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Operating Instructions
TransSteel 2200 EN

MIG/MAG Power source

42,0426,0241,EN 004-10082018
2
Dear reader,

EN
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

Explanation of
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
safety symbols
rious injury will result.

WARNING! Indicates a potentially dangerous situation. Death or serious injury

may result if appropriate precautions are not taken.

CAUTION! Indicates a situation where damage or injury could occur. If it is not

avoided, minor injury and/or damage to property may result.

NOTE! Indicates a risk of flawed results and possible damage to the equipment.

IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

3
4
Contents

EN
Safety 9

Safety rules ................................................................................................................................................ 11

Explanation of safety symbols .............................................................................................................. 11
General ................................................................................................................................................. 11
Proper use ............................................................................................................................................ 12
Mains connection .................................................................................................................................. 12
Environmental conditions...................................................................................................................... 12
Obligations of the operator.................................................................................................................... 13
Obligations of personnel ....................................................................................................................... 13
Residual current protective device........................................................................................................ 13
Protecting yourself and others .............................................................................................................. 13
Noise emission values .......................................................................................................................... 14
Danger from toxic gases and vapours .................................................................................................. 14
Danger from flying sparks ..................................................................................................................... 15
Risks from mains current and welding current...................................................................................... 15
Meandering welding currents................................................................................................................ 16
EMC Device Classifications .................................................................................................................. 16
EMC measures ..................................................................................................................................... 17
EMF measures...................................................................................................................................... 17
Specific hazards.................................................................................................................................... 17
Factors affecting welding results........................................................................................................... 19
Danger from shielding gas cylinders..................................................................................................... 19
Danger from escaping shielding gas..................................................................................................... 19
Safety measures at the installation location and during transport ........................................................ 20
Safety measures in normal operation ................................................................................................... 20
Commissioning, maintenance and repair.............................................................................................. 21
Safety inspection................................................................................................................................... 21
Disposal ................................................................................................................................................ 21
Safety symbols...................................................................................................................................... 22
Data protection...................................................................................................................................... 22
Copyright............................................................................................................................................... 22

General information 23

General ...................................................................................................................................................... 25
Device concept ..................................................................................................................................... 25
"Power limitation" function .................................................................................................................... 25
Application areas .................................................................................................................................. 26
Warning notices on the device.............................................................................................................. 27

Control elements and connections 29

Control panel.............................................................................................................................................. 31
General ................................................................................................................................................. 31
Safety.................................................................................................................................................... 31
Control panel......................................................................................................................................... 32
Keylock ................................................................................................................................................. 36
Connections, switches and mechanical components ................................................................................ 38
Safety.................................................................................................................................................... 38
Front and rear of the power source....................................................................................................... 38
Side view............................................................................................................................................... 39

Before installation and commissioning 41

General ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Proper use ............................................................................................................................................ 43
Setup regulations .................................................................................................................................. 43

5
 Mains connection .................................................................................................................................. 43
Generator-powered operation.................................................................................................................... 44
Generator-powered operation............................................................................................................... 44
Mains fuse protection................................................................................................................................. 45
Adjustable mains fuse protection .......................................................................................................... 45

Carrying strap option 49

Fitting the carrying strap ............................................................................................................................ 51

Fitting the carrying strap to the power source....................................................................................... 51

MIG/MAG 53

Start-up ...................................................................................................................................................... 55
Connecting a MIG/MAG welding torch.................................................................................................. 55
Inserting the feed rollers ....................................................................................................................... 56
Inserting the D100 wirespool ................................................................................................................ 57
Inserting the D200 wirespool ................................................................................................................ 57
Feeding in the wire electrode................................................................................................................ 58
Setting the contact pressure ................................................................................................................. 59
Connecting the gas cylinder.................................................................................................................. 60
Connecting the polarity reverser and establishing a grounding (earthing) connection ........................ 60
Adjusting the brake of the wirespool holders ............................................................................................. 62
General ................................................................................................................................................. 62
Adjusting the brake of the D200 wirespool holder ................................................................................ 63
Adjusting the brake of the D100 wirespool holder ................................................................................ 63
Description of MIG/MAG operating modes ................................................................................................ 64
Symbols ................................................................................................................................................ 64
2-step mode .......................................................................................................................................... 64
4-step mode .......................................................................................................................................... 64
Special 4-step mode ............................................................................................................................. 64
Spot welding ......................................................................................................................................... 65
2-step stitch welding ............................................................................................................................. 65
4-step stitch welding ............................................................................................................................. 65
MIG/MAG standard manual welding .......................................................................................................... 66
General ................................................................................................................................................. 66
Available parameters ............................................................................................................................ 66
MIG/MAG standard manual welding ..................................................................................................... 66
Corrections during welding ................................................................................................................... 66
MIG/MAG standard synergic welding ........................................................................................................ 67
MIG/MAG standard synergic welding ................................................................................................... 67
Corrections during welding ................................................................................................................... 67
Spot and stitch welding .............................................................................................................................. 68
General ................................................................................................................................................. 68
Spot welding ......................................................................................................................................... 68
Stitch welding........................................................................................................................................ 68

TIG 69

Start-up ...................................................................................................................................................... 71
Commissioning ..................................................................................................................................... 71
TIG welding........................................................................................................................................... 73
Description of TIG operating modes .......................................................................................................... 74
Symbols and their explanations ............................................................................................................ 74
2-step mode .......................................................................................................................................... 74
4-step mode .......................................................................................................................................... 75
Pulse welding............................................................................................................................................. 76
Pulse welding........................................................................................................................................ 76

Rod electrode 77

Start-up ...................................................................................................................................................... 79
Preparatory work................................................................................................................................... 79
MMA welding ........................................................................................................................................ 80

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 Functions for optimising the welding process ............................................................................................ 81
Arc-force dynamic ................................................................................................................................. 81
HotStart (Hti) function ........................................................................................................................... 81

EN
Anti-stick (Ast) function ......................................................................................................................... 81

EasyJobs 83

Saving and retrieving EasyJobs................................................................................................................. 85

General ................................................................................................................................................. 85
Saving an EasyJob ............................................................................................................................... 85
Retrieving an EasyJob .......................................................................................................................... 85
Deleting an EasyJob ............................................................................................................................. 85

Setup menu 87

Operation ................................................................................................................................................... 89
Operation .............................................................................................................................................. 89
Parameters for MIG/MAG standard manual welding ................................................................................. 90
Parameters for MIG/MAG standard manual welding ............................................................................ 90
Parameters for MIG/MAG standard synergic welding................................................................................ 92
Parameters for MIG/MAG standard synergic welding........................................................................... 92
Parameters for TIG welding ....................................................................................................................... 94
Parameters for TIG welding .................................................................................................................. 94
Parameters for MMA welding..................................................................................................................... 95
Setup parameters for MMA welding...................................................................................................... 95

Setup menu - Level 2 97

Operation ................................................................................................................................................... 99
Operation .............................................................................................................................................. 99
Parameters for MIG/MAG standard manual welding ................................................................................. 100
Parameters for MIG/MAG welding ........................................................................................................ 100
Parameters for MIG/MAG standard synergic welding................................................................................ 101
Parameters for MIG/MAG welding ........................................................................................................ 101
Parameters for MMA welding..................................................................................................................... 102
Parameters for MMA welding................................................................................................................ 102
Parameters for TIG welding ....................................................................................................................... 103
Parameters for TIG welding in the Setup menu level2 ......................................................................... 103

Optimising welding quality 105

Measuring welding circuit resistance r ....................................................................................................... 107

General ................................................................................................................................................. 107
Measure the welding circuit resistance r............................................................................................... 107
Displaying welding circuit inductivity L ....................................................................................................... 108
General ................................................................................................................................................. 108
Displaying welding circuit inductivity L .................................................................................................. 108
Laying the hosepacks correctly............................................................................................................. 108

Troubleshooting and maintenance 109

Display service parameters........................................................................................................................ 111

Service parameters............................................................................................................................... 111
Troubleshooting ......................................................................................................................................... 112
Safety.................................................................................................................................................... 112
Fault diagnosis...................................................................................................................................... 112
Displayed service codes ....................................................................................................................... 115
Care, maintenance and disposal ............................................................................................................... 119
General ................................................................................................................................................. 119
Safety.................................................................................................................................................... 119
At every start-up.................................................................................................................................... 119
As required, at least every two months................................................................................................. 120
Every 6 months ..................................................................................................................................... 120
Disposal ................................................................................................................................................ 120

7
 Removing stiff drive rollers......................................................................................................................... 121
Removing a stiff drive roller .................................................................................................................. 121

Technical data 123

Technical data............................................................................................................................................ 125

Special voltages.................................................................................................................................... 125
Explanation of the term "duty cycle" ..................................................................................................... 125
TSt 2200 ............................................................................................................................................... 126
TSt 2200 MV ......................................................................................................................................... 128

8
Safety
Safety rules

EN
Explanation of
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
safety symbols
rious injury will result.

WARNING! Indicates a potentially dangerous situation. Death or serious injury

may result if appropriate precautions are not taken.

CAUTION! Indicates a situation where damage or injury could occur. If it is not

avoided, minor injury and/or damage to property may result.

NOTE! Indicates a risk of flawed results and possible damage to the equipment.

IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

General
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safe-
ty.
This is for your personal safety!

11
Proper use
The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufac-
turer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.

