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Manual Welding: / Product Guide
Manual Welding: / Product Guide
/ Product Guide
EXPERT
KNOWLEDGE
/ Making it our personal business
to work out the best solution for you
APPLICATION
SUPPORT
/ Maximise the use of your Fronius
equipment
/ Submit parts for trial welding to
determine best processes TRAINING
/ Expert advice from highly qualified / Thorough product training
personnel / Basic to advanced welder
training
/ Service and application
training
/ Variety of systems training
AFTER-SALES
SUPPORT
/ In house repair centre and call out technicians
/ Comprehensive service packages including
calibration and maintenance
/ Fronius service technicians available on-site
for installation and troubleshooting
Contents
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VIRTUAL WELDING
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virtual tools?
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hands-on way.
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MIG/MAG
TPS/i
TPS/i
Operating Voltage 14.2-30V
Welding Current / Duty Cycle (10min/40C) 220A / 100%
Welding Current / Duty Cycle (10min/40C) 320A / 40%
Welding Current / Duty Cycle (10min/40C) 260A / 60%
Min-max. welding current 3A - 320A
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TPS 270i C Pulse NEW
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TPS/i MODELS!
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Processes
Every welding process - from MIG/MAG (steel, CrNi, aluminium application) and MIG brazing to
TIG DC and MMA - can be carried out using a single unit thanks to the multiprocess capability.
A plethora of options, such as a TIG installation kit or a polarity reverser for welding special flux
core wires, provides even greater flexibility to this unbelievably wide range of applications.
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TPS/i Accessories
Wirefeeders for TPS/i
The WF 25i Case wirefeeders (D200 & D300) feel
most at home in extreme environments. The
ergonomically shaped plastic housing offers
optimum protection against external influences
WF 25i Case Wirefeeders D200 / D300 and can withstand even the heaviest
stressing. Minimised obstacle contours largely
avoid the risk of damage.
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SO YOU ARE LOOKING TO BUY THE MOST SOPHISTICATED
WELDING MACHINE ON THE MARKET. LET IT PERFORM AT
ITS BEST...
/ The new generation of welding torches have been specially designed to get the absolute best
performance out of the Fronius TPS/i range. You wouldn’t buy a performance car and fit budget
tyres, so why compromise on your welding torch? Let us take you through the major benefits of
using the right torch...
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/ SPEEDNET - UNLOCK THE POTENTIAL
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JUST FEEL THE DIFFERENCE
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/ The total redesign of this ergonomic and well balanced torch
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/ EFFICIENT TORCH COOLING
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INTELLIGENT
TRY BEFORE YOU BUY
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REVOLUTION
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simply return it to us.
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*Terms and conditions apply.
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lightest on the market. What’s more the
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Fronius Job Master gives you the same
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welding requirements.
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9
Manual Welding Torch Gascooled MTG 250i / MTG 320i
MTG 400i / MTG 550iNEW / MTG 5300 S
Standard Equipment
Screw-on gas nozzle
Outer tube of stainless steel
Heat-protection shield (MTG 400i)
Non-slip handle with soft components
MTG 250i MTG 320i
Rubber anti-kink feature with ball joint
2-wire bus
Coaxial cable
Rubber anti-kink feature at the central
connector side
Fronius System Connector (FSC)
MTB 250i G + MHP 250i G MTB 320i G + MHP 400i G MTB 400i G + MHP 400i G
Standard Equipment
Screw-on gas nozzle
Outer tube of stainless steel
360° turnable, twist safety device at 0°
Heat-protection sheild (MHP 400i)
MTB 250i W + MHP 500i W MTB 320i W + MHP 500i W MTB 500i W + MHP 500i W
Standard Equipment
Screw-on gas nozzle Rubber anti-kink feature with ball joint
Outer tube of stainless steel 2-wire bus
360° turnable, twist safety device at 0° Swivel mounted wire feed hose
Heat-protection sheild Anti-kink feature at the central connector side
Non-slip handle with soft components Fronius System Connector (FSC)
Integrated water stop at the hose pack
Standard Equipment
Small number of wear parts 2-wire bus
Heat protection shield Coaxial cable
Anti-kink feature at the central connector side
360° turnable, twist safety device at 0°
Fronius System Connector (FSC)
Non-slip handle with soft components
Rubber anti-kink feature at the gip plate side
with ball joint
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PullMig Manual Welding Torch MHP 280i G PM / MHP 320i W PM
Standard Equipment
Multilock torch bodies: Integrated water stop at the hose pack
Screw-on gas nozzle Rubber anti-kink feature with ball joint
Outer tube of stainless steel 2-wire bus and SpeedNet
360° turnable, twist safety device at 0° Rubber anti-kink feature at the central
Hose packs: connector side
Non-slip handle with soft components Fronius System Connector (FSC)
CU 1400i CU 1400i
Pro Pro / MC
Dimensions HxWxL mm 230x300x710 230x300x710
Weight 12kg 12kg
Mains Frequency 50-60Hz 50-60Hz
Max. lift of the pump 45000mm 35000mm
Coolant volume 6l 6l
Max. pump pressure 4bar 4bar
Cooling capacity (25°C) Q=1l/min 1400W 1400W
Cooling capacity (40°C) Q=1l/min 900W 900W
Max. throughput 3l/min 3l/min
Mains Voltage [+/-10%] 24 VDC 24 VDC
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MIG/MAG
The TransSteel 3500/5000 and now
the 3500 compact version embody
an intelligent industrial design,
tremendous ease of handling,
rugged construction and long
service life. This digitally controlled
MIG/MAG welding system comes
with Steel Transfer Technology to
give you optimum steel welding
characteristics.
