MIG Welding Equipment Operations Reference Guide

Transcription

1 MIG Welding Equipment Operations Reference Guide Fronius USA Office:

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3 General Information Table of Contents Conversion Charts page 1 3d-Drawing page 2 Weld System Component Layout page 3 Configurations page 4 Power Source Models page 7 Nameplate page 9 Technical Specifications page 10 Connections and Controls page 11 Use and Operation Initial Set-up and Turn-on page 35 Quick Reference Sheet, TPS page 36 Weld Correction Value page 41 Front Panel, TPS page 42 Front Panel, CMT page 45 Quick Reference Sheet, TsT page 55 Front Panel, TsT page 57 Processes Synergic Lines page 48 Jobs page 49 Resistance Test page 50 Push-Pull Alignment page 51 Cooler Verification page 53 Output Tests page 54 Wire Feeder Models page 15 Motor-plate page 17 Connections and Controls page 18 Welding Torch page 22 Cooler page 23 Weld Process Overview page 24 MIG, short circuit page 26 MIG, pulse page 27 Gas Characteristics page 28 Torch Movement and Position page 32 Discontinuity page 33 Consumables Drive Rolls page 61 Liners page 62 Contact Tips page 63 Torch Breakdown page 64 Changing a Liner page 67 Part Numbers page 69 Interface Models page 76 General Information page 77 Inputs/Outputs page 78 Signal Interaction page 82 Fronius Xplorer page 85 Basic Troubleshooting page 87

4 General Information Conversion Charts Fraction* Decimal* Millimeters Wire Guage** 2/ / / Ft 3 /hour L/min Inch/min Mm/sec Cm/min Meters Feet / / / ¼ / / Conversion Factors Inch/min to Mm/sec x Inch/min to Cm/min x 2.54 Mm/sec to Inch/min x Cm/min to Inch/min x Ft 3 /hour to L/min x L/min to Ft 3 /hour x Meter to Feet x Feet to Meter X

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

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

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

9 Weld System Configurations Data Control Voltages Data Control Voltages Welding Current Welding Current Shielding Gas Wire Coolant Lines Coolant Lines Robot Mounted Wire Feeder The wire feeder can be mounted directly to the robot arm or automated system. This type of configuration has no built in mechanism for manually starting the torch and is intended only for robotic/automated applications. Interconnecting hose packs can vary in length. The length must be accommodate for the distance between the power source and feeder but also for the motion of the robot. This configuration allows for the wire feeder to be kept within a restricted area while the power source is left accessible area for monitoring and adjusting parameters

10 Power Source Models TPS amp pulse machine with a built in wire feeder. Multi-voltage model is available Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of filler metal, gas types, and wire diameters Power source is lightweight, easily updateable, and expanded through a plug and play interface. Trans Synergic TS) 3200/4000/5000 Three amp ranges available 320, 400, and 500. Multi-voltage model is available Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal, gas types, and wire diameters Power source is equally suited to robotic, automated, and manual tasks based on application demands. Trans-Pulse Synergic TPS) 3200/4000/5000 Three amp ranges available 320, 400, and 500. Multi-voltage model is available Welder is capable of pulse welding pre-loaded with pulse-designed synergic lines Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with over 50 standard and pulse synergic lines over a large variety of filler metal, gas types, and wire diameters Power source is lightweight, easily updateable, and expanded through a plug and play interface

11 Power Source Models Trans-Steel TsT) 3500 Compact 350-amp pulse machine with a built in wire feeder. Multi-voltage model is NOT available Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with multiple standard synergic lines over a large variety of filler metal, gas types, and wire diameters Power source is lightweight, easily updateable, and expanded through a plug and play interface. Trans-Steel TsT) 3500/5000 Manual Two amp ranges available 350 and 500. Multi-voltage model available. Welder is designed specifically for steel welding, offering a large variety of options at a low price. Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal, gas types, and wire diameters Trans-Steel TsT) 3500/5000 Robotic Two amp ranges available 350 and 500. Multi-voltage model available. Welder is designed specifically for steel welding, offering a large variety of options at a low price. Fully digital, inverter based technology that provides stable, reproducible arc through ENTIRE arc range. Welder comes pre-loaded with over 30 standard synergic lines over a large variety of filler metal, gas types, and wire diameters Designed with robotic or automated welding in mind

12 Power Source Name Plate The identification portion of the label will give a detailed description of the welder, the full part number, and a unique serial number. Using the format below, the serial number can be used to determine the approximate age of the welding power supply. This technique can be used to age any Fronius product with an 8-digit serial number subtract 11 to get the year of manufacture 08 this is the week of manufacture 1 52) 0753 this is the item number for the day of manufacture. The name plate is found on the top of the machine just underneath the carrying handle. This label includes identification, technical, upgrade, and duty-cycle information about the welding power supply. The middle portion of the label include technical that includes duty cycle, amp drops, input and output voltage ranges, and maximum outputs

13 Power Source Tech Specs TPS 2700 MV TPS 3200 MV TS/TPS 4000 MV TS/TPS 5000 MV CMT-A 4000 MV Mains Voltage Range 3 x x V V V V V V V V V V Mains Tolerance +/-10% +/-10% +/- 10% +/- 10% +/- 10% Mains Frequency 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz 50 / 60 Hz Fuse Protection, slow-blow 3 x x A 16 A Primary Continuous Current 100% dc) A A A A n/a Primary Continuous Power 100% dc) KVA kva kva kva kva Electrical Efficiency 88 91% 90 91% 88 91% 88 91% n/a Welding Current Range Welding Voltage Range MIG Stick TIG MIG Stick TIG A A A V V V 35 A 35 A A A A V V V 63 A 35 A A A A V V V 63 A 35 A A A A V V V 63 A 35 A A A n/a V V n/a Max Welding Voltage 34.6 V V 48 V 49.2 V n/a Open Circuit Voltage 50 V V V V 90 V Duty Cycle 77º F 25º C) Duty Cycle 104º F 40º C) 270 A 210 A 270 A 170 A 320 A 304 A 320 A 260 A 220 A 400 A 365 A 400 A 365 A 320 A 500 A 450 A 500 A 450 A 340 A 400 A 380 A 400 A 350 A 290 A

14 Power Source Connections TPS 3200/4000/5000 Front Panel The front panel allows the welder to control the power source s welding characteristics. LocalNet Connection This connection is for the LocalNet connection to the wirefeeder and/or interface device. - Current Socket Connection The connection depends on the operating mode of the power source MIG Welding: Connect the welding ground to this socket. TIG Welding: Connect the current connection on the torch to this socket. STICK Welding: Connect the electrode cable to this socket depending on the type of electrode being used. Blanking Covers These connections are for optional upgrades to the power source. Mains Connection This connection is for the 3- phase input power. Power Switch This switch turns the power source on 1 and off 0. + Current Socket Connection The connection depends on the operating mode of the power source MIG Welding: Connect the current connection of the interconnection hose pack to this socket. TIG Welding: Connect the welding ground to this socket. STICK Welding: Connect the electrode cable to this socket depending on type of electrode being used. Current Connection optional This connection is reserved for an optional current socket

15 Power Source Connections TPS 2700 Front Panel Carrying Strap Power Switch LocalNet Connection Blanking Covers Ground Connection optional Current Connection Gas Connection bottle Current Connection torch Ground Connection Trigger Connection torch Mains Connection

16 Power Source Connections TsT 3500/5000 Front Panel Optional Add-ons Ground Connection Mains Connection Power Switch Current Connection LocalNet Connection

17 Power Source Connections TsT Compact Front Panel Gas Purch / Wire Feed Switch Ground Connection Mains Connection Current Connection Torch Connector LocalNet Connection Power Switch Gas Connection

18 Wire Feeder Models VR 1500 This wire feeder is designed specifically for robotic or automated applications. Using this wire feeder for manual welding is not feasible without special modifications A push/pull torch requires an additional, internally installed kit. VR 1550 This wire feeder is designed specifically for robotic or automated applications. Using this wire feeder for manual welding is not feasible without special modifications This feeder can be used for CMT and/or push/pull applications using a series of specially designed kits. VR 4000 This wire feeder is designed specifically for manual applications. This device has the trigger connections required for manual torches to operate. A removable wire-spool holder is mounted to the rear of the feeder. Robotic/automated connections and controls can easily be added to this wire feeder A push/pull torch requires an additional, internally installed kit. VR 7000 CMT This wire feeder was developed specifically for the Cold Metal Transfer CMT process. The feeder is equally suited to both manual and robotic/automated needs. A wire spool holder is integrated to the feeder allowing for both spool and drum use. This feeder is designed to operate with either a push or a push/pull torch