Mains connection
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance *)
- criteria with regard to the minimum short-circuit power requirement *)

*) at the interface with the public grid

see Technical Data
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly

Environmental
Operation or storage of the device outside the stipulated area will be deemed
conditions
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

12
Obligations of the

EN
The operator must only allow persons to work with the device who:
operator
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the
section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.

Obligations of
Before using the device, all persons instructed to do so undertake:
personnel
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.

Residual current
Local regulations and national guidelines may require a residual current pro-
protective device
tective device when connecting equipment to the public grid.
RCD The type of residual current protective device recommended by the manufac-
turer for the equipment is indicated in the technical data.

Protecting your-
Anyone working with the device exposes themselves to numerous risks, e.g.
self and others
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin

- Hazardous electromagnetic fields, which can endanger the lives of those

using cardiac pacemakers

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups

13
 Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter
- Wear regulation protective goggles with side protection behind the protec-
tive visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent
injury
Keep all persons, especially children, out of the working area while any devic-
es are in operation or welding is in progress. If, however, there are people in
the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.

Noise emission
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
values
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.

Danger from toxic

The fumes produced during welding contain harmful gases and vapours.
gases and va-
pours Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/
hour.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
ing place.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
Amongst others, the following components are responsible for the degree of
toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.

14
 The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.

EN
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.

Danger from fly-

Flying sparks may cause fires or explosions.
ing sparks
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of in-
jury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in ac-
cordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.

Risks from mains

An electric shock is potentially life threatening and can be fatal.
current and weld-
ing current Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
the feed rollers and all pieces of metal that are in contact with the welding wire
are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suit-
able, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Replace loose connections and scorched, damaged or inade-
quately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the
welding electrodes of two power sources. Touching the potentials of both elec-
trodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician
to ensure the ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.

15
 Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.

Meandering weld-
If the following instructions are ignored, meandering welding currents can de-
ing currents
velop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be weld-
ed.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.

EMC Device Clas-

Devices in emission class A:
sifications
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.

16
EMC measures

EN
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rec-
tify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation

EMF measures
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body

Specific hazards
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.

17
 During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).

Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling cool-
ant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when

transporting devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the
load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG de-
vices).
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, coun-
terbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the device-
side thread of the adapter for the shielding gas connection using suitable Tef-
lon tape.

18
Factors affecting

EN
The following requirements with regard to shielding gas quality must be met if
welding results
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used

Danger from
Shielding gas cylinders contain gas under pressure and can explode if dam-
shielding gas cyl-
aged. As the shielding gas cylinders are part of the welding equipment, they
inders
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instruc-
tions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only
use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.
The manufacturer's instructions must be observed as well as applicable na-
tional and international regulations for shielding gas cylinders and accesso-
ries.

Danger from es-

Risk of suffocation from the uncontrolled escape of shielding gas
caping shielding
gas Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place the oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least
20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylin-
der or the main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is
taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.

19
Safety measures
A device toppling over could easily kill someone. Place the device on a solid,
at the installation
level surface such that it remains stable
location and dur-
- The maximum permissible tilt angle is 10°.
ing transport

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport
or lifting.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.

Safety measures
Only operate the device when all safety devices are fully functional. If the safe-
in normal opera-
ty devices are not fully functional, there is a risk of
tion
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper func-
tioning of safety devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if
the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices
due to its properties (electrical conductibility, anti-freeze agent, material com-
patibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other
system components or a different coolant. In addition, all warranty claims will
be forfeited.

20
 Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ig-
nite under certain conditions. Transport the coolant only in its original, sealed

EN
containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na-
tional and international regulations. The coolant safety data sheet may be ob-
tained from your service centre or downloaded from the manufacturer's
website.
Check the coolant level before starting to weld, while the system is still cool.

Commissioning,
It is impossible to guarantee that bought-in parts are designed and manufac-
maintenance and
tured to meet the demands made of them, or that they satisfy safety require-
repair
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the
specified torque.

Safety inspection
The manufacturer recommends that a safety inspection of the device is per-
formed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international stand-
ards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.

Disposal
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its im-
plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa-
cility. Any device that you no longer require must either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!

21
Safety symbols
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can
be found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the rele-
vant standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.

Copyright
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.

22
General information
General

EN
Device concept The TransSteel (TSt) 2200 power source is
a completely digitised, microprocessor-
controlled power source.

This power source is designed for the wel-

ding of steel and can be used for the follo-
wing welding processes:
- MIG/MAG welding
- MMA welding
- TIG welding with touchdown ignition

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

"Power limita- The power source has a "Power limitation" safety feature.
tion" function
This function is only available for the MIG/MAG standard synergic welding process.

Mode of operation:
If necessary, the power source reduces the welding power to prevent the arc from being
extinguished during welding at the power limit of the power source. The reduced parame-
ters are displayed on the control panel until welding starts again or until the next parameter
change.

This results in:

- A more precise welding process
- A high degree of reproducibility of all results
- Exceptional weld properties

As soon as the function is active, the indicator for the wire speed parameter on the
control panel flashes. The flashing continues until welding starts again or until the
next parameter change.

25
Application areas

MIG/MAG welding

TIG welding

MMA welding

26
Warning notices Warning notices and safety symbols are affixed to the power source. These warning notic-

EN
on the device es and safety symbols must not be removed or painted over. They warn against incorrect
operation, as this may result in serious injury and damage.

42,0409,0160
1 1.1 1.2 1.3

2 2.1 2.2 2.3

Steel: 3-4
CrNi: 3-4

3 3.1 3.2 3.3 FCW: 3

Al: 1-3

?
4 4.1
.023 0.6

5 6
Aslgk
ds;lg

Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk
Asl

k s;ldfg
dhf
s gkds

Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk
k s;dgl
;lgk

k
Aslgk

s;ldfg

Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk
ds;lg

k
S ;ldkg

s;dgl
k s;ldfg

k
sldgk

k s;dgl
sdlks
;ldfgk

k
s;dgl
k

Welding is dangerous. The following basic requirements must be met to ensure

the equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wirefeed-
er and the welding process

Do not use the functions described here until you have fully read and under-
stood the following documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the
safety rules

27
 Do not dispose of used devices with domestic waste. Dispose of them accord-
ing to the safety rules.

Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.

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

28
Control elements and connections
Control panel

EN
General NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individ-
ual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules

31
Control panel

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

No. Function

(1) Spot welding indicator

The spot welding indicator lights up if:
- Spot welding/stitch welding mode is selected
- The SPt parameter (spot welding time/stitch welding time) in the Setup menu is
not set to OFF

(2) 2-step stitch welding indicator

The 2-step stitch welding indicator lights up if:
- Spot welding/stitch welding mode is selected and
- The SPb parameter (spot welding/stitch welding pause time) is set to a value
greater than 0 and
- The Int (interval) parameter is set to 2T

(3) 4-step stitch welding indicator

The 4-step stitch welding indicator lights up if:
- Spot welding/stitch welding mode is selected and
- The SPb parameter (spot welding/stitch welding pause time) is set to a value
greater than 0 and
- The Int (interval) parameter is set to 4T

(4) Hold indicator

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

(5) Intermediate arc indicator

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

32
 EN
(6)

No. Function

(6) "Parameter selection" button (left)

For selecting the parameters listed below

The relevant symbol lights up when a welding parameter is selected.

Sheet thickness in mm or in. *)

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

Welding current in amperes *)

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

Wire speed in m/min or ipm *)

*) If one of these parameters is selected in the MIG/MAG standard synergic welding pro-
cess, then the synergic function ensures that all other synergic parameters are adjusted
automatically.

33
 (7)

No. Function

(7) "Parameter selection" button (right)

For selecting the parameters listed below

The relevant symbol lights up when a welding parameter is selected.

Arc length correction

For correcting the arc length

Welding voltage in V *)
Before the start of welding, the device automatically displays a standard val-
ue based on the programmed parameters. The actual value is displayed
during welding.

Arc-force dynamic
For influencing the short-circuiting dynamic at the moment of droplet transfer
- ... harder, more stable arc
0 ... neutral arc
+ ... soft, low-spatter arc

Real Energy Input **)

For displaying the energy applied during the welding operation

*) If one of these parameters is selected in the MIG/MAG standard synergic welding

process, then the synergic function ensures that all other synergic parameters are
adjusted automatically.
**) This parameter can only be selected if the EnE parameter is set to ON in the Level
2 Setup menu. The value continuously rises during welding in line with the perma-
nently increasing energy yield. The final value at the end of welding remains stored
until welding starts again or the power source is switched back on - the HOLD indi-
cator lights up.

34
 EN
(8) (10)

(9) (11)

No. Function

(8) Gas-test button

For setting the required gas flow rate on the gas pressure regulator/for filling the
torch hosepack with shielding gas.
When the "Gas-test" button is pressed, shielding gas will flow for 30 s. Press the
button again to stop the gas flow prematurely.

