to the unit. The warning
affixed to the labels must NOT be removed or painted over.
machine
Only on the “TPS 2700” power source

and on wirefeeder units
Fig.2 US “Remote” power source with additional warning signs
6
Special versions
General remarks Professional processing of specific materials requires welding programs that are special-
ly matched to the different materials in question. The special versions of the digital power
sources are perfectly matched to these requirements. As a result the most important
welding programs can be called up directly from the operating panel. Furthermore, the
power sources are characterised by standard features that assist the user when welding
these materials.
Important! The Technical Data of the special versions corresponds to the Technical
Data of the standard power sources.
Alu-Edition The Alu-Edition power sources were developed for perfect and careful processing of
aluminium. Special aluminium welding programs assist in the professional processing of
aluminium. The Alu-Edition power sources are equipped as standard with the following
options:
- Special aluminium welding programs

- SynchroPuls option
CrNi-Edition The CrNi-Edition power sources were developed for perfect and careful processing of
CrNi. Special CrNi welding programs assist in the professional processing of high-grade
steels. The CrNi-Edition power sources are equipped as standard with the following
options:
- Special CrNi welding programs

- SynchroPuls option
- TIG-Comfort-Stop option
- TIG torch connection
- Gas solenoid valve
Important! It is not possible to install the “Uni Box” system add-on on the CrNi-Edition
(e.g. for the field bus connection of a robot control). However, the CrNi-Edition supports
a robot connection via robot interfaces ROB 4000 / 5000.
CMT Variants In addition to conventional welding processes, the CMT variants can also control the
CMT process. CMT (Cold Metal Transfer) is a special MIG short-arc process. Its special
features include low heat application and a controlled, low-current material transfer. CMT
is suitable for:
- Virtually spatter-free MIG soldering
- Welding on light-gauge sheet with minimal distortion
- Joining steel and aluminium (weld soldering)
7
TIME 5000 Digital Concept
As a universal power source, the TIME 5000 Digital is particularly suited for manual
applications. In addition to conventional welding processes, the TIME 5000 Digital also
supports high-performance welding processes. The TIME high-performance welding
process now has a welding system with digital technology.
Functional principle
Compared with conventional MIG/MAG processes, the following features bring about
faster welding speeds, with a 30 % increase in welding performance:
- Power module with high voltage reserves
- High-performance welding programs
- Specially selected shielding gases
- High-performance wirefeeder with water-cooled disk armature motor for wirefeed
speeds of up to 30 m/min
- TIME welding torch with dual circuit cooling system
Field of application
Anywhere where long seams, large weld cross-sections and controlled heat insertion are
required, e.g.:
- machine construction
- steel engineering
- crane construction
- shipbuilding
- boiler manufacture
The new TIME 5000 Digital power source can also be used in automated applications.
Material types
The high-performance welding process is especially suitable for
- unalloyed steels
- low-alloy steels EN 10027
- fine-grained structural steels up to 890 N/mm²
- steels resistant to low temperatures
8
System components
General remarks The power sources of the Digital Series can be run with various system components and
options. This makes it possible to optimize procedures and to simplify machine handling
and operation, as necessitated by the particular field of application for which the power
source is to be used.
Overview
“Human” hosepack boom
FR
O
NI
US
Remote control unit
Welding torch
Wirefeeders
Wirefeeder mount
Interconnecting cables
Robot accessories
Power source
Cooling units
Trolley, and
gas-cylinder holders
Grounding (earthing) cable

and electrode cable
Fig.3 Overview of system components
9
Descriptions of the control panels
General remarks The functions on the control panels are all arranged in a very logical way. The various
parameters needed for welding are easy to select, by pressing the appropriate button,
and can easily be
- altered with buttons (“Standard”) or the adjusting dial (“Comfort”), and
- shown on the display during welding
Thanks to the “Synergic” function, whenever you alter any one parameter, suitable
adjustments will automatically be made to all the other parameters.
Note! Owing to software updates, you may find that your machine has certain
functions that are not described in these Operating Instructions, or vice-versa.
Also, certain illustrations may be very slightly different from the actual controls
on your machine. However, these controls function in exactly the same way.
Standard control Important! On the “Standard” control panel, only the MIG/MAG standard synergic
panel welding process is available. The following processes and functions are not available
and cannot be retro-fitted:
- MIG/MAG pulse synergic welding process,

- Job Mode
- TIG welding
- Rod electrode (MMA) welding
- Spot welding
Any changes to the parameters “Welding current” and “Arc-length correction” have to be
made on the wirefeeder.
10
“Standard”
Warning! Operating the equipment incorrectly can cause serious injury and
control panel
damage. Do not use the functions described here until you have read and
(continued)
completely understood all of the following documents:
- these Operating Instructions
- all operating instructions for the system components, especially the “Safety
rules”
(22) (23) (2) (11) (8) (12) (13) (14) (9)
(21) (20) (7) (6) (5)

Fig.4 “Standard” control panel
Item Function
(2) Parameter selection button
for selecting the following parameters:
- sheet thickness
- welding current
- wirefeed speed
(5) Mode button(s)
for selecting the operating mode
2-step mode
4-step mode
special 4-step mode (aluminium welding start-up)
(6) Material button(s)
for selecting the filler metal and shielding gas to be used. Parameters SP1 and
SP2 are reserved for additional materials.
(7) Wire diameter button
for selecting the wire diameter to be used. Parameter SP is reserved for additional
wire diameters.
11
Standard control
(8) Welding current parameter
panel
for selecting the welding current. Before the start of welding, the machine auto-
(continued)
matically displays a guideline value based on the programmed parameters. During
welding, the actual value is displayed.
(9) Welding voltage parameter
for selecting the welding voltage. Before the start of welding, the machine auto-
(11) Sheet thickness parameter
for selecting the sheet thickness in mm or in. This automatically sets all the other
parameters as well.
(12) Wirefeed speed parameter
for selecting the wirefeed speed in m/min or ipm. Other parameters that are
dependent on this are also automatically adjusted accordingly.
(13) Overtemperature indicator
lights up if the power source overheats (e.g. because the duty cycle has been
exceeded). For more information on this, see the “Troubleshooting” section.
(14) HOLD indicator
every time a welding operation is finished, the actual values for welding current
and welding voltage are stored, and the “Hold” indicator lights up.
(20) Intermediate arc indicator
a spatter-prone “intermediate arc” occurs between the dip-transfer arc and the
spray arc. To alert you to this critical area - and help you avoid it - the intermediate
arc indicator lights up.
(21) Store button ... for accessing the Set-up menu
Important! If you press the Store button (21) and the “Material” button (6) at the
same time, the display shows the software version.
If you then press the “Material” button (6) on its own, the version number of the
welding database appears on the display (e.g.: 0 | 029 = M0029).
If you then press the “Material” button (6) a second time, the number of the wire-
feeder (A, or B in the case of twin-head mounts) and the software version n° of
the wirefeeder appear on the display (e.g.: A 1.5 | 0.23).
If you press the “Material” button (6) a third time, the operating time is displayed.
This registers the actual arc burning time since the initial start-up.
- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min
Important! The operating time display is not suitable as a basis for calculating
hiring fees, guarantee, etc.
To exit, press the Store button (21).

(22) Gas-test button
to set the required quantity of gas at the pressure regulator.
After you press this button, gas will flow out for 30 s. Press the button again to
stop the gas test-flow before the end of this period.
Important! If you press the Store button (21) and the gas test button (22) at the
same time, the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s).
- You can alter the gas pre-flow time with the adjusting dial (1)
12
Standard control If you now press the “Process” button (4), the display gives you a read-out of the
panel pre-set gas post-flow time (e.g. “GPo | 0.5 s”)
(continued)
- The gas post-flow time can be altered with the adjusting dial (1)

(23) “Feeder inching” button
for feeding the welding wire into the torch hosepack with no accompanying flow of
gas or current
For information on the various wire inching sequences that are possible when the
welder presses and holds the “Feeder inching” button, see the section headed
“The Set-up Menu”.
- sub-section “Process parameters”, parameter “Fdi”.
Important! If you press the Store button (21) and the feeder inching button (23) at
the same time, the display gives a read-out of the pre-set feeder-inching speed
(e.g. Fdi | 10 m/min or Fdi | 393.70 ipm).
- You can alter the feeder inching speed with the “Material” buttons (6)
13
“Comfort” cont-
rol panel
rules”
(24) (19) (11) (12) (14) (16) (17) (19) (1)

(23) (2) (10) (8) (13) (15) (9) (18) (3)
(21) (20) (5)

(22) (7) (6) (4)
Fig.5 “Comfort” control panel
Item Function
(1) Adjusting dial
for changing parameters. If the indicator next to the adjusting dial is lit up, then the
selected parameter is one that can be altered.
for selecting the following parameters
- “a”-dimension
- sheet thickness
- welding current
- wirefeed speed
- F1 indicator
- wirefeed-drive current-input indicator
If the indicator is lit up on the parameter selection button and on the adjusting dial,
then the indicated / selected parameter can be altered with the adjusting dial.
14
“Comfort” cont-
(3) Parameter selection button ... for selecting the following parameters:
rol panel
- arc-length correction
(continued)
- droplet-detachment / arc-force (dynamic) correction
- welding voltage
- welding speed
- job n°
- F3 indicator
(4) Process button(s)
for selecting the welding process
MIG/MAG pulse synergic welding
MIG/MAG standard synergic welding
MIG/MAG standard manual welding
Job mode
TIG welding with touch-down ignition
rod electrode (MMA) welding
(5) Mode button(s)
2-step mode
4-step mode
spot welding mode
operating Mode
wire diameters.
Important! The power source has a pulsating open-circuit voltage. Where the
“Rod electrode (MMA) welding” process has been selected, the display indicates
an average welding-voltage value of 40 V before the start of welding (open circuit).
For welding start-up and the main welding operation itself, however, a welding
voltage of max. 50 V (TPS 2700) or 70 V (TS 4000 / 5000, TPS 3200 / 4000 /
5000) is available. Optimum ignition properties are ensured.
(10) “a”-dimension parameter
for selecting the „a“-dimension. The wirespeed and welding current/voltage are
calculated as a function of the specified welding speed.
Important! Before you select the “a”-dimension, the welding speed parameter
(17) must be set (recommended welding speed for manual welding: ~35 cm/min
or 13.78 ipm)
parameters as well.
15
“Comfort” cont-
rol panel
(continued)
exceeded). For more information on this, see the “Troubleshooting” section
(14) HOLD indicator
(15) Arc-length correction parameter
for correcting the arc length
- shorter arc length
0 neutral arc length
+ longer arc length
(16) Droplet detachment, arc force correction and arc force parameter
a different function depending on the process being used.
MIG/MAG standard synergic welding ... for influencing the short-circuiting dynamic
at the instant of droplet transfer
- harder, more stable arc

0 neutral arc
+ soft, low-spatter arc
MIG/MAG pulse synergic welding ... continuous correction facility for the droplet
detachment force
- lower droplet-detachment force

0 neutral droplet-detachment force
+ increased droplet-detachment force
MIG/MAG standard manual welding ... for influencing the short-circuiting dynamic
0 harder, more stable arc

10 soft, low-spatter arc
Rod electrode (MMA) welding ... for influencing the short-circuiting amperage at
the instant of droplet transfer

(17) Welding speed parameter
for selecting the welding speed. The wirespeed and welding current & voltage are
calculated as a function of the “a”-dimension parameter (10).
(18) JOB N° parameter
for retrieving parameter records/job numbers that were previously saved with the
“Store” button.
(19) F1/wirefeed drive current input/F3 indicators
for displaying defined parameters
between the dip-transfer arc and the spray arc, a spatter-prone “intermediate arc”
occurs. To alert you to this critical area - and help you avoid it - the intermediate
16
“Comfort” cont-
(21) „Store“ button
rol panel
for accessing the Set-up menu or (in Job Mode) for storing parameter settings.
(continued)
- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

to set the required quantity of gas at the pressure regulator. After you press this
button, gas will flow out for 30 s. Press the button again to stop the gas test-flow
before the end of this period.
Now press the “Process” button (4) to display the specified gas post-flow time
(e.g. “GPo | 0.5 s”)

gas or current
For information on the various wire-inching sequences that are possible when the
“The Set-up Menu”,
Important! If you press the Store button (21) and the “Feeder inching” button (23)
at the same time, the display shows the specified feeder inching speed (e.g. “Fdi |
10 m/min” or “Fdi | 393.70 ipm”).
- You can alter the feeder-inching speed with the adjusting dial (1)
17
“Comfort” control
(24) Keylock switch (optional)
panel
When the key is in the horizontal position, the following functions are disabled:
(continued)
- selecting the welding process with the “Process” button(s) (4)
- selecting the operating mode with the “Mode” button(s) (5)
- selecting the filler metal with the “Material” button(s) (6)
- accessing the set-up menu with the “Store” button (21)
- accessing the job-correction menu (see the section headed “Job mode”)
Important! In this case, the functions available on the control panel of the system
components are then restricted in the same way as those of the control panel on
the power source.
“US” control
panel
rules”
(24) (19) (11) (12) (14) (16) (19) (1)

(23) (2) (8) (13) (15) (9) (18) (3)
(21) (20) (5)

(22) (7) (6) (4)
Fig.6 “US” control panel
Item Function
(1) Adjusting dial
18
“US” control
panel
- sheet thickness
(continued)
- welding current
- wirefeed speed
- F1 indicator
- wirefeed-drive current input indicator
- droplet-detachment / arc-force (dynamic) correction
- welding voltage
- job n°
- indicator F3
Job mode
(5) Mode button(s)
2-step mode
4-step mode
spot welding mode
operating Mode
wire diameters.
19
“US” control
panel
(continued)
parameters as well.
(14) HOLD indicator
(15) Arc length correction parameter ... for correcting the arc length
+ longer arc length

0 neutral arc
detachment force



“Store” button.
20
“US” control
panel
(continued)
welding database appears on the display (e.g.: “0 | 029” = M0029).
- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

If you press the Store button (21) and the gas test button (22) at the same time,
the display shows the specified gas pre-flow time (e.g. “GPr | 0.1 s”).
Now press the “Process” button (4) to display the specified gas post-flow time
(e.g. “GPo | 0.5 s”)

gas or current
10 m/min” or 393.70 ipm).
21
“US” control
panel
(continued)
the power source.
TIME 5000 Digital

control panel
rules”
(24) (19) (11) (12) (14) (16) (17) (19) (1)

(23) (2) (10) (8) (13) (15) (9) (18) (3)
(21) (20) (5)

(22) (7) (6) (4)
Fig.7 TIME 5000 Digital control panel
Item Function
(1) Adjusting dial
22
TIME 5000 Digital
control panel
for selecting the following parameters
(continued)
- “a”-dimension
- sheet thickness
- welding current
- wirefeed speed
- F1 indicator
- wirefeed-drive current-input indicator
- droplet-detachment/arc-force (dynamic) correction
- welding voltage
- welding speed
- job n°
- F3 indicator
Job mode
(5) Mode button(s)
2-step mode
4-step mode
spot welding mode
operating Mode
wire diameters.
23
TIME 5000 Digital
(10) “a”-dimension parameter
control panel
for selecting the „a“-dimension. The wirespeed and welding current/voltage are
(continued)
calculated as a function of the specified welding speed.
Important! Before you select the “a”-dimension, the welding speed parameter
(17) must be set (recommended welding speed for manual welding: ~35 cm/min
or 13.78 ipm)
parameters as well.
(14) HOLD indicator
(15) Arc-length correction parameter
for correcting the arc length
+ longer arc length

0 neutral arc
detachment force



(17) Welding speed parameter
for selecting the welding speed. The wirespeed and welding current & voltage are
calculated as a function of the “a”-dimension parameter (10).
24
TIME 5000 Digital
control panel
(continued)
“Store” button.
- Example: “654 | 32.1” = 65,432.1 h = 65,432 h | 6 min

If you now press the “Process” button (4), the display gives you a read-out of the
pre-set gas post-flow time (e.g. “GPo | 0.5 s”)
25
TIME 5000 Digital
control panel
(continued)
gas or current
10 m/min” or “Fdi | 393.70 ipm”).

the power source.
26
“Remote” opera- The “Remote” operating panel goes with the “Remote” power source. The “Remote”
ting panel power source is designed for use with automatic welders and robots, and is controlled
via the LocalNet only.
The “Remote” power source can be operated via the following system add-ons:
- Remote control units
- Robot interfaces
- Field bus coupler
(25)
(26)
(27)
(28)
Fig.8 “Remote” operating panel
Item Function
(25) Error indicator
lights up if an error has occurred. All the units which are connected to the Local-
Net, and which have a digital display, support the display of the relevant error
message.
The error messages displayed are described in the section headed “Troubleshoo-
ting”.
(26) Robot interface indicator
glows as long as the power source is switched on and a robot interface or a field-
bus coupler is connected to the LocalNet.
(27) Power source ON indicator
glows as long as the mains cable is plugged into the mains and the mains switch
is in the “I” position
(28) Operating instructions symbol
Observe all the safety, operating, care and maintenance instructions in the “Ope-
rating instructions” manual
27
CMT control The CMT operating panel is part of the CMT power source. The CMT power source is
panel designed for use with automatic welders and robots, and is controlled solely via the
LocalNet.
The “Remote” power source can be operated via the following system add-ons:
- RCU 5000i remote control unit
- ROB 5000 robot interface
- Field bus systems
(28)
(25)
(29)
(26)
(27)
Fig.9 CMT control panel
Item Function
(25) Error indicator
lights up if an error has occurred. All the units which are connected to the Local-
Net, and which have a digital display, support the display of the relevant error
message.
The error messages displayed are described in the section headed “Troubleshoo-
ting”.
(26) Robot interface indicator
glows as long as the power source is switched on and a robot interface or a field-
bus coupler is connected to the LocalNet.
(27) Power source ON indicator
glows as long as the mains cable is plugged into the mains and the mains switch
is in the “I” position
(28) Operating instructions symbol
Observe all the safety, operating, care and maintenance instructions in the “Ope-
rating instructions” manual
28
Connections - switches - mechanical components
TPS 2700 power Front view Rear view Side view

source
(E) (C) (G) (J)
(A) (B) (F) (D) (I) (H) (K) (L)