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

20 Wire Feeder Motor Plate Tension Knobs Drive Rolls top Wire Guide Insert steel or synthetic Main Drive Roll Drive Rolls bottom Torch Connectors Fronius Connector F++ Fronius System Connector FSC Euro Connector E Tweeco Connector T

21 Wire Feeder Connections & Controls VR 1500 Current/Gas Connection torch Gas Purge Button Current Connection welder LocalNet Connection spare Gas Connection bottle Wire Inch Button Coolant Feed - hot torch Robacta Connection torch Coolant Feed - cold torch Coolant Feed - hot welder LocalNet Connection welder Coolant Feed - cold welder

22 Wire Feeder Connections & Controls VR 7000 Spool Holder Gas Purge up / Wire Feed down switch LHSB Connection welder Current Connection welder LocalNet Connection welder Coolant Feed - hot welder Gas Connection bottle Coolant Feed - cold welder Motor-plate Power Control WFS, Current, etc. Arc Length Control Buffer Connection torch LHSB Connection torch Robacta Connection torch LocalNet Connection spare Current/Gas Connection torch Trigger Connection torch Coolant Feed - cold torch Coolant Feed - hot torch

23 Wire Feeder Connections & Controls VR 5000 Rob Gas Connection bottle - PAP System Only - Current Connection welder Gas Connection bottle - Standard System Only - Current/Gas Connection torch Wire Inlet drum or spool LocalNet Connection welder Standard System Only - LocalNet Connection welder PAP System Only - Wire Inch Button Motor-plate

24 Wire Feeder Connections & Controls VR 5000 Manual Handle Current Connection welder Spool Window Spool Holder Synergic Selection -Synergic version only - Gas Connection bottle Weld Control Panel Motor-plate Current/Gas Connection torch LocalNet Connection welder Coolant Feed - cold welder - optional add on - Coolant Feed - cold torch - optional add on - Coolant Feed - hot torch - optional add on - Coolant Feed - hot welder - optional add on

25 Welding Torch Models Manual Torches Trigger to start/stop the arc. Water-cooled or Air-cooled Several control options None Up/Down U/D Jobmaster JM Several wire feeder connections Fronius F/F++ Fronius System Connector FSC Euro E Tweeko Z Robotic Torches Robotic/Automated control of the arc Water-cooled or Air-cooled No parameter control options. Wire feed and gas control Only on drive-based torches. Several wire feeder connections Fronius F/F++ Fronius System Connector FSC Euro E Tweeko Z Will have Robacta in the description BAAN/Price-book Description Examples AL 4000 G/E/UD/4.5m/14.5ft - AL 4000 torch type-manual G gas-cooled E Euro connector UD up/down control Robacta Drive Ext. W/F++/1.75m/5.7ft - Robacta Drive Ext torch type-robotic W water-cooled F++ Fronius connector PullMig CMT W/F/6m/19.7ft - PullMig CMT torch type-manual W water-cooled F Fronius connector

26 Cooler Models Cooling Units Standard Features Integrated system linked directly to power source for power and control. Fuse protection against potential over-voltage damage. Flow sensor to verify proper coolant movement. Variable flow measurements to account for lengthy hose-packs. FK 4000 / FK 5000 Standard water cooler for most MIG and TIG packages Internal reservoir that allows for a completely closed system. FK 9000 High volume water cooler for specialized system that require a larger coolant capability. Two separate units with integral components divided between them

27 Weld Process Overview Shielded Metal Arc Welding SMAW) An arc welding process that produces coalescence of metals by heating them with an arc between a covered metal electrode and the workpieces). Shielding is obtained from decomposition of the electrode covering. Pressure is not used, and filler metal is obtained from the electrode. Stick Welding Performed with a basic constant current CC) power source that is equipped with an electrode holder and a ground clamp Manual Gas Tungsten Arc Welding GTAW) An arc welding process that produces coalescence of metals by heating them with an arc between a tungsten electrode non-consumable) and the workpieces). Shielding is obtained from a gas. Pressure may or may not be used, and filler may or may not be used. TIG welding Performed with a constant current CC) power source equipped with a GTA welding torch that supplies current through a tungsten electrode and ground clamp GTAW requires an inert gas such as Argon most commonly used) or Helium or a mixture of the two) to support the arc Manual, Mechanized, and Automated Gas Metal Arc Welding GWAW) An arc welding process that produces coalescence of metals by heating them with an arc between a continuous filler metal electrode and the workpieces). Shielding is obtained entirely from an externally supplied gas. MIG/MAG welding Performed with a constant voltage CV) power supply equipped with a wire feeder to supply welding wire through a GMA welding torch to the workpieces) and with a ground clamp to complete the electrical circuit Semi auto process manual), Mechanized, and Automated

28 Weld Process Overview Synergic Welding Computer control of the welding arc based on a single user-defined characteristic wirefeed speed, material thickness, amps, etc.) Changing the wire-feed speed will automatically adjust the voltage necessary for the filler metal and gas being used. This is done through the use of a digital signal processor and a synergic line Provides an extremely high level of repeatability and precision The synergic line can be modified slightly to account for environmental differences between laboratory testing and production VOLTAGE Synergic Line WIRE-FEED SPEED current) An arc-characteristic curve that links a number of welding parameters together giving the most ideal values for a specific filler metal, wire diameter, shielding gas, and operating mode This line is created through a complex set of measurements taken while welding with the specified settings A standard line can be chosen/programmed in a matter of seconds with the simple selection of a few base parameters TransSynergic and TransPulseSynergic Standard MIG power sources available from Fronius Both have the ability to do standard conventional 2 dial ) welding and synergic welding one dial) The TransPulse Synergic power source has the added ability to perform pulse-synergic welding

29 Weld Process MIG Short Circuit Transfer Short Circuit Transfer This is a transfer mode where the electrode wire touches the work piece snubbing out the arc and the heat from electrical resistance violently pinches off and deposits the molten wire electrode into the weld pool. - The wire heats up forming a ball of metal at the end of the wire which is then reintroduced into the molten weld pool where it shorts the circuit, then gets pinched off and deposited into the weld pool. The cycle then repeats itself. Disadvantages include: Limited wire feed speed and therefore lower deposition rates - Cold lapping/lack of fusion is also more likely to occur proper technique is needed to avoid cold lapping/lack of fusion) Moderate amount of spatter dependent on environmental factors and parameters). Advantages Include: Low heat input - All positions Gap bridging - Capable Process for thick and thin materials Globular Transfer: This is an uncontrolled spray transfer mode. When CO2 or Argon-CO2 is used, a molten ball tends to form on the end of the electrode and may grow in size until its diameter is greater than the diameter of the electrode. These droplets, larger in size, may cause short circuits and this mode is known as globular transfer. This method of transfer produces a large amount of spatter and higher heat input when compared to the short circuit transfer mode. Disadvantages include: High level of spatter and arc instability Advantages: Can use 100% CO 2, an inexpensive gas - Has good penetration on thick metals Spray Transfer: This is a high heat input transfer mode where the shielding gas is an Argon rich Argon-Oxygen - 8% Oxygen maximum) or Argon-CO2-18% CO2 maximum) mixture. The droplets being sprayed across the arc are very fine and never short circuit the arc therefore propelling small molten droplets of the electrode across an open arc to the workpieces). Disadvantages include: High heat input - Limited range of welding positions - Higher percentages of argon required thus increasing gas cost Advantages include: High deposition rates - Good penetration - Good weld appearance with little to no spatter

30 Weld Process MIG Pulsed Current Welding Pulse) Pulse Welding GMAW-P): This is a GMAW process variation in which the welding current is pulsed resulting in a lower heat input for a given set of welding parameters when compared to conventional GMAW. Disadvantages include: Special power source required to support pulsing current - Higher argon percentages required to support arc diameter of spatter balls typically larger than conventional GMAW spatter ball size Advantages include: High deposition rates - Lower heat inputs - Viable solution to many welding situations - Less spatter when compared to conventional GMAW Good weld appearance Note Concerning Synergic Welding: Synergic is a term used to describe single dial manipulation of multiple welding parameters at the same time. Disadvantages include: Specific power source designed to allow single dial manipulation of multiple welding parameters at the same time Advantages include: Reduced parameter development time due to the ability to change multiple parameters with a single dial turn current and voltage with single dial)