(9) Adjusting dial (left)

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

(10) "Wire threading" button

For threading the wire into the torch hosepack with no accompanying flow of gas.
While the button is being held down, the wire drive runs at feeder inching speed

(11) Adjusting dial (right)

For changing the arc length correction, welding voltage and arc-force dynamic pa-
rameters as well as changing parameters in the Setup menu

35
 (12) (18)

(13) (14) (15) (16) (17)

No. Function

(12) "Material" button

For selecting the filler metal to be used

(13) "Save" button 1

For saving an EasyJob

(14) "Mode" button

For selecting the operating mode
2 T = 2-step mode
4 T = 4-step mode
S 4 T = Special 4-step mode
Spot welding/stitch welding

(15) "Wire diameter" button

For selecting the wire diameter to be used

(16) "Save" button 2

For saving an EasyJob

(17) "Process" button

For selecting the welding process
MANUAL = MIG/MAG standard manual welding
SYNERGIC = MIG/MAG standard synergic welding
STICK = Manual metal arc (MMA) welding
TIG = TIG welding

(18) "Shielding gas" button

For selecting the shielding gas to be used

Keylock A keylock can be activated to prevent the settings from being inadvertently changed on the
control panel. As long as the keylock is active
- Settings cannot be adjusted on the control panel
- Parameter settings can be displayed
- It is possible to switch between EasyJobs if an EasyJob was selected before activating
the keylock

Activate/deactivate the keylock as follows:

1 Press and hold the "Mode" button

36
 2 Press the "Parameter selection" button (right)

EN
3 Release the "Mode" and "Parameter selection" buttons

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

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

37
Connections, switches and mechanical components

Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules

Front and rear of

the power source (2) (1) Welding torch connection
For connecting the welding torch

Steel
CrNi .023 0,6
(2) (-) - current socket with bayonet
latch
CuSi .030 0,8 Ar 100%
Rutil FCW .035 0,9 CO² 100%
Metal cored .040 1,0 Ar + 2.5%CO²
Self-shielded .045 1,2 Ar+ 15-20% CO²

2T S4T STICK MANUAL

4T TIG SYNERGIC

Used for
(3) - Connecting the grounding cable or
(1)
(4) polarity reverser during MIG/MAG
welding (depending on the wire
electrode used)
- Connecting the electrode cable or
grounding cable during MMA wel-
ding (depending on the type of
(5) electrode used)
- Connecting the TIG welding torch

(3) TMC connection (TIG Multi Connector)

For connecting the TIG welding torch

(4) (+) - current socket with bayonet latch

Used for
- Connecting the polarity reverser or grounding cable during MIG/MAG welding
(depending on the wire electrode used)
- Connecting the electrode cable or grounding cable during MMA welding (depend-
ing on the type of electrode used)
- Connecting the grounding cable during TIG welding

(5) Polarity reverser

For selecting the welding potential on the MIG/MAG welding torch

38
 (6) (7) (6) MIG/MAG shielding gas connec-
tion socket

EN
For the shielding gas supply to the
welding torch connection (1)

(7) Mains switch

For switching the power source on
and off

(8) Mains cable with strain relief de-

vice
Not prefitted on all models

(9) TIG shielding gas connection so-

(9) (8) cket
For the shielding gas supply to the
(-) - current socket (2)

Side view
(1) (2) (3) (1) D100 wirespool holder with bra-
ke
For holding standard wirespools
with a max. diameter of 100 mm
(3.94 in)

(2) D200 wirespool holder with bra-

ke
For holding standard wirespools
with a max. diameter of 200 mm
(7.87 in.) and a max. weight of 6.8
kg (14.99 lbs.)

(3) 2-roller drive

39
40
Before installation and commission-
ing
General

EN
Safety
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All activities described in these operating instructions may only be
carried out by trained and qualified personnel. All functions described in these op-
erating instructions may only be used by trained and qualified personnel. Do not
carry out any of the work or use any of the functions described until you have fully
read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules

Proper use The power source is intended exclusively for MIG/MAG, MMA and TIG welding.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac-
cordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such usage.

Proper use also includes

- complying with all the instructions in the Operating Instructions
- performing all stipulated inspection and maintenance work

Setup regulations The device is tested to IP 23 protection, meaning:

- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49
in.)
- Protection against spraywater at any angle up to 60° to the vertical

The device can be set up and operated outdoors in accordance with degree of protection
IP 23.
Avoid direct wetting (e.g. from rain).

WARNING! If one of these machines topples over or falls it could cause serious
or even fatal injury. Place device on a solid, level surface in such a way that it re-
mains stable.

CAUTION! Electroconductive metallic dust may damage the device. The air filter
is a very important safety device for adhering to IP 23 protection. The device may
only be operated with an air filter fitted.

The venting duct is a very important safety device. When choosing the device location, en-
sure that the cooling air can enter and exit unhindered through the air ducts on the front
and back of the device. Electroconductive metallic dust (e.g. from grinding work) must not
be allowed to get sucked into the device.

Mains connection The devices are designed to run on the mains voltage shown on the respective rating
plates. If your version of the device does not come with mains cables and plugs ready-fit-
ted, these must be fitted in accordance with national regulations and standards. For details
of fuse protection of the mains lead, please see the Technical Data.

NOTE! Inadequately dimensioned electrical installations can cause serious dam-

age. The incoming mains lead and its fuse must be dimensioned to suit the local
power supply. The technical data shown on the rating plate applies.

43
Generator-powered operation

Generator-pow- The power source is generator-compatible.

ered operation
The maximum apparent power S1max of the power source must be known in order to select
the correct generator output.
The maximum apparent power S1max of the power source is calculated as follows:
S1max = I1max x U1

See device rating plate or technical data for I1max and U1 values

The generator apparent power SGEN needed is calculated using the following rule of
thumb:
SGEN = S1max x 1.35

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

NOTE! The generator apparent power SGEN must always be higher than the max-
imum apparent power S1max of the power source.

When using single-phase devices with a three-phase generator, note that the specified
generator apparent power is often only available as a whole across all three phases of the
generator. If necessary, obtain further information on the single-phase power of the gener-
ator from the generator manufacturer.

NOTE! The voltage delivered by the generator must never exceed the upper or
lower limits of the mains voltage tolerance range. Details of the mains voltage tol-
erance can be found in the "Technical data" section.

44
Mains fuse protection

EN
Adjustable mains The mains fuse protection selected on the power source limits the power drawn in from the
fuse protection mains and in turn the possible welding current. This prevents the automatic circuit breaker
(e.g. in the fuse box) from tripping straight away.

The desired mains fuse protection can be selected on the power source depending on the
mains voltage and automatic circuit breaker used.

The following table shows which mains voltages and fuse ratings limit the welding current.

TSt 2200:
Mains Country- Power source fuse Welding current limitation
voltage specific set- rating
ting
230 V Std 10 A MIG/MAG welding:
max. 145 A; 110 A at 100%*
MMA welding:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*
230 V Std 13 A MIG/MAG welding:
max. 170 A; 140 A at 100%*
MMA welding:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*
230 V Std 16 A MIG/MAG welding:
max. 210 A; 150 A at 100%*
MMA welding:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*

TSt 2200 MV:

Mains Country- Power source fuse Welding current limitation
voltage specific set- rating
ting
120 V Std 10 A MIG/MAG welding:
max. 100 A; 75 A at 100%*
MMA welding:
max. 85 A; 55 A at 100%*
TIG welding:
max. 130 A; 95 A at 100%*
120 V Std 13 A MIG/MAG welding:
max. 105 A; 80 A at 100%*
MMA welding:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*

45
 TSt 2200 MV:
Mains Country- Power source fuse Welding current limitation
voltage specific set- rating
ting
120 V US 15 A MIG/MAG welding:
max. 105 A; 80 A at 100%*
MMA welding:
max. 90 A; 70 A at 100%*
TIG welding:
max. 135 A; 105 A at 100%*
120 V Std 16 A MIG/MAG welding:
max. 115 A; 105 A at 100%*
MMA welding:
max. 100 A; 85 A at 100%*
TIG welding:
max. 140 A; 130 A at 100%*
120 V US 20 A MIG/MAG welding:
max. 135 A; 105 A at 100%*
MMA welding:
max. 110 A; 90 A at 100%*
TIG welding:
max. 160 A; 130 A at 100%*
230 V Std 10 A MIG/MAG welding:
max. 145 A; 110 A at 100%*
MMA welding:
max. 125 A; 90 A at 100%*
TIG welding:
max. 180 A; 135 A at 100%*
230 V Std 13 A MIG/MAG welding:
max. 170 A; 140 A at 100%*
MMA welding:
max. 150 A; 120 A at 100%*
TIG welding:
max. 200 A; 160 A at 100%*
230 V Std 16 A MIG/MAG welding:
max. 210 A; 150 A at 100%*
MMA welding:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*
240 V US 15 A MIG/MAG welding:
max. 210 A; 150 A at 100%*
MMA welding:
max. 180 A; 130 A at 100%*
TIG welding:
max. 230 A; 170 A at 100%*
A 20 A fuse can only be selected if:
- The country-specific setting has been set to "US"
- The mains lead has a 20 A fuse
- The power source is supplied with a mains voltage of 120 V

* 100% values = welding with no time limits and without cooling breaks.

The welding current data applies at an ambient temperature of 40 °C (104 °F).

A safety cut-out prevents the automatic circuit breaker from tripping at higher welding pow-
ers. The safety cut-out defines the possible welding duration without the automatic circuit
breaker tripping. If the precalculated weld time is exceeded, thus causing the welding cur-

46
rent to switch off, the service code "toF" is displayed. A countdown immediately appears
next to the "toF" indicator, which shows the remaining time until the power source is ready
for welding again. After this time, the message disappears and the power source can be

EN
used again.

Depending on the selected fuse, the safety cut-out limits the maximum currents of the se-
lected process. As a result, it is possible that welding can no longer occur at the saved op-
erating points if these were saved before selecting the fuse.