Fig.10 TPS 2700 power source
Item Function
(A) Central torch connector **)
for connecting the welding torch
(B) (-) - current socket with bayonet latch
used
- for connecting the grounding (earthing) cable in MIG/MAG welding
- for the current connection on the TIG welding torch
- for connecting the electrode (or grounding/earthing) cable in rod electrode
(MMA) welding, depending on the type of electrode being used
(C) (+) - current socket with bayonet latch
used
- for connecting the grounding (earthing) cable in TIG welding
(D) Torch control connection socket
for connecting the torch control plug
(E) LocalNet connection socket
standardised connection socket for system extensions (e.g. remote control,
JobMaster torch, etc.)
(F) Blanking cover
(G) Mains switch
for switching the power source on and off.
(H) Shielding gas connection socket
(I) Mains cable with strain-relief device
(J) Blanking cover
intended for LocalNet connection socket
(K) Wirespool holder with braking device
for holding standard welding wire spools weighing up to 16 kg (35.27 lbs) and with
a max. diameter of 30.00 cm (11.81 in)
(L) 4-roller drive
**)
Connections, switches and mechanical components are denoted with capital letters, e.g.: (F)
29
TS 4000 / 5000,
Front view Rear view
TPS 3200 / 4000 /
5000 power (J) (J) (M) (N)
sources
(B) (G) (C) (I) (F)

Fig.11 TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources
Item Function
(B) (-) - current socket with bayonet latch
- for connecting the grounding (earthing) cable in MIG/MAG welding
- for the current connection on the TIG welding torch
(C) (+) - current socket with bayonet latch
- for connecting the interconnecting hosepack in MIG/MAG welding
- for connecting the grounding (earthing) cable in TIG welding
(F) Second (-) current socket with bayonet latch (optional)
- for connecting the interconnecting hosepack in MIG/MAG welding for polarity
reversal (e.g. for innershield and flux-core wire welding)
- specially for automated and robot applications where the interconnecting
hosepack and grounding/earthing cable are to be connected to one side of
the power source (e.g. in a control cubicle)
Second (+) current socket with bayonet latch (optional)

- for connecting a second current cable
Blanking cover
- for use where the optional second current socket with bayonet latch has not
been selected
(G) Mains switch
for switching the power source on and off.
(I) Mains cable with strain-relief device
(J) Blanking cover
intended for LocalNet or LHSB (Local High-Speed Bus) connection socket
(M) LocalNet connection socket
Interconnecting hosepack
(N) Blanking cover
intended for LHSB (Local High-Speed Bus) connection socket
30
Minimum equipment needed for welding
General remarks Depending on which weld process you intend to use, a certain minimum level of equip-
ment will be needed in order to work with the power source.
This section contains lists of the minimum equipment levels required for welding with
each of the weld processes.
MIG/MAG wel- - Power source

ding - Grounding (earthing) cable
- MIG/MAG welding torch
- Gas connection (for supplying the machine with shielding gas)
- Wirefeeder (TS 4000 / 5000, TPS 3200 / 4000 / 5000 only)
- Interconnecting hosepack (only on TS 4000/5000, TPS 3200/4000/5000)
- Welding wire
TIG-DC welding - Power source

- Grounding (earthing) cable
- TIG gas-valve torch
- Gas connection (for supplying the machine with shielding gas)
- Filler metal (depending on the application)
Rod electrode - Power source

(MMA) welding - Grounding (earthing) cable
- Electrode holders
- Rod electrodes
31
Before commissioning
General remarks
rules”
Utilisation for The power source may only be used for MIG/MAG, rod electrode (MMA) and TIG wel-
intended purpose ding.
only Utilisation for any other purpose, or in any other manner, shall be deemed to be “not in
accordance with the intended purpose”. The manufacturer shall not be liable for any
damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises

- following all the instructions given in this manual
- performing all stipulated inspection and servicing work.
Machine set-up The machine is tested to “Degree of protection IP23”, meaning:

regulations - Protection against penetration by solid foreign bodies with diameters greater than 12
mm (0.49 in.)
- Protection against direct sprays of water up to 60° from the vertical
The machine can be set up and operated outdoors in accordance with IP23. However,
direct wetting (e.g. from rain) should be avoided.
Warning! A machine that topples over or falls from its stand can easily kill
someone. Place equipment on an even, firm floor in such a way that it stands
firmly.
The venting duct is a very important safety feature. When choosing the machine locati-
on, make sure that it is possible for the cooling air to enter and exit unhindered through
the louvres on the front and back of the machine. Any electroconductive metallic dust
from e.g. grinding-work must not be allowed to get sucked into the machine.
Mains connection The equipment is designed to run on the mains voltage given on the respective rating
plates. If your version of the machine does not come with the mains cables and plugs
ready-mounted, these must be mounted in accordance with your national regulations
and Standards. For details of fuse protection of the mains supply lead, please see the
Technical Data.
Note! Inadequately dimensioned electrical installations can lead to serious

damage. The mains lead, and its fuse protection, must be dimensioned in
accordance with the local power supply. The technical data shown on the rating
plate shall apply.
Applies to TIME 5000 Digital power source: The standard mains plug allows the
user to operate with a mains voltage of up to 400 V. For mains voltages up to
460 V, fit an approved mains plug or install the mains supply directly.
32
Connecting up the mains cable on US power sources
General remarks The US power sources are supplied without mains cable. A mains cable appropriate for
the connection voltage must be fitted prior to putting the unit into service.
A strain relief device for a cable cross-section AWG 10 is installed on the power source.
Strain relief devices for larger cable cross-sections must be designed accordingly.
Stipulated mains Power source Mains voltage Cable cross-section

cables and strain
TS 4000/5000, TPS 4000/5000 3 x 460 V AWG 10
relief devices
3 x 230 V AWG 6
TPS 3200 3 x 460 V AWG 10
3 x 230 V AWG 8
AWG ... American wire gauge
Safety
damage. The following activities must only be carried out by Fronius-trained
qualified personnel! Pay particular attention to the “Safety rules” section.
Connecting up 1. Remove the left side panel of the power source

the mains cable 2. Strip about 100 mm (4 in.) of insulation from the end of the mains cable.
Important! The PE conductor (green, or green with yellow stripes) should be approx. 10
- 15 mm (0.4 - 0.6 in.) longer than the phase conductors.
3. Fit wire end ferrules to phase conductors and PE conductors of the mains cable;
crimp ferrules with pliers
Note! If wire end ferrules are not used, there is a risk of short circuits between
the phase conductors or between phase conductors and the PE conductor. Fit
wire end ferrules to all phase conductors and the PE conductor of the stripped
mains cable.
4. Undo the screws (2x) and clamping

nut (width-across 30) on the strain
relief device
Fig.12 Undoing the screws and clamping nut
33
Connecting up 5. Insert the mains cable into the strain
the mains cable relief device
(continued)
Important! Push the mains cable in far
enough to make it possible to connect the
PE conductor and the phase conductors to
the block terminal properly.
PE
W1
V1
U1
6. Tighten the clamping nut (width-
8
across 30)
7 7. Tighten the screws (2x)
6
8. Connect the mains cable to the block
terminal properly:
5 - PE conductor (green, or green with
yellow stripes) to the PE connec-
tion
Fig.13 Connecting up the mains cable - phase conductors to connections
L1 - L3
9. Replace the left side panel of the
power source
Exchanging the 1. Remove the left side panel of the

strain relief power source
device 2. Remove the screws (2x) from the old
strain relief device
3. Pull the old strain relief device for-
wards to detach it
4. Remove the screws for the adapter
2
4 plate, and remove the adapter plate
2
3 4
Fig.14 Removing an existing strain relief device
5. Fit the large strain relief device

together:
- Insert the hexagon nut (width-
across 50) into the holding plate
Important! The points of the hexagon

nut must point towards the holding
plate for a reliable earth connection to
the power source housing.
- Screw the front of the large strain

relief device into the hexagon nut
(width-across 50).
The hexagon nut (width-across 50)
now bites into the holding plate
Fig.15 How to fit the large strain relief device

together
34
Exchanging the 6. Slot the large strain relief device into
strain relief the housing and fasten it with 2
device screws
(continued) 7. Connecting up the mains cable
8. Replace the left side panel of the
power source
7 6
7
Fig.16 Fitting a large strain relief device
35
Commissioning
General remarks
Warning! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the machine when
- the mains switch is in the “O” position,
- the machine is unplugged from the mains.
Remarks on the We recommend using an FK 4000 R cooling unit for the following applications and
cooling unit situations:
- TS 4000 / 5000, TPS 3200 / 4000 / 5000 power sources
- Jobmaster welding torches
- Push-Pull welding torches
- Robot welding
- Hosepacks over 5 m long
- MIG/MAG pulse synergic welding
- In general, where welding is performed in higher power ranges
The cooling unit is powered from the power source. As soon as the mains switch (G) of
the power source is switched to the “I” position, the cooling unit will be ready for use.
Overview The section on commissioning deals with the following activities:

- Installation of the system components
- Fixing strain relief device in place and connecting interconnecting hosepack
- Connecting gas cylinder and making a ground (earth) connection
- Fitting the welding torch and putting the cooling unit into service
Important! Please refer to the relevant wirefeeder’s operating instructions for informati-
on regarding fitting and adjusting the wirefeeder.
- inserting/replacing feed rollers

- Inserting the wirespool/inserting the basket-type spool
- Feeding in the welding wire
- Adjusting the brake
36
Installation of the system components
Installation of the Note! The diagram below is intended to show you how to put the power source
system compon- into service.
ents (overview) See the instructions for the relevant system components for detailed information
relating to the individual steps.
Fig.18 Installation of the system components
37
Fixing strain relief device in place and connecting
interconnecting hosepack
Fixing the strain 1. Fit the strain relief device of the

relief device in interconnecting hosepack to the
place trolley
Important! Where the strain relief device

is subjected to heavy loads, it must be
screwed to the floor of the trolley. A strain
1
relief device is not provided in the case of
1.2 m (4 ft.) interconnecting hosepacks.
Fig.19 Fixing the strain relief device to the trolley
2. Fit the strain relief device of the

interconnecting hosepack to the
wirefeeder
Fig.20 Fitting the strain relief device to the

wirefeeder
38
Connecting Important! There is no cooling device present in the case of gas-cooled systems. There
interconnecting is no need to attach the water connections in the case of gas-cooled systems.
hosepack
Gas cylinder / (J)

pressure
regulator
(M)
Power source
(f) (c) (b) (C)
(a)
(e)
Red
Cooling unit
(d)
Blue
Fig.21 Connecting interconnecting hosepack - overview
1. Connect interconnecting hosepack to the power source:

- Plug the welding potential bayonet plug (a) of the interconnecting hosepack to
the socket (C), and turn it to fasten it
- Plug the LocalNet connector (b) of the interconnecting hosepack into the Local-
Net connection socket (M) and fix by turning the swivel nut
- For CMT power sources only: Plug LHSB plug (c) into LHSB connection socket
(J)
2. Connect interconnecting hosepack to cooling unit with these connections:

- Water flow (d) - blue
- Water return (e) - red
3. Connect shielding gas hose (f) to pressure regulator on the gas cylinder
3. Connecting interconnecting hosepack

to wirefeeder
Fig.22 Wirefeeder
39
Connecting gas cylinder and making a ground
(earth) connection
Connecting up 1. Stand the gas cylinder on the floor of

the gas cylinder the trolley and secure it by fixing the
cylinder strap around a point in the top
third of the cylinder - but never around
the neck of the cylinder
2. Connect the gas cylinder:
- Take the protective cap off the gas
cylinder
- Briefly turn the gas-cylinder valve
anticlockwise, to blow off any dust
and dirt
- Inspect the seal on the pressure
regulator
- Screw the pressure regulator onto
the gas cylinder and tighten it
- TS 4000/5000, TPS 3200/4000/
5000:
Connect the shielding-gas connec-
tor (on the end of the gas hose of
the interconnecting hosepack) to
Fig.23 Fixing the gas cylinder on the trolley the pressure regulator
- TPS 2700:
Connect the shielding-gas connec-
tor (H) (on the end of the gas
hose) to the pressure regulator
Note! Where a gas adapter is being used for the gas hose, glue in and seal the
adapter and test to ensure that it is gas-tight.
Making an earth 1. Plug the grounding (earthing) cable

connection (c) into the current socket (B) and turn
it to fasten it
2. With the other end of the grounding
(earthing) cable, establish a connec-
tion to the workpiece
(B)
(c)
Fig.24 Plugging in the grounding (earthing) cable
40
Mounting the welding torch and putting the cooling
unit into service
Mounting the 1. Switch the mains switch (G) to the “0”

welding torch position
2. Check that the torch is correctly and
completely tooled up. Insert it - infeed
tube first - into the central torch
connector (A)
3. Tighten the swivel nut by hand to fix
(A) the torch in place
4. Plug the control plug of the welding
torch onto the torch control connec-
(D) tion (D) and turn it to fasten it
Fig.25 Central torch connector and torch-control

connection point on the VR 4000
Important!
- On the TPS 2700, water-cooled torches can only be used with an external water
connection.
- On the TPS 2700, the central torch connector (A) and the torch-control connection
point (D) are located at the front of the power source.
Putting the The cooling unit is powered from the power source. As soon as the mains switch (G) of
cooling unit into the power source is switched to the “I” position, the cooling unit will be ready for use.
service
Note! Before starting up the cooling unit, check the level and purity of the
coolant.
41
MIG/MAG operating modes
General remarks
rules”
For information on settings, setting range and units of measurement, please see the
section headed “Set-up Menu: Level 1”.
Symbols and
abbreviations
Press the torch trigger Hold the torch trigger Release the torch trigger
Fig.26 “Press torch trigger” Fig.27 “Hold torch trigger” Fig.28 “Release torch trigger”
symbol symbol symbol
GPr ....... Gas pre-flow time

I-S ......... Starting-current phase: The base metal is heated up rapidly, despite the high
thermal dissipation that occurs at the start of welding
SL ......... Slope: The starting current is continuously lowered down as far as the welding
current or the welding current as far as the crater-fill current
I ............ Welding-current phase: Uniform thermal input into the base metal, whose
temperature is raised by the advancing heat
I-E ......... Crater-fill phase: To prevent any local overheating of the base metal due to
heat build-up towards the end of welding. This eliminates any risk of weld drop-
through.
SPt ....... Spot-welding time
GPo ...... Gas post-flow time
42
2-step mode “2-step mode“ is suitable for
- tacking-work
- short seams
- automatic-welder and robot welding
GPr I GPo t
Fig.29 2-step mode
4-step mode “4-step mode“ is suitable for longer weld seams.
+ +
GPr GPo t
I
Fig.30 4-step mode
43
Special 4-step The “Special 4-step (aluminium welding start-up)” mode is particularly suitable for wel-
mode (aluminium ding aluminium materials. The special pattern of the welding-current curve takes account
welding start-up) of the high thermal conductivity of aluminium:
+ +
GPr I-S SL I SL I-E GPo t
Fig.31 Special 4-step mode
Spot welding The “Spot welding” mode is suitable for welding joins on overlapped sheets.
Step-by-step guide to welding a spot:

1. Hold the welding torch in the vertical
2. Press and release the torch trigger
3. Keep the torch in the same position
4. Wait until the end of the gas post-flow time
5. Lift the torch off the workpiece
+ +
GPr GPo t
SPt
Fig.32 Spot welding
The welding operation can be aborted by pressing the torch trigger a second time.
44
MIG/MAG welding
MIG/MAG wel-
ding
rules”
1. Plug the grounding (earthing) cable into current socket (B) and latch it
2. With the other end of the grounding (earthing) cable, establish a connection to the
workpiece
3. Plug the torch into the central torch connector (A)
(see also “Putting the power source into service / Fitting the welding torch”)
4. Only where a cooling unit and water-cooled torch are used:
- TS 4000/5000, TPS 3200/4000/5000 with water cooling: Plug the water hoses of
the welding torch to the correct plug-type connectors on the wirefeeder
- TPS 2700 with water cooling: Plug the water hoses of the welding torch to the
correct plug-type connectors on the cooling unit
5. Plug in the mains plug
Caution! Risk of injury and damage from electric shock and from welding wire
emerging at speed from the torch. When you press the torch trigger:
- hold the torch so that it points away from your face and body
- do not point the welding torch at people
- make sure that the welding wire does not touch any electrically conducting
or earthed (grounded) parts, such as the housing, etc.
6. Switch the mains switch (G) to the “I” position - all the indicators on the control panel
now briefly light up
Note! If the flow of coolant water is insufficient, damage may result. Check the
coolant flow at regular intervals while the machine is in operation - it must be
possible to see that coolant is flowing properly.
7. With the “Process” button (4), select the desired welding process:
- MIG/MAG pulse synergic welding
- MIG/MAG standard synergic welding
- MIG/MAG standard manual welding
8. With the “Material” button (6), select which filler metal and shielding gas are to be
used
9. With the “Wire diameter” button (7), select the diameter of the wire
10. With the “Mode” button (5), select the desired operating mode:
- 2-step mode
- 4-step mode
- Special 4-step mode (aluminium welding start-up)
- Spot welding
For details of how to set the parameters for the “Special 4-step” mode and the “Spot
welding” mode please see the section headed “The set-up menu”.
45
MIG/MAG wel- Important! Parameters that have been set on one control panel (e.g. wire feeder or
ding remote control unit) might not be able to be changed on another control panel (e.g.
(continued) power source).
11. Specify the desired welding power with reference to any of the following parameters:
- a-dimension (10)
- Sheet thickness (11)
- Welding current (8)
- Wirefeed speed (12)
Important! The parameters “a”-dimension (10), sheet thickness (11), welding current (8)
and wirefeed speed (12) are directly interlinked. It is only necessary to alter one of the
parameters, as the other parameters are immediately adjusted to match.
Before you select the “a”-dimension, the welding-speed parameter (17) must be set
(recommended welding speed for manual welding: approx. 35 cm/min or 13.78 ipm).
12. Open the gas-cylinder valve

13. Set the gas-flow rate:
- Press the “Gas-test” button (22)
- Turn the adjusting-screw on the underside of the pressure regulator until the
manometer indicates the desired shielding gas flow-rate
14. Press the torch trigger and start welding
All parameter command values that have been set by means of either the adjusting dial
(1) or the buttons on the torch will remain stored until the next time they are changed.
This is true even if the power source is switched off and on again in the meantime.
In order to achieve an optimum welding result, it is necessary in some cases to make

corrections to the arc-length correction and droplet-detachment / arc-force correction
parameters as well as to background parameters such as gas pre-flow, gas post-flow
and/or soft-start (feeder creep). For details of how to set the background parameters gas
pre-flow, gas post-flow and soft-start (feeder creep), please see “Set-up menu: Level 1”.
Important! It is not possible to correct the arc-length on the “Standard” control panel.
However, you can set the arc-force correction as a background parameter in the Set-up
Menu.
Ignition time-out The power source has an “Ignition time-out” function. This function is not factory-activa-
function ted as standard.
To activate the ignition time-out:

- Launch “Set-up menu: Level 2“
- Set a value of between 5 mm and 100 mm, or between 0.20 in and 3.94 in. (ito | 5 ...
100 or
ito | 0.20 ... 3,94)
Please see the section headed “Set-up menu: Level 2” (“Parameters 2nd”) for more
details regarding the settings, setting range and units of measurement of the “Ignition
time-out” parameter (ito).
Once the torch trigger is pressed, gas pre-flow begins immediately. Wire inching then
begins, followed by ignition. If no current starts flowing before the length of wire specified
in the set-up menu has been fed, the power source cuts out automatically. The service
code “no | IGn“ appears on the control panel.
“E55” is displayed on the JobMaster torch and on the field-bus module.
To make another attempt to achieve ignition, press the torch trigger again.
46
Arc break watch- In the factory settings, the arc break watchdog function (Arc) is set to OFF.
dog function
To activate the arc break watchdog function:
- Set a value of between 0.01 s and 2 s (Arc | 0.01 ... 2)
To deactivate the arc break watchdog function:

- Set it to OFF (Arc | OFF)
See the section headed “Set-up menu: Level 2” (“Parameters 2nd”) for information on
setting the arc break watchdog parameter (Arc).
If the arc breaks and no current starts to flow again within the time defined in the set-up
menu, the machine cuts out automatically. The service code “no | Arc“ appears on the
control panel.
To start welding again, press the torch trigger again.
Note! At maximum welding current and very low arc length it is possible that the
arc will break without the service code “no | Arc” appearing. If the arc is reduced
significantly, the welding current would have to be increased to more than the
maximum current in order to be able to maintain the requested welding power.
As this is not acceptable, the power source switches off for safety reasons.
Standard manual The ‘Standard manual welding’ process is a MIG/MAG standard synergic welding pro-
welding cess with no synergic function. In the same way as where the synergic function is active,
the user selects the welding program (by way of the filler metal, shielding gas and wire
diameter) and the operating mode, and then sets the parameters. However, changing
one parameter does not result in any automatic adjustments to the other parameters. All
of the variable parameters must thus be adjusted individually, as dictated by the welding
process in question.
Important! As long as the “Standard manual welding” process is selected, the “Synchro-
Puls” option is not supported.
In the “Standard manual welding” process, the following parameters are available:
- Wirefeed speed (12) ... 0.5 m/min - maximum wirefeed speed (e.g. 22.0 m/min) or
19.69 ipm. - maximum wirefeed speed (e.g. 866.14 ipm.)
- Welding voltage (9) ... 10.0 - 40.0 V (TPS 2700: 10.0 - 34.0 V)
- Arc force (dynamic) correction (16) ... for influencing the short-circuiting dynamic at
0,0 harder, more stable arc
10,0 soft, low-spatter arc
- Welding current (8) - only displayed as actual value
1. Switch the mains switch (G) to the “I” position (all the indicators on the control panel
briefly light up)
2. Select the “Standard manual welding” process with the Process button (4)
3. With the “Material” button (6), select which filler metal and shielding gas are to be
used
4. With the “Wire diameter” button (7), select the diameter of the wire
Important! In the “Standard manual welding” process, the “Special 4-step” mode
only corresponds to conventional 4-step operation.
47
Standard manual 5. With the “Mode” button (5), select the desired operating mode
welding
(continued) Important! Parameters that have been set on one control panel (e.g. wire feeder or
remote control unit) might not be able to be changed on another control panel (e.g.
power source).
Note! If the machine does not reach the specified welding voltage, the power
source delivers the highest voltage that is possible at that time.
6. Set the parameters “Wirefeed speed” (12), “Welding voltage” (9) and “Arc-force
correction” (16) separately
7. Open the gas-cylinder valve
8. Set the gas-flow rate:
- Press the “Gas-test” button (22)
- Turn the adjusting-screw on the underside of the pressure regulator until the
manometer indicates the desired shielding gas flow-rate
9. Press the torch trigger and start welding
All parameter command values that have been set by means of either the adjusting dial
(1) or the buttons on the torch will remain stored until the next time they are changed.
This is true even if the power source is switched off and on again in the meantime.
“Spatter-free Important! External enabling of the “spatter-free ignition” option is possible from softwa-
ignition” option re version 2.70.1 (power source) upwards. At present, this option only supports alumini-
um wires of diam.
- 0.8 mm, 1.0 mm, 1.2 mm and 1.6 mm.
- USA: 0.9 mm (0.035 in.), 1.2 mm (0.045 in.) and 1.6 mm (1/16 in.)
Note! Optimum functioning of the “spatter-free ignition” option can only be

ensured in conjunction with Fronius push-pull wirefeed systems.
System requirements:
- Software version 2.60.1 (power source)
- Software version 1.40.15 (wirefeeder)
The Spatter Free Ignition option (SFi) makes it possible to ignite the arc with practically
no spatter. At the beginning of welding, the wire is slowly fed as far as the surface of the
workpiece and then stopped as soon as it touches down. Next, the welding current is
activated and the wire is pulled back. Once the correct arc length has been reached, the
wire starts being fed at the speed specified for this weld process.
Important! There is a sticker showing a program table on the power source. The stored
welding programs are listed in this table. Not all of these welding programs support the
SFI function. SFI is automatically deactivated on changing to a program that does not
support the SFI function. SFI must be re-activated on changing back to a program that
supports the SFI function.
To activate the SFi option:

- Select your welding program
- Select SFi (parameter Fdc - feeder creep) in the set-up menu
- Exit from the set-up menu
48
SynchroPuls Important! External enabling of the “SynchroPuls” option is possible from software
option version 2.70.1 (power source) upwards. This option only supports Fronius manual push-
pull and Robacta Drive push-pull (slave) wirefeed systems.
- Software version 1.40.15 (wirefeeder)
The “SynchroPuls” option is recommended for welds using aluminium alloys where you
want to give the weld-seams a rippled appearance. This effect is achieved by having the
welding power alternate between two operating points.
For details on setting the available parameters, please see the section headed “Set-up
menu: Level 1”.
F ........... Frequency (SynchroPuls) ... OFF ... 0.5 - 5 Hz

Factory setting: OFF
dFd ....... Offset welding output (SynchroPuls) ... 0.0 - 2.0 m/min or 0.0 - 78.74 ipm.
Factory setting: 2.0 m/min or 78.74 ipm.
Al.2 ....... Arc-length correction (SynchroPuls) ... +/- 30 % of welding voltage
Factory setting: 0
- The two operating points result from the welding output being changed - positively
and negatively - by a value dFd (Welding-output offset: 0.0 - 2.0 m/min or 0.0 -78.74
ipm) that can be adjusted in the Set-up menu.
- The frequency F of the alternation (OFF ... 0.5 - 5 Hz) between the two operating
points can also be specified in the Set-up menu
- The arc-length correction for the lower of the two operating points is made by way of
the arc-length correction parameter (15) - see “Description of the control panel”.
- The arc-length correction for the higher of the two operating points must be made in
the Set-up menu, by way of the parameter Al.2 (+/- 30 %).
Note! In order to activate SynchroPuls, you must (as a minimum) change the
value of the parameter F (frequency) from OFF to a value of between 0.5 Hz
and 5 Hz.
The graph below shows how SynchroPuls functions, in this case when used with the
“Special 4-step” mode (I-S = Starting-current phase, SL = Slope,
I-E = Crater-fill phase):
+ +
SL 1/F SL
I vD
Al.2
dFd
Wirefeed speed
I-S dFd
I-E
t
Fig.33 SynchroPuls - Mode of functioning
49
Special 2-step The Special 2-step mode for robot interface is available when a robot interface or a field
mode for robot bus coupler for robot control is connected to the LocalNet.
interface
Important! As soon as a ROB 4000/5000 robot interface or a field-bus coupler is con-
nected to the LocalNet, 2-step mode is automatically selected. After this, it is only pos-
sible to exit from 2-step mode (by pressing the “Mode” button (5) ) once the robot inter-
face has been disconnected from the LocalNet.
If a ROB 3000 robot interface is connected, it is possible to select any of the modes (2-
step mode, 4-step mode, Special 4-step mode, ...).
Please see the section headed “Set-up menu: Level 1” for details on the settings, setting
range and units of measurement of the available parameters.
The parameters for the “Special 2-step mode for robot interface” can only be selected in
“Set-up menu: Level 1“ (“Mode” parameter) when a robot interface, or a field bus coupler
for robot control, is connected to the LocalNet.
The graph below illustrates the mode of functioning of the “Special 2-step mode” (I-S =
Starting-current phase, SL = Slope, I-E = Crater-fill phase, t-S = Starting-current duration,
t-E = Final-current duration):
I t-S SL SL t-E
welding current
I-S
I-E
Robot signal
1
0
t
Welding on Welding off
Fig.34 Mode of functioning of “Special 2-step mode”
50
Special 2-step “Wire-stick control” function
mode for robot
interface The “Wire-stick control” function is available when a robot interface, or a field bus
(continued) coupler for robot control, is connected to the LocalNet.
Important! The standard factory setting is that the “Wire-stick control” function is not
activated. Where needed, activate the “Wire-stick control” function in the “Set-up menu:
Level 2” (“Stc | ON”).
After the end of welding, the “Wire-stick control” function detects any “sticking” of the
wire in the solidifying weld pool. If a sticking wire-tip is detected within 750 ms after the
end of welding, the error message “Err | 054” will be output.
Warning! A welding process that starts automatically can pose a risk to life.
The “Arc on” signal must not be set while the error is being rectified, otherwise
welding will start as soon as the error is rectified.
- Cut off the sticking wire-tip
Important! The error message “Err | 054” does not need to be acknowledged.
- The power source is now ready for operation.
51
TIG welding
General remarks
rules”
The TIG welding process is only possible

- in conjunction with the “Comfort” or the “US” control panel
- with a TIG gas-valve torch
Preparations 1. Switch the mains switch (G) to the “O” position

2. Unplug the machine from the mains
3. Dismount the MIG/MAG welding torch
4. Plug the grounding (earthing) cable into current socket (C) and latch it in firmly
workpiece
6. Plug the welding cable of the TIG gas-valve welding torch into current socket (B)
and latch it by turning it clockwise
7. Screw the pressure regulator onto the (argon) shielding-gas cylinder and tighten it
8. Attach the gas hose to the pressure regulator
TIG welding
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 electrical-
ly conducting or earthed parts (e.g. housing etc.)
will now briefly light up
2. With the “Process” button (4), select the TIG welding process - the welding voltage
to the welding socket is switched on after a 3 s timelag.
Important! Parameters that have been set on one control panel (e.g. wire feeder or
power source).
3. Press the “Parameter selection” button (2) (indicator on the button must light up)
4. Set the desired amperage, using the adjusting dial (1) (value can be read off from
the left-hand indicator)
5 Open the gas cut-off valve on the TIG gas-valve torch and set the desired shielding-
gas flow rate on the pressure regulator
6. Start welding
52
Igniting the arc Ignition of the welding arc is effected by touching down the tungsten electrode onto the
workpiece.
1. Place the gas nozzle on the ignition

location so that there is a gap of 2 - 3
mm (0.08 - 0.12 in.) between the
tungsten tip and the workpiece
Fig.35 Placing the gas nozzle down
2. Gradually tilt up the welding torch until

the tungsten tip touches the workpi-
ece
Fig.36 Arc ignites when electrode is touched down

on workpiece
3. Raise the torch and pivot it into the

normal position - the arc ignites
4. Start welding
Fig.37 Arc ignited - welding commences
Finishing welding 1. Lift the TIG gas-valve torch away from the workpiece until the arc goes out.
2. After the end of welding and a suitable gas post-flow time, close the gas shut-off
valve on the TIG gas-valve torch
All parameter command values that have been set by means of the adjusting dial (1) will
remain stored until the next time they are changed. This is true even if the power source
is switched off and on again in the meantime.
53
TIG-Comfort-Stop If desired, the power source can also be fitted with the optional “TIG Comfort Stop”.
option
At the end of the welding operation, the welding current is switched off automatically if
the length of the arc increases by more than a defined amount.
This prevents the arc being unnecessarily elongated when the TIG gas-valve torch is
lifted off the workpiece.
Important! For details of how to activate and make settings for the optional “TIG Com-
fort Stop” function, please refer to the section headed “CSS parameter”.
The standard factory setting is that the optional “TIG Comfort Stop” function of the power
source is deactivated.
1. Welding
Fig.38 Welding
2. During welding, briefly raise torch

- The arc length is increased signifi-
cantly
Fig.39 Raising torch
54
TIG-Comfort-Stop 3. Lower the welding torch
option - The arc length is decreased
(continued) significantly
- the optional TIG Comfort Stop
function is triggered
Fig.40 Lowering the torch
4. Keep the welding torch at the same

height:
- the welding current is continuously
decreased (downslope) and
- the arc goes out.
Important! The downslope is pre-set

and cannot be adjusted.
5. Raise the torch from the workpiece.
Fig.41 Keeping the torch at the same height and

then removing it
55
TIG welding with TIG welding: the following diagram shows the welding current sequence when the
TIG Comfort Stop optional TIG Comfort Stop function is activated.
I Pre-set welding current
Downslope
Fig.42 TIG welding process with the optional TIG Comfort Stop function activated
CSS parameter The “TIG Comfort Stop” function is activated and set by means of the CSS parameter.
The CSS parameter is located in the “Set-up Menu - Level 2”, “TIG welding”.
For more detailed information on how to access the Set-up menu and set the parame-
ters, please refer to the section headed “Set-up Menu - Level 2” in the User Manual.
56
Rod electrode (MMA) welding
General remarks The “Rod electrode (MMA) welding” process is only possible in conjunction with the
“Comfort” und “US” control panels.
rules”
If the rod electrode (MMA) welding process is selected, any cooling device present is
automatically deactivated. It is not possible to switch it on.
Preparations 1. Unplug the machine from the mains

2. Switch the mains switch (G) to the “O” position
3. Dismount the MIG/MAG welding torch
4. Plug the grounding (earthing) cable into either current socket (B) or (C), depending
upon which type of electrode is to be used, and latch it in firmly
workpiece
6. Plug the welding cable into either current socket (B) or (C), depending upon which
type of electrode is to be used, and latch it by turning it clockwise
Rod electrode
Caution! Risk of injury and damage from electric shock. As soon as the mains
(MMA) welding
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
conducting or earthed parts (e.g. the housing etc.)
will now briefly light up
2. With the “Process” button (4), select the rod electrode (MMA) welding process - the
welding voltage to the welding socket is switched on after a 3 s timelag.
Important! Parameters that have been set on one control panel (e.g. wire feeder or
power source).
4. Set the desired amperage, using the adjusting dial (1) (value can be read off from
the left-hand indicator)
6. Set the desired arc-force dynamic, using the adjusting dial (1) (value can be read off
from the right-hand indicator)
7. Start welding
57
Rod electrode All parameter command values that have been set by means of the adjusting dial (1) will
(MMA) welding remain stored until the next time they are changed. This is true even if the power source
(continued) is switched off and on again in the meantime.
Hot-Start func- In order to obtain optimum welding results, it will sometimes be necessary to set or
tion adjust the Hot-Start function:
Advantages:
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base metal in the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
For details on setting the available parameters, please see the section headed “Set-up
menu: Level 2”.
Legend
I (A)
Hti Hti ...... Hot-current time,
0-2 s, factory setting: 0.5 s
300 HCU .. Hot-start current, 0-100%, factory
setting: 50 %
HCU IH ........ Main current = Pre-set welding
current
200
Mode of functioning
IH During the specified hot-current time (Hti),
the welding current is increased to a
certain value. This value (HCU) is 0-100%
t (s) higher than the selected welding current
(IH).
0,5 1 1,5
Fig.43 Example of “Hot-Start” function
Example: A welding current (IH) of 200 A has been set. For the hot-start current (HCU), a
value of 50 % has been selected. During the hot-current time (Hti, e.g. 0.5 s), the actual
welding current will be 200 A + (50 % of 200 A) = 300 A.
Anti-stick func- The anti-stick function can be activated and deactivated in the “Set-up menu: Level 2”
tion (see the section headed: “Set-up menu: Level 2”).
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode
will tend to “stick”. This may also cause “burn-out” of the rod electrode.
Electrode burn-out is prevented if the anti-stick function has been activated. If the rod
electrode begins to stick, the power source immediately switches the welding current off.
After the rod electrode has been detached from the workpiece, the welding operation
can be continued without difficulty.
58
Job mode
General remarks “Job Mode” enhances the quality of welding-engineering fabrication, both in manual
welding and also in semi-automatic and fully automated operation.
The traditional way of reproducing often-needed jobs (operating points) has been to
document the required parameters by hand. In Job Mode, it is now possible to create,
copy, delete and retrieve up to 100 different jobs.
Important! Job Mode is only available on power sources equipped with either the
“Comfort” or “US” control panels.
Important! If using the TR 2100 TIME remote control unit and VR 4000-30 TIME wire-
feeder, the „Job mode“ function is not available. Once the remote control unit or wirefee-
der is connected, the MIG/MAG pulse synergic welding process is automatically se-
lected. No other process can be selected on the power source.
The following syntax is used in Job Mode, on the left-hand indicator:

- - - ........ No job in this program location (only when you try to retrieve a job from this
location, otherwise nPG)
nPG ...... No job in this program location
PrG ....... There is a job in this program location
Pro ........ Job is being created / copied in this program location
dEL ....... Job is being deleted from this program location
Creating a job The machine comes with no jobs pre-programmed. A job has to be created before it can
be retrieved.
To create a job, proceed as follows:
1. Set the desired welding parameters

that you want to store as a “Job”.
2. Briefly press the Store button (21) to

change to the job menu. The first
vacant program location for the job is
now indicated.
3. Select the desired program location

with the adjusting dial (1), or else
leave the suggested program location
unchanged.
4. Press and hold the Store button (21).