31 INERT GASES INERT MIXED GASES Argon Ionizes easily, deep fusion penetration, finger-shaped, low cost to manufacture filtered out of ambient air. Helium Weld Process Gas Characteristics Difficult to ionize; high heat conductivity; deep, wide penetration; fluid weld pool; good wetting; more expensive than argon filtered out of natural gas Argon-Helium Mix The advantages/disadvantage of each gas increases and decreases in relation to the proportion within the mix. ACTIVE GASES ACTIVE MIXED GASES CO 2 Reacts with the material, deeper reduced-pore fusion penetration, tends towards spattering, cheap to manufacture Argon CO2 Combines advantages of its components, the most used gas combination for unalloyed steel and chrome-nickel Argon Oxygen Arc more stable, reduced surface tension of weld pool, pore-sensitive, Oxygen 8% maximum

32 Weld Process Overview of Active Mixed Gas CO 2 Ar/CO 2 Ar/O 2 Fusion Penetration Horizontal Very Good Good Good Positional Welding Very Good More CO 2 = better fusion penetration Critical Pores Very Little Normal More CO 2 = fewer pores Pore-sensitive Arc Stability Poor, except KL Good Very Good Spatter Level High Medium Low Fusion Penetration Profile

33 Weld Process Impact of CO 2 on the Arc 5% CO 2 18% CO 2 Narrow arc range Deeper, narrower fusion penetration Pore creation possible Wider arc range Wider fusion penetration Little pore creation The proportion of CO 2 in the gas is mainly responsible for the shape of the arc and the resulting behavior of it fusion penetration, pore creation, etc.)

34 Weld Process Gas Flow The flow rate of the shielding gas is a critical aspect of the welding process. Too high OR too low will have a serious impact on weld results. Fronius Options Typically, the weld system opens and closes the gas valve. If flow monitoring is desired within the system, the following options are available. Rule of thumb for the flow rate: times the diameter in l/min of flow - 1.2mm x 10 = 12 l/min - 1 l/min = 2.1 CFH - 12 l/min x 2.1 = 25 CFH Helium and Hydrogen require about 50% more flow than other gases due to their lighter weights. Gas Pressure Sensor 4,100,343) Manually set gas valve that reports a gas error to the weld system when flow is too low. Only errors out for low flow and doesn t report specific flow information. Correct flow rate Excessive flow rate Digital Gas Sensor 4,100,374) The specific gas flow is set, regulated, and monitored using this device. Not only is a low or high flow rate detected, but the system also reports back specific gas flow data

35 Weld Process Torch Movement and Handling Neutral Travel Angle Arc heats and transmits it s total power into the weld pool Stable, quiet arc Fusion penetration is MEDIUM Weld Width is MEDIUM Push Travel Angle Arc heats and transmits it s total power into the weld pool Stable, quiet arc Fusion penetration is SHALLOW Weld Width is WIDE Drag Travel Angle Arc partially heats the base material and the weld pool Not a particularly quiet arc Fusion penetration is DEEP Weld Width is NARROW

36 Weld Process Discontinuity Excessive Reinforcement Weld bead reinforcement is too high and lumpy Possible Causes Travel speed too slow Weld current too low Improper travel angle Undercut Cutting away at the toes Possible Causes Amperage too high Arc length too long voltage too high Improper work angle Insufficient Throat The weld bead is too shallow Possible Causes Combination of travel speed too fast and current too low Improper placement of weld beads when doing multiple passes Insufficient Leg undersized weld Leg size too small Possible Causes Using the wrong work angle Insufficient wire feed speed for travel speed Lack of Fusion Weld not fused completely Insufficient Penetration Not penetrated at root or between passes Possible Causes Amperage too low Travel speeds too fast Too large or wrong electrode Improper travel angle Possible Causes Amperage too low Travel speed too high Improper work/travel angle Improper weave parameters

37 Weld Process Discontinuity Overlap / Weld Bead Rollover Weld metal cold and lapped at toe or root Possible Causes Amperage too high Travel speed too slow Electrode too large Slag Inclusions Slag trapped in weld Possible Causes Improper manipulation of covered electrode Improper cleaning and/or slag removal between passes Porosity Pinholes Possible Causes Dirty, painted, or galvanized base metal Arc length too long Moisture in weld Insufficient shielding gas coverage Cracking Cracks in the weld and/or base metal Possible Causes Using the wrong electrode Using excessively high amperage Underfill or improper crater geometry crater cracking Moisture in low hydrogen processes Excessive Spatter Possible Causes Amperage too high Electrode angle too extreme Arc length too short/long Process driven

38 Use and Operation Initial Set-up and Turn On Step 6: If using a cooler, verify cooler is turned on and set properly C-C and C-T. Step 1: Connect main power, gas and wire to the welder/wire feeder. If equipped with one, fill the cooler with Fronius Coolant. Step 2: Connect or clamp the ground connection to the fixture or work piece. Plug the other end into the welder ground connection. Step 3: Turn the welder on. Almost immediately, you will hear a click from the wire feeder. Within a minute, the display should come on. Step 4: Load the consumables into the wire feeder and torch as necessary. Store extras in a safe place for later use. Step 5: Perform a resistance test. Step 5: If using a non-cmt push-pull gun, perform a PPU alignment Step 7: Select proper synergic-line for the application to be done. Step 8: If using jobs, set and edit them as needed. If not, select all other needed weld parameters. Step 9: Start welding Notes If you encounter an error code or weld problems, attempt to perform a basic check-out. Note any failure points before calling support. When calling support, please have the following information available: - Welder serial number - Welder firmware/database - Error Codes if any - Filler metal type, diameter, and gas

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44 Use and Operation MIG Correction Values Correction Value 1 Correction Value = longer arc length more voltage +5 = More inductance Lower peak current, soft arc Standard Synergic Pulse Synergic Standard CMT Steel) Standard CMT Aluminum and Stainless) CMT Pulse Steel) CMT Pulse Aluminum and Stainless) 0 = Standard arc length 0 = Standard inductance -30 = Shorter arc length Less voltage -5 = Less inductance Higher peak current, hard arc +30 = longer arc length more voltage +5 = Wider arc Higher pulse force 0 = Standard arc length 0 = Standard width -30 = Shorter arc length Less voltage -5 = Narrower arc Lower pulse force +30 = Lower droplet detach freq more voltage +5 = Less SC2 Current Colder melt pool 0 = Standard Plasma WFS 0 = Standard SC2 Current -30 = Higher droplet detach freq Less voltage -5 = More SC2 Current Hotter melt pool +30 = Slower Burn WFS more voltage +5 = Increased arc length at ignition 0 = Standard Burn WFS 0 = No increased arc length at ignition -30 = Faster Burn WFS Less voltage -5 = No impact +30 = longer arc length more voltage +5 = More energy Drop falls with more pressure 0 = Standard arc length 0 = Standard energy -30 = Shorter arc length Less voltage -5 = Less energy Drop falls with less pressure +30 = Slower Pulse WFS more voltage +5 = More energy Drop falls with more pressure 0 = Standard Pulse WFS 0 = Standard energy -30 = Faster Pulse WFS Less voltage -5 = Less energy Drop falls with less pressure

45 Use and Operation Front Panel Controls TPS) Keylock Switch optional Used to lock and unlock the front panel control, limiting access to who can change welding settings. Parameter Selection Button Used to determine what welding parameter will be displayed on the first 3 digit display sheet thickness, welding current, wire-feed speed, or drive current. Parameter Selection Button Used to determine what welding parameter will be displayed on the SECOND 3-digit display arc-length correction, dynamic, welding voltage, or job number Inch Forward Button Used to inch the filler wire forward through the torch without gas or current flow. Adjustment Dial Used to change the value of a parameter or setting. Purge Button Used to test the gas flow. One press will allow gas flow for 30s, a second press will stop the flow. Store Button Used in conjunction with other buttons to get into various other menu s. Can also be used to exit any menu. Mode Selection Buttons up/down Used to change the welding process of the power source. Diameter Selection Button Used to select the diameter of the filler metal to be used during the welding process. Material Selection Buttons up/down Used to select the shielding gas and filler metal to be used during the welding process. Trigger Selection Buttons up/down Used to changed the type of trigger setting for the welding torch