If welding is nevertheless carried out at one of these operating points, the power source
operates at the limit value of the selected fuse – the power limitation is active. The operat-
ing point should be re-saved in accordance with the power limitation.

47
48
Carrying strap option
Fitting the carrying strap

EN
Fitting the carry-
1 2

1 2
ing strap to the
power source

3 4

3 4

5 6

5 6

51
52
MIG/MAG
Start-up

EN
Connecting a NOTE! Before connecting the welding torch to the power source, equip the weld-
MIG/MAG welding ing torch according to the welding torch Operating Instructions: fit wearing parts
torch to the torch body, fit the inner liner.
1

2 Unscrew the knurled screw (1) slightly so that the welding torch can be easily pushed
into the welding torch connection.
2

(1)

4 CAUTION! Risk of damage if the

welding torch is not fully inserted.
After inserting the welding torch, it
must be in the end position shown.

55
 5

Inserting the feed NOTE! In order to achieve optimum wire electrode feed, the feed rollers must be
rollers suitable for the diameter and alloy of the wire being welded.
1 2

1 2

3 4

3 4

56
Inserting the
1 2

EN
1 2
D100 wirespool

Inserting the
1

1
D200 wirespool

CAUTION! Risk of injury and material damage if the wirespool topples over be-
cause the locking ring has been placed the wrong way around. Always secure the
locking ring as shown below.
2 3

2 3

57
Feeding in the
CAUTION! Risk of injury due to elasticity of spooled wire electrode. When insert-
wire electrode
ing the wire electrode into the wire drive, hold the end of the wire electrode firmly
to avoid injuries caused by the wire springing back.
1 2

1 2

3 4

3 4

5 NOTE! It is only necessary to con-

nect the mains cable to the power
source for multivoltage power
sources.

58
 CAUTION! Risk of injury from emerging wire electrode. When pressing the "Wire
threading" button/the torch trigger:

EN
- Keep the welding torch away from your face and body
- Wear suitable protective goggles
- Do not point the welding torch at people
- Make sure that the wire electrode does not touch any conductive or earthed
parts (e.g. housing)
7 8

6 7

Wire threading process (press the "Wire

threading" button on the control panel):
- Hold down the button for up to one se-
(m/min, ipm) cond (briefly press the button): the
wire speed stays at 1 m/min (39.37
ipm) for the first second
- Hold down the button for up to 2.5 se-
Fdi conds: after one second, the wire
speed increases over the next 1.5 se-
conds.
1 t (s) - Hold down the button for longer than
2.5 seconds: after 2.5 seconds, the
1 2 2,5 3 4 5 wire is fed at a constant rate equal to
the wire speed set for the Fdi welding
parameter.

Setting the con- NOTE! Set the contact pressure according to the table below, so that the wire
tact pressure electrode is not deformed and proper wirefeeding is ensured.

59
 Standard values Smooth feed roll-
ers
Steel 3-4
CrNi 3-4

Standard values "Intermeshed"

feed rollers
Tubular cored elec- 3
trodes
Aluminium 1-3

Connecting the
WARNING! There is a high risk of very serious injury and damage if a gas cylin-
gas cylinder
der falls over. When using gas cylinders:
- Place them on a solid, level surface in such a way that they remain stable
- Secure the gas cylinders to prevent them from falling over

Observe the safety rules of the gas cylinder manufacturer.

1 2

1 2

Connecting the
1

1
polarity reverser
1

NOTE! Connect the polarity re-

and establishing verser according to the wire elec-
a grounding trode used.
(earthing) con- 1

nection NOTE! Check the wire electrode

packaging to determine whether
the wire electrode is for (+) or (-)
welding

60
2 3

2 3

EN

61
Adjusting the brake of the wirespool holders

General D200 wirespool holder:

Adjust the brake when using the wirespool holder for the first time and after changing the
wirespool. To do so, proceed as described in the following section "Adjusting the brake of
the D200 wirespool holder".

D100 wirespool holder:

Adjust the brake when using the wirespool holder for the first time and after changing the
wirespool. To do so, proceed as described in the following section "Adjusting the brake of
the D100 wirespool holder"

NOTE! After releasing the torch

trigger (end of welding, end of
wirefeeding), the wirespool must
stop unreeling. If it continues unreeling,
adjust the brake.

62
Adjusting the

EN
CAUTION! Risk of injury and material damage from an emerging wire electrode
brake of the D200
and moving parts due to inadvertent activation of the power source. Before com-
wirespool holder
mencing work:
- Turn the power source mains switch to the "O" position
- Disconnect the power source from the mains
- Ensure that the power source remains disconnected from the mains until all
work has been completed

Adjust the brake:

- Turn the brake to the right = increase
4

1
braking force
- Turn the brake to the left = decrease
braking force

Adjusting the
CAUTION! Risk of injury and material damage from an emerging wire electrode
brake of the D100
and moving parts due to inadvertent activation of the power source. Before com-
wirespool holder
mencing work:
- Turn the power source mains switch to the "O" position
- Disconnect the power source from the mains
- Ensure that the power source remains disconnected from the mains until all
work has been completed

Adjust the brake:

1 Tighten the knurled screw (1)
- Knurled screw fully tightened =
high braking force
(1) - Knurled screw slightly tightened =
low braking force

63
Description of MIG/MAG operating modes

Symbols

press hold release

2-step mode "2-step mode" is suitable for

- Tacking work
+
- Short weld seams
I I

t
GPr GPo

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

+ +
seams.

I I

t
GPr GPo

Special 4-step "Special 4-step mode" is ideal for welding in

mode higher power ranges. In special 4-step mo-
+ +
de, the arc starts at a low power, which ma-
I kes it easier to stabilise.
I

I-S I-E

t
GPr SL SL GPo

64
Spot welding The "Spot welding" mode is suitable for

EN
+
welded joints on overlapped sheets.

I I

t
GPr SPt GPo

2-step stitch The "2-step stitch welding" mode is suitable

welding for welding short weld seams on thin
+
sheets, to prevent the weld seams from
I dropping through the base material.
I

t
GPr SPt SPb SPt GPo

4-step stitch The "4-step stitch welding" mode is suitable

welding for welding longer weld seams on thin
+ +
sheets, to prevent the weld seams from
I dropping through the base material.
I

t
GPr SPt SPb SPt GPo

65
MIG/MAG standard manual welding

General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no
synergic function.
Changing one parameter does not result in any automatic adjustments to the other param-
eters – all variable parameters must be adjusted individually.

Available parame- The following parameters are available for MIG/MAG manual welding:
ters
Wire speed
Welding voltage
Arc-force dynamic
For influencing the short-circuiting dynamic at the instant of droplet transfer
Welding current
Only the actual value is displayed

MIG/MAG stand- 1 Press the "Process" button to select MANUAL

ard manual weld- Press the "Mode" button to select the desired MIG/MAG mode:
2
ing
2-step mode
4-step mode
Spot welding/stitch welding

3 Select and set the wire speed parameter

4 Select and set the welding voltage parameter

All parameter set values remain stored until the next time they are changed. This applies
even if the power source is switched off and on again.

5 Ensure that the grounding (earthing) connection has been established

6 Ensure that the shielding gas supply has been established
- Power source is ready for welding

Corrections dur- The arc-force dynamic parameter can be used to optimise the welding result.
ing welding
The arc-force dynamic parameter is used to influence the short-circuiting dynamic at the
moment of droplet transfer:
- = hard, stable arc
0 = neutral arc
+ = soft, low-spatter arc

66
MIG/MAG standard synergic welding

EN
MIG/MAG stand- 1 Press the "Process" button to select SYNERGIC
ard synergic Press the "Mode" button to select the desired MIG/MAG mode:
2
welding
2-step mode
4-step mode
S 4 T - Special 4-step mode
Spot welding/stitch welding

NOTE! Under certain circumstances, it may not be possible to change weld-

ing parameters that have been set for a system component (remote control,
etc.) on the control panel of the power source.

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

4 Press the "Wire diameter" button to select the diameter of the wire electrode used
5 Press the "Shielding gas" button to select the shielding gas used
6 Use the "Parameter selection" buttons to select and set the welding parameters to be
used to specify the welding power:
Sheet thickness
Welding current
Wire speed
Welding voltage

All parameter set values remain stored until the next time they are changed. This applies
even if the power source is switched off and on again.

8 Ensure that the grounding (earthing) connection has been established

9 Ensure that the shielding gas supply has been established
- Power source is ready for welding

Corrections dur- The arc length correction and arc-force dynamic parameters can be used to optimise the
ing welding welding result.

Arc length correction:

- = shorter arc, reduced welding voltage
0 = neutral arc
+ = longer arc, increased welding voltage

Arc-force dynamic:
For influencing the short-circuiting dynamic at the moment of droplet transfer
- = hard, stable arc
0 = neutral arc
+ = soft, low-spatter arc

67
Spot and stitch welding

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

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

Stitch welding is used for light-gauge sheets.

As the wire electrode is not fed continuously, the weld pool can cool down during the inter-
vals. Local overheating leading to the base material being melted through is largely avoid-
ed.