The left-hand display reads “Pro” - the
job is stored in the program location
you have just selected.
59
Creating a job Important! If the selected program location already has a job stored in it, then this
(continued) existing job will be overwritten with the new job. This action cannot be undone.
5. “PrG” appears on the left-hand display

to indicate that the job is now stored.
Release the Store button (21).

exit from the job menu
Important! The parameters in the set-up menu are stored automatically with every job -
except for the functions “PushPull Unit”, “Cooling-unit cut-out”, “Welding-circuit resis-
tance measurement” and “Welding-circuit inductivity”
Copying/overwri- You can copy a job that has already been stored in one program location to any other
ting a job program location. To copy a job, proceed as described below:
1. With the “Process” button (4), select

“Job Mode” as the process. The
display now shows the last job to be
used.
2. Use the adjusting dial (1) to select

which job you want to copy

vacant program location for the job to
be copied is now indicated.
4. Select the desired program location

with the adjusting dial (1), or else
leave the suggested program location
unchanged.
5. Press and hold the Store button (21).

The left-hand display reads “Pro” - the
job is copied to the program location
you have just selected.
Important! If the selected program location already has a job stored in it, then this
existing job will be overwritten with the new job. This action cannot be undone.
6. “PrG” appears on the left-hand display

to indicate that the job is now stored.
Release the Store button (21).

60
Deleting a job A job that has been stored to a program location can also be deleted again. To delete a
job, proceed as described below:

vacant program location is indicated.
2. With the adjusting dial (1), select the

job to be deleted the “DEL” symbol
lights up on the “Wire diameter”
button (7).
3. Press and hold the “Wire diameter”

button “DEL” (7). The left-hand
display reads “dEL” - the job is dele-
ted.
4. “nPG” appears on the left-hand

display to indicate that the job is now
deleted. Release the Wire diameter
“DEL” button (7).

Retrieving a job Once programmed, all jobs can be retrieved in Job Mode. To retrieve a job, proceed as
follows:
1. With the “Process” button (4), select

“Job Mode” as the process - the last
job used is displayed. To view the
settings programmed in this job, use
the “Parameter selection” buttons (2)
and (3). The process and operating
mode of the stored job are also
displayed.
2. With the adjusting dial (1), select the

desired job
The job can also be selected from the
JobMaster or Up/Down torch.
Important! When you retrieve a job directly from the power source, you can also select
vacant program locations (symbolised by “- - -”). From the JobMaster or Up/Down
torches, on the other hand, you can only select program locations that have already
been programmed.
3. Start welding - during welding you can

always change to another job without
interruption.
4. When you change to another process,
this finishes Job Mode.
61
Job correction
General remarks The “Job correction” function allows the user to tailor the set-up parameters to suit
individual jobs.
(21) (2)
(4)
(1)
(4)
(4)
(1) (1)
(4)
(21)
Fig.44 Selection menu for the special function: “Job correction”
Accessing the The selection menu can be accessed from:

job correction - the power-source control panel
menu - the RCU 4000 and RCU 5000i remote-control panels
- Win RCU (JobExplorer software)
- ROB 4000 / 5000 robot interface
1. Press and hold the Store button (21)

2. Press the parameter selection button (2)
3. Release the Store button (21).
The power source is now in the job correction selection menu - the first parameter, “Job”
(for selecting the job whose parameters are to be adjusted), is now displayed.
Changing a 1. Use the “Process” button (4) to select the desired parameter
parameter 2. Use the adjusting dial (1) to alter the value of this parameter
62
Exiting the job 1. Press the Store button (21)
correction menu
Important! Any alterations are saved by exiting from the “Job correction” menu.
The available parameters are listed below:
Available parame- permanently settable parameters ... subsequently correctable parameters ...
ters - cannot be altered apart from in the - with boundary values for which an
“Job correction“ menu. adjusting range can be defined
- can only be corrected in the “Job - Within this setting range, these
correction” menu. parameters can be corrected from the
following control elements:
- “Comfort” control panel
- “US” control panel
- JobMaster welding torch
- RCU 4000 remote control unit
Permanently “Min.” and “max.” are used for setting ranges that differ according to power source, wire
settable parame- feed, welding program etc.
ters
Job
Job whose parameters are to be adjusted
unit -
setting range 0-99 = numbers of the programmed jobs, n = memory location
vacant
factory setting -
P
Power correction - Correction of the welding power as defined by the wirefeed speed
unit m/min ipm.
setting range e.g.: 5 - 22 e.g.: 0.2 - 866.14
(setting range depends upon which job has been selected)
factory setting -
AL.1
Arc Length correction.1 - general
unit % of the welding voltage
setting range +/- 30
factory setting -
Important! When the SynchroPuls option is enabled, AL.1 is the arc length correction
for the lower operating point of the pulsed welding power.
The arc-length correction for the upper operating point is made using Parameter AL.2.
63
Permanently
dYn
settable parame-
dynamic - Arc force dynamic correction (standard arc) or pulse correction (pulsed arc),
ters
(functionality is analogous to the parameter “Arc force dynamic correction” or “Arc force
(continued)
dynamic” - see the section headed “Description of the control panel”)
unit 1
setting range +/- 5
factory setting -
GPr
Gas pre-flow time
Unit s
Setting range 0 - 9,9
Factory setting 0,1
GPo
Gas post-flow time
Unit s
Factory setting 0,5
Fdc
Feeder creep
unit m/min ipm.
setting range AUT, OFF, 0.5 - max. AUT, OFF, 19.69 - max.
Additional possible setting with SFi option: SFi
factory setting AUT AUT
Important! If Fdc is set to AUT, the value from the welding program database will be
used. If Fdc values are set manually and these values are faster than the wirefeed
speed that was set for the welding operation
Feeder-creep speed = the wirefeed speed that was set for the welding operation
Fdi
Feeder inching
unit m/min ipm.
setting range 1 - max. 39.37 - max.
factory setting 10 393.70
bbc
burn-back time correction
unit s
setting range +/- 0,20
factory setting 0
I-S
I (current) - Starting
unit % of starting current
setting range 0 - 200
factory setting 135
64
Permanently
SL
settable parame-
Slope
ters
(continued) unit s
setting range 0,1 - 9,9
factory setting 1,0
I-E
I (current) - End
unit % of welding current
factory setting 50
Important! The parameters “Starting-current duration” (t-S) and “Final-current duration”

(t-E) are available when a robot interface, or a field bus coupler for robot control, is
connected to the LocalNet.
t-S
time - Starting current
unit s
setting range OFF, 0.1 - 9.9
factory setting OFF
t-E
time - End current
unit s
factory setting OFF
Important! The parameters above are illustrated by a graph in the section headed “MIG/
MAG welding”.
SPt
Spot-welding time ... Spot-welding time
unit s
factory setting 1,0
F
Frequency - for SynchroPuls option
unit Hz
setting range 0,5 - 5
factory setting OFF
dFd
delta Feeder - Welding power offset for the SynchroPuls option (defined by the wirefeed
speed)
unit m/min ipm.
setting range 0,0 - 2,0 .0 - 78.74
65
Permanently
AL.2
settable parame-
Arc-Length correction0.2 - for the upper operating point of the pulsed welding power
ters
where the SynchroPuls option is enabled:
(continued)
unit %
setting range +/- 30 of the welding voltage
factory setting 0
Important! The arc-length correction for the lower operating point is made using Para-
meter AL.1.
tri
Trigger - subsequent correction of operating mode: 2-step, 4-step, special 2-step,
special 4-step and spot-welding
unit -
setting range 2-step, 4-step, special 4-step, spot-welding
factory setting 2-step
Parameters that Important! A correction of the welding power (defined by the wire feed speed) and the
can be corrected arc length - also during welding - can only be carried out from the
at a later time - Comfort control panel
- “US” control panel
- JobMaster welding torch
- RCU 4000 remote control unit
- within the defined boundaries (listed below for the parameters PcH, PcL and AL.c)
As long as the power source is switched on, the corrected parameter values remain
saved. After the power source has been switched on again, the parameters are reset to
the permanently settable values.
“Min.” and “max.” are used for setting ranges that differ according to power source, wire
feed, welding program etc.
PcH
Power correction High ... Correction boundary (high) for the welding power
unit % of the value set for P (see section “permanently settable parame-
ters”)
factory setting 0
66
Parameters that
PcL
can be corrected
Power correction Low - Correction boundary (low) for the welding power
at a later time
(continued) unit % of the value set for P (see section “permanently settable parame-
ters”)
factory setting 0
Important! The parameter P can be decreased by means of the wirefeed speed para-
meter (e.g. from the JobMaster welding torch). The maximum such decrease is by the
value set for PcL.
AL.c
Arc Length.correction - correction boundary for arc length high and low
unit % of the value set for AL.1 (see section “permanently settable
parameters”)
factory setting 0
Important! The parameter AL.c can be increased or decreased by means of the para-
meter arc length correction (e.g. from the JobMaster welding torch). The maximum such
correction is by the value set for AL.1.
JSL
Job Slope - defines the time between the currently selected job and the next one
unit s
setting range OFF or 0.1 - 9.9
factory setting OFF
Job
Job
(2)
Job 1
JSL = OFF
Job 1
JSL = 0.1 - 9.9 s
Job
(2)
Job 1
t (s)
JSL
Fig.45 Job Slope
The value that has been set for Job Slope is stored along with the Job currently se-
lected.
67
Shielding gas set-up menu
General remarks The shielding gas set-up menu offers easy access to the shielding gas settings.
Standard control Accessing the shielding gas set-up menu

panel: Accessing 1. Plug in the mains plug
2. Switch the mains switch (G) to the “I” position
3. Press and hold the store button (21)
4. Press the gas-test button (22)
5. Release the store button (21).
Changing a parameter
6. Use the “Material” button (6) to select the required parameter
7. Use the “Mode” button (5) to alter the value of the parameter
Exiting the set-up menu

8. Press the store button (21)
“Comfort”/“US” Accessing the shielding gas set-up menu

control panel: 1. Plug in the mains plug
Accessing 2. Switch the mains switch (G) to the “I” position
4. Press the gas-test button (22)
5. Release the store button (21).
The power source is now in the shielding gas setup menu - the first parameter GPr (gas
pre-flow time) is displayed.
Changing the parameters

7. Use the “Process” button (4) to select the desired parameter
8. Use the adjusting dial (1) to alter the value of this parameter
Exiting from the Set-up menu

1. Plug in the mains plug 3. Press and hold the store button (21)
2. Switch the mains switch (G) to 4. Press the gas-test button (4)
the “I” position 5. Release the Store button (21) ...
... the last parameter to be
selected is displayed
6. Use the “Process”

button (4) to
select the desired
parameter
7. Use the adjusting dial (1) to alter the
values of the parameters
Fig.46 “Comfort” control panel: Shielding gas set-up menu
68
Gas test parame- “Min.” and “max.” are used for setting ranges that differ according to power source, wire
ter feed, welding program etc.
GPr
Gas pre-flow time
Unit s
Factory setting 0,1
GPo
Gas post-flow time
Unit s
Factory setting 0,5
GPU
Gas Purger
Unit min
Setting range OFF, 0.1 -10.0
Factory setting OFF
Purging of the shielding gas begins as soon as GPU is allocated a value.
For safety reasons, purging of the shielding gas cannot be restarted until a new GPU
value is entered.
Important! Purging with shielding gas is necessary if condensation forms when the
device is left unused in a cold environment for a prolonged period. Long hosepacks are
most affected.
69
Set-up menu: Level 1
General remarks The digital power sources come with a wealth of expert knowledge already built in! You
can retrieve and use any of the optimised parameters stored in the machine whenever
you wish.
The set-up menu provides simple access to this expert knowledge plus some additional
functions. It enables the parameters to be easily adapted to the various tasks.
Standard control Accessing the Set-up menu: Level 1

panel: Accessing 1. Plug in the mains plug
4. Press the “Mode” button (5)
6. Use the “Material” button (6) to select the required parameter
7. Use the “Mode” button (5) to alter the value of the parameter

8. Press the Store button (21)
Standard control Important! The number of parameters available for the “Standard” control panel, and the
panel: Parame- order in which they are arranged, is not the same as in the extended set-up menu
ters structure found on the “Comfort” and “US” control panels.
- GPr ****) - bbc ****) - I-E *****) Options:

- GPo ****) - dYn ****) - FAC ****) - SFI
- Fdc ****) - I-S *****) - 2nd ****) - tS *****)
- Fdi ****) - SL *****) - tE *****)
****)
A complete description of the parameters may be found in the section headed “Process parameters”.
*****)
A complete description of the parameters may be found in the section headed “Operating mode
parameters”.
SFi Spatter Free Ignition option (only where a Push-Pull unit is plugged in and where
the SFI option has been enabled)
“Comfort”/“US” Accessing the Set-up menu for “Process” parameters

control panel: The mode of functioning is explained here with reference to the “MIG/MAG standard
Accessing synergic welding” process. The procedure for changing other “Process” parameters is
identical.

3. Use the “Process” button (4) to select the “MIG/MAG standard synergic welding”
process
5. Press the “Process” button (4)
70
“Comfort” / “US” The power source is now in the set-up menu for the “MIG/MAG standard synergic
control panel: welding” process, and the first parameter GPr (gas pre-flow time) is displayed.
Accessing
(continued) Changing the parameters
7. Use the “Process” button (4) to select the desired parameter


3. With the “Process” button (4) ...
... select the “MIG/MAG standard synergic welding” process

6. Release the Store button (21) ...
... the last parameter to be
selected is displayed
7. Use the
“Process”
button (4) to
select the
desired 8. Use the adjusting dial (1) to alter the values of the
parameter parameters
Fig.47 “Comfort” control panel: Example with the “MIG/MAG standard synergic welding” process
Accessing the Set-up menu for “Mode” parameters

The mode of functioning is explained here with reference to the “Special 4-step” mode.
The procedure for changing other “Mode” parameters is identical.

3. Use the “Process” button (4) to select the “MIG/MAG standard synergic welding” or
“MIG/MAG pulse synergic welding” process
4. With the “Mode” button (5), select the “Special 4-step” mode
71
“Comfort” / “US” 6. Press the “Mode” button (5)
control panel: 7. Release the Store button (21).
Accessing
(continued) The power source is now in the set-up menu for the “Special 4-step” mode, and the first
parameter I-S (starting current) is displayed.
8. Use the “Mode” button (5) to select the desired parameter


3. With the “Process” button (4) ...
... select “MIG/MAG standard synergic ... “MIG/MAG pulse synergic welding”
welding” or ... .
4. With the “Mode” button (5) ...
... select the “Special 4-step” mode

9. Use the adjusting dial (1) to

8. Use the “Mode” button alter the values of the
(5) to select the desired parameters
parameter
Fig.48 “Comfort” control panel: Example with the “Special 4-step” process
“Comfort”/“US” The parameters of the “Set-up menu: Level 1” are described in the following sections:
control panel: “Process parameters” and “Operating mode parameters”.
Parameters
72
Process parameters
MIG/MAG stan- “Min.” and “max.” are used for setting ranges that differ according to power source, wire
dard synergic/ feed, welding program etc.
pulse synergic
welding
GPr
Gas pre-flow time
unit s
setting range 0 - 9,9
factory setting 0,1
GPo
Gas post-flow time
unit s
factory setting 0,5
Fdc
Feeder creep - with SFi option
unit m/min ipm.
setting range AUT, OFF, ON, 0.5 - max. AUT, OFF, ON, 19.69 - max.
factory setting AUT AUT
Important! If Fdc is set to AUT, the value from the welding program database will be
used. If Fdc values are set manually and these values are faster than the wirefeed
speed that was set for the welding operation
Feeder-creep speed = the wirefeed speed that was set for the welding operation
Fdi
Feeder inching
unit m/min ipm.
setting range 1 - max. 39.37 - max.
Important! To facilitate exact positioning of the welding wire, the following sequences
are possible when the welder presses and holds the feeder inching button (23):
- Hold down the button for up to one

second ... Irrespective of what value
“Feeder inching” button
has been set, the wire speed remains
at 1 m/min or 39.37 ipm for the first
Wirefeed speed
second.
(m/min or ipm) - Hold down the button for up to 2.5
Fdi
(e.g. 22) seconds ... After the end of a 1-
second period, the wire speed increa-
ses at a uniform rate over the next 1.5
1 t (s) seconds.
- Hold down the button for longer than
1 2 2,5 3 4 5 2.5 seconds ... After a total of 2.5
seconds, the wire starts to be inched
at a constant rate equal to the speed
Fig.49 Time-path of the wirespeed when the feeder
inching button is pressed and held down set for the parameter “Fdi”.
73
MIG/MAG stan- If you release the feeder inching button (23) and press it again before the end of a 1-
dard synergic/ second period, the sequence starts again from the beginning. This makes it possible to
pulse synergic position the wire continuously at the low wirespeed of 1 m/min or 39.37 ipm when nee-
welding ded.
(continued)
bbc
burn-back time correction
unit s
setting range +/- 0,20
factory setting 0
F
Frequency ... Frequency for the SynchroPuls option:
unit Hz
setting range OFF, 0.5 -5
factory setting OFF
Note! In order to activate SynchroPuls, you must (as a minimum) change the
value of the parameter F (frequency) from OFF to a value of between 0.5 Hz
and 5 Hz.
The parameters and the mode of functioning of SynchroPuls are explained in more detail
in the section headed “MIG/MAG welding”.
dFd
delta Feeder - Welding power offset for the SynchroPuls option (defined by the wirefeed
speed)
unit m/min ipm.
setting range 0,0 - 2,0 .0 - 78.74
AL.2
Arc Length correction0.2 - for the upper operating point of the pulsed welding power
where the SynchroPuls option is enabled
setting range +/- 30
factory setting 0
Important! The arc-length correction for the lower operating point is made using the arc-
length correction parameter (15) (see the section headed “Descriptions of the control
panels”)
dYn
dynamic - arc force correction (only on „Standard“ control panel)
unit 1
setting range +/- 5
factory setting 0
ALS
Arc Length Start - increased welding voltage as striking voltage at welding start-up, for
MIG/MAG standard synergic welding. In conjunction with the Alt parameter explained
below, ALS makes an optimised ignition sequence possible.
factory setting 0
Example:
- ALS = 100 %
- welding voltage currently set: 13 V
- Striking voltage: 13 V + 100 % = 26 V
74
MIG/MAG stan-
ALt
dard synergic/
Arc Length time - time of the arc length increased by ALS. During the ALt time there is a
pulse synergic
continuous decrease in the arc length to the currently set value.
welding
(continued) unit s
setting range 0-5
factory setting 0
FAC
Factory - for resetting the welding machine to factory settings
Press and hold the Store button (21) for 2 s to reset the machine to its original (i.e.
factory) settings. If the display reads “PrG”, then the welding machine has been reset
Important! When the welding machine is reset, all the personal settings in Level 1 of the
set-up menu are lost.
When the welding machine is re-set, jobs are not deleted, but continue to be stored in
the memory. The functions in the second level of the set-up menu (2nd) are not deleted
either. Exception: The “Ignition time-out” parameter (ito).
2nd
Second level of the Set-up menu (see: “Set-up menu: Level 2”)
TIG welding
2nd
Rod electrode Important! When you re-set the welding machine with the “Factory” (FAC) parameter
(MMA) welding (Set-up menu: Level 1), the parameters Hot current time (Hti) and Hot start current
(HCU) will also be re-set.
Hti
Hot-current time
unit s
factory setting 0,5
HCU
Hot-start current
unit %
factory setting 50
2nd
75
Operating-mode parameters
Special 2-step The parameters for the “Special 2-step mode for robot interface” are available when a
mode for robot robot interface or a field bus coupler for robot control are connected to the LocalNet.
interface
I-S
I (current) - Starting: Starting current
factory setting 135
SL
Slope
unit s
factory setting 1,0
I-E
I (current) - End: End current
factory setting 50
t-S
time - Starting current: Duration of starting-current
unit s
factory setting OFF
t-E
time - End current: Duration of final current
unit s
factory setting OFF
Important! The parameters above are illustrated in the section headed “MIG/MAG
welding”.
76
Special 4-step
I-S
mode (aluminium
I (current) - Starting: Starting current
welding start-up)
factory setting 135
SL
Slope: 0.1 - 9.9 s
unit s
factory setting 1
I-E
I (current) - End: End current
setting range 0-200
factory setting 50
Spot welding
SPt
Spot-welding time
unit s
factory setting 1,0
77
Set-up menu: Level 2
General remarks The following functions are located in a second menu level:
- PPU (push-pull unit) - S4t (gun trigger option)
- C-C (cooling unit cut-out) - Gun (“Changing between operating
- Stc (wire-stick - only where there is a modes with the JobMaster torch”
robot interface) option)
- Ito (ignition time-out) - r (measuring the welding circuit
- Arc (arc break watchdog) resistance)
- L (indicating the welding circuit induc-
tivity)
- Eln ( Characteristic selection -not on
“Standard” control panel)
- ASt (Anti-Stick - not on “Standard”
control panel)
A complete list of parameters for “Set-up menu: Level 2” may be found in the section
headed “Parameters 2nd”.
Standard control Changing to the second menu level (2nd)

panel 1. Access Set-up menu: Level 1
2. Select parameter “2nd”
The power source is now in the second level (2nd) of the Set-up menu. The function
“PPU” (push-pull unit) is now displayed.
Selecting the function