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

47 Use and Operation Front Panel Indicators TPS) Globular Transfer Arc Indicator When lit, conditions are correct for the power source to weld between short circuit and spray arcs. Wire Diameter Indicator When lit, this will indicate which wire diameter is selected to weld with. Wire Diameter Special Indicator When lit, this indicates that a size other than the normal ones are selected to weld with. Mode Indicators These indicators determine which welding mode the power source is in for welding. Filler Metal/Gas Indicator When lit, this indicates the shielding gas and filler metal combination used during the welding process. Filler Metal/Gas Special Indicator When lit, this indicated that a special filler metal/gas combination has been selected. These two lines generally vary based on the synergic data loaded into the power source. Trigger Indicators These indicators determine how the torch trigger reacts during the welding process. Conventional: Press and hold torch trigger to start arc. Release trigger to stop. Trigger Lock 2-step : Press and release torch trigger to start arc. Press and release trigger to stop arc. Special 4-Step: Press and hold torch trigger to begin welding at Current start value. Release trigger to move to normal welding current. Press and hold trigger to move to ending current value. Finally, release torch trigger to stop the arc. Spot Mode: Press and release torch trigger to start the weld, it will run until the time runs out and then stop automatically. You can abort the weld by pressing and releasing the torch trigger a second time. Pulse Synergic: This will set the power source for welding in pulse MIG welding using stored synergic line. Synergic: This will set the power source for conventional MIG welding using a stored synergic line. Standard: This will set the power source for conventional MIG welding using NO synergic line. JOB: This will set the power source for welding based on the JOB previously set up there will be a second indicator showing the saved mode for the JOB. TIG: This will set the power source for TIG welding assuming optional components are installed. Stick: This will set the power source for Stick CV welding

48 Use and Operation Front Panel Controls CMT) Keylock Switch if equipped Used to lock and unlock the front panel control, limiting access to who can change welding settings. Parameter Selection Button Used to determine what welding parameter will be displayed on the LEFT 3 digit display sheet thickness, welding current, wire-feed speed, or drive current. Parameter Selection Button Used to determine what welding parameter will be displayed on the RIGHT 3-digit display arc-length correction, dynamic, welding voltage, or job number Inch Forward Button Used to inch the filler wire forward through the torch without gas or current flow. Adjustment Dial Used to change the value of a parameter or setting. Purge Button Used to test the gas flow. One press will allow gas flow for 30s, a second press will stop the flow. Mode Selection Buttons up/down Used to change the welding process of the power source. Store Button Used in conjunction with other buttons to get into various other menu s. Can also be used to exit any menu. Diameter Selection Button Material Selection Buttons up/down Trigger Selection Buttons up/down Used to select the diameter of the filler metal to be used during the welding process. Used to select the shielding gas and filler metal to be used during the welding process. Used to changed the type of trigger setting for the welding torch

49 Use and Operation Front Panel Indicators CMT) Wire Feeder Current Indicator When lit, the wire-feeder motor current is shown on the first 3-digit display. Torch Motor Current Indicator if equipped When lit, the torch motor current is shown on the first 3-digit display. Parameter Adjustment Indicator When lit, the left3-digit display is active and adjustable when applicable. Hold Indicator When lit, the last welding values are shown on the 3-digit displays. Only lights after a weld has completed. 3-Segment Display When lit, the right 3-digit display is active and adjustable when applicable. Parameter Adjustment Indicator When lit, the parameter being looked at can be adjusted to a new value. 3-Segment Display When lit, the first 3-digit display is active and adjustable when applicable. Coolant Flow if equipped Power Indicators When lit, the first 3-digit display shows one of several power values depending on the power source mode. Sheet Thickness: When lit, the first 3-digit display will show the sheet thickness of the material to be welded to. This value is adjustable in any synergic mode. Welding Current: When lit, the first 3-digit display will show the welding current that will be welded with. This value is adjustable in any synergic mode. Temperature Indicator When lit, the internal temperature for the power source is too high. Arc Length Correction Indicator Welding Voltage Indicator When lit, the second 3- digit display will show the voltage that will be welded with. This value is adjustable. When lit and equipped with a digital flow meter the 3-segment display will show the coolant flow. Parameter Adjustment Indicator When lit, the second 3-digit display is active and adjustable when applicable. Job Number Indicator Wire Feed Speed: When lit, the first 3-digit display will show the wire feed speed that will be welded with. This value is adjustable in any mode. Synergic & Pulse: The three values are linked to each other. As you change one, the other two will adjust automatically. Standard: Only current and wire feed are available as selections. Wire feed speed is the ONLY parameter that can be adjusted. When lit, the second 3- digit display shows the current arc length correction. This value is adjustable. Dynamic/Droplet Correction Indicator When lit, the second 3- digit display will show either the dynamic correction synergic or the droplet-detachment pulse. When lit, the second 3-digit display shows the number of the job being used

50 Use and Operation Front Panel Indicators CMT) CMT-Pulse Indicator This will light when a CMT-Pulse synergic line has been selected. Wire Diameter Indicator When lit, this will indicate which wire diameter is selected to weld with. Wire Diameter Special Indicator When lit, this indicates that a size other than the normal ones are selected to weld with. Filler Metal/Gas Indicator When lit, this indicates the shielding gas and filler metal combination used during the welding process. Filler Metal/Gas Special Indicator When lit, this indicated that a special filler metal/gas combination has been selected. These two lines generally vary based on the synergic data loaded into the power source. Trigger Indicators These indicators determine how the torch trigger reacts during the welding process. Conventional: Press and hold torch trigger to start arc. Release trigger to stop. Trigger Lock 2-step : Press and release torch trigger to start arc. Press and release trigger to stop arc. Special 4-Step: Press and hold torch trigger to begin welding at Current start value. Release trigger to move to normal welding current. Press and hold trigger to move to ending current value. Finally, release torch trigger to stop the arc. Spot Mode: Press and release torch trigger to start the weld, it will run until the time runs out and then stop automatically. You can abort the weld by pressing and releasing the torch trigger a second time. Mode Indicators These indicators determine which welding mode the power source is in for welding. Pulse Synergic: This will set the power source for welding in pulse MIG welding using stored synergic line. Synergic: This will set the power source for conventional MIG welding using a stored synergic line. CMT / CMT Pulse: This mode will set the power source for CMT and CMT Pulse using selected synergic lines. STANDARD: This will set the power source for conventional MIG welding using NO synergic lines. JOB: This will set the power source for welding based on the JOB previously set up there will be a second indicator showing the saved mode for the JOB. Stick: This will set the power source for Stick CV welding

51 Processes Use and Operation Checking Software Select a Synergic Line 1 / Step 1: Choose the desired filler metal wire diameter Step 2: Choose the desired shield gas/filler metal combination. Step 3: Choose the desired trigger type. Step 4: Choose the desired welding mode. Step 1: Press and hold the STORE button and then press the MATERIAL SELECTION button. Release both buttons. One of four numbers will appear. UST Firmware: sample number Welding Database: sample number SR41 Firmware: A sample number Arc Hours: sample number Synergic Line: r0209 sample number The machine may enter any of the four codes above, but will cycle through in the same order. Step 2: Use the MATERIAL SELECTION buttons to cycle through the software codes. Step 3: Press and release the STORE button to return to the main welding screen

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

53 C A Processes Resistance Test Step 1: Remove gas nozzle from torch and retract wire so that no wire inside the tip. Step 2: Firmly touch the contact tip as close to the welding point as possible. If the work-piece is not available, use a bare part of the fixture instead. Step 3: On the front panel, press the store button A and the process select up arrow B at the same time. Once the display changes, release both buttons. Step 4: Use the process select up arrow B to cycle through the parameters until 2 nd appears on the display. Step 5: On the front panel, press the store button A and the process select up arrow B at the same time. Once the display changes, release both buttons. B Step 6: Use the process select up arrow to cycle through the parameters until r appears in the display. Step 7: Ensure that no one is touching any part of the welding circuit. Step 8: Press the wire feed button C on the front panel, the trigger on the torch, or the arc-on command through the robot to activate the test. Step 9: Display value should change to a new number. Repeat this process three times. Step 10: Press the Store button A twice to return to main menu. Error Codes r E30 There is an open measurement in the welding circuit r E31 Calibration procedure was interrupted by a repeated pressing of the start button wire feed, torch trigger, etc. before test is finished. r E32 Measured value is too low.5 m or too high 30 m. r E33 Poor contact between the contact tip and the work-piece. r E34 Poor contact between the contact tip and the work-piece