Spot welding 1 Press the "Process" button to select MANUAL or SYNERGIC

2 Press the "Mode" button to select the spot welding/stitch welding mode:
= spot welding/stitch welding
3 Set the SPt parameter in the Setup menu (spot welding time/stitch welding time) to the
desired value
4 Set the desired parameters depending on the process (MANUAL or SYNERGIC)
5 Ensure that the grounding (earthing) connection has been established
6 Ensure that the shielding gas supply has been established
- Power source is ready for welding

Stitch welding 1 Press the "Process" button to select MANUAL or SYNERGIC

2 Press the "Mode" button to select the spot welding/stitch welding mode:
= spot welding/stitch welding
3 Set the SPt parameter in the Setup menu (spot welding time/stitch welding time) to the
desired value
4 Set the SPb parameter in the Setup menu (spot welding/stitch pause time) to the de-
sired value
5 Set the Int parameter in the Setup menu (interval) to the desired value
6 Set the desired parameters depending on the process (MANUAL or SYNERGIC)
7 Ensure that the grounding (earthing) connection has been established
8 Ensure that the shielding gas supply has been established
- Power source is ready for welding

68
TIG
Start-up

EN
Commissioning
1 2

1 2

3 4

3 4

71
 6

6 NOTE! It is only necessary to con-

nect the mains cable to the power
source for multivoltage power
sources.

7 CAUTION! Risk of injury and

damage from electric shock. As
soon as the power source is
switched on, the tungsten elec-
trode in the welding torch is live.
Make sure the electrode does not
touch any persons or electrically
conductive or earthed parts (e.g.
the housing, etc.).

72
TIG welding

EN
1 Press the "Process" button to select TIG
2 Set the desired welding current

When using a welding torch with a torch trigger and TIG Multi Connector plug (with
2-step mode factory setting):
3 Place the gas nozzle down on the ignition location in such a way that there is a gap
of approx. 2 to 3 mm (0.078 to 0.118 in.) between the tungsten electrode and the
workpiece
4 Gradually tilt the welding torch up until the tungsten electrode touches the workpiece
5 Pull back and hold the torch trigger
– Shielding gas flows
6 Raise the welding torch and rotate it into its normal position
– The arc ignites
7 Carry out welding

3 4 6

73
Description of TIG operating modes

Symbols and
their explanations

Pull back and hold the Release the torch trigger Push forward and hold Release the torch trigger
torch trigger forwards the torch trigger backwards

GPr GPo
Gas pre-flow time Gas post-flow time
I-S I-E
Starting-current phase: the temperature is Final current phase: to prevent crater
raised gently at low welding current, so cracks or cavitations
that the filler metal can be positioned cor-
rectly
tS tE
Starting current duration Final current duration
tup tdown
UpSlope phase: the welding current is DownSlope phase: the welding current is
continually increased continuously reduced
Duration: 0.5 seconds Duration: 0.5 seconds
I-1 I-2
Main current phase (welding current Reduced current phase: intermediate low-
phase): uniform thermal input into the ering of the welding current in order to pre-
base material, whose temperature is vent any local overheating of the base
raised by the advancing heat material

2-step mode

I I-1

tup tdown GPo

1 2 3

1 Place the tungsten electrode onto the workpiece and then pull the torch trigger back
and hold => shielding gas flows
2 Raise the tungsten electrode => arc ignites
3 Release torch trigger => end of welding

74
4-step mode

EN
I
I-1 I-1

I-2

I-S I-E

ts tup tdown te GPo

1 2 3 4 5 6 7
4-step mode with intermediate lowering I-2

Intermediate lowering means that the welder uses the torch trigger during the main current
phase to lower the welding current to the specified reduced current I-2.

1 Place the tungsten electrode onto the workpiece and then pull the torch trigger back
and hold => shielding gas flows
2 Raise the tungsten electrode => start of welding with starting current I-S
3 Release torch trigger => welding with main current I-1
4 Push forward and hold the torch trigger => activation of intermediate lowering with re-
duced current I-2
5 Release torch trigger => welding with main current I-1
6 Pull back and hold the torch trigger => lowering to final current I-E
7 Release torch trigger => end of welding

75
Pulse welding

Pulse welding Pulse welding is welding with a pulsing welding current. It is used for out-of-position weld-
ing of steel pipes or when welding thin sheets.

In these applications, the welding current set at the start of welding is not always ideal for
the whole welding process:
- if the amperage is too low, the base material will not melt sufficiently
- if overheating occurs, the liquid weld pool may drip.

Setting range: 1 - 990 Hz

Operating principle:
- A low base current I-G rises steeply to the significantly higher pulse current I-P and
drops back to the base current I-G after the Duty cycle dcY time.
- This results in an average current that is lower than the set pulse current I-P.
- During pulse welding, small sections of the welding location melt quickly and then rap-
idly re-solidify.

NOTE! The power source controls the Duty cycle dcY parameter and base cur-
rent I-G according to the set pulse current (welding current) and pulse frequency.

1/F-P
I
dcY

I-P
I-E
I-G I-S

tup tdown t

Pulse welding - welding current curve

Adjustable parameters:
I-S = Starting current F-P = Pulse frequency (1/F-P = time
interval between two pulses)
I-E = Final current I-P = Pulse current (set welding cur-
rent)

Fixed parameters:
tup = UpSlope dcY = Duty cycle
tDown = DownSlope I-G = Base current

Activating pulse welding:

1 Set a value for the F-P setup parameter (pulse frequency)

76
Rod electrode
Start-up

EN
Preparatory work
1

1 1

NOTE! Check the rod electrode

packaging to determine whether
the rod electrode is for (+) or (-)
welding

2 3

2 3

CAUTION! Risk of injury and damage from electric shock. As soon as the power
source is switched on, the rod electrode is live. Make sure the rod electrode does
not touch any persons or electrically conductive or earthed parts (e.g. the hous-
ing, etc.).
4

4 5

NOTE! It is only necessary to con-

nect the mains cable to the power
source for multivoltage power
sources.

79
 6

MMA welding 1 Press the "Process" button to select STICK

2 Set the desired welding current
- Power source is ready for welding

80
Functions for optimising the welding process

EN
Arc-force dynam-
The arc-force dynamic is used to influence the short-circuiting dynamic at the moment of
ic
droplet transfer.
- = hard, stable arc
0 = neutral arc
+ = soft, low-spatter arc

HotStart (Hti) This function is activated at the factory.

function
Advantages
- Improved ignition properties, even when using electrodes with poor ignition properties
- Better fusion of the base material during the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions

Legend
I (A)
Hti: Hot-current time,
0 - 2 s, factory setting 0.5 s
Hti HCU: HotStart current,
300 HCU > IH 100 - 200%, factory setting 150%
IH: Main current = set welding current
NOTE! The Hti and HCU parame-
200 ters can be set in the Setup menu.
HCU
Function
IH
During the specified hot-current time (Hti),
the welding current is increased to a certain
t (s) value. This value (HCU) is higher than the
selected welding current (IH).
0,5 1 1,5

Anti-stick (Ast) This function is activated at the factory.

function
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will
tend to stick. This may also cause the rod electrode to burn out.

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

Deactivating the function:

1 Set the Ast (anti-stick) setup parameter to OFF

81
82
EasyJobs
Saving and retrieving EasyJobs

EN
General The "Save" buttons allow two EasyJobs to be saved. The adjustable parameters on the
control panel are saved as EasyJobs.

NOTE! Setup parameters are not saved as EasyJobs.

Saving an Easy- 1 Press and hold one of the "Save" buttons to save the current settings on the control
Job panel, e.g.:

- The left indicator displays "Pro"

- After a short time, the left indicator switches to the original value
2 Release the "Save" button

Retrieving an 1 To retrieve saved settings, press the corresponding "Save" button briefly, e.g.:
EasyJob
- The control panel will show the saved settings

Deleting an Easy- 1 Press and hold the relevant "Save" button to delete the memory content of that "Save"
Job button, e.g.:

- The left indicator displays "Pro".

- After a short time, the left indicator switches to the original value
2 Keep the "Save" button held down
- The left display shows "CLr".
- After a while, both displays show "---"
3 Release the "Save" button

85
86
Setup menu
Operation

EN
Operation NOTE! Accessing the Setup menu is described with reference to the MIG/MAG
standard synergic (SYNERGIC) welding process. Access is the same for the oth-
er welding processes.

Accessing the Setup menu:

1 Press the "Process" button to select the SYN-
ERGIC welding process (to access the Setup
menu for MIG/MAG standard manual welding,
press the "Process" button and select the MAN-
UAL welding process)
2 Press and hold the "Mode" button

3 Press the "Process" button

4 Release the "Mode" and "Process" buttons

Changing welding parameters

5 Select the desired setup parameter using the
left-hand adjusting dial

6 Alter the setup parameter value using the right-

hand adjusting dial

Exiting the Setup menu

7 Press and hold the "Mode" button

8 Press the "Process" button

9 Release the "Mode" and "Process" buttons

89
Parameters for MIG/MAG standard manual welding

Parameters for GPr Gas pre-flow time

MIG/MAG stand- Unit: Seconds
ard manual weld- Setting range: 0 - 9.9
ing
Factory setting: 0.1

GPo Gas post-flow time

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

Fdi Feeder inching speed

Unit: m/min (ipm)
Setting range: 1 - 18.5 (39.37 - 728.35)
Factory setting: 10 (393.7)

bbc Burn-back effect

Burn-back effect through wire withdrawal at the end of welding
Unit: -
Setting range: Aut (automatic), 0 - 0.3
Factory setting: 0

IGc Ignition current

Unit: Ampere
Setting range: 100 - 390
Factory setting: 300

Ito Length of wire that is fed before the safety cut-out trips
Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF

NOTE! The ignition time-out function (Ito) is a safety feature – if the power
source determines that no ignition has occurred after the preset wire length
has been fed, wirefeeding is stopped.