6. Use the “Material” button (6) to select the desired function (parameter)
7. Make the settings for this function with the “Mode” button (5)
Exiting from the second menu level (2nd)

“Comfort”/“US” Changing to the second menu level (2nd)

control panel 1. Access Set-up menu: Level 1
The power source is now in the second menu level (2nd) of the Set-up menu. The
function “PPU” (push-pull unit) is now displayed.
Selecting the function

6. Use the “Process” button (4) to select the desired function
7. Set the function with the adjusting dial (1) (see also the sections headed “Push-pull
unit”, “Measuring the welding circuit resistance r” and “Indicating the welding circuit
inductivity L”)
Exiting from the second menu level (2nd)

78
“Comfort” / “US”
control panel 1. Access Set-up menu: Level 1
(continued)

6. Use the
“Process”
7. Set the function with the adjusting dial (1)
button (4) to
select the
desired
function Example where “MIG/MAG
standard synergic welding” is
the selected process
Fig.50 “Comfort” control panel: “Set-up menu: Level 2” for MIG/MAG standard synergic welding
79
Parameters 2nd
MIG/MAG stan- The following parameters are not re-set to the factory settings when the FAC parameter
dard synergic/ is used (see: “Set-up menu: Level 1”):
pulse synergic - PPU - Arc
welding - C-C - S4t
- Stc - Gun
PPU
Push-Pull Unit (see section „Push-pull unit“)
C-C
Cooling unit Control ... Cooling unit control
unit -
setting range Aut, On, Off
factory setting Aut
- Aut ...... The coolant pump cuts out after a 2-minute welding off-time.
Important! If the optional “FK 4000 thermostat” has been installed in the cooling unit, the
coolant pump cuts out as soon as the return-flow temperature has dropped below 50 °C,
but no sooner than after a 2-minute welding off-time.
- On ...... The coolant pump remains switched on.

- Off ...... The coolant pump remains switched off.
Where an FK 9000 cooling unit is being used, the only possible settings are ON and
OFF.
Important! It is possible to set the parameter C-C for the MIG/MAG welding process
irrespective from the TIG welding process.
Example:
- MIG/MAG welding process ... e.g. use of a water-cooled welding torch: C-C = Aut
- TIG welding process ... e.g. use of a gas-cooled welding torch: C-C = Off
C-t
Cooling Time ... Time from when the rate-of-flow watchdog is triggered until the “no |
H2O” service code is output. For example, if air bubbles occur in the cooling system, the
cooling unit will only cut out at the end of this period.
unit s
factory setting 10
Important! Every time the power source is switched on, the cooling unit will do a 180-
second test run.
80
MIG/MAG stan-
Stc
dard synergic/
Wire Stick control
pulse synergic
welding unit -
(continued) setting range OFF, ON
factory setting OFF
The parameters for the wire-stick function (Stc) are available when a robot interface or a
field bus coupler for robot control is connected to the LocalNet.
Important! The wire-stick control (Stc) function is explained in the section headed
“Special 2-step mode for robot interface”.
Ito
Ignition time out: Length of wire that is fed before the safety cut-out is triggered:
unit mm in.
setting range OFF, 5 -100 OFF, 0.20 -3.94
factory setting OFF
Note! The “Ignition time-out” function (ito) is a safety function. Particularly when
the wire is being fed at high wirefeed speeds, the length of wire which is fed
before the safety cut-out is triggered may deviate from the pre-set wire length.
The “Ignition time-out” function (ito) is explained in the section headed “MIG/MAG
welding”.
Arc
Arc break watchdog
unit s
setting range OFF, 0.01 - 2
factory setting 1
Important! The “Arc break watchdog” function (Arc) is explained in the section headed
“MIG/MAG welding”.
FCO
Feeder Control - switching off of wirefeed (wire-end sensor option)
unit -
setting range OFF / ON / noE
factory setting OFF
- OFF .... The power source halts wire feed when the wire-end sensor is triggered.
„Err|056“ appears on the display.
- ON ...... The power sources halts wire feed after completion of the current weld
when the wire-end sensor is triggered. „Err|056“ appears on the display.
- noE ..... The power source does not halt wire feed when the wire-end sensor is
triggered. The wire-end alarm is not displayed and is only transmitted to the robot
control via the field bus.
Important! The setting „noE“ only functions in conjunction with the field bus applications.
Robot interfaces ROB 4000 / 5000 do not support this function.
Dismiss Err | 056:

Insert a new wirespool and feed the welding wire into the hosepack
81
MIG/MAG stan-
SEt
dard synergic/
Setting - Country-specific setting (Standard / USA) ... Std / US
pulse synergic
welding unit -
(continued) setting range Std, US (Standard / USA)
factory setting Standard version: Std (measurements in cm/mm)
USA version: US (measuring properties: in.)
S4t
Special 4-step - Gun trigger option
unit -
setting range 0, 1 (Off, On)
factory setting 1
Important! The “GunTrigger” (S4t) and “Changing between operating modes with the
JobMaster torch” (Gun) options are explained in more detail in the “Job mode” section of
the JobMaster operating instructions.
Gun
Gun (welding torch) - Changing between operating modes with the JobMaster torch
(optional)
unit -
setting range 0, 1 (Off, On)
factory setting 1
S2t
Special 2-step (only on “US” control panel) - for selecting jobs and groups using the
torch trigger
Press 1 x (< 0.5 s) ... next job within a group is selected
Press 2 x (< 0.5 s) ... next group is selected
r
r (resistance) - welding circuit resistance (in mW)
(see the section headed: “Measuring the welding circuit resistance r”)
L
L (inductivity) - welding circuit inductivity (in microhenrys)
(see the section headed: “Measuring the welding circuit inductivity L”)
Operating power
P-C
sources in paral-
Power Control - for defining the Master and Slave power sources when two power
lel
sources are operated in parallel
unit -
setting range On (Master power source), Off (Slave power source)
factory setting OFF
Important! The P-C parameter is only available when two power sources are connected
via an LHSB (Local High-Speed Bus).
82
TimeTwin T-C
Digital pro- Twin Control - for defining the leading and trailing power sources in the TimeTwin Digital
cess process
unit -
setting range On (Leading power source), Off (Trailing power source)
factory setting -
The T-C parameter is only available when two power sources are connected via an
LHSB (Local High-Speed Bus) and the “TimeTwin Digital” option has been enabled.
Important! When a robot interface is connected to the power source, the T-C parameter
can only be adjusted via the robot interface.
TIG welding
C-C
Cooling unit control
unit -
setting range Aut, On, Off
factory setting Aut
- Aut .... The coolant pump cuts out after a 2-minute welding off-time.
Important! If the coolant unit is provided with the optional “temperature limit controller”,
the coolant return-flow temperature is checked all the time. If the return-flow temperature
is less than 50 °C, the cooling unit is switched off automatically.
- On .... The coolant pump remains switched on

- Off .... The coolant pump remains switched off.
If you are using an FK 9000 cooling unit, the only possible settings are ON and OFF.
Important! You can set the C-C parameter for the TIG welding process separately from
the C-C parameter for the MIG/MAG welding process.
Example:
- TIG welding process ... e.g. use of a gas-cooled welding torch: C-C = Off
- MIG/MAG welding process ... e.g. use of a water-cooled welding torch: C-C = Aut
CSS
Comfort Stop Sensitivity - sensitivity of the response characteristic of TIG Comfort Stop
unit -
setting range 0.5 - 5.0, OFF
factory setting OFF
Important! We recommend a value of 2.0. However, if welding frequently stops unex-

pectedly, increase the value of the CSS parameter.
83
TIG welding Depending on the value that has been set for the CSS parameter, the following is re-
(continued) quired for triggering the TIG Comfort Stop function:
0.5 - 2.0 small increase in the size of the arc

2.0 - 3.5 medium increase in the size of the arc
3.5 - 5.0 large increase in the size of the arc
r
r (resistance) - welding circuit resistance (in mΩ)
L
L (inductivity) - welding circuit inductivity (in microhenrys)
Rod electrode
Eln
(MMA) welding
Electrode line ... Characteristic selection function
unit 1
setting range con, 0.1 - 20, P
factory setting con
(1) Load line for rod electrode

con - 20 A / V (2) Load line for rod electrode where arc length is
U (V)
(4) increased
(6) (3) Load line for rod electrode where arc length is
reduced
(5) (1)
(2) (4) Characteristic where “con” parameter is
(3) selected (constant welding current)
(5) Characteristic where “0.1 - 20” parameter is
selected (falling characteristic with adjustable
(7) (8) slope)
(6) Characteristic where “P” parameter is selected
(constant welding power)
(7) Example of pre-set arc force dynamic where
0 100 200 300 400 I (A) characteristic (4) is selected
(8) Example of pre-set arc force dynamic where
characteristic (5) or (6) is selected
Fig.51 Characteristics that can be selected using the Eln function
“con” (constant welding current) parameter

- If the “con” parameter is set, the welding current will be kept constant, irrespective
of the welding voltage. This results in a vertical characteristic (4).
- The “con” parameter is especially suitable for rutile electrodes and basic electrodes,
as well as for gouging.
- For gouging, set the arc-force dynamic to “100”.
Parameter “0.1 - 20” (falling characteristic with adjustable slope)

- Parameter “0.1 - 20” is used to set a falling characteristic (5). The setting range
extends from 0.1 A / V (very steep) to 20 A / V (very flat).
- Setting a flat characteristic (5) is only advisable for cellulose electrodes.
84
Rod electrode Important! When setting a flat characteristic (5), set the arc-force dynamic to a higher
(MMA) welding value.
(continued)
“P” parameter (constant welding power)
- If the “P” parameter is set, the welding power is kept constant, irrespective of the
welding voltage and welding current. This results in a hyperbolic characteristic (6)
(Fig.54).
- The “P” parameter is particularly suitable for cellulose electrodes.
Important! If there are problems with a rod electrode tending to “stick”, set the arc-force
dynamic to a higher value.
(9)
U (V) (a)
60 (6)
(2)
50
(a)
(1)
40 (b)
(5)
(c) (3)
30
20 (c)
(4)
10
(8)
100 200 300 400 I (A)
IH - 50 % IH + arc-force
dynamic
(1) Load line for rod electrode (8) Example of pre-set arc force dynamic where
(2) Load line for rod electrode where arc length is characteristic (5) or (6) is selected
increased (9) Possible change in the current where
(3) Load line for rod electrode where arc length is characteristic (5) or (6) is selected, as a
reduced function of the welding voltage (arc length)
(4) Characteristic where “con” parameter is (a) Operating point where arc-length is long
selected (constant welding current) (b) Operating point where welding current IH is set
(5) Characteristic where “0.1 - 20” parameter is (c) Operating point where arc-length is short
selected (falling characteristic with adjustable
slope)
(6) Characteristic where “P” parameter is selected
(constant welding power)
Fig.52 Settings example: IH = 250 A, arc-force dynamic = 50
The characteristics (4), (5) and (6) shown here apply when using a rod electrode whose
characteristic corresponds - at a given arc length - to the load line (1).
Depending on the welding current (i) set, the point of intersection (operating point) of
characteristics (4), (5) and (6) is displaced along the load line (1). The operating point
provides information on the actual welding voltage and the actual welding current.
Where the welding current (IH) is permanently set, the operating point may migrate along
the characteristics (4), (5) and (6), depending on the welding voltage at that moment in
time. The welding voltage U is dependent upon the length of the arc.
85
Rod electrode If the arc length changes, e.g. in accordance with the load line (2), the resulting opera-
(MMA) welding ting point will be the point where the corresponding characteristic (4), (5) or (6) intersects
(continued) with the load line (2).
Applies to characteristics (5) and (6): Depending upon the welding voltage (arc length),
the welding current (I) will also become either smaller or larger, even though the value
set for IH remains the same
r
r (resistance) - Welding circuit resistance (in mΩ)
L
L (inductivity) - Welding circuit inductivity (in microhenrys)
ASt
Anti-Stick
unit -
setting range On, OFF
factory setting OFF
Uco
U (Voltage) cut-off - Limiting the welding voltage:
unit V
setting range OFF or 5 -95
factory setting OFF
Important! The arc-length is basically dependent upon the welding voltage. In order to
end the welding operation, it is usually necessary to make a pronounced lifting motion of
the rod electrode away from the workpiece. With the “Uco” parameter, the welding
voltage can be limited to a value that makes it possible to end the welding operation
simply by slightly lifting the rod electrode.
Note! If, during welding, you often find that the welding operation is ended
unintentionally, set the “Uco” parameter to a higher value.
86
Push-pull unit
General remarks The push-pull unit must be aligned prior to each initial start-up and each time the wire-
feeder software is updated. If no alignment of the push-pull unit is carried out, the stan-
dard parameters will be used - which may result in the welding result not being satisfac-
tory.
Calibrating the 1. Select the “PPU” function in the

push-pull unit second menu level (2nd).
For an overview of the error messages that may occur during alignment of the push-pull
unit, please refer to “Service codes for push-pull alignment”.
2. Use the adjusting dial (1) (or “Mode”

button (5) on the “Standard” control
panel) to select the relevant push-pull
unit from the following list:
0 ... Fronius unreeling device “VR 1530-22” 22 m/min or 865 ipm *)

1 ... Fronius unreeling device “VR 1530-30” 30 m/min or 1180 ipm (display reads: 1.18) *)
2 ... Fronius robot push-pull “KD Drive” 10m/min *)
3 ... Fronius robot push-pull “Robacta Drive” (Master control) *)
4 ... Fronius robot push-pull “Robacta Drive” (Slave-control)
5 ... Fronius manual push-pull “PullMig” with power potentiometer
6 ... Fronius manual push-pull “PullMig” without power potentiometer
7 ... Binzel manual push-pull 42V” with power potentiometer **)
8 ... Binzel manual push-pull 42V” without power potentiometer **)
9 ... Binzel robot push-pull 42V **)
10 . Binzel robot push-pull 24V **)
11 . Dinse robot push-pull 42V **)
12 . Hulftegger manual push-pull 24 V **)
13 . Fronius “VR 143-2“ intermediate drive
14 . Fronius unreeling device “MS” 22 m/min or 865 ipm *)
16 . “Cobra Gold” manual push-pull 24 V **)
20 . Fronius unreeling device “VR 1530-12” 12 m/min or 470 ipm *)
23 . Binzel robot push-pull 32V **)
24 . Dinse robot push-pull new 42V **)
50 . Fronius manual push-pull “PT Drive” (d=0.8 mm or 0.030 in.; material: aluminium) ***)
53 . Fronius manual push-pull “PT Drive” (d=1.6 mm or 1/16 in; material: aluminium) ***)
54 . Binzel robot push-pull “Master Feeder BG II” *) **) ***)
55 . Fronius “VR 1530 PD” unreeling device (d = 1.0mm or 0.040 in; material: steel) ***)
56 . Fronius “VR 1530 PD” unreeling device (d = 1.2mm or 0.045 in; material: steel) ***)
57 . Fronius “VR 1530 PD” unreeling device (d = 1.6mm or 1/16 in; material: steel) ***)
59 . Fronius manual push-pull “PT Drive” (d=1.0 mm or 0.040 in.; materials: steel, CrNi,
CuSi3) ***)
60 . Fronius manual push-pull “PT Drive” (d=1.2mm or 0.045 in; materials: steel, CrNi) ***)
61 . Fronius manual push-pull “PT Drive” (d=0.8mm or 0.030 in; materials: steel, CrNi) ***)
62 . Binzel robot push-pull 32V with IWG *) **) ***)
*)
......It is not necessary to calibrate the unit under load (St2)
**)
.....Motor and gear tolerances may cause functional anomalies. Calibration may have to be carried out by
Fronius.
***)
... Software must be specially enabled
87
Calibrating the 3. Press the torch trigger or the “Feeder
push-pull unit inching” button
(continued) 4. Disengage the drive units of both
wirefeeder motors (e.g. welding torch
and wirefeeder) - the wirefeeder
motors must not be under load (push-
pull alignment - open circuit)
Caution! Danger from rotating cogs and drive parts. Keep hands away from
rotating cogs and the wire drive.
5. Press the torch trigger or the “Feeder

inching” button
The wirefeeder motors are aligned
while not under load. During the
alignment operation, the right-hand
display will read “run”.
6. As soon as the alignment operation -

in the unloaded state - is complete,
the display will read “St2”.
7. Engage the drive units of both wirefeeder motors (e.g. welding torch and wirefeeder)
once again - the wirefeeder motors must be under load (push-pull alignment -
engaged)
Caution! Danger from welding wire emerging at speed and from rotating cogs
and drive parts. Hold the torch so that it points away from your face and body.
Keep hands away from rotating cogs and the wire drive.
8. Press the torch trigger or the “Feeder

inching” button
The wirefeeder motors are aligned
while under load. During the align-
ment operation, the right-hand display
will read “run”.
If it is not necessary to perform the

alignment on a push-pull unit while
this unit is under load (St2), the
previously set values - e.g. “PPU” and
“5” - will appear on the display as
soon as you press the torch trigger or
the “Feeder inching” button.
9. The alignment operation on the push-

pull unit is finished when the previous-
ly set values - e.g. “PPU” and “5” -
reappear on the display.
10. Press the Store button twice to exit
from the Set-up menu.
88
Calibrating the
push-pull unit
(continued)
- Access Set-up menu: Level 1
- Select “Parameter 2nd”
- Press and hold the Store button (21)