Processes
MIG/MAG welding
Electrode welding
Processes
MIG/MAG welding
Electrode welding
MIG/MAG
reproducibility and best weld properties, anytime, anywhere. The
multiprocess power source is suitable for MIG/MAG, TIG and
electrode welding, as well as manual or robotic applications.
Processes
MIG welding, MIG pulsed arc welding, MIG brazing, TIG-DC, Manual
electrode welding, Arc air gouging (TPS 5000)
Processes
CMT brazing, CMT welding, MIG welding, MIG pulsed arc
welding
her
Up to 30% hig TIME 5000 Digital, a digitised high-performance welding process
ra te s with all the associated benefits: 100 % reproducible welding
deposition results, modular system principle, digital microprocessor control
on steels. and outstanding weld properties.
TIME 5000
Dimensions (HxWxLmm) 480x290x625
Weight 36 kg
Mains Frequency 50-60Hz
Mains Fuse 35A
Protection Class IP23
Open-circuit Voltage 70V
Mains Voltage (+/-10%) 3 x 400V
Processes Operating Voltage 28 - 48V
MIG/MAG welding, MIG/MAG pulsed arc Welding Current / Duty Cycle 360A / 100%
welding, MAG high-performance welding, (10min/40C) 450A / 60%
MIG brazing, TIG-DC, Manual electrode 500A / 40%
(MMA) welding, Arc air gouging Min-max. Welding current 3A - 500A
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Remote control units for digital machines
MIG/MAG Accessories
Display remote control TR1000 with
with cable 5m
with cable 5m
cable 5m
cable 5m
5m
with cable/5m
RCU 4000 RCU 5000i
MIG/MAGACCESSORIES
Accessories
cable 5m
Standard Features - S / Options •
SD
I-kit magnet for RC • •
I-kit mounting RCU5000i •
Adjustable parameter
Welding current S S S S S S
MIG/MAG
MIG/MAG Accessories
Cooling capacity (25°C) Q=1l/min 505W 1120W 1360W
Max lift of the pump 30000mm 5000mm 30000mm
Coolant volume 5.5l 5.5l 5.5l
Mains Frequency 50-60Hz 50Hz 50-60Hz
Mains voltage [+/-10%] 230V 230 / 400V 400V
Protection class IP23 IP23 IP23
There are many options available for this product. Please call one of our sales representatives
for more details on 01908 512 300.
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TIG
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TransTig 800 Job / 2200 / 2200 Job
The Transtig 800 and 2200 are both light and robust, self explanatory in
operation and completely digitised.
TIG
TransTig 2500 / 3000 / 2500 Job / 3000 Job
2500 Comfort / 3000 Comfort
Weighing just 24kg, the TransTig 2500 and 3000 are the lightest Tig power
sources with a 3-phase power supply. They are extremely easy to use, very
intuitive in their operation, very robust, powerful and completely digitised.