54 D A Processes Push Pull Alignment Step 1: On the front panel, press the Store button A and the Process Select up arrow B at the same time. Once the display changes, release both buttons. Step 2: Use the Process Select up arrow B to cycle through the parameters until 2 nd appears on the display. Step 3: On the front panel, press the Store button A and the Process Select up arrow B at the same time. Once the display changes, release both buttons. Step 4: Use the process select up arrow B to cycle through the parameters until PPU appears in the display. Step 5: 5 Use the red selection knob C to select the PPU number that corresponds to the torch being used. C B Step 6: Press the torch trigger or the wire feed button D on the front panel. The display should change to St.1. Step 7: Open all drive rolls on the wire feeder and torch. Step 8: Press the torch trigger or the wire feed button D again. The display should change to St. 1 run and the drive rolls in the torch and gun should both run. Step 9: When the test is finished, the display will read St. 2. Ensure there is wire loaded and close the drive rolls on the wire feeder and torch. Step 10: Press the torch trigger or wire feed button D on the front panel. Depending on the PPU number, the display with either immediately change to PPU # or run both sets of drive rolls and wire. Once finished, it will then display PPU #. Step 11: Press the Store button A twice to return to main menu. Step 12: Once finished, press the Store button A twice, cut off the excess wire and dispose of it. Note: when using a standard torch with a CMT wire feeder, select PPU 0 and press the wire feed button. You can then set up the torch as normal

55 Processes PPU - Additional Information PPU Error Codes PPU Number for Push Pull Torch PPU 2 Fronius KD Drive push-pull PPU 3 Fronius Robacta Drive, master 3.5m or more PPU 4 Fronius Robacta Drive, slave less than 3.5m PPU 5 Fronius PullMig, with potentiometer PPU 6 Fronius PullMig, without potentiometer PPU 16 MK Cobra Gold PPU 26 MK Python PPU 28 Fronius CMT PullMIG, with potentiometer PPU 29 Fronius CMT PullMIG, without potentiometer PPU 50 Fronius PT Drive,.030 aluminum PPU 51 Fronius PT Drive,.040 aluminum PPU 52 Fronius PT Drive,.045 aluminum PPU 53 Fronius PT Drive, 1/16 aluminum PPU 59 Fronius PT Drive,.040 steel PPU 60 Fronius PT Drive,.045 steel PPU 61 Fronius PT Drive,.030 steel Err Eto Incorrect measurement during PPU alignment St1 E1 No feedback from wire-feeder motor at min speed St1 E2 No feedback from wire-feeder motor at max speed St1 E3 No feedback from wire-feeder motor at min speed St1 E4 No feedback from torch motor at min speed St1 E5 No feedback from wire-feeder motor at max speed St1 E6 No feedback from torch motor at max speed St1 E16 PPU alignment interrupted by torch trigger press St2 E7 PPU open drive roll has not been accomplished St2 E8 No feedback from wire-feeder motor at min speed St2 E9 No feedback from torch motor at min speed St2 E10 Wire-feeder motor current out of range at min speed St2 E11 Torch motor current out of range at min speed St2 E12 No speed value from wire-feeder at max speed St2 E13 No speed value from torch motor at max speed St2 E14 Wire-feeder motor current out of range at min speed St2 E15 Torch motor current out of range at max speed St2 E16 PPU alignment interrupted by torch trigger press

56 D A Processes Functional Tests Cooler Verification Step 1: On the front panel, press the Store button A and the Process Select up arrow B at the same time. Once the display changes, release both buttons. Step 2: Use the Process Select up arrow B to cycle through the parameters until 2 nd appears on the display. Step 3: On the front panel, press the Store button A and the Process Select up arrow B at the same time. Once the display changes, release both buttons. Step 4: Use the process select up arrow B to cycle through the parameters until C-C appears in the display. C B Step 5: Use the red selection knob C to select from one of three options ON Turns the cooler on as soon as the welder powers up. OFF Turns the cooler off and disables flowmonitoring Auto Turns the cooler on during welding and for 2 minutes after welding stops. Step 6: Use the process select up arrow B to cycle through parameters until C-T appears in the display. Step 7: Use red selection knob C to select the amount of time before flow sensor shuts the welding process down. If unsure, set to ten. Step 8: Press the Store button A twice to return to main display. Note: the flow switch will only shut the system down after the first weld has been done. When initially turned on, the flow sensor is ignored

57 Processes Functional Tests Motor Draw Test Output Voltage Test B A D E B A C D C Step 1: Press the Parameter Selection button A until the main motor indicator B is lit. Step 2: First test the motor without load by opening up the drive rolls on the wire feeder Step 3: Press the Wire Feed button C and check the left most display D. It should be ~.7 amps +/- 1 amp. Step 4: Check the motor under load by closing the drive rolls on the wire feeder Step 5: Press the Wire Feed button C and check the left most display D. It should be ~1.0 amps. +/- 20% Step 1: Press the Parameter Selection button A until the voltage indicator B is lit. Step 2: Disconnect the ground connection from the front of the power supply. Step 3: Press the process select button C until the Stick indicator D lights up. Step 4: The right most display E should indicate 40V within one minute. Step 5: Press the process select button C until the process changes to something other than TIG or Stick

58 Use and Operation TsT Parameter Reference MIG)

59 Use and Operation TsT Parameter Reference Stick)

60 Hold Indicator Use and Operation Front Panel TsT - Manual) This indicator will light up after a weld has been completed and the 3-digit displays will show the last values used during welding. When welding starts up again or the values are changed, this indicator will go out. 3-digit Display Amperage This value will increase as the wire feed speed increases Control Knob Wire Feed Speed This control will vary the wire feed speed the machine is set for. The value corresponds with the numbers around the dial and will increase or decrease the current value displayed on the 3-digit display.. 3-digit Display Voltage This value will display the voltage dialed into the machine. Inductance Controls and Indicators This is used to control and display the inductance for the welding machine. The buttons increase and decreased the inductance to the desired value. The value is then displayed as a representation with one bar being the minimum value and 7 bars being the maximum. Control Knob Voltage This control will vary the voltage the machine is set for and will directly change the value displayed on the 3-digit display. Trigger Control and Indicators The button switches between the two trigger options, 2-step 2T and 4-step 4T. 2-step: Press and hold torch trigger to start the arc. Release trigger to stop the arc. 4-step: Press and release trigger to start the arc, press and release trigger to stop the arc. Process Control and Indicators The button switches between the machines processes. The indicator displays the process the machine is currently set up for

61 Use and Operation Front Panel TsT - Synergic) Hold Indicator This indicator will light up after a weld has been completed and the 3-digit displays will show the last values used during welding. When welding starts up again or the values are changed, this indicator will go out. Weld Power Controls and Indicators These controls and indicators are used to display and change the weld power values. The three segment display will show the value of the power indicator lit below. The button control switches between the three power values. Material Thickness: The display will show the sheet thickness of the material to be welded to. This value is adjustable in synergic mode only. Welding Current: The display will show the value of the welding current that will be welded with. This value is adjustable in any process. Wire-Feed Speed: The display will show the value of the feed speed that will be welded with. Control Knob power : This will control the value on the 3-digit display. Please note that the three power values material thickness, welding current, and wirefeed speed are linked to one another in synergic mode. Globular Transfer Mode This indicator will light when the settings on the synergic line will result in globular arc. Weld Adjustment Controls and Indicators These controls and indicators are used to display and change the weld adjustment values. The three segment display will show the value of the adjustment indicator lit below. The button control switches between the three adjustment values. Arc Length Correction: The display will show the current arc length correction set into the machine. Note that this value is NOT available in manual mode. Welding Voltage: The display will show the welding voltage currently set in the machine. Note that this is only adjustable in manual mode. Dynamic Correction: The display will show the value of the current dynamic set in the machine. Control Knob adjustment : This will control the value on the 3-digit display

62 Use and Operation Front Panel TsT - Synergic) Operating Point Save/Selection Buttons These buttons are used to save and recall weld settings stored in memory by the user. Trigger Control and Indicators The button switches between the three trigger options, 2-step 2T, 4-step 4T, and special 4-step S4T 2-step: Press and hold torch trigger to start the arc. Release trigger to stop the arc. 4-step: Press and release trigger to start the arc, press and release trigger to stop the arc. Special 4-step: 4 Press and hold the trigger to begin welding at the starting value, release trigger to change to normal power value, press and hold for ending power value, and finally release trigger to stop the weld. Process Control and Indicators The button switches between the machines processes. Manual Mode: Welding will occur using with no link between wirefeed speed and voltage. Synergic Mode: Welding will occur using one of several synergic lines that establishes a link between current, wire-feed speed, and voltage. Stick Mode: This mode is for welding using the MMA process. Filler Metal Selection and Indicator Wire Diameter Selection and Indicator Shield Gas Selection and Indicator The button is used to cycle through the different filler metal types available. The finals SP selection is designed for customized synergic selections. The button is used to cycle through the different wire diameters available. The finals SP selection is designed for customized synergic selections. The button is used to cycle through the different shielding gas types available. The finals SP selection is designed for customized synergic selections