- Press the “Process” button (4)
- Release the Store button (21).
1. Select the “PPU” function
2. With the adjusting dial (1),

select the relevant push-pull 3. Press the torch trigger or the
unit “Feeder inching” button (23) ...
... “St1” is shown on the display

4. Disengage the
drive units
5. Press the torch trigger or the

“Feeder inching” button (23) ...
... “St1 | run” is shown on the display
6. “St2” is shown on the display

7. Engage the drive units
8. Press the torch trigger or the

“Feeder inching” button (23) ...
... “St2 | run” is shown on the display
9. The alignment
operation on the push-
pull unit is finished
Fig.53 “Comfort” control panel: Aligning the push-pull unit
89
Service codes for push-pull calibration
Safety
Warning! An electric shock can be fatal. Before opening up the machine
- Switch the mains switch to the “O” position
- Unplug machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrical-
ly charged components (e.g. capacitors) have been discharged
Error codes Err | Eto

shown when the
drive units are Cause: Incorrect measurement during push-pull alignment.
engaged (“enga- Remedy: Repeat push-pull alignment
ged” calibration)
St1 | E 1
Cause: At minimum wirefeed speed, the wirefeeder motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull alignment. If the error message re-appears: Contact
After-Sales Service
St1 | E 2
Cause: At maximum wirefeed speed, the wirefeeder motor does not deliver any
After-Sales Service.
St1 | E 3
St1 | E 4
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver
any actual rotational speed value.
St1 | E 5
St1 | E 6
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
90
Error codes
St1 | E 16
shown when the
drive units are Cause: Push-pull alignment has been interrupted: Quick-stop was activated by
engaged (“enga- pressing the torch trigger.
ged” calibration) Remedy: Repeat push-pull alignment
St2 | E 7
Cause: “Push-pull alignment - open-circuit” has not been carried out
Remedy: Carry out “push-pull alignment - open-circuit”
St2 | E 8
St2 | E 9
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver
any actual rotational speed value.
St2 | E 10
Cause: At minimum wirefeed speed, the motor current of the wirefeeder motor is
outside the permitted range. Possible causes of this include the wirefeeder
motors not being engaged, and other wirefeed problems.
Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in
as straight a line as possible; check the inner liner for kinks or soiling;
check the contact pressure on the 2-roller or 4-roller drive of the push-pull
unit.
Repeat the push-pull alignment. If the error message re-appears: Contact
St2 | E 11
Cause: At minimum wirefeed speed, the motor current of the push-pull unit is
unit.
St2 | E 12
St2 | E 13
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
After-Sales Service (faulty actual-value pick-up)
91
Error codes
St2 | E 14
shown when the
drive units are Cause: At maximum wirefeed speed, the motor current of the wirefeeder motor is
engaged (“enga- outside the permitted range. Possible causes of this include the wirefeeder
ged” alignment) motors not being engaged, and other wirefeed problems.
(continued) Remedy: Engage the drive units of both wirefeeder motors, arrange the hosepack in
unit.
After-Sales Service
St2 | E 15
Cause: At maximum wirefeed speed, the motor current of the push-pull unit is
unit.
St2 | E 16
Cause: Push-pull alignment has been interrupted: Quick-stop was activated by
pressing the torch trigger.
Remedy: Repeat push-pull alignment
92
Measuring the welding circuit resistance “r”
General remarks Measuring the welding circuit resistance “r” makes it possible to have a constant welding
result at all times, even with hosepacks of different lengths. The welding voltage at the
arc is then always precisely regulated, regardless of the length and cross-sectional area
of the hosepack. It is no longer necessary to adjust with the “Arc length correction”
parameter (15).
After it has been measured, the welding circuit resistance is indicated on the right-hand
display.
r ... Welding circuit resistance (in mΩ)
If the welding circuit resistance “r” has been measured correctly, the welding voltage will
correspond exactly to the welding voltage at the arc. If you manually measure the volta-
ge on the output jacks of the power source, this voltage will be higher than the welding
voltage at the arc - that is, higher by the same amount as the voltage-drop taking place
in the hosepack.
Note! The welding circuit resistance “r” will depend upon which hosepack is
being used. This means that the measurement to find out the welding circuit
resistance “r” will have to be:
- repeated if there is any change in the length or cross-sectional area of the
hosepack
- repeated if there is any change in the length or cross-sectional area of the
hosepack
Measuring the 1. Make a ground (earth) connection to the workpiece

welding circuit
resistance “r” Note! In order to obtain good welding results, it is essential to measure the
welding circuit resistance correctly. Make sure that the contact between the
grounding (earthing) clamp and the workpiece is on a clean part of the workpiece.

4. Select function “r” in the second menu level (2nd)
5. Take off the gas nozzle from the welding torch

6. Tighten the contact tube
7. Place the contact tube down firmly on the surface of the workpiece
Note! Make sure that the contact between the contact tube and the workpiece is
on a clean part of the workpiece. While the measurement is being performed,
the wirefeeder and the cooling unit are deactivated.
8. Briefly press the torch trigger or the “Feeder inching” button.

The welding circuit resistance is now calculated; during the measurement, the right-
hand display reads “run”.
93
Measuring the 9. The measurement is finished when the welding circuit resistance is shown on the
welding circuit right-hand display (e.g. 11.4 milliohms)
resistance “r”
(continued)
10. Fit the gas nozzle back onto the welding torch
94
Indicating the welding circuit inductivity L
Indicating the The way that the hosepack is arranged has a very significant effect on the welding
welding circuit properties. Particularly with MIG/MAG pulse synergic welding, a high welding circuit
inductivity L inductivity may occur, depending on the length of the hosepack and the way it is arran-
ged. The result is that the current rise during the droplet transfer is limited.
The welding circuit inductivity L is calculated during welding and shown on the right-hand
display.
- Select function “L” in the second menu level (2nd)
L ... Welding circuit inductivity (in microhenrys)
Important! Wherever possible, compensation for the welding circuit inductivity is perfor-
med automatically. Where very high welding circuit inductivity occurs, it is also possible
to attempt to influence the welding results with the droplet detachment correction para-
meter (16). If this does not lead to the desired result, you must re-arrange the hosepack.
Correct arrange-
ment of the
hosepack
Fig.54 Correct arrangement of the hosepack
95
Troubleshooting
General remarks The digital power sources are equipped with an intelligent safety system. This means
that apart from the fuse for the coolant-pump, it has been possible to dispense with
melting-type fuses entirely. After a possible malfunction or error has been remedied, the
power source can be put back into normal operation again without any melting-type
fuses having to be changed.

Caution! Inadequate PE conductor connections can cause serious injury and

damage. The housing screws provide a suitable PE conductor connection for
grounding (earthing) the housing and must NOT be replaced by any other
screws that do not provide a reliable PE conductor connection.
Displayed service If any error message that is not described here appears on the displays, then the fault is
codes one that can only be put right by a service technician. Make a note of the error message
shown in the display, and of the serial number and configuration of the power source,
and get in touch with our after-sales service, giving them a detailed description of the
error.
-St | oP-
Where the power source is being operated with a robot interface or a field bus
Cause: Robot not ready
Remedy: Initialise “Robot ready” signal, initialise “Source error reset” signal (N.B.
“Source error reset” only available in conjunction with ROB 5000 and field-
bus coupler for robot control)
dsP | A21
Can only occur when power sources are being operated in parallel or in “Twin” mode
Cause: The power source is configured for either parallel operation (set-up parame-
ter P-C is set to “ON”) or for TimeTwin Digital (set-up parameter T-C is set
to “ON”). However, the LHSB link has been disconnected, or has become
faulty, while the power source was switched on.
Remedy: Dismiss the service code: Switch the power source off and back on again.
If necessary, restore or repair the LHSB link.
dSP | Axx, dSP | Cxx, dSP | Exx, dSP | Sy, dSP | nSy
Cause: Fault in central control and regulation unit
Remedy: Contact After-Sales Service
96
Displayed service
EFd | xx.x, EFd | 8.1
codes
(continued) Cause: Fault in the wirefeed system (overcurrent in wirefeeder drive)
Remedy: Arrange the hosepack in as straight a line as possible; check that there
are no kinks or dirt in the inner liner; check the contact pressure on the 2-
roller (or 4-roller) drive
Cause: Wirefeeder motor is stuck or defective

Remedy: Check / change the wirefeeder motor
EFd | 8.2
Cause: Fault in the wirefeed system (overcurrent in drive of push-pull unit)
Remedy: Arrange the hosepack in as straight a line as possible; check the inner
liner for kinks or soiling; check the contact pressure on the 2-roller or 4-
roller drive of the push-pull unit
EFd | 9.1
Cause: External supply voltage: Supply voltage has dropped below the tolerance
range
Remedy: Check the external supply voltage
Cause: Wirefeeder motor is stuck or defective

Remedy: Check / change the wirefeeder motor
EFd | 9.2
Cause: External supply voltage: Supply voltage has risen above the tolerance range
Remedy: Check the external supply voltage
EFd | 12.1
Cause: No actual rotational speed value from the wirefeeder motor
Remedy: Check the actual-value pick-up and the cable connections to and from it,
and replace if necessary
EFd | 12.2
Cause: No actual rotational speed value from the motor of the push-pull unit
Remedy: Check the actual-value pick-up and the cable connections to and from it,
and replace if necessary
EFd | 15.1 Wire buffer not reached

Cause: counter lever on main wirefeeder open
Remedy: close counter lever on main wirefeeder
Acknowledge service code by pressing “feeder inching” button
Cause: main wirefeeder slipping

Remedy: check wearing parts on wire feeder
use suitable feed rollers
decrease wire braking force
increase contact pressure on main wirefeeder
acknowledge service code by pressing “Feeder inching” button
Cause: end of wire reached

Remedy: check whether sufficient wire available
acknowledge service code using “Feeder inching” button
97
Displayed service
EFd | 15.2 Wire buffer exceeded
codes
(continued) Cause: counter lever on push-pull unit open
Remedy: close counter lever on push-pull unit
acknowledge service code by pressing “feeder inching” button
Cause: push-pull unit slipping

Remedy: check wearing parts for wire inching
use suitable feed rollers
increase contact pressure on the push-pull unit
acknowledge service code by pressing the “Feeder inching” button”
Cause: arc not igniting

Remedy: select wire diameter and material type in accordance with material used
check earth connection
acknowledge service code by pressing “Feeder inching” button
Cause: end of wire reached

Remedy: check whether sufficient wire available
acknowledge service code using “Feeder inching” button
EFd | 15.3 No wire buffer available

Cause: connection to wire buffer missing
Remedy: check connection to wire buffer
EFd | 30.1
Cause: LHSB connection to power source missing
Remedy: check LHSB connection to power source
EFd | 30.3
Cause: LHSB connection to CMT drive unit missing
Remedy: check LHSB connection to CMT drive unit
EFd | 31.1
Cause: CMT drive unit - rotor calibration failed
Remedy: switch power source off and on again; if the service code “EFd | 31.1”
remains, switch off power source, disengage CMT drive unit and switch
power source back on again; if still unsuccessful, contact After-Sales
Service
EFd | 31.2
Cause: CMT drive unit - rotor calibration running
Remedy: wait for rotor calibration to finish
EiF XX.Y
The values XX and Y should be taken from the Operating Instructions for Robot Inter-
face
Cause: Interface error
Remedy: See Operating Instructions for Robot Interface
Err | 049
Cause: Phase failure
Remedy: Check the mains fuse protection, the mains supply lead and the mains
plug
Err | 050
Cause: Intermediate circuit-balance error
98
Displayed service
Err | 051
codes
(continued) Cause: Mains undervoltage: The mains voltage has dropped below the tolerance
range
Remedy: Check the mains voltage
Err | 052
Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check the mains voltage
Err | 054
Cause: “Sticking” of the wire in the solidifying weld pool
Remedy: Cut off the sticking wire-tip; there is no need to dismiss this error message
Err | 056
Cause: The “Wire-end check” option has detected the end of the welding wire
Remedy: Insert a new wire spool and feed the wire into the hosepack; dismiss Err |
056 by pressing the Store button (21)
Cause: Additional fan filter of the VR 1500 - 11 / 12 / 30 is contaminated -air supply

for the additional fan is no longer sufficient for cooling the power electronics
-the power electronics temperature switch has responded
Remedy: Clean filter or replace; dismiss Err | 056 by pressing the Store button (21)
Cause: Excessive ambient temperature on the VR 1500 - 11 / 12 / 30

Remedy: Reduce ambient temperature, if necessary position and operate welding
machine at a cooler location; dismiss Err | 056 by pressing the Store
button (21)
Cause: Excessive motor current on the VR 1500 - 11 / 12 / 30, e.g. due to wire feed
problems or an adequately dimensioned feed
Remedy: Check wire feed conditions, rectify errors; dismiss Err | 056 by pressing
the Store button (21)
Cause: Wire feeder cover VR 1530 open or interlock release handles not snapped
into place
Remedy: Close wire feeder cover VR 1530 properly, dismiss Err | 056 by pressing
the Store button (21)
Err | 062
„E62“ is displayed simultaneously on remote controller TP 08
Cause: Overheating of remote controller TP 08
Remedy: Allow remote controller TP 08 to cool down
Err | 069
Cause: Illegal mode change during welding
Remedy: Re-start welding procedure
Err 70.X
Cause: Fault in digital gas sensor
Err 70.1 ... Gas sensor not found
Err 70.2 ... No gas
Err 70.3 ... Calibration error
Err 70.4 ... Solenoid valve faulty
Err 70.5 ... Solenoid valve not found
Remedy: Check gas supply
99
Displayed service
Err 71.X
codes
Set limits have been exceeded or have not been reached.
(continued)
Cause: Err 71.1 ... Current limit exceeded
Err 71.2 ... Current limit not reached
Err 71.3 ... Voltage limit exceeded
Err 71.4 ... Voltage limit not reached
Remedy: Check quality of weld seam
Err | bPS
Cause: Fault in power module
Err | Cfg
Can only occur when power sources are being operated in parallel or in “Twin” mode
Cause: Power source is configured for parallel operation (set-up parameter P-C is
set to “ON”) or TimeTwin Digital (set-up parameter T-C is set to “ON”).
However, after being switched on, the power source was unable to estab-
lish an LHSB link (LHSB link was previously detached or became faulty).
Remedy: Dismiss the service code: Switch the power source off and back on again.
If necessary, restore or repair the LHSB link.
Err | IP
Cause: Primary overcurrent
Err | PE
Cause: The earth fault-current watchdog has triggered the safety cut-out of the
power source.
Remedy: Switch off the power source, wait for 10 seconds and then switch it on
again. If you have tried this several times and the error keeps on occurring
- contact After-Sales Service.
Err tJo
Cause: Jobmaster temperature sensor faulty
hot | H2O
Cause: Thermostat on cooling unit has been tripped
Remedy: Wait until the end of the cooling phase, i.e. until “Hot | H2O” is no longer
displayed. ROB 5000 or field-bus coupler for robot control: Before resu-
ming welding, initialise the “Source error reset” signal.
no | Arc
Cause: Arc-break
Remedy: Shorten the wire stickout; press the torch trigger repeatedly; clean the
surface of the workpiece
no | GAS
Cause: The “Gas watchdog” option has detected that there is no gas pressure
Remedy: Connect a new gas cylinder and open the gas cylinder valve/pressure
regulator;
Dismiss no | GAS by pressing the Store button
100
Displayed service
no | IGn
codes
(continued) Cause: “Ignition time-out” function is active: No current started flowing before the
length of wire specified in the set-up menu had been fed. The safety cut-out
of the power source has been triggered.
Remedy: Shorten the wire stickout; press the torch trigger repeatedly; clean the
surface of the workpiece; if necessary, increase the setting in “Set-up
menu: Level 2” for the length of wire that is fed before the safety cut-out is
triggered.
no | H2O
Cause: Cooling-unit flow watchdog has been triggered
Remedy: Check the cooling unit; if necessary, top up the coolant and/or vent the
water forward-flow hose as described in “Putting the cooling unit into
service”. Then dismiss the error by pressing the “Store” button.
no | Prg
Cause: No pre-programmed program has been selected
Remedy: Select a pre-programmed program
r | E30
Cause: r-Alignment: There is no contact with the workpiece.
Remedy: Connect the grounding (earthing) cable; ensure a tight connection
r | E31
Cause: r-Alignment: Procedure has been interrupted by repeated pressing of the
torch trigger.
Remedy: Ensure a tight connection between the contact tube and the workpiece -
press the torch trigger once only.
r | E32
Cause: r-Alignment: Grounding (earthing) cable, current cable or hosepack defecti-
ve (value is below 0.5 mOhm or exceeds 30 mOhm)
Remedy: Check grounding (earthing) cable, current cable and/or hosepack, and
change if necessary
r | E33, r | E34
Cause: r-Alignment: Poor contact between the contact tube and the workpiece.
Remedy: Clean the point of contact, tighten the contact tube, check the grounding
(earthing) connection
tJO | xxx
At the same time, “E66” is displayed on the JobMaster
Remark: xxx stands for a temperature value
Cause: Overtemperature in Jobmaster welding torch
Remedy: Allow the torch to cool, then dismiss the error by pressing the “Store”
button
tP1 | xxx, tP2 | xxx, tP3 | xxx, tP4 | xxx, tP5 | xxx, tP6 | xxx
Cause: Over-temperature in the primary circuit of the power source
Remedy: Allow the power source to cool down
tS1 | xxx, tS2 | xxx, tS3 | xxx