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Processes MagicWave MagicWave
TIG - DC
1700 G/F 2200 Job G/F
Manual eletrode (MMA)
welding Dimensions (HxWxLmm) 344x180x485 390x180x485
TIG - AC/DC Weight 15 kg 17.4 kg
Mains Frequency 50 - 60Hz 50 - 60Hz
Mains Fuse 16A 16A
Recommended base Protection Class IP23 IP23
materials Open-circuit Voltage 88V 88V
Constructional steels Mains Voltage (+/-10%) 230V 230V
Ferritic / austenitic CrNi steels Operating Voltage 10.1 - 26V 10.1 - 24V
Duplex-steels Welding Current / Duty Cycle 100A / 100% 150A / 100%
Nickel-based materials (10min/40C) 130A / 60% 170A / 60%
Special materials 170A / 35% 220A / 35%
Copper materials Min-max. Welding current 3A - 170A 3A - 220A
TIG
MagicWave M.W. 3000
2500 G/F Comfort G/F
Dimensions (HxWxLmm) 435x250x560 390x180x485
Weight 26.6 kg 28.1 kg
Mains Frequency 50 - 60Hz 50 - 60Hz
Mains Fuse 16A 16A
Protection Class IP23 IP23
Open-circuit Voltage 89V 88V
Mains Voltage (+/-10%) 3 x 400V 3 x 400V
Operating Voltage 10.1 - 20V 10.1 - 22V
Welding Current / Duty Cycle 180A / 100% 200A / 100%
(10min/40C) 210A / 60% 250A / 60%
250A / 40% 300A / 40%
Processes
TIG - DC, TIG - AC/DC,
Manual electrode (MMA) welding
4000 G/F 5000 Job G/F Job G/F MV 5000 Job G/F
Dimensions (HxWxLmm) 705x290x625 705x290x625 705x290x625 705x290x625
Weight 58.2 kg 58.2 kg 58.2 kg 58.2 kg
Mains Frequency 50 - 60Hz 50 - 60Hz 50 - 60Hz 50 - 60Hz
Mains Fuse 35A 35A 63A / 35A 63A / 35A
Protection Class IP23 IP23 IP23 IP23
Open-circuit Voltage 90V 90V 90V 90V
Mains Voltage (+/-10%) 3 x 400V 3 x 400 3 x 200 - 240V / 3 x 200 - 240V /
3 x 380 - 460V 3 x 380 - 460V
Operating Voltage 10.1 - 33V 10.1 - 33V 10.1 - 32V 10.1 - 30V
Welding Current / Duty Cycle 310A / 100% 350A / 100% 300A / 100% 350A / 100%
(10min/40C) 365A / 60% 440A / 60% 360A / 60% 440A / 60%
400A / 45% 500A / 40% 400A / 45% 500A / 40%
Min - Max. Welding current 3A - 400A 3A - 500A 3A - 400A 3A - 500A
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TTG1200A / 1600A / 2200A / 2600A / PL10
Processes
TIG - DC
TIG - AC/DC
Recommended base
materials
Ferritic / austenitic CrNi-steels
Aluminium materials
Magnesium materials
Standard equipment
Plug-on gas nozzle system, Torch body rotates through 90°, Easy-to-use rocker switch,
Swivel-mounted protective hose, UV and ozone-resistant protective hose, Gas nozzle, Tungsten
electrode, Torch cap long, Anti-kink feature at machine and torch end.
TIG Torches
Welding current / Duty cycle (AC) 85A / 35% 120A / 35% 180A / 35% 220A / 35% 60A / 40%
Welding current / Duty cycle (AC) 65A / 60% 90A / 60% 130A / 60% 170A / 60% 50A / 60%
Welding current / Duty cycle (DC) 120A / 35% 160A / 35% 220A / 35% 260A / 35% 80A / 40%
Diameter electrode 1 - 3.2 mm 1 - 3.2 mm 1 - 4 mm 1.6 - 6.4 mm 1 - 2.4 mm
Recommended base
materials
Ferritic / austenitic CrNi-steels
Duplex-steels
Nickel-based materials
Aluminium materials
Magnesium materials
Copper materials
Standard equipment
Plug-on gas nozzle system, Torch body rotates through 90°, Easy-to-use rocker switch,
Swivel-mounted protective hose, UV and ozone-resistant protective hose, Gas nozzle, Tungsten
electrode, Torch cap long, Anti-kink feature at machine and torch end.
Welding current / Duty cycle (DC) 200A / 60% 300A / 60% 400A / 60% 500A / 60% 180A / 60%
Welding current / Duty cycle (AC) 140A / 60% 250A / 60% 350A / 60% 400A / 60% 140A / 60%
Diameter electrode 1 - 3.2 mm 1 - 3.2 mm 1 - 4 mm 1.6 - 6.4 mm 1 - 2.4 mm
TIG Accessories
Coolant volume 1.5l 4l 4l 5.5l 9l
Mains Frequency 50-60Hz 50-60Hz 50-60Hz 50-60Hz 50-60Hz
Mains voltage [+/-10%] 230V 400V 230 / 460V 400V 230 / 400V
Protection class IP23 IP23 IP23 IP23 IP23
There are many options available for this product. Please call one of our sales representatives for
more details on 01908 512 300.
