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MIG Welding Equipment

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

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

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

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

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

Feet to Meter X 0.3048
-1-
-2-
 Components consist of

Weld System -1- Power Source
-2- Wire Feeder
Component Layout -3- Torch
-4- Work Surface/Fixture
-5- Main Power (230 or 460V AC⁄
-6- Front Panel
-7- Gas Tank
-8- Remote Control Unit (RCU⁄
5 6 -9- Robot Interface
-10-
10- Cooler
-11-
11- PC Interface Tool
8
B 11  Connections consist of

D -A- Ground Connection
D -B- Main Power (230 or 460V AC⁄
-C- Gas
-D- LocalNet
-E- Motor Voltage (55V DC⁄
D D -F- Main Current
-G- Pump Voltage (230 or 400V AC⁄
E -H- Data Lines (non LocalNet⁄
F -I- Coolant Out
9 D -J- Coolant In
1
F
A
C
3
2
J
G
D
H
 Component Management
4  Controlled by LocalNet (Fronius communication

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

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

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

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

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

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

 Two amp ranges available (350 and 500⁄. Multi-voltage model available.
 Welder is designed specifically for steel welding, offering a large variety of options at a low price.
range.
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 Designed with robotic or automated welding in mind. -8-
Power Source
Name Plate
The identification portion of the label will give a detailed
description of the welder, the full part number, and a unique
serial number.
Using the format below, the serial number can be used to

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

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

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

The connection depends on the These connections are for
operating mode of the power source optional upgrades to the power
Welding: Connect the
MIG Welding source.
welding ground to this socket.
TIG Welding
current connection on the torch
to this socket.
STICK Welding Mains Connection
electrode cable to this socket This connection is for the 3-
(depending on the type of phase input power.
electrode being used⁄.
Current Connection
Power Switch (+⁄ Current Socket Connection
(optional⁄
This switch turns the power source on The connection depends on the operating mode of the power source
(1⁄ and off (0⁄. This connection is reserved for
MIG Welding:
Welding Connect the current connection of the interconnection an optional current socket
hose pack to this socket.
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TIG Welding:
Welding Connect the welding ground to this socket.
STICK Welding:
Welding Connect the electrode cable to this socket (depending
on type of electrode being used⁄. - 11 -
Power Source
Connections – TPS 2700
Carrying Strap
Power Switch
Front Panel
Blanking Cover(s⁄
LocalNet Connection
Ground Connection (optional⁄
Current Connection
Gas Connection (bottle⁄

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

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

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

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

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

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Coolant Feed - cold (welder⁄ - 18 -

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

Arc Length Control
Buffer Connection (torch⁄

LHSB Connection (torch⁄
Robacta Connection (torch⁄

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

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

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

 Standard System Only -

 PAP System Only -
Motor-
Motor-plate
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Wire Inch Button - 20 -

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

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

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

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

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

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

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

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

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

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

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

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

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

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

13 SEP 12
- 29 -

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/ Battery Charging Systems / Welding Technology / Solar Electronics

MIG Welding Equipment

 Wire Feeder  Consumables

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

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

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

135 63.71 150 63.50 381.00

 Components consist of

B 11  Connections consist of

4  Controlled by LocalNet (Fronius communication

Control Voltages Control Voltages

Welding Current Welding Current

Coolant Lines Coolant Lines

Remote Mounted Wire Feeder

Control Voltages Control Voltages

Welding Current Welding Current

Coolant Lines Coolant Lines

Robot Mounted Wire Feeder

Trans Synergic (TS) 3200/4000/5000

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

Trans-Steel (TsT) 3500/5000 Manual

Trans-Steel (TsT) 3500/5000 Robotic

gas types, and wire diameters

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

The name plate is found on the top of the

welding power supply. maximum outputs.

(-⁄ Current Socket Connection Blanking Cover(s⁄

Ground Connection (optional⁄

Gas Connection (bottle⁄

Current Connection LocalNet Connection

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

large range of options and fixtures to choose from.

Drive Rolls (top⁄

Wire Guide Insert (steel or synthetic⁄

Main Drive Roll

Drive Rolls (bottom⁄

Current Connection (welder⁄

Gas Connection (bottle⁄ Wire Inch Button

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

Coolant Feed - cold (torch⁄

Coolant Feed - hot (welder⁄

LocalNet Connection (welder⁄

Coolant Feed - cold (welder⁄ - 18 -

Current Connection (welder⁄

LocalNet Connection (welder⁄

Coolant Feed - hot (welder⁄

Gas Connection (bottle⁄

Coolant Feed - cold (welder⁄

Power Control (WFS, Current, etc.⁄

Buffer Connection (torch⁄

Robacta Connection (torch⁄

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

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

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

LocalNet Connection (welder ⁄

LocalNet Connection (welder⁄

Wire Inch Button - 20 -

Handle Current Connection (welder⁄

Gas Connection (bottle⁄