63 Consumables Drive Rolls Please note that drive rolls are wire diameter specific and the wires mentioned above are suggestions based on past experience. Standard T Rolls Tension ~ 2 Standard drive rolls for steel and stainless wire when working through single shift operations. Three points of contact on the wire red dots Standard H Rolls Tension ~ 1.5 to 2 Standard drive rolls for aluminum and CuSi wire when working through single shift operations. Two points of contact on the wire red dots Knurled K Rolls Tension ~ 2 to 3 Ridged drive rolls for flux and solid-cored wire. One style for single or multiple shift operations. Four points of contact on the wire red dots Professional U Rolls Tension ~ 2.5 to 3 Heavy duty drive rolls for steel and stainless wire when working through multiple shift operations. These are designed to last much longer than the standard rolls. Four points of contact on the wire red dots Professional H Rolls Tension ~ 1.5 to 2 Heavy duty drive rolls for aluminum and CuSi wire when working through multiple shift operations. These are designed to last much longer than the standard rolls. Two points of contact on the wire red dots Synthetic Rolls Tension ~ 3 Specialized drive rolls for soft aluminum or special care wire. Tend to wear out quickly and must be replaced regularly. Total point of contact on the wire red dots

64 Teflon Consumables Liners Teflon is a specialty liner that is used when precise wire feed is needed or for high heat applications that would typically melt graphite liners. Graphite Graphite liners are used for aluminum and other wires that are susceptible to marring or damage from the liner. Graphite - Combi Combi liners are graphite liners with a brass end. The brass is used in the contact tip end for withstanding higher heat applications with malleable wire. Bare Steel Standard for steel and metal core/flux core wires with a water-cooled torch. Insulated Steel This is the standard steel liner for gas cooled, steel applications

65 Consumables Contact Tips Quality standard or high This trait refers to the tolerance of the wire diameter the tip is designed for. Standard quality tips have a much looser tolerance than High Quality tips. High Quality tips wear at a slower rate than Standard quality tips. Bore Size none, Center-Bore 2 3 This trait refers to how the inner linger fits into the contact tip. This is critical with Aluminum wire especially. None: There is no center bore, the contact tip end is cone shaped to guide the wire through the tip. Wire Size see below The wire size refers to the diameter of the wire the tip is designed for. This size can be either standard US or metric EU. Basic sizes used in the US are Fraction Standard Metric / Thread Size M6, M8, and M10 This trait refers to the size of the threads the contact tip will screw into. M8 and M10 are typical sizes for most MIG applications. Center Bore CB : The contact tip is squared off internally see figure 2 and will come in one of two sizes 4.1mm or 4.8mm depending on the size of the inner liner. 1/ CB tips are required for aluminum welding. This type of tip allows the liner to be exactly centered in the tip. Figure 2: no bore versus center-bore

66 Consumables Torch Breakdown No Drive Fixing Sleeve Nozzle Stock Contact Tip Insulating Ring if used Spatter Guard Gas Nozzle Guide Nozzle if used Clamping Lock Clamping Nut Steel Liner Combi Liner Teflon Liner

67 Consumables Torch Breakdown Whip Drive Fixing Sleeve Nozzle Stock Contact Tip Guide Nozzle if used Clamping Lock 2-piece Drive Roll 1-piece Drive Roll Insulating Ring if used Spatter Guard Gas Nozzle Clamping Nut Guide Nozzle 2-piece Drive Roll keyed or 1-piece Drive Roll keyed Steel Liner Graphite Liner Teflon Liner Ceramic Insert/Liner Brass Insert/Liner Combi Insert/Liner Steel Insert/Liner Teflon Insert/Liner

68 Consumables Torch Breakdown - CMT Teflon Insert/Liner Fixing Sleeve Nozzle Stock Contact Tip Insulating Ring if used Spatter Guard Gas Nozzle Guide Nozzle if used Clamping Lock 1-piece Drive Roll Clamping Nut 1-piece Drive Roll keyed Steel Liner Graphite Liner Teflon Liner Ceramic Insert/Liner Brass Insert/Liner Combi Insert/Liner Steel Insert/Liner Teflon Insert/Liner

69 Consumables Liner Installation Procedure Graphite/Teflon Liner Tools 1 - Whips should be laid out straight prior to installation 2 - Be sure liner is fully inserted in the whip and remove all of the free play. 3 - Cut liner flush with the diffuser and remove any burrs present after cutting. 4 - Contact tip should apply pressure against the inner liner as it is threaded into the diffuser

70 Consumables Liner Installation Procedure Feeder End of Torch Fully insert inner liner Cut liner flush Install clamp nut install wire guide

71 TS/TPS/KD Consumables Feeder and Cooler Standard Steel T-groove) 42,0001,1732 Pressure Roll, smooth 42,0001,3275 Feeder Roll,.035.9) 42,0001,1361 Feeder Roll, ) 42,0001,3570 Feeder Roll, ) 42,0001,1362 Feeder Roll, 1/16 1.6) TS/TPS/KD Flux-cored K-groove) 42,0001,0404 Feeder Roll, ) 42,0001,0352 Feeder Roll, 1/16 1.6) TsT Standard Steel U-groove) 44,0001,1406 Feeder Roll,.035.9) 44,0001,1407 Feeder Roll, ) 44,0001,1408 Feeder Roll, ) 44,0001,1408 Feeder Roll, 1/16 1.6) TS/TPS/KD Heavy Steel U-groove) 44,0001,1376 Feeder Roll,.035.9) 44,0001,1378 Feeder Roll, ) 44,0001,1379 Feeder Roll, ) 44,0001,1323 Feeder Roll, 1/16 1.6) TS/TPS/KD Standard Aluminum H-groove) 42,0001,1613 Feeder Roll,.035.9) 42,0001,0385 Feeder Roll, ) 42,0001,3053 Feeder Roll, ) 42,0001,0386 Feeder Roll, 1/16 1.6) TS/TPS/KD Heavy Aluminum H-groove) 44,0001,1185 Feeder Roll, ) 44,0001,1209 Feeder Roll, 1/16 1.6) TsT Flux-cored R-groove) 44,0001,1431 Feeder Roll, ) 44,0001,1432 Feeder Roll, ) 44,0001,1433 Feeder Roll, 1/16 1.6) TS/TPS/KD Misc Wire Feeder Consumables 42,0100,0333 Wire Guide Insert, synthetic, ,0100,0334 Wire Guide Insert, synthetic, ,0001,3481 Wire Guide Insert, steel 44,0001,1203 Main Drive Roll Cooler Consumables 40,0009,0046 Coolant, standard, -10 outside 40,0009,0079 Coolant, pipe, up to -50 outside 40,0009,0084 Coolant, indoor

72 Consumables Manual Torch-body Consumables 1 42,0100, ,0100,1016 AL 4000 / AW 5000 Insulating Ring, AL 4000 Insulating Ring, AW ,0001,2970 Fixing Sleeve 3 42,0001,5122 Nozzle Stock, M ,0100,1007 Spatter Guard ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,5060 Contact Tip, standard,.035.9) Contact Tip, standard, ) Contact Tip, standard, ) Contact Tip, standard, 1/16 1.6) Contact Tip, center-bore CB),.035.9) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), 1/16 1.6) 6 42,0001,5128 Gas Nozzle, standard AL ,0100,1205 Insulating Ring, AL ,0100,0312 Insulating Sleeve 3 42,0001,5912 Nozzle Stock, M ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,5060 Contact Tip, standard,.035.9) Contact Tip, standard, ) Contact Tip, standard, ) Contact Tip, standard, 1/16 1.6) Contact Tip, center-bore CB),.035.9) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), 1/16 1.6) 5 42,0001,5652 Gas Nozzle, standard d1 d2 d3 L mm) mm) n/a mm) d1 d2 d3 L mm) mm) n/a mm)

73 Consumables Manual Torch-body Consumables 1 42,0100, ,0100,1010 AL 3000 / AW 4000 Insulating Ring, AL 3000 Insulating Ring, AW ,0001,2930 Fixing Sleeve 3 42,0001,5084 Nozzle Stock, M ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,3485 Contact Tip, standard,.035.9) Contact Tip, standard, ) Contact Tip, center-bore CB),.035.9) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), 1/16 1.6) 5 42,0001,5096 Gas Nozzle, standard MTG 5300 S 1 42,0100,1205 Insulating Ring, MTG ,0100,0312 Nozzle Stock, M8 3 42,0001, ,0001, ,0001, ,0001,3893 Contact Tip, sharp,.035.9) Contact Tip, sharp, ) Contact Tip, sharp, ) Contact Tip, sharp, 1/16 1.6) 4 44,0350,3180 Gas Nozzle, standard d1 d2 d3 L mm) mm) mm) mm) d1 d2 d3 L mm) mm) n/a mm)