Standard Equipment
Waterlevel control outside
Stainless steel coil evaporator
High tech scroll compressor / low noise
High efficiency air cooled condensor
Digital thermostat hysteresis +/- 1.0K
Refrigerent circuit with high pressure switch
Operating temperature max. 42°C ambient
Plastic water tank, Chiller IP 44
Draining through water level control
Environment friendly refrigerant R 407 c
Internal by-pass for pump protection
Non ferrous water circuit
Water connection quick cuppling
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Remote Control Units For TIG DC / TIG AC/DC inverter power sources
cable 5m
cable 5m
TR 2000 TR 2200 F
TIG Accessories
Power sources
TT 1750 Puls • • • •
TT800 Job • • • • •
MW 1700 / 1700 Job • • • • •
TT/MW 2200 • • • • •
TT/MW 2200 Job • • • • •
TT/MW 2500 / 3000 • • • • •
TT/MW 2500 / 3000 Job / Comfort • • • • •
TT/MW 4000 / 5000 • • • • •
TT/MW 4000 Job / 5000 Job • • • • •
Options
Equipment
Welding current X X X X X
MMA arc force E E
Hotstart
Polarity reversal
Puls / Standard
Puls Duty-Cycle
Pulsing frequency range
Spot welding time
AC-balance
AC-frequency
Magnetic holder X O
Display X
I2 W W
Job recall X
Switch of TIG/E mode
E = Mode: Electrode
W = Mode: TIG
X = Mode: TIG/Electrode
O = Option
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Remote Control Units continued
cable 5m
cable 5m
cable 5m
TR 4000 RCU 2000
TIG Accessories
Power sources
TT 1750 Puls •
TT800 Job • • • •
MW 1700 / 1700 Job • • • •
TT/MW 2200 • • • •
TT/MW 2200 Job • • • •
TT/MW 2500 / 3000 • • • •
TT/MW 2500 / 3000 Job / Comfort • • • •
TT/MW 4000 / 5000 • • • •
TT/MW 4000 Job / 5000 Job • • • •
Options
Welding current X X X X
MMA arc force E E E
Hotstart E E
Polarity reversal E X
Puls / Standard X
Puls Duty-Cycle X
Pulsing frequency range X
Spot welding time X
AC-balance W X
AC-frequency W X
Magnetic holder X O
Display X X X
I2 W
Job recall X
Switch of TIG/E mode X X
E = Mode: Electrode
W = Mode: TIG
X = Mode: TIG/Electrode
O = Option
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Coldwire
There are many options available for
cold wire, wire feed hoses and wire coil
mountings. Call us to find out more on
01908 512 300.
KD 4000 KD 7000
Power sources
TT 2500/3000 Job / Comfort • • •
TT 4000/5000/4000 Job / 5000 Job • • •
MW 2200 Job • • •
MW 2500/3000 Job / Comfort • • •
MW 4000 Job / 5000 Job • • •
Options
I-kit KD Drive • •
I-kit digital gas sensor • •
I-kit digital gassensor gas 10 •
I-kit wire end VR 4000 •
I-kit wire end VR 7000 •
I-kit wire end socket (Attention: only factory-installation) • • •
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Manual Metal Arc
A common welding method for rust-, acid- and heatproof steel
is arc welding with a consumable coated electrode. It takes
place by hand and is suitable for plate thicknesses of 1mm and
above.
CORDLESS WELDING
MMA
AccuPocket 150/400 MMA welder now with TIG
The AccuPocket is the world’s first-ever portable unit and can be charged in just 30 minutes to
MMA welding unit to run on integrated lithium- over 90% of its total capacity. A fully charged
ion batteries. This marriage of welding battery delivers sufficent power to weld up to 16
technology and rechargeable battery technology electrodes of 2.5mm diameter and for TIG mode,
lets users weld anywhere, whether there is a upto 17 minutes of continuous operation at full
mains supply or not, and without any current power.
cables. The Accupocket is supplied with a
charging device specially tailored to the welding
Processes
Manual electrode (MMA) welding
(C-version)
Cel-compatible
TIG-DC
AccuPocket 150/230V/E, EU
Dimensions (HxWxLmm) 310x160x435
Weight 10.9kg
Protection class IP23
Open-circuit voltage 91V
Operating voltage 0-91V
Welding current / Duty cycle [10min/40C] 40A/100% ED [Hybrid]
Welding current / Duty cycle [10min/40C] 140A/18% ED [Hybrid]
Welding current / Duty cycle [10min/40C] 100A/25% ED [Hybrid]
Max. welding current 140A
Welding current min. 10A
MMA
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Technology that detects the state of the battery and
optimally adapts the charging characteristic – together
ensure safe operation and long battery-cell life.