Cause: Over-temperature in the secondary circuit of the power source
101
Power source -
tSt | xxx
troubleshooting
Cause: Over-temperature in the control circuit
Power source does not function

Mains switch is ON, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains supply lead, make sure that the mains plug is plugged in
Cause Mains outlet socket or plug is faulty

Remedy: Exchange faulty components
Power source does not function

Mains switch is ON, but indicators are not lit up
Cause: Mains fuse is faulty
Remedy: Change the mains fuse
No welding current
Mains switch is ON, overtemperature indicator is lit up
Cause: Overloading; the duty cycle has been exceeded
Remedy: Do not exceed the duty cycle
Cause: Thermostatic cut-out system has been tripped

Remedy: Wait until the power source automatically comes back on after the end of
the cooling phase
Cause: The fan in the power source is defective

Remedy: Change the fan
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is wrong
Remedy: Check the grounding (earthing) connection and clamp for correct polarity
Cause: There is a break in the current cable in the welding torch

Remedy: Exchange the torch
The machine does not function when the torch trigger is pressed
Cause: The control plug is not plugged in
Remedy: Plug in the control plug
Cause: The welding torch or torch control lead is defective

Remedy: Exchange the torch
The machine does not function when the torch trigger is pressed
Cause: the interconnecting hosepack is defective or not connected properly (not in
the case of TPS 2700)
Remedy: check interconnecting hosepack
102
Power source -
No shielding gas
troubleshooting
All other functions are OK
(continued)
Cause: The gas cylinder is empty
Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty

Remedy: Change the gas pressure regulator
Cause: The gas hose is not mounted, or is damaged

Remedy: Mount / change the gas hose
Cause: The welding torch is defective

Remedy: Change the welding torch
Cause: The gas solenoid valve is defective

Remedy: Change the gas solenoid valve
Poor welding properties

Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor grounding (earthing) connection

Remedy: Ensure good contact to workpiece
Cause: Not enough shielding gas, or none at all

Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas
connection etc.
Cause: Welding torch is leaking

Remedy: Change the welding torch
Cause: Wrong contact tube, or contact tube is worn out

Remedy: Change the contact tube
Cause: Wrong wire alloy and/or wrong wire diameter

Remedy: Check the wire spool that has been inserted
Cause: Wrong wire alloy and/or wrong wire diameter

Remedy: Check the weldability of the base metal
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
Irregular wirefeed speed

The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the
welding torch
Cause: The braking force has been set too high
Remedy: Loosen the brake
Cause: The borehole of the contact tube is too narrow

Remedy: Use a suitable contact tube
Cause: The wirefeed inner liner in the welding torch is defective

Remedy: Check the wire inner liner for kinks, dirt etc.
103
Power source -
Irregular wirefeed speed
troubleshooting
The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the
(continued)
welding torch
Cause: The wirefeed rollers are unsuitable for the wire being used
Remedy: Use suitable wirefeed rollers
Cause: The wirefeed rollers have the wrong contact pressure

Remedy: Optimize the contact pressure
The welding torch becomes very hot

Cause: The design dimensions of the torch are not sufficient for this task
Remedy: Respect the duty cycle and loading limits
Cause: Only on water-cooled machines: Water through-flow is insufficient

Remedy: Check the coolant level, through-flow rate, cleanliness of coolant etc.
104
Care, maintenance and disposal
General remarks Under normal operating conditions the power source requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the
welding machine remains in a usable condition for many years.

Every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and
grounding (earthing) connection for damage
- Check whether the allround distance of 0.5 m (1 ft 8 in.) is kept to ensure that the
cooling air can easily flow and escape.
Note! Furthermore, air inlets and outlets must in no case be covered, not even
covered partly.
Every 2 months - Optional: clean air filter
Every 6 months - Dismantle machine side panels and clean machine inside with dry reduced com-
pressed air
Note! Risk of damage to electronic components. Clean electronic components

from a certain distance only.
- If a lot of dust has accumulated, clean the cooling-air ducts.
Disposal Carry out disposal in accordance with the valid national and local regulations.
105
Technical data
Special voltages For machines designed for special voltages, the technical data on the rating plate ap-
plies.
For all machines with a permitted mains voltage of up to 460 V: the mains plug supplied
as standard allows operation at voltages of up to 400 V. For mains voltages up to 460 V,
fit an approved mains plug or install the mains supply directly.
TPS 2700 Mains voltage 3 x 400 V

Mains voltage tolerance ± 15 %
Power frequency 50 / 60 Hz
Mains fuse protection 16 A slow-blow
Primary continuous current (100 % d.c.) 6.6 A
Primary continuous power 4.5 - 8.7 kVA
Cos phi 0,99
Degree of efficiency 87 %
Welding current range:
MIG/MAG 3 - 270 A
Rod electrode (MMA) 10 - 270 A
TIG 3 - 270 A
Welding current at 10 min/40°C (104°F) 40 % d.c. 270 A
60 % d.c. 210 A
100 % d.c. 170 A
Welding voltage range according to standard characteristic
MIG/MAG 14.2 - 27.5 V
Rod electrode (MMA) 20.4 - 30.8 V
TIG 10.1 - 20.8 V
Max. welding voltage -
Open-circuit voltage 50 V
Protection IP 23
Type of cooling AF
Insulation class B
Marks of conformity CE, CSA
Safety S
Measurements l x b x h 625 x 290 x 475 mm
24.6 x 11.4 x 18.7 in.
Weight 27 kg
59.5 lb.
106
TPS 2700 MV Mains voltage 3 x 200-240 V
3 x 380-460 V
Power frequency 50/60 Hz
Mains fuse protection 25/16 A slow-blow
Primary continuous current (100 % d.c.) 6.4 -14.2 A
Cos phi 0,99
Degree of efficiency 88 - 91 %
Welding current range
MIG/MAG 3 - 270 A
TIG 3 - 270 A
60 % d.c. 210 A
100 % d.c. 170 A
MIG/MAG 14.2 - 27.5 V
TIG 10.1 - 20.8 V
Protection IP 23
Type of cooling AF
Insulation class B
Safety S
24.6 x 11.4 x 18.7 in.
Weight 27 kg
59.5 lb.
107
TPS 3200 Mains voltage 3 x 400 V
Power frequency 50/60 Hz
Cos phi 0,99
MIG/MAG 3 -320 A
Rod electrode (MMA) 10 -320 A
TIG 3 -320 A
60 % d.c. 260 A
100 % d.c. 220 A
MIG/MAG 14.2 - 30.0 V
TIG 10.1 - 22.8 V
Max. welding voltage (320 A) 52,1
Degree of protection IP 23
Type of cooling AF
Insulation class F
Marks of conformity CE
Safety S
Dimensions l x b x h 625 x 290 x 475 mm
24.6 x 11.4 x 18.7 in.
Weight 35.6 kg
35.61 lb.
108
TPS 3200 MV Mains voltage 3 x 200-240 V
3 x 380-460 V
Cos phi 0,99
MIG/MAG 3 -320 A
TIG 3 -320 A
60 % d.c. 260 A
100 % d.c. 220 A
MIG/MAG 14.2 - 30.0 V
TIG 10.1 - 22.8 V
Max. welding voltage (320 A) 49.1 -63.1 V
Open-circuit voltage 64 -67 V
Degree of protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 35.6 kg
78.5 lb.
109
TS/TPS 4000 Mains voltage 3 x 400 V
Primary continuous current (100 % d.c.) -
Primary continuous power 12.2 kVA
Cos phi 0,99
MIG/MAG 3 -400 A
TIG 3 -400 A
60 % d.c. 365 A
100 % d.c. 320 A
MIG/MAG 14.2 - 34.0 V
TIG 10.1 - 26.0 V
Protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 35.2 kg
77.6 lb.
110
TS/TPS 4000 MV Mains voltage 3 x 200-240 V
3 x 380-460 V
Primary continuous current (100 % d.c.) 15.3 - 34.4 A
Cos phi 0,99
MIG/MAG 3 - 400 A
TIG 3 - 400 A
60 % d.c. 365 A
100 % d.c. 280 - 320 A
MIG/MAG 14.2 - 34.0 V
TIG 10.1 - 26.0 V
Open-circuit voltage 68 - 78 V
Protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 35.2 kg
77.6 lb.
111
TS/TPS 5000 Mains voltage 3 x 400 V
Primary continuous current (100 % d.c.) 18 - 29.5 A
Cos phi 0,99
MIG/MAG 3 - 500 A
TIG 3 -500 A
60 % d.c. 450 A
100 % d.c. 360 A
MIG/MAG 14.2 - 39.0 V
TIG 10.1 - 30.0 V
Protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 35.6 kg
78.5 lb.
112
TS/TPS 5000 MV Mains voltage 3 x 200-240 V
3 x 380-460 V
Primary continuous current (100 % d.c.) 10.1 - 36.1 A
Cos phi 0,99
MIG/MAG 3 - 500 A
TIG 3 - 500 A
60 % d.c. 450 A
100 % d.c. 320 - 340 A
MIG/MAG 14.2 - 39.0 V
TIG 10.1 - 30.0 V
Open-circuit voltage 68 - 78 V
Protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 35.6 kg
78.5 lb.
Technical data - See TPS 2700 MV / 3200 MV / 4000 MV / 5000 MV

US power source
Technical data The technical data of the Alu-Edition, CrNi-Edition and CMT special versions are identi-
Alu-Edition, CrNi- cal to those of the standard power sources.
Edition and CMT
variants
113
TIME 5000 Digital Mains voltage 3 x 380-460 V
Primary continuous current (450 A, 60 % d.c.) 32.5 A
Cos Phi (500 A) 0,99
Welding current range
TIME 3 - 500 A
MIG/MAG 3 - 500 A
TIG 3 - 500 A
60 % d.c. 450 A
100 % d.c. 360 A
TIME 28.0 - 48.0 V
MIG/MAG 14.2 - 39.0 V
TIG 10.1 - 30.0 V
Protection IP 23
Type of cooling AF
Insulation class F
Safety S
24.6 x 11.4 x 18.7 in.
Weight 37.4 kg
82.45 lb.
114
Welding program databases
Explanation of The key symbols for the welding program databases are explained below. The databa-
symbols ses contain the welding programs depending on the following settings on the control
panel:
- Operating mode:
P = pulse synergic welding
S = standard synergic welding
Example:
- Material (A)
- Wire diameter (B)
(D) (C) (B)
(A)
Fig.55 Example of a welding database
Welding programs that require the SFi (spatter free ignition) option have a grey back-
ground.
- Example:
Every welding database has

- The date of the last change (C)
- A number (D)
115
Terms and abbreviations used
General remarks The terms and abbreviations listed here are used in connection with functions that are
either included in the standard scope of supply or that are available as optional extras.
Terms and abbre- AL.c .... Arc length.correction ... Correction boundaries (high and low) for the arc length
viations (JobCorrection function)
AL.1 .... Arc length correction.1 ... General arc-length correction (JobCorrection function)
AL.2 .... Arc length correction.2 ... Arc length correction for the higher operating point of
the pulsed welding power (SynchroPuls)
Arc ...... Arc ... Arc-break monitoring
ASt ...... Anti-stick ... For reducing the effect of a “sticking” rod electrode (MMA welding)
bbc ..... burn-back time correction
C-C ..... Cooling unit cut-out. In position “Aut“, it is switched off automatically as a func-
tion of the coolant temperature. In position “On“ / “Off“, the cooling unit remains
always switched-on/switched-off. Separate adjustment for the MIG/MAG and
TIG processes is supported.
CSS .... Comfort stop sensitivity ... sensitivity of the response characteristic of the TIG
Comfort Stop function. The TIG Comfort Stop function supports the TIG welding
process without torch trigger. A down-slope is triggered by briefly lifting or
lowering the welding torch (ramp decrease of the welding current).
C-t ...... Cooling time ... Time from when the rate-of-flow watchdog is triggered until the
“no | H2O” service code is output
dFd ..... delta Feeder ... Welding-power offset (SynchroPuls - defined by the wirefeed
speed)
dYn ..... Dynamic ... Arc-force dynamic correction (standard arc) or pulse correction
(pulsed arc) (JobCorrection option, i.e. background setting of the arc-force
dynamic or pulse correction for the “Standard” control panel)
Eln ...... Electrode-line ... Characteristic selection (rod electrode [MMA] welding)
F ......... Frequency ... (SynchroPuls)
FAC .... Factory ... Reset the welding machine
FCO .... Feeder Control ... Wirefeeder cut-out (“Wire-end sensor” option)
Fdc ..... Feeder creep ... Soft start
Fdi ...... Feeder inching ... inching speed
GPo .... Gas post-flow time
116
Terms and GPr ..... Gas pre-flow time
abbreviations
(continued) Gun .... Gun (welding torch) ... “Changing between operating modes with the JobMaster
torch” (optional) ... 0 / 1
HCU ... Hot-start current ... (for rod electrode [MMA] welding)
Hti ....... Hot current time ... (for rod electrode [MMA] welding)
I-E ....... I (current) - End ... End current
I-S ....... I (current) - Starting ... Starting current
Ito ....... Ignition Time-Out
Job ..... Job for which the parameters are to be adjusted (JobCorrection function)
JSL ..... Job Slope ... defines the time between the Job that is currently selected and the
next following Job
L ......... L (inductivity) ... Indicating the welding-circuit inductivity
P ......... Power correction ... (defined by the wirefeed speed, JobCorrection function)
P-C ..... Power Control ... for defining the Master and Slave power sources when two
power sources are operated in parallel
PcH .... Power-correction High ... Correction boundary (high) for the welding power
(JobCorrection function)
PcL ..... Power-correction Low ... Correction boundary (low) for the welding power
(JobCorrection function)
PPU .... Push-pull unit ... For selecting and aligning the connected push-pull unit
r .......... r (resistance) ... Measuring the welding-circuit resistance
SEt ..... Setting ... Country-specific setting (Standard / USA)
SL ....... Slope
Spt ...... Spot-welding time
Stc ...... Wire stick control ... For detecting a “stuck” wire tip
S2t ...... Special 2-Step (only on “US” control panel) ... for selecting Jobs and Groups by
pressing the torch trigger
S4t ...... Special 4-step ... GunTrigger option, switching from one job to the next from the
JobMaster welding torch; is also the symbol for the “Special 4-step” mode on the
Jobmaster torch
t-C ...... Twin Control ... for defining the leading and trailing power sources in the Ti-
meTwin Digital process
t-E ....... time - End current ... Duration of final current
t-S ....... time - Starting current ... Duration of starting-current
tri ........ Trigger ... Subsequent correction of the operating mode
117
Terms and Uco ..... U (voltage) cut-off ... Limiting the welding voltage in the case of rod-electrode
abbreviations welding. Makes it possible to stop the welding process by slightly raising the rod
(continued) electrode.
2nd ..... Second level of set-up menu
118
D Ersatzteilliste
GB Spare Parts List
F Liste de pièces de rechange
I Lista parti di ricambio
E Lista de repuestos
P Lista de peças sobresselentes
NL Onderdelenlijst
N Reservdelsliste
CZ Seznam náhradních dílů
RUS Ñïèñîê çàïàñíûõ ÷àñòåé
ud_fr_st_tb_00150 012002
TransPulsSyn. 2700 4R/Z 4,075,095
TransPulsSyn. 2700 4R/E 4,075,095,001
TransPulsSyn. 2700 4R/D 4,075,095,002
MV
TransPulsSyn. 2700 MV/4R/Z 4,075,095,630
TransPulsSyn. 2700 MV/4R/E 4,075,095,631
ALU - Edition
TransPulsSyn. 2700 4R/Z/ALU 4,075,095,633
TransPulsSyn. 2700 4R/E/ALU 4,075,095,634
MV / ALU - Edition
TransPulsSyn. 2700 MV/4R/Z/ALU 4,075,095,635
TransPulsSyn. 2700 MV/4R/E/ALU 4,075,095,636
CrNi
TransPulsSynerg.2700 4R/Z CrNi 4,075,095,856
TransPulsSynerg.2700 4R/E CrNi 4,075,095,857
MV / CrNi
TransPulsSynerg.2700 MV/4R/Z CrNi 4,075,095,858
TransPulsSynerg.2700 MV/4R/E CrNi 4,075,095,859
DUO / TIG
TransPulsSyn. 2700 4R/Z TIG 4,075,095,850
TransPulsSyn. 2700 4R/Z DUO 4,075,095,851
TransPulsSyn. 2700 4R/Z DUO/TIG 4,075,095,852
TransPulsSyn. 2700 4R/E TIG 4,075,095,853
TransPulsSyn. 2700 4R/E DUO 4,075,095,854
TransPulsSyn. 2700 4R/E DUO/TIG 4,075,095,855
US
TransPulsSyn. 2700 MV/4R/Z US 4,075,095,800
TransPulsSyn. 2700 MV/4R/E US 4,075,095,801
AUS
TransPulsSyn. 2700 4R/E AUS 4,075,095,638

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/3
el_fr_st_mi_00154 012004
42,0407,0449
42,0406,0292
32,0405,0164
42,0200,8860
AM2,0200,9330
44,0001,1309 45,0200,0918
45,0200,1078 - ALU
45,0200,1186 - CrNi
45,0200,1030
45,0200,1077 - ALU
45,0200,1187 - CrNi
12,0405,0208
42,0405,0220
44,0550,0060
42,0001,3045,Z
42,0405,0219
44,0001,1195 - Z 33,0024,0032
44,0001,1196 - E
44,0001,1207 - D
43,0001,1139
43,0001,1092
43,0010,0164
43,0001,0600
43,0030,0045
12,0405,0206 41,0003,0215
40,0009,0043
33,0010,0227

el_fr_st_mi_00154 012004
42,0001,3541 - US
43,0013,0015
42,0407,0063
42,0407,0284 - E
* gewünschte Länge angeben 40,0001,0012 - *

* Specify the length required 43,0004,2382 - DUO
* Indiquer la longueur désirée
* Indicar la longitud deseada
* Indicare la lunghezza desiderat 43,0002,0371
* indicar o comprimento desejado
* uved'te požadovanou délku 42,0406,0297
42,0409,2649 32,0409,2640
42,0409,2760 - ALU 42,0409,2914 - TIG
42,0409,2930 - TIG
42,0409,2931 - DUO
42,0409,2932 - DUO/TIG 32,0409,2976
42,0409,3012 - AUS
43,0004,0789
43,0001,3234 43,0004,0507 - MV
43,0001,3260 - US 43,0004,2323 - US
43,0001,3268 - AUS 42,0300,1511
43,0001,3270 - CrNi 42,0407,0532 - US
43,0004,2384 - DUO 43,0003,0031 - DUO