SPt Spot welding time

Unit: Seconds
Setting range: OFF, 0.3 - 5
Factory setting: 1

SPb Spot pause time

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

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

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds to restore
the factory settings
- when "PrG" appears on the digital display, the power source has been reset

90
 NOTE! If the power source is reset, the majority of the applied settings are

EN
deleted. The following values remain:
- Welding circuit resistance and welding circuit inductivity
- Country-specific setting

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

91
Parameters for MIG/MAG standard synergic welding

Parameters for GPr Gas pre-flow time

MIG/MAG stand- Unit: Seconds
ard synergic Setting range: 0 - 9.9
welding
Factory setting: 0.1

GPo Gas post-flow time

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

SL Slope
Unit: Seconds
Setting range: 0 - 9.9
Factory setting: 1

I-S Starting current

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

I-E Final current

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

t-S Starting current duration

Unit: Seconds
Setting range: 0 - 9.9
Factory setting: 0

t-E Final current duration

Unit: Seconds
Setting range: 0 - 9.9
Factory setting: 0

Fdi Feeder inching speed

Unit: m/min (ipm)
Setting range: 1 - 18.5 (39.37 - 728.35)
Factory setting: 10 (393.7)

bbc Burn-back effect

Burn-back effect through wire withdrawal at the end of welding
Unit: -
Setting range: Aut (automatic), 0 - 0.2
Factory setting: Aut

Ito Length of wire that is fed before the safety cut-out trips
Unit: mm (in.)
Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94)
Factory setting: OFF

92
 NOTE! The ignition time-out function (Ito) is a safety feature – if the power
source determines that no ignition has occurred after the preset wire length

EN
has been fed, wirefeeding is stopped.

SPt Spot welding time

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

SPb Spot pause time

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

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

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds to restore
the factory settings
- when "PrG" appears on the digital display, the power source has been reset.

NOTE! If the power source is reset, the majority of the applied settings are
deleted. The following values remain:
- Welding circuit resistance and welding circuit inductivity
- Country-specific setting

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

93
Parameters for TIG welding

Parameters for F-P Pulse frequency

TIG welding Unit: Hertz
Setting range: OFF; 1 - 990
(up to 10 Hz: in 0.1 Hz increments)
(up to 100 Hz: in 1 Hz increments)
(over 100 Hz: in 10 Hz increments)
Factory setting: OFF

tUP UpSlope
Unit: Seconds
Setting range: 0.01 - 9.9
Factory setting: 0.5

tdo DownSlope
Unit: Seconds
Setting range: 0.01 - 9.9
Factory setting: 1

I-S Starting current

Unit: % of main current
Setting range: 1 - 200
Factory setting: 35

I-2 Reduced current

Unit: % of main current
Setting range: 1 - 100
Factory setting: 50

I-E Final current

Unit: % of main current
Setting range: 1 - 100
Factory setting: 30

GPo Gas post-flow time

Unit: Seconds
Setting range: 0 - 9.9
Factory setting: 9.9

tAC Tacking
Unit: Seconds
Setting range: OFF, 0.1 - 9.9
Factory setting: OFF

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds to restore
the factory settings
- when "PrG" appears on the digital display, the power source has been reset.

NOTE! If the power source is reset, the majority of the applied settings are
deleted. The following values remain:
- Welding circuit resistance and welding circuit inductivity
- Country-specific setting

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

94
Parameters for MMA welding

EN
Setup parameters HCU HotStart current
for MMA welding Unit: %
Setting range: 100 - 200
Factory setting: 150

Hti Hot current time

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

Ast Anti-stick function

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

FAC Reset power source to factory settings

Press and hold one of the "Parameter selection" buttons for two seconds to restore
the factory settings
- when "PrG" appears on the digital display, the power source has been reset.

NOTE! If the power source is reset, the majority of the applied settings are
deleted. The following values remain:
- Welding circuit resistance and welding circuit inductivity
- Country-specific setting

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

95
96
Setup menu - Level 2
Operation

EN
Operation
Accessing the Setup menu:
1 Press the "Process" button to select the SYN-
ERGIC welding process (to access the Setup
menu for MIG/MAG standard manual welding,
press the "Process" button and select the MAN-
UAL welding process)
2 Press and hold the "Mode" button

3 Press the "Process" button

4 Release the "Mode" and "Process" buttons

5 Select the "2nd" setup parameter using the left-

hand adjusting dial

6 Press and hold the "Mode" button

7 Press the "Process" button

Changing welding parameters

1 Select the desired setup parameter using the
left-hand adjusting dial

2 Alter the setup parameter value using the right-

hand adjusting dial

Exiting the Setup menu

1 Press and hold the "Mode" button

2 Press the "Process" button

3 Release the "Mode" and "Process" buttons

- A parameter is displayed in the first level of
the Setup menu
4 Press and hold the "Mode" button

5 Press the "Process" button

6 Release the "Mode" and "Process" buttons

99
Parameters for MIG/MAG standard manual welding

Parameters for
SEt Country-specific setting (Standard/USA) Std/US
MIG/MAG welding
Unit: -
Setting range: Std, US (Standard/USA)

If Std is selected, the EURO welding programs are used as stated in the welding
program table.
If US is selected, the US welding programs are used as stated in the welding pro-
gram table.

Factory setting:
Standard version: Std (measurements: cm/mm)
USA version: US (measurements: inches)
FUS Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse
protection.

Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V mains voltage)
Factory setting: OFF
r Welding circuit resistance (in mOhm)
See section "Measuring welding circuit resistance r"
L Welding circuit inductivity (in microhenrys)
See section "Displaying welding circuit inductivity L"
EnE Real Energy Input

Unit: kJ
Setting range: ON / OFF
Factory setting: OFF

Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three-
digit display, the following display format has been selected:

Value in kJ: 1 to 999 / indicator on display: 1 to 999

Value in kJ: 1000 to 9999 / indicator on display: 1.00 to 9.99 (without unit digit,
e.g. 5270 kJ -> 5.27)
Value in kJ: 10000 to 99999 / indicator on display: 10.0 to 99.9
(without unit digit or tens digit, e.g. 23580 kJ -> 23.6)

100
Parameters for MIG/MAG standard synergic welding

EN
Parameters for
SEt Country-specific setting (Standard/USA) Std/US
MIG/MAG welding
Unit: -
Setting range: Std, US (Standard/USA)

If Std is selected, the EURO welding programs are used as stated in the welding
program table.
If US is selected, the US welding programs are used as stated in the welding pro-
gram table.

Factory setting:
Standard version: Std (measurements: cm/mm)
USA version: US (measurements: inches)
FUS Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse
protection.

Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V mains voltage)
Factory setting: OFF
r Welding circuit resistance (in mOhm)
See section "Measuring welding circuit resistance r"
L Welding circuit inductivity (in microhenrys)
See section "Displaying welding circuit inductivity L"
EnE Real Energy Input

Unit: kJ
Setting range: ON / OFF
Factory setting: OFF

Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three-
digit display, the following display format has been selected:

Value in kJ: 1 to 999 / indicator on display: 1 to 999

Value in kJ: 1000 to 9999 / indicator on display: 1.00 to 9.99 (without unit digit,
e.g. 5270 kJ -> 5.27)
Value in kJ: 10000 to 99999 / indicator on display: 10.0 to 99.9
(without unit digit or tens digit, e.g. 23580 kJ -> 23.6)
ALC Arc length correction display
(For setting how the arc length correction parameter is displayed)

Setting range: ON / OFF

Factory setting: OFF

Set to ON if the welding voltage parameter is selected and set on the con-
trol panel
- The left-hand display shows the arc correction value for three seconds
- The right-hand display shows the value for the welding voltage at the same
time

101
Parameters for MMA welding

Parameters for
SEt Country-specific setting (Standard/USA) Std/US
MMA welding
Unit: -
Setting range: Std, US (Standard/USA)

If Std is selected, the EURO welding programs are used as stated in the welding
program table.
If US is selected, the US welding programs are used as stated in the welding pro-
gram table.

Factory setting:
Standard version: Std (measurements: cm/mm)
USA version: US (measurements: inches)
r Welding circuit resistance (in mOhm)
See section "Measuring welding circuit resistance r"
L Welding circuit inductivity (in microhenrys)
See section "Displaying welding circuit inductivity L"
FUS Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse
protection.

Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V mains voltage)
Factory setting: OFF

102
Parameters for TIG welding

EN
Parameters for
SEt Country-specific setting (Standard/USA) Std/US
TIG welding in the
Setup menu
Unit: -
level 2
Setting range: Std, US (Standard/USA)
Factory setting:
Standard version: Std (measurements: cm/mm)
USA version: US (measurements: inches)
FUS Mains fuse protection
The maximum possible welding power is limited by the rating of the mains fuse
protection.

Unit: A
The available mains fuse ratings are determined by the SEt parameter setting:
SEt parameter set as Std: OFF / 10 / 13 / 16
SEt parameter set as US: OFF / 15 / 20 (only for 120 V mains voltage)
Factory setting: OFF

103
104
Optimising welding quality
Measuring welding circuit resistance r

EN
General Measuring the welding circuit resistance r makes it possible to have a constant welding re-
sult 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. The use of arc length correction is no longer required.

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

If the welding circuit resistance r has been measured correctly, the set welding voltage will
correspond exactly to the welding voltage at the arc. If you manually measure the voltage
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 of the hosepack.