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TransPocket 150 / 180 / RC / TIG / MV NEW
Recommended base materials
Constructional steels, Ferritic / austenitic CrNi steels,
Duplex steels, Aluminium materials
Processes
Manual electrode (MMA) welding, TIG-DC,
Cel-compatible
MMA
Welding Current / Duty Cycle (10min/40C) 90A / 100% 120A / 100% 120A / 100%
Welding C. / D. Cycle (10min/40C) 120V/20A - - 120A/ 40A
Welding C. / D. Cycle (10min/40C) 120V/20A - - 90A/ 100%
Max. Welding current 150A 180A / WIG: 220A 220A (TIG)
Welding Current min. 10A 10A 10A
TransPocket
1500
Dimensions (HxWxLmm) 200 x 110 x 315
Weight 4.7 kg
Mains Frequency 50 - 60Hz
Mains Fuse 16A
Protection Class IP23
Open-circuit Voltage 92V
Mains Voltage (+/-10%) 230V
Operating Voltage 10.4 - 25.6V
Recommended base materials Welding Current / Duty Cycle (10min/40C) 80A / 100%
Constructional steels, Ferritic / austenitic Welding Current / Duty Cycle (10min/40C) 140A / 30%
CrNi steels, Min - Max. Welding current 10A - 150A
Processes
TIG - DC, Manual electrode (MMA) welding, Cel-compatible
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PLASMA WELDING
In plasma welding, the arc is constricted by a cooled gas nozzle. The powerfully bunched
arc that results does away with the need for time-consuming weld preparation work,
saving as much as 30% of the filler metal. Also, being enveloped in plasma gas, the
tungsten electrode has a much longer service life.
Plasma
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Softplasma and MicroPlasma welding
TT800/2200 manual continued
Plasma Processes
Module 10 SoftPlasma
PlasmaKeyhole
Dimensions (HxWxLmm) 344x180x505
Plasma brazing (DC mode)
Weight 14.2 kg
Mains Frequency 50 - 60Hz
Mains Fuse 16A Options
Protection Class IP23 Robot interface
Open-circuit Voltage 88V Plasma torch
Mains Voltage (+/-10%) 230V Hot wire
Operating Voltage 10 - 16V Coldwire feeder unit
Test Mark CE Push Pull system (not for manual
Technology Inverter welding)
Water recooler
Processes
Plasma
Plasma DC negative pole
Standard equipment
Swivel-mounted protective hose
UV- and ozone-resistant protective hose
Flexible leather protection hose 0.7m
Anti-kink feature at machine and torch end
Easy-to-use rocker switch
Options
Fabric-reinforced protection hose
KD-feeding external
Special lengths of hose pack up to 0.8m
WeldCube NEW
The WeldCube solution is based on an
WeldCube
Protective Equipment
Welding protective Protective Vizor 3000 Air/3 Pro, Plus &
clothing, gloves & goggles & Standard
boots welding glasses Battery powered fan filter device with
adjustable airflow
Fronius Automation
Did you know that Fonius offers a wide range of automation and robotic welding
equipment? Call us on 01908 512 300 or for the full range visit www.fronius.co.uk
Automation
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N IV E R SAL
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A P P LI C AT IO
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AUTOMATION GUIDE
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Fronius Automation
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Automation
Fronius Multi
Welding Machine
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All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.
of our resources forms the basis of our corporate policy.
Text and images correspond to the current state of technology at the time of printing. Subject to modifications.
PERFECT WELDING SOLAR ENERGY PERFECT CHARGING
/ We develop products and complete / The challenge is to make the leap / As know-how leaders in the world
systems - both manual and automated to a regenerative energy supply. Our of battery charging, we deliver
- as well as the corresponding ser- vision is to use renewable energy to exceptional solutions to create the
vices for our customers in the global achieve energy independence. With maximum benefit for our customers.
welding technology market. We have our services, inverters and energy- For the intralogistics sector, we are
made it our goal to decode the “DNA storage systems for optimising committed to energy flow optimisation
of the arc”. energy yields, we are one of the for electric forklift trucks and are
leading suppliers in the photovoltaics constantly striving for the next
sector. innovation. Our powerful charging
systems for vehicle workshops
guarantee safe and reliable processes.