42,0409,2973 - DUO
42,0406,0073 - DUO
4,070,627,Z - NT60
4,070,662,Z - NF3160
42,0406,0315 4,070,691,Z - ASU27-MV
60
31
42,0406,0093 NF
7
U2
43,0003,0485 AS
32,0405,0229
60
32,0405,0183
24
A NT 41 4,100,217 - PM41
NT SR SN
T 4
4,070,626,Z - NT24A T2
US 41
42,0405,0056 PM
43,0003,0485 32,0409,2639
4,070,860,Z - UST2A
4,070,776 - SNT4-DUO
43,0001,1095 4,070,677,Z - SR41
40,0001,0352 - *
42,0404,0024 41,0002,0059
42,0407,0284
42,0405,0154 4,070,739,Z - BPT27
T 27
4,100,423 BP 40,0009,0043
43,0003,0031

el_fr_st_mi_00154 012004
TransPuls Synergic 3200 4,075,124 US
TransSynergic 4000 C 4,075,097 TransPuls Synergic 3200 MV 4,075,124,800
TransSynergic 5000 C 4,075,098 TransSynergic 4000 C MV 4,075,097,800
TransSynergic 4000 4,075,099 TransSynergic 5000 C MV 4,075,098,800
TransSynergic 5000 4,075,101 TransPuls Synergic 4000 MV 4,075,100,800
TransPuls Synergic 4000 4,075,100 TransPuls Synergic 5000 MV 4,075,102,800
TransPuls Synergic 5000 4,075,102 TransPuls Syn. 4000 MV Pipe 4,075,100,810
MV US/RC
TransPuls Synergic 3200 MV 4,075,124,630 TransPuls Synergic 3200 MV R 4,075,124,800,R
TransSynergic 4000 C MV 4,075,097,630 TransSynergic 4000 MV R 4,075,097,800,R
TransSynergic 5000 C MV 4,075,098,630 TransSynergic 5000 MV R 4,075,098,800,R
TransSynergic 4000 MV 4,075,099,630 TransPulsSynergic 4000 MV R 4,075,100,800,R
TransSynergic 5000 MV 4,075,101,630 TransPulsSynergic 5000 MV R 4,075,102,800,R
TransPuls Synergic 4000 MV 4,075,100,630
TransPuls Synergic 5000 MV 4,075,102,630 460V
TransPuls Synergic 3200 460V 4,075,124,801
RC TransPuls Syn. 3200 460V Pipe 4,075,124,809
TransPuls Synergic 3200 R 4,075,124,R TransPuls Syn. 3200 460V Pipe HE 4,075,124,810
TransSynergic 4000 R 4,075,097,R TransPuls Syn. 3200 460V Pipe BA 4,075,124,811
TransSynergic 5000 R 4,075,098,R TransSynergic 4000 C 460V 4,075,097,801
TransPuls Synergic 4000 R 4,075,100,R TransSynergic 4000 C 460V 4,075,097,930
TransPuls Synergic 5000 R 4,075,102,R TransSynergic 4000 460V 4,075,099,930
TransSynergic 5000 C 460V 4,075,098,801
MV/RC TransSynergic 5000 C 460V 4,075,098,930
TransPuls Synergic 3200 MV R 4,075,124,630,R TransSynergic 5000 460V 4,075,101,930
TransSynergic 4000 MV R 4,075,097,630,R TransPuls Synergic 4000 460V 4,075,100,801
TransSynergic 5000 MV R 4,075,098,630,R TransPuls Synergic 4000 460V 4,075,100,930
TransPulsSynergic 4000 MV R 4,075,100,630,R TransPuls Synergic 5000 460V 4,075,102,801
TransPulsSynergic 5000 MV R 4,075,102,630,R TransPuls Synergic 5000 460V 4,075,102,930
AUS 460V/RC
TransPuls Synergic 3200 4,075,124,638 TransSynergic 4000 460V R 4,075,097,930,R
TransPuls Synergic 4000 4,075,100,638 TransSynergic 5000 460V R 4,075,098,930,R
TransPuls Synergic 5000 4,075,102,638 TransPulsSynergic4000 460V R 4,075,100,930,R
TransPulsSynergic5000 460V R 4,075,102,930,R
CMT
TransPuls Synergic 3200 CMT 4,075,137 CrNi
TransPuls Synergic 4000 CMT 4,075,138 TransPuls Synergic 3200 CrNi 4,075,124,631
TransPuls Synergic 5000 CMT 4,075,139 TransPuls Synergic 3200 MV CrNi 4,075,124,632
TransPuls Synergic 3200 CMT MV 4,075,137,630 TransPuls Synergic 4000 CrNi 4,075,100,631
TransPuls Synergic 4000 CMT MV 4,075,138,630 TransPuls Synergic 4000 MV CrNi 4,075,100,632
TransPuls Synergic 5000 CMT MV 4,075,139,630 TransPuls Synergic 5000 CrNi 4,075,102,631
TransPuls Synerg.3200 CMT MV US 4,075,137,800 TransPuls Synergic 5000 CrNi 460V 4,075,102,632
TransPuls Synerg.4000 CMT MV US 4,075,138,800
TransPuls Synerg.5000 CMT MV US 4,075,139,800
TransPuls Synerg.3200 CMT 460 V 4,075,137,801 TIME 5000 Digital 4,075,140,930
TransPuls Synerg.4000 CMT 460 V 4,075,138,801
TransPuls Synerg.5000 CMT 460 V 4,075,139,801
CMT/RC
TransPuls Synergic 3200 CMT R 4,075,137,R
TransPuls Synergic 3200 CMT MV R 4,075,137,630,R
TransPulsSynerg.3200 CMT MV US R 4,075,137,800,R
TS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

el_fr_st_mi_00153 032006
42,0200,8860
32,0405,0164
AM2,0200,8819
45,0200,918 45,0200,918
45,0200,1186 - CrNi 45,0200,1186 - CrNi
45,0200,1201 - CMT 45,0200,1201 - CMT
41,0003,0203 12,0405,0208
40,0009,0043
43,0001,1103
43,0001,0600
43,0001,1139 41,0003,0203
33,0005,4112
33,0005,4120 - MV
33,0005,4120 - 460V/US
33,0010,0335
43,0001,1186
43,0001,1187
43,0006,0152
43,0001,1092 - TPS3200
41,0009,0187
41,0002,0060
S
BP
40,0009,0043
43,0001,0600
33,0010,0345 - TIME 5000

43,0001,1104
4,070,681,Z - BPS32 TS/TPS 3200

12,0405,0208 4,070,738,Z - BPS42 TS/TPS 3200/4000
4,070,771,Z - BPS43 TS/TPS 3200/4000
4,100,413 4,070,658,Z - BPS50 TS/TPS 5000/TIME
4,070,772,Z - BPS53 TS/TPS 5000/TIME

el_fr_st_mi_00153 032006
43,0004,0664 - MV 43,0004,0987
43,0004,0586 - 460V 43,0004,2727 - TIME 5000
43,0004,2324 - US AWG 6
43,0004,2955 - US AWG 10
42,0407,0437 - MV
42,0407,0533 - US AWG 6
42,0407,0534 - US AWG 10
43,0001,1213 - MV/US 80A
43,0013,0015
BE2,0201,1934 - MV
BE2,0201,1355 - US
BE2,0201,1593 - US
42,0300,1511
43,0001,1199 - 40A 42,0300,1815 - TIME 5000
4,070,685,Z - ASU40
32,0405,0183
0
42,0409,5083 - TPS 3200 U4 32,0405,0229
42,0409,3055 - TPS 3200 AUS
42,0409,2650 - TS 4000
AS 43,0003,0485
42,0409,2651 - TPS 4000 32,0409,2657
42,0409,2652 - TS 5000
42,0409,2653 - TPS 5000
42,0409,3013 - TPS 4000 AUS
42,0409,3014 - TPS 5000 AUS 42,0400,0132 43,0003,0031
42,0409,3027 - TPS 4000 Pipe
42,0300,1523
42,0409,3097 - TPS 3200 Pipe
42,0409,3082 - TIME 5000 41,0005,0288 32,0409,2658
32,0409,2740 - MV/US
43,0001,3234 - COMF
43,0001,3235 - TS
43,0001,3253 - RC 4,070,627,Z - NT60
43,0001,3260 - US
43,0001,3268 - AUS
43,0001,3270 - CrNi 4,070,677,Z - SR41
43,0001,3276 - CMT Rem.
43,0001,3277 - TIME 5000
43,0001,3306 - CMT COMF
60 1
42,0406,0315
NT SR4
42,0406,0093
24
32,0409,2656
NT T2
43,0003,0031
US
40,0001,0352 - *
43,0006,0168
4,100,423
42,0407,0284 4,070,860,Z - UST2B

* gewünschte Länge angeben 4,070,960,Z - UST2C
42,0406,0299 * Specify the length required
* Indiquer la longueur désirée 4,070,626,Z - NT24
* Indicar la longitud deseada 4,070,928 - NT24T Pipe
43,0002,0358
* Indicare la lunghezza desiderat
* indicar o comprimento desejado
* uved'te požadovanou délku

el_fr_st_mi_00153 032006
Fronius Worldwide - www.fronius.com/addresses
FRONIUS International GmbH FRONIUS France SARL

A 4600 Wels, Buxbaumstraße 2
CZ 586 01 JIHLAVA, Brněnská 65 F 60306 SENLIS CEDEX,
Tel: +43 (0)7242 241-0 Tel: +420 567 584 911 13 avenue Félix Louat - B.P.195
Fax: +43 (0)7242 241-3940 Fax: +420 567 305 978 Tél: +33 (0)3 44 63 80 00
E-Mail: sales@fronius.com E-Mail: sales.jihlava@fronius.com Fax: +33 (0)3 44 63 80 01
http://www.fronius.com E-Mail: sales.france@fronius.com
709 00 OSTRAVA - Mariánské Hory,
4600 Wels, Buxbaumstraße 2 Kollárova 3
Tel: +43 (0)7242 241-0 Tel: +420 595 693 811 FRONIUS Norge AS
Fax: +43 (0)7242 241-3490 Fax: +420 596 617 223 N 3056 Solbergelva, P.O. BOX 32
Service: DW 3070, 3400 E-Mail: sales.ostrava@fronius.com Tel: +47 (0)32 232080,
Ersatzteile: DW 3390 Fax: +47 (0)32 232081
E-Mail: sales.austria@fronius.com 760 01 ZLÍN E-Mail: sales.norway@fronius.com
ul. Malá (za čerp. st. ARAL)
6020 Innsbruck, Amraserstraße 56 Tel: +420 577 311 011
Tel: +43 (0)512 343275-0 Fax: +420 577 311 019 FRONIUS Slovensko s.r.o.
Fax: +43 (0)512 343275-725 E-Mail: sales.zlin@fronius.com SK 917 01 Trnava, Nitrianská 5
Tel: +421 (0)33 590 7511
5020 Salzburg, Lieferinger Hauptstr.128 Fax: +421 (0)33 590 7599
Tel: +43 (0)662 430763 FRONIUS Deutschland GmbH E-Mail: sales.slovakia@fronius.com
Fax: +43 (0)662 430763-16 D 67661 Kaiserslautern, Liebigstraße 15
Tel: +49 (0)631 35127-0 974 03 Banská Bystrica,
1100 Wien, Daumegasse 7, Fax: +49 (0)631 35127-50 Zvolenská cesta 14
Team Süd / Ost E-Mail: sales.germany@fronius.com Tel: +421 (0)48 472 0611
Tel: +43 (0)1/600 41 02-7410 Fax: +421 (0)48 472 0699
Fax: +43 (0)1/600 41 02-7490 90530 Wendelstein, E-Mail: sales.b.bystrica@fronius.com
Wilhelm-Maisel-Straße 32
Team Nord / West Tel: +49 (0)9129 2855-0
Tel: +43 (0)1/600 41 02-7050 Fax: +49 (0)9129 2855-32
Fax: +43 (0)1/600 41 02-7160 FRONIUS Ukraine GmbH
UA 07455 Ukraine, Kiewskaya OBL..,
51149 Köln, Gremberghoven,
Haberkorn Ulmer GmbH S. Knjashitschi, Browarskogo R-NA
Welserstraße 10 b
6961 Wolfurt, Hohe Brücke Tel: +38 044 94-62768
Tel: +49 (0)2203 97701-0
Tel: +43 (0)5574 695-0 +38 044 94-54170
Fax: +49 (0)2203 97701-10
Fax: +43 (0)5574 2139 Fax: +38 044 94-62767
http://www.haberkorn.com E-Mail: sales.ukraine@fronius.com
57052 Siegen, Alcher Straße 51
Tel: +49 (0)271 37515-0
Wilhelm Zultner & Co. Fax: +49 (0)271 37515-15
8042 Graz, Schmiedlstraße 7 USA FRONIUS USA LLC
10421 Citation Drive,
Tel: +43 (0)316 6095-0 38640 Goslar, Im Schleeke 108
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Service: DW 325, Ersatzteile: DW 335 Fax: +49 (0)5321 3413-31 Tel: +1(0) 810 220-4414
E-Mail: vkm@zultner.at Fax: +1(0) 810 220-4424
10365 Berlin, Josef-Orlopp-Str. 92-106 E-Mail: sales.usa@fronius.com
Wilhelm Zultner & Co. Tel: +49 (0)30 557745-0
9020 Klagenfurt, Fallegasse 3 Fax: +49 (0)30 557745-51
Tel: +43 (0)463 382121-0
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Service: DW 430, Ersatzteile: DW 431 Tel: +49 (0)4156 8120-0
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70771 Leinfelden-Echterdingen
FRONIUS do Brasil LTDA (Stuttgart),
BR Av. Senador Vergueiro, 3260 Kolumbus-Straße 47
Vila Tereza, Sao Bernado do Campo - SP Tel: +49 (0)711 782852-0
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E-Mail: sales.brazil@fronius.com Tel: +49 (0)341 27117-0
Fax: +49 (0)341 27117-10
01723 Kesselsdorf (Dresden),

CH FRONIUS Schweiz AG
8153 Rümlang, Oberglatterstraße 11
Zum alten Dessauer 13
Tel: +49 (0)35204 7899-0
Tel: +41 (0)1817 9944 Fax: +49 (0)35204 7899-10
Fax: +41 (0)1817 9955
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Tel: +49 (0)6363 993070
Fax: +49 (0)6363 993072
FRONIUS Česká republika s.r.o.
CZ 381 01 ČESKÝ KRUMLOV, Tovární 170 18059 Rostock, Erich Schlesinger Str. 50
Tel: +420 380 705 111 Tel: +49 (0)381 4445802
Fax: +420 380 711 284 Fax: +49 (0)381 4445803
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81379 München, Gmunder Straße 37a
100 00 PRAHA 10, V Olšinách 1022/42 Tel: +49 (0)89 748476-0
Tel.: +420 272 111 011, 272 742 369 Fax: +49 (0)89 748476-10
Fax: +420 272 738 145
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Tel: +49 (0)8621 8065-0
315 00 PLZEŇ-Božkov, Letkovská 38 Fax: +49 (0)8621 8065-10
Tel: +420 377 183 411
Fax: +420 377 183 419 94491 Hengersberg, Donaustraße 31
E-Mail: sales.plzen@fronius.com Tel: +49 (0)9901 2008-0
Fax: +49 (0)9901 2008-10
500 04 HRADEC KRÁLOVÉ,
Pražská 293/12
Tel.: +420 495 070 011
Fax: +420 495 070 019
E-Mail: sales.h.kralove@fronius.com
Under http://www.fronius.com/addresses you will find all addresses of our sales branches and partner firms!
ud_fr_st_so_00082 022006

Fronius TPS Operating Instructions

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Fronius TPS Operating Instructions

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TransSynergic 4000 / 5000

TransPuls Synergic 2700

Important! “Important!” indicates practical hints and other useful special-information. It

Any malfunctions which might impair machine safety must be eliminated

It’s your safety that’s at stake!

Utilisation in accordance with the “intended purpose” also comprises

The appliance must never be used for the following:

The machine is designed to be used in industrial and workshop

Temperature range of ambient air:

Relative atmospheric humidity:

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

III ud_fr_st_sv_00467 012005

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an

Have a suitable, approved fire extinguisher at the ready.

Welding must NEVER be performed on containers that have had gases,

Always place the wirefeeder on an adequately insulated floor or base, or else

Never immerse the welding electrode (rod electrode, tungsten electrode,

Wherever necessary, use suitable measures to ensure that the workpiece is

Switch off any appliances that are not in use.

When working at great heights, wear a safety harness.

Put up a clearly legible and easy-to-understand warning sign to stop anybody

After opening up the machine:

If work needs to be performed on any live parts, there must be a second

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

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way

If electromagnetic interference is found to be occurring, the owner/operator is

Examine and evaluate any possible electromagnetic problems that may

Ancillary measures for preventing EMC problems:

d) Workpiece grounding (earthing)

e) Shielding, where necessary

Electromagnetic fields may cause as yet unknown damage to health.

Covers and sideguards may only be opened or removed for as long as is

VII ud_fr_st_sv_00467 012005

Risk of scalding from accidental discharge of hot coolant. Before unplugging

When hoisting the machines by crane, only use suitable manufacturer-

If a machine is fitted with a carrying strap or carrying handle, remember that

Danger of colourless and odourless inert gas escaping unnoticed, when

ud_fr_st_sv_00467 012005 VIII

Protect shielding-gas cylinders containing compressed gas from excessive

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas

Observe the manufacturer’s instructions and all relevant national and

When installing the appliance, please ensure a clearance radius of 0.5 m

Before switching on the machine, ensure that nobody can be endangered by

Do not make any alterations, installations or modifications to the machine

Replace immediately any components that are not in perfect condition.

A safety inspection, by a trained and certified electrician, is prescribed:

Observe the relevant national and international standards and directives in

More detailed information on safety inspections and calibration is available

Disposal Do not dispose of this device with normal domestic waste!

ud_fr_st_sv_00467 012005 XII

Machine concept The TransSynergic (TS) 4000 and TS

The modular design and potential for

All machines except TS 4000/5000 have

This results in:

Only on the “TPS 2700” power source