74 Consumables Robotic Torch-body Consumables MTG ,0350,2616 Gas Nozzle Holder, twist-lock 2 42,0100,0510 Insulating Ring, MTG ,0001,5528 Nozzle Stock, M ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,5060 Contact Tip, standard,.035.9) Contact Tip, standard, ) Contact Tip, standard, ) Contact Tip, standard, 1/16 1.6) Contact Tip, center-bore CB),.035.9) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), 1/16 1.6) 5 42,0001,5532 Gas Nozzle, standard Robacta ,0001,2970 Fixing Sleeve 2 42,0100,1016 Insulating Ring, Robacta ,0001,5122 Nozzle Stock, M ,0100,1007 Spatter Guard ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,5060 Contact Tip, standard,.035.9) Contact Tip, standard, ) Contact Tip, standard, ) Contact Tip, standard, 1/16 1.6) Contact Tip, center-bore CB),.035.9) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), ) Contact Tip, center-bore CB), 1/16 1.6) 6 42,0001,5128 Gas Nozzle, standard d1 D2 d3 L mm) mm) mm) mm) d1 d2 d3 L mm) mm) mm) mm)

75 Consumables Torch Drive Consumables PullMig 1 42,0001,6210 Wire Inlet Guide, PullMig ,0100, ,0100, ,0001, ,0001, ,0001, ,0001, ,0100, ,0100, ,0350, ,0350, ,0350, ,0350,1838 Intake Nozzle, ) Intake Nozzle, 1/16 1.6) Pressure Roll, ) Pressure Roll, 1/16 1.6) Driver Roll, ) Driver Roll, 1/16 1.6) Guide Nozzle, ) Guide Nozzle, 1/16 1.6) Torch Body Insert, combi, ) Torch Body Insert, combi, 1/16 1.6) Torch-body Insert, ceramic, ) Torch-body Insert, ceramic, 1/16 1.2) Inner Liner, bulk ordered by the meter) 40,0002,0002 Inner Liner, steel, ) 40,0002,0004 Inner Liner, steel, 1/16 1.6) 40,0001,0074 Inner Liner, graphite, ) 40,0001,0054 Inner Liner, graphite, 1/16 1.6) 40,0001,0415 Inner Liner, teflon, ) 40,0001,0416 Inner Liner, teflon, 1/16 1.6) Pre-cut Liners, F++ 42,0300,0343 Inner Liner, graphite, 1/16 1.6), 19.7ft 6m) 42,0300,0344 Inner Liner, graphite, 1/16 1.6), 26.2ft 8m) 42,0300,0345 Inner Liner, graphite, 1/16 1.6), 32.8ft 10m)

76 Consumables Torch Drive Consumables ,0100, ,0100, ,0403, ,0403, ,0403, ,0403, ,0403, ,0403, ,0403, ,0403,0152 Robacta Drive Guide Nozzle, ) Guide Nozzle, 1/16 1.6) Pressure Roll,.035.9) Pressure Roll, ) Pressure Roll, ) Pressure Roll, 1/16 1.6) Driver Roll, slot,.035.9) Driver Roll, slot, ) Driver Roll, slot, ) Driver Roll, slot, 1/16 1.6) 4 42,0400,1024 Clamping Nut, threaded 5 42,0001,5412 Clamping Piece ,0350, ,0350, ,0350, ,0350,1838 Torch Body Insert, combi, ) Torch Body Insert, combi, 1/16 1.6) Torch-body Insert, ceramic, ) Torch-body Insert, ceramic, 1/16 1.2) Basic Kit Inner Liner, bulk ordered by the meter) 40,0002,0002 Inner Liner, steel, ) 40,0002,0004 Inner Liner, steel, 1/16 1.6) 40,0001,0074 Inner Liner, graphite, ) 40,0001,0054 Inner Liner, graphite, 1/16 1.6) 40,0001,0415 Inner Liner, teflon, ) 40,0001,0416 Inner Liner, teflon, 1/16 1.6) 44,0350,2006 Basic Kit,.035.9) 44,0350,2008 Basic Kit, ) 44,0350,2009 Basic Kit, 1/16 1.6) Basic kits include items 1-6 and graphite liner

77 Consumables Torch Drive Consumables ,0100, ,0100, ,0001, ,0001, ,0001, ,0001, ,0001, ,0001,5729 CMT Robacta - PullMig Guide Nozzle, ) Guide Nozzle, 1/16 1.6) Pressure Roll,.035.9) Pressure Roll, ) Pressure Roll, 1/16 1.6) Driver Roll, slot,.035.9) Driver Roll, slot, ) Driver Roll, slot, 1/16 1.6) 4 42,0400,1024 Clamping Nut, threaded 5 42,0001,5412 Clamping Piece ,0350, ,0404, ,0350, ,0350, ,0350, ,0350,1838 Wire Buffer Insert, ) Wire Buffer Insert, 1/16 1.6) Torch Body Insert, combi, ) Torch Body Insert, combi, 1/16 1.6) Torch-body Insert, ceramic, ) Torch-body Insert, ceramic, 1/16 1.2) Inner Liner, bulk ordered by the meter) 40,0002,0002 Inner Liner, steel, ) 40,0002,0004 Inner Liner, steel, 1/16 1.6) 40,0001,0074 Inner Liner, graphite, ) 40,0001,0054 Inner Liner, graphite, 1/16 1.6) 40,0001,0415 Inner Liner, teflon, ) 40,0001,0416 Inner Liner, teflon, 1/16 1.6) Basic Kit 44,0350,2399 Basic Kit, aluminum,.035.9) 44,0350,2383 Basic Kit, aluminum, ) 44,0350,2384 Basic Kit, aluminum, 1/16 1.6) 44,0350,2401 Basic Kit, steel,.035.9) 44,0350,2391 Basic Kit, steel, ) Basic kits include items 1-6 and graphite liner

78 Interface Models Discrete I/O Rob 3000, 4000, 5000, 5000 OC) Each interface signal is indivually wired into the robot/automation controller Source/sync signal for on/off based interface signals 0-10 VDC analog signal for variable signals No modification or changes are possible with the signal set. Fieldbus DeviceNet, Profibus, CANbus) Each interface signal is converted to a fieldbus protocol and digitally transferred between the welding power supply and the robot/automation controller A single bit is used for on/off based interface signals Multiple bits are put together to form a binary value for variable signals. No modification or changes are possible with the signal set. Ethernet Ethernet IP, WeldCOm) Each interface signal is converted to a TCP/IP protocol and digitally transferred between the weldign power supply and the automation controller. A single bit is used for on/off based interface signals Multiple bits are put together for form a binary value for variable signals. The bit-map can be changed though time-consuming and expensive Offers the most versatile and capable of all interfaces

79 Interface General Information Provide communication between the welding system and an automated controller PLC, robot, automation, etc.). Connects to the power source through LocalNet Power source is a slave to the controller. STOP is displayed on the power source until the Robot Ready and the Source Error Reset signal is initialized. An additional LocalNet connect is provided that connects directly to the ROB If no LocalNet connection is available, a passive distributor 4,100,261 may be used. Power source functions are controlled through the use of analog command values 0-10 VDC or binary equivalent for welding power and arc length correction. Welding programs may be selected on the by the robot/plc, the power source control panel, or through an RCU. Digital inputs/outputs are galvanically separated ROB series only): From one another, From the LocalNet and the welding potential. For a maximum voltage difference of 100 V