NOTE! The welding circuit resistance r depends on the hosepack used:

- If the length or cross-sectional area of the hosepack has changed, measure
the welding circuit resistance r again
- Measure the welding circuit resistance for every welding process separately
with the appropriate welding power-leads

Measure the NOTE! In order to obtain good welding results, it is essential to measure the weld-
welding circuit re- ing circuit resistance correctly. Make sure that the contact between the earthing
sistance r clamp and the workpiece is on a cleaned workpiece surface.

1 Establish a grounding (earthing) connection to the workpiece

2 Accessing the Level 2 (2nd) Setup menu
3 Select parameter "r"
4 Remove the gas nozzle from the welding torch
5 Screw on the contact tip

NOTE! Make sure that the contact between the contact tip and the workpiece is
on a cleaned workpiece surface.

6 Place the contact tip flush against the workpiece surface

7 Press the torch trigger briefly
- The welding circuit resistance is calculated. "run" is shown on the display during
the measurement

The measurement is finished when the welding circuit resistance is shown on the display
in mOhm ( for example, 11.4).

8 Fit the gas nozzle back onto the welding torch

107
Displaying welding circuit inductivity L

General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore
affects the welding process. It is important to lay the hosepacks correctly in order to obtain
the best possible welding result.

Displaying weld- The setup parameter "L" is used to display the most recently calculated welding circuit in-
ing circuit induc- ductivity. The welding circuit inductivity is calibrated at the same time as the welding circuit
tivity L resistance r is calculated. Detailed information can be found in the "Measuring welding cir-
cuit resistance r" section.

1 Access the setup menu level 2 (2nd)

2 Select parameter “L”

The most recently calculated welding circuit inductivity L is shown on the right-hand digital
display.

L ... Welding circuit inductivity (in microhenry)

Laying the hose-

packs correctly

108
Troubleshooting and maintenance
Display service parameters

EN
Service parame- Various service parameters can be retrieved by pressing the left and right-hand "Parame-
ters ter selection" buttons at the same time.

Opening the display

1 Press and hold the "Parameter selection" button (left)

2 Press the "Parameter selection" button (right)

3 Release the "Parameter selection" buttons

- The first welding parameter, "Firmware version", is displayed
4 Select the desired service parameter using the left-hand adjust-
ing dial

Available parameters
Firmware version Example:
1.00 | 4.21
Welding program configuration Example:
2 | 491
Number of the currently selected welding program Example:
r 2 | 290
Indicates the actual arc time since first use Example:
Note: The arc time indicator is not suitable as a basis for calcu- 654 | 32.1
lating hiring fees, warranty services, etc. = 65,432.1 hours
= 65,432 hours 6 mins
Motor current for wire drive in amperes Example:
(The value changes as soon as the motor is running) iFd | 0.0
2nd menu level for service technicians 2nd

111
Troubleshooting

Safety
WARNING! Work that is carried out incorrectly can cause serious injury and dam-
age. All the work described below must only be carried out by trained and quali-
fied personnel. Do not carry out any of the work described below until you have
fully read and understood the following documents:
- This document
- all the operating instructions for the system components, especially the safe-
ty rules

WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- Turn the power source mains switch to the "O" position
- Disconnect the power source from the mains
- Ensure that the power source remains disconnected from the mains until all
work has been completed

After opening the device, use a suitable measuring instrument to check that elec-
trically charged components (e.g. capacitors) have been discharged.

WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for grounding the housing and must NOT be replaced by any other screws
that do not provide a reliable ground conductor connection.

Fault diagnosis Make a note of the serial number and configuration of the device and contact our After-
Sales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful

Power source has no 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 lead, ensure that the mains plug is plugged in

Cause: Mains socket or mains plug faulty

Remedy: Replace faulty parts

Cause: Mains fuse protection

Remedy: Change the mains fuse protection

Nothing happens when the torch trigger is pressed

Power source mains switch is ON and indicators are lit up

Cause: Welding torch or welding torch control line is faulty

Remedy: Replace the welding torch

112
No welding current
Mains switch is on, one of the overtemperature service codes "to" is displayed. Detailed

EN
information on the service codes "to0" to "to6" can be found in the section "Displayed ser-
vice codes".

Cause: Overloading
Remedy: Check duty cycle

Cause: Thermostatic automatic circuit breaker has been tripped

Remedy: Wait until the power source automatically comes back on after the end of the
cooling phase

Cause: Limited supply of cooling air

Remedy: Clean air filter, ensure accessibility to cooling air ducts

Cause: The fan in the power source is faulty

Remedy: Contact After-Sales Service

No welding current
Mains switch is ON and indicators are lit up

Cause: Grounding (earthing) connection is incorrect

Remedy: Check the grounding (earthing) connection for correct polarity

Cause: There is a break in the power cable in the welding torch

Remedy: Replace the welding torch

No shielding gas
All other functions are OK

Cause: Gas hose is not connected to the correct connection socket for the current
welding process
Remedy: Connect the gas hose to the correct connection socket for the current welding
process

Cause: Gas cylinder is empty

Remedy: Change the gas cylinder

Cause: Gas pressure regulator faulty

Remedy: Replace gas pressure regulator

Cause: Gas hose is not fitted or is damaged

Remedy: Fit or change the gas hose

Cause: Welding torch is faulty

Remedy: Change the welding torch

Cause: Gas solenoid valve faulty

Remedy: Contact After-Sales Service

113
 Irregular wire speed
Cause: Braking force has been set too high
Remedy: Loosen the brake

Cause: Hole in the contact tip is too narrow

Remedy: Use a suitable contact tip

Cause: Faulty inner liner in welding torch

Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary

Cause: The wirefeeder rollers are not suitable for the wire electrode being used
Remedy: Use suitable feed rollers

Cause: Feed rollers have the wrong contact pressure

Remedy: Optimise the contact pressure

Wirefeed problems
Cause: Incorrect arrangement of welding torch hosepack
Remedy: Arrange the welding torch hosepack in as straight a line as possible, avoiding
bends

Welding torch becomes very hot

Cause: The design dimensions of the welding torch are not sufficient for this task
Remedy: Observe the duty cycle and loading limits

Poor weld properties

Cause: Incorrect welding parameters
Remedy: Check the settings

Cause: Poor ground earth connection

Remedy: Ensure good contact to workpiece

Cause: Inadequate or no protective gas shield

Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.

Cause: Welding torch is leaking

Remedy: Change the welding torch

Cause: Wrong contact tip, or contact tip is worn out

Remedy: Replace the contact tip

Cause: Wrong wire alloy or wrong wire diameter

Remedy: Check the wire electrode that has been inserted

Cause: Wrong wire alloy or wrong wire diameter

Remedy: Check weldability of the base material

Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas

114
Displayed service If an error message that is not described here appears on the displays, proceed as follows

EN
codes to resolve the problem:

1 Turn the power source mains switch to the "O" position

2 Wait 10 seconds
3 Turn the mains switch to the "I" position

If the error occurs again despite several attempts to eliminate it, or if the troubleshooting
measures listed here are unsuccessful:

1 Make a note of the error message displayed

2 Note down the configuration of the power source
3 Contact our After-Sales Service team with a detailed description of the error

ELn | 13
Cause: Invalid change of welding process during welding
Remedy: During welding do not carry out any illegal change of the welding process, re-
set error message by pressing any button

Err | IP
Cause: The control unit of the power source has detected a primary overvoltage
Remedy: Check mains voltage, if the service code still remains, switch off the power
source, wait for 10 seconds and then switch the power source on again, if the
error keeps recurring, contact After-Sales Service

Err | 51
Cause: Mains undervoltage: the mains voltage has fallen below the tolerance range
Remedy: Check the mains voltage. If the service code remains, contact After-Sales
Service

Err | 52
Cause: Mains overvoltage: the mains voltage has risen above the tolerance range
Remedy: Check the mains voltage. If the service code remains, contact After-Sales
Service

EFd | 14, EFd | 81, EFd | 83

Cause: Fault in the wirefeed system - overcurrent in the wirefeeder motor (2-roller
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
drive; check that there is no entangled wire in the 2-roller drive

Cause: Wirefeeder motor is sticking or defective

Remedy: Check the wirefeeder motor or contact After-Sales Service

to0 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the PC board LSTMAG20 (secondary circuit)

Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on

115
 to2 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature in the secondary circuit of the power source

Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on

to3 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the PC board LSTMAG20 (wirefeeder)

Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on

to6 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the PC board LSTMAG20 (voltage doubler)

Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on

to7 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature in the power source

Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on

to8 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the power module

Remedy: Allow power source to cool down, check that fan is on

to9 | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the PFC module

Remedy: Allow power source to cool down, check that fan is on

toA | xxx
Note: xxx stands for a temperature value

Cause: Overtemperature on the PC board LSTMAG20(PFC)

Remedy: Allow power source to cool down, check that fan is on

toF | xxx
Cause: The power source's safety cut-out reacted in order to prevent tripping of the
mains fuse.
Remedy: After a pause in welding of around 90 s, the message disappears and the
power source is operational again.