80 Interface Major Signals Major Digital Inputs Robot to the Power Source) Robot Ready: This signal indicated that the robot is communicating, functioning, and ready to weld. This is one of two signals REQUIRED for any sort of operation or adjustment of the welding system. Without this signal, the power supply will continuously display STOP on the front panel display and send an error code to the robot. Source Error Reset: This signal is designed to clear any error state the welder is currently in. For proper use, this signal should be toggled on and then off again. So long as the error is no longer valid, the error will clear and a normal display will appear on the front panel. Otherwise an error code will be displayed such as the STOP error code). Arc On: This signal will start the welding process, beginning with pre-welding gas pre-flow, hot start) and then automatically moving to the welding process. Once this signal goes low, the post welding process crater fill and gas post-flow) will then start automatically. Welding Mode: This is a combination of three signals joined together to form a single binary number. Each number corresponds to a specific mode the welding power source can be set to. Some of the major modes are Mode 2 - Job: When the welder is in this mode, the welding characteristics are controlled by a schedule number 0-99) that will link to a set of welding parameters stored on the welding power source. This mode allows for the maximum capability of the welding process as all activated parameters are usuable. Mode 3 Set Up: When the welder is in this mode, the front panel is fully functional and anything can be programmed in. If welding occurs while the welder is set to this mode, the weld will be based on whatever is currently programmed into the power source. Job Number: This is a combination of several bits joined together to form a binary number between 0 and 99. When the welder is in job mode, this set of bits tells the welder which schedule specifically to use

81 Interface Major Signals Major Digital Inputs Robot to the Power Source) Gas Test: This signal is used to purge gas from the robot controller or through the robot pendant. This can be used as a gas pre-flow and/or post flow as necessary. Wire Inching/Retracting: These signals are used to move the wire forward and backward from the robot controller or through the robot pendant without gas or current flow. Weld Simulation: When this signal is turned on, the power source will go through the welding process and respond with/to all the proper inputs/outputs WITHOUT feeding wire, moving gas, or current flow. Major Analog Inputs Robot to the Power Source) Welding Power: This combination of bits will form an analog value that will measure the welders wire feed speed or current between 0% and 100% with 0 being the lowest welding value and 100% being the maximum. This input is only used when welding in synergic, pulse synergic, or manual mode WITHOUT the use of the Job mode. This can be used during JOB mode, but the job settings will limit how much it can be adjusted up or down. Arc Length Correction: This combination of bits will form an alalog value that will measure the welders arc length correction value between -30 and +30. This value is controllable in any mode though job settings will limit how much this value can be adjusted. Pulse or Dynamic Correction: This combination of bits will form an alalog value that will measure the welders arc length correction value between -5 and +5. This value is controllable in any mode though job settings will limit how much this value can be adjusted

82 Interface Major Signals Major Digital Outputs Power Source to the Robot) Power Source Ready: This signal is sent to the robot when the power source has established successful communication AND there are no errors that will interfere with the function of the welder. Note this signal will not be active is a STOP or E-STOP is displayed on the power source for any reason. Arc Stable: This signal is sent to the robot once an arc has been started AND that arc is within acceptable parameters as determined by the welding power source. Process Active: This signal will go high once the welding process has started after an Arc On signal beginning with the gas pre-flow if set by the welder note this signal will not go high is the gas is controlled by the robot instead

83 Interface Major Signals Bit 0 X2:6 Bit 1 X8:1 Bit 2 X8:2 Dec Hex Standard Mode LOW LOW LOW 0 0 Pulse-Synergic Mode HIGH LOW LOW 1 1 Job Mode LOW HIGH LOW 2 2 Parameter Selection internal mode HIGH HIGH LOW 3 3 Manual HIGH HIGH LOW 4 4 CC/CV HIGH LOW HIGH 5 5 TIG LOW HIGH HIGH 6 6 CMT/Special Process HIGH HIGH HIGH 7 7 Standard Mode: This allows the power source to weld using the synergic mode. Pulse-Synergic Mode: This allows the power source to weld using the pulse-synergic mode. Job Mode: This allows the power source to weld in job mode using one or more jobs specified by the robot. Parameter Selection: Set-up mode for operator to make weld changes. Use caution when in this mode. Manual Mode: This allows the power source to be controlled using analog inputs. There are NO job/program options. CC/CV Mode: This allows the power source to be operated in a constant current or constant voltage mode. TIG Mode: This allows the power source to be operated in TIG mode. CMT/Special Process: This allows the power source to weld using CMT or a special process

84 Interface Signal Interaction Job Mode Regardless of the mode, the welder must see the Robot Ready and Source Error Reset signals before it will allow any sort of welding or selections to occur: When using this mode, the welder controls the entire weld process. The robot will put the welder in job mode, call out a job number, and control the weld travel speed. Everything else is typically handled by the welder itself. Robot movement usually based off of the process active signal. This mode allows for the most customization of the weld and ensures that the timing between weld factors are smooth, efficient, and quick. Adjust the weld parameters is typically done from the welder or a separate pendant. This is not true of every interface, however. NOTE: The points above are intended as a general guide. Exceptions can be made as the application requires

85 Interface Signal Interaction Program Mode Regardless of the mode, the welder must see the Robot Ready and Source Error Reset signals before it will allow any sort of welding or selections to occur: When using this mode, the robot controls all of the weld and gas parameters it is capable of and the travel speed. The welder is only responsible for creating and controlling the arc. Robot movement usually based off of the process active signal. This mode will only have weld parameter adjustments based on the capability of the robot interface and almost never as completely as job mode Usually the robot will need to be scaled based on the synergic line being used. If multiple lines are being used a separate scale file may be required. NOTE: The points above are intended as a general guide. Exceptions can be made as the application requires

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

87 Fronius Xplorer Overview Tab The Options button opens up a submenu that has several useful functions including the Show connection data and Machine Configuration selections. By using these buttons, Weld Jobs can be saved to a computer Backup or loaded from one Restore. As long as the synergic lines exist in the database loaded into the machine, any Weld Job set can be used. These job sets are NOT compatible with other Backup/Restore tools. Show connection data shows the IP and connection interface for any Ethernet card connected to LocalNet. This option also allows for these settings to be changed as needed. This display shows everything that is currently connected through LocalNet. In addition, hardware, firmware, and database information will be displayed for each piece of equipment that is selected yellow bar indicated selection. The license button is used to see which software options are loaded into the machine. Unlocked options are displayed as green locks while locked ones are red locks. New ones can be loaded in using the Enter new software code button. Machine Configuration outputs a text file that includes all equipment connected through LocalNet. Serial numbers, firmware, and hardware versions are also saved

88 Fronius Xplorer Job and Docu Tab The Job tab give a quick view of jobs loaded into the welder, the weld parameters for these jobs, and any changes that have been made recently. Group and job names can be changed to reflect the application and/or production floor. The Docu tab allows you to monitor the weld parameters of one or more welders AFTER they have completed a weld. The parameters can be customized based on the user desires by right clicking on the data screen. Previous data can be viewed by opening up older files. Each days welding is stored for future viewing and/or importing. A job can be copied to one or more other locations and than customized to suit the needs of the application. When a change is made, there is an option to either accept the change or undo the change. Finally, a history of job changes is kept that can not only be reviewed but also loaded from should the need arise. The Options button opens up a submenu that has several useful functions including the Set consumption figures and the Country settings selections. The Set consumption figures allows you to set the costs of your wire, gas and energy as well as specify the travel speeds used during the welding process. The Country settings changes the unit of measurement between metric and imperial depending on the needs of the plant

89 Troubleshooting Weld System Many factors can effect weld quality and many times the poor quality will come from wear parts rather than weld settings. However in some cases the weld quality can be effected by the weld settings. This would be the case if the settings have been adjusted from settings that were known to work for specific process. Also a change in base materials or parts can make the predetermined settings no longer the best viable settings to produce quality welds. When trouble shooting weld quality it is very important to go through a number of checks prior to designating a certain cause to the problem. These checks include: Consumables Loose Connections Settings that differ from pre determined settings Torch Quality Torch Itself internal/externally or liner itself Wire Drive unit Damaged or loose connections Damage to drive motor or drive rolls Firmware Hose Pack Damage to any connections, hoses or cabling included in the hose pack Power Source Internal Hardware or Firmware

90 Troubleshooting Welder Error Codes DSP xxx Error with the Digital Signal Processor Reload firmware/database or replace UST EFD xxx Error with the wire feed system, refer to wire feeder error codes for more details Err 049, 051, and 052 Error detected in mains power input phase missing or voltage too low/high). Check mains and then replace NT 24 Err 050 Intermediate circuit imbalance. Further troubleshooting needed Err IP Primary transformer over-current detected. Check the secondary power module and the BPS board. Err PE Voltage detected on earth ground. Check for isolation between welding ground points and earth ground points. No H2O Error with the coolant system, check cooler for operation and system for good flow. No Prg Synergic line selected doesn t exist. Verify synergic line settings, reprogram UST, or replace UST. STOP Communication or E-Stop condition with robot. Check for Robot Ready and Error Reset signals from robot. Tsx xxx and Tpx xxx Internal temperature errors on the secondary or primary side. Check for duty cycle and proper air flow

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

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