116
tu0 | xxx
Note: xxx stands for a temperature value

EN
Cause: Undertemperature on the PC board (secondary circuit)
Remedy: Place power source in a heated room and allow it to warm up

tu2 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature in the power source secondary circuit

Remedy: Place power source in a heated room and allow it to warm up

tu3 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature on the PC board LSTMAG20 (wirefeeder)

Remedy: Place power source in a heated room and allow it to warm up

tu6 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature on the PC board LSTMAG20 (voltage doubler)

Remedy: Place power source in a heated room and allow it to warm up

tu7 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature in the power source

Remedy: Place power source in a heated room and allow it to warm up

tu8 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature on the power module

Remedy: Place power source in a heated room and allow it to warm up

tu9 | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature on the PFC module

Remedy: Place power source in a heated room and allow it to warm up

tuA | xxx
Note: xxx stands for a temperature value

Cause: Undertemperature on the PC board LSTMAG20(PFC)

Remedy: Place power source in a heated room and allow it to warm up

no | Prg
Cause: No saved program selected
Remedy: Select saved program

117
 no | IGn
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 power source
safety cut-out has tripped.
Remedy: Shorten the wire end; press the torch trigger again; clean the surface of the
workpiece; if necessary, increase the wire length until the safety cut-out trips
in "Set-up menu: Level 2".

no | ARC
Cause: Arc break during TIG welding
Remedy: Press the torch trigger repeatedly, clean the surface of the workpiece

EPG | 17
Cause: The welding program selected is invalid
Remedy: Select valid welding program

EPG | 35
Cause: Measurement of the welding circuit resistance "r" failed
Remedy: Check grounding cable, current cable or hosepack and replace if necessary,
recalculate welding circuit resistance "r"

118
Care, maintenance and disposal

EN
General Under normal operating conditions, the welding system requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the weld-
ing system remains in a usable condition for many years.

Safety
WARNING! Work that is carried out incorrectly can cause serious injury and dam-
age. All the work described below must only be carried out by trained and quali-
fied personnel. Do not carry out any of the work described below until you have
fully read and understood the following documents:
- This document
- all the operating instructions for the system components, especially the safe-
ty rules

WARNING! An electric shock can be fatal. Before starting the work described be-
low:
- Turn the power source mains switch to the "O" position
- Disconnect the power source from the mains
- Ensure that the power source remains disconnected from the mains until all
work has been completed

After opening the device, use a suitable measuring instrument to check that elec-
trically charged components (e.g. capacitors) have been discharged.

WARNING! An inadequate ground conductor connection can cause serious inju-

ry or damage. The housing screws provide a suitable ground conductor connec-
tion for grounding the housing and must NOT be replaced by any other screws
that do not provide a reliable ground conductor connection.

At every start-up - Ensure that the mains plug and mains cable as well as the welding torch / electrode
holder are undamaged. Replace any damaged components
- Ensure that a proper ground earth connection has been established to the workpiece
- Check that there is an all-round clearance of 0.5 m (1 ft. 8 in.) around the device to
ensure that cooling air can flow in and out freely

NOTE! Air inlets and outlets must never be covered, not even partially.

119
As required, at
1 2

1 2
least every two
months

CAUTION! Risk of damage. Ensure that the air filter is dry when it is fitted.

Every 6 months NOTE! Risk of damage to electronic components. Do not bring the air nozzle too
close to electronic components.

- Dismantle device side panels and clean inside of device with dry, reduced com-
pressed air
- If a lot of dust has accumulated, clean the cooling air ducts

Disposal Dispose of in accordance with the applicable national and local regulations.

120
Removing stiff drive rollers

EN
Removing a stiff NOTE! If a drive roller is difficult to remove by hand, the knurled screw on the
drive roller D100 brake can be used to remove it.
1 2

1 2

3 4

3 4

121
122
Technical data
Technical data

EN
Special voltages For devices designed for special voltages, the technical data on the rating plate applies.

Explanation of Duty cycle (D.C.) is the proportion of time in a 10-minute cycle at which the device may be
the term "duty cy- operated at its rated output without overheating.
cle"
NOTE! The D.C. values specified on the rating plate are based on an ambient
temperature of 40°C. If the ambient temperature is higher, either the D.C. or out-
put must be reduced accordingly.

Example: Welding at 150 A at 60% D.C.

- Welding phase = 60% of 10 minutes = 6 minutes
- Cooling phase = remaining time = 4 minutes
- After the cooling phase, the cycle begins anew.

60 %
6 Min. 4 Min.

150 A

0A
0 Min. 6 Min. 10 Min.

If the device is to be continuously operated without stopping:

1 look in the technical data for a D.C. value of 100% for the reigning ambient tempera-
ture.
2 Reduce the output or amperage in line with this value so that the device can remain in
use without observing a cooling phase.

125
TSt 2200
Mains voltage (U1) 1x 230 V
Max. effective primary current (I1eff) 16 A
Max. primary current (I1max) 26 A
Mains fuse protection 16 A slow-blow
Max. apparent power (S1max) 5.98 kVA

Mains voltage tolerance -20 / +15%

Grid frequency 50/60 Hz
Cos phi (1) 0.99
Max. permissible mains impedance Zmax on 250.02 mOhm
PCC1)
Recommended earth-leakage circuit breaker Type B

Welding current range (I2)

MIG/MAG 10 - 210 A
Rod electrode 10 -180 A
TIG 10 - 230 A
Welding current at 10 min/40 °C (104 °F) 30% 60% 100%
MIG/MAG U1 230 V 210 A 170 A 150 A
Welding current at 10 min/40 °C (104 °F) 35% 60% 100%
Rod electrode U1 230 V 180 A 150 A 130 A
Welding current at 10 min/40 °C (104 °F) 35% 60% 100%
TIG U1 230 V 230 A 200 A 170 A
Output voltage range according to standard characteristic
(U2)
MIG/MAG 14.5 – 24.5 V
Rod electrode 20.4 - 27.2 V
TIG 10.4 - 19.2 V
Open circuit voltage (U0 peak / U0 r.m.s) 90 V

Degree of protection IP 23
Type of cooling AF
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE
Dimensions l x w x h 560 x 215 x 370 mm
22.05 x 8.46 x 14.57 in.
Weight 15 kg
33.07 lb.

Max. shielding gas pressure 5 bar

72.52 psi

Wire speed 1.5 - 18 m/min

59.06 - 708.66 ipm
Wire drive 2-roller drive

126
Wire diameter 0.6 - 1.2 mm
0.025 - 0.047 in.

EN
Wirespool diameter max. 200 mm
max. 7.87 in.
Wirespool weight max. 6.8 kg
max. 14.99 lb
Max. noise emission (LWA) 65.5 dB
1) Interface to a 230 V, 50 Hz public grid

127
TSt 2200 MV
Mains voltage (U1) 1x 120 V
Max. effective primary current (I1eff) 15 A
Max. primary current (I1max) 20 A
Mains fuse protection 15 A slow-blow
Max. apparent power (S1max) 2.40 kVA

Mains voltage (U1) 1x 120 V

Max. effective primary current (I1eff) 20 A
Max. primary current (I1max) 29 A
Mains fuse protection 20 A slow-blow
Max. apparent power (S1max) 3.48 kVA

Mains voltage (U1) 1x 230 V

Max. effective primary current (I1eff) 16 A
Max. primary current (I1max) 26 A
Mains fuse protection 16 A slow-blow
Max. apparent power (S1max) 5.98 kVA

Mains voltage (U1) 1x 240 V

Max. effective primary current (I1eff) 15 A
Max. primary current (I1max) 26 A
Mains fuse protection 15 A slow-blow
Max. apparent power (S1max) 6.24 kVA

Mains voltage tolerance -20 / +15%

Grid frequency 50/60 Hz
Cos phi (1) 0.99
Max. permissible mains impedance Zmax on 250.02 mOhm
PCC1)
Recommended earth-leakage circuit breaker Type B

Welding current range (I2)

MIG/MAG 10 - 210 A
Rod electrode 10 -180 A
TIG 10 - 230 A
Welding current at 10 min/40 °C (104 °F) 30% 60% 100%
MIG/MAG U1 120 V (15 A) 105 A 95 A 80 A
U1 120 V (20 A) 135 A 120 A 105 A
U1 230 V 210 A 170 A 150 A
Welding current at 10 min/40 °C (104 °F) 35% 60% 100%
Rod electrode U1 120 V (15 A) 90 A 80 A 70 A
U1 120 V (20 A) 110 A 100 A 90 A
U1 230 V 180 A 150 A 130 A
Welding current at 10 min/40 °C (104 °F) 35% 60% 100%
TIG U1 120 V (15 A) 135 A 120 A 105 A

128
 U1 120 V (20 A) 160 A 150 A 130 A
U1 230 V 230 A 200 A 170 A

EN
Output voltage range according to standard characteristic
(U2)
MIG/MAG 14.5 – 24.5 V
Rod electrode 20.4 - 27.2 V
TIG 10.4 - 19.2 V
Open circuit voltage (U0 peak / U0 r.m.s) 90 V

Degree of protection IP 23
Type of cooling AF
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE, CSA
Dimensions l x w x h 560 x 215 x 370 mm
22.05 x 8.46 x 14.57 in.
Weight 15.2 kg
33.51 lb.

Max. shielding gas pressure 5 bar

72.52 psi

Wire speed 1.5 - 18 m/min

59.06 - 708.66 ipm
Wire drive 2-roller drive
Wire diameter 0.6 - 1.2 mm
0.025 - 0.047 in.
Wirespool diameter max. 200 mm
max. 7.87 in.
Wirespool weight max. 6.8 kg
max. 14.99 lb
Max. noise emission (LWA) 65.5 dB
1) Interface to a 230 V, 50 Hz public grid

129
130
 EN

131
 FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: [email protected]
www.fronius.com

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Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations