42,0426,0270, en

Operating
instructions
Calibration system 2.0
EN Operating instructions
42,0426,0270,EN 012-14032022
Contents
EN
Safety rules 5
Explanation of safety notices 5
General 5
Proper use 6
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Mains connection 7
Protecting yourself and others 7
Risks from mains current and welding current 7
EMC Device Classifications 8
EMC measures 8
EMF measures 9
Specific hazards 9
Danger from shielding gas cylinders 10
Safety measures at the installation location and during transport 10
Safety measures in normal operation 11
Commissioning, maintenance and repair 11
Safety inspection 11
Calibration of the calibration system 11
Disposal 12
Safety symbol 12
Data protection 12
Copyright 12
General information 13
General 15
Device concept 15
Proper use / intended purpose 15
Crane transport 16
Accessories and options 17
Interface and trolley 17
Accessories 17
Options 19
Required for calibration 20
Computer & software 20
Hardware & accessories 20
Required for calibration of the WeldCube Connector 20
Controls, connections and mechanical components 23

Controls and connections on calibration system 25
Front of device 25
Rear of device (without trolley) 26
Mechanical components on trolley 27
Calibration system trolley 27
Installation 29
Installing the calibration system 31
General 31
TwinCat 31
USB to LAN driver(Windows® 7) 31
TPS/i SmartCard driver 32
LocalNet FTDI driver 33
Desktop software installation 33
Changing network settings 34
Changing the network settings for USB calibration 34
Setting a TwinCat route 35
Setting the language, system information 37
3
Setting the language 37
Retrieving system information 37
Calibrating welding systems 39

General information 41
Mains voltage measurement for single-phase power sources 41
Correcting set values and load resistances 41
Calibrating welding systems with LocalNet (TPS, TSt, MW, TT) 42
Overview - LocalNet 42
Connecting the power source and calibration system 42
Connecting the welding wire calibration system 45
Connecting the computer to the calibration system and signature pad 46
Preparing the gas calibration system 48
Calibrating the welding system 49
Calibrating welding systems with SpeedNet (TPS /i, iWave 300i - 500i) 53
Overview - SpeedNet 53
Calibrating welding systems with USB / SpeedNet 59
Overview - USB 59
Calibrating other Fronius welding systems 65
Overview - other Fronius devices 65
Calibrating the TransPocket welding system 67
Calibrating TransTig 1750 Puls 70
Calibrating VarioSynergic 3400 74
Calibrating TransTig 170 / 210 78
Calibrating WeldCube Connector 82
Overview 82
Connecting the TPS /i power source, WeldCube Connector and calibration system 82
Calibrating WeldCube Connector 85
Troubleshooting 91
Troubleshooting 93
The status indicator is not lit up 93
The status indicator lights up red 93
No connection 93
No USB/SpeedNet connection 94
Technical data 95
Technical data 97
Calibration system 2.0 97
Wire speed measuring system 97
Interface box 98
Gas measurement option 98
4
Safety rules
EN
Explanation of
DANGER!
safety notices
Indicates immediate danger.
▶ If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.

▶ If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.

▶ If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to

recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating
company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the

device must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device

- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
5
Proper use The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use includes:

- carefully reading and following all the instructions given in the operating in-
structions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic set-
ting.
The manufacturer likewise accepts no liability for unexpected or incorrect res-

ults.
Environmental Operation or storage of the device outside the stipulated area will be deemed as
conditions not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient air temperature range:

- during operation: 0 °C to + 40 °C (32 °F to 104 °F)
- during transport and storage: 0 °C to + 40 °C (32 °F to 104 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)
Obligations of The operator must only allow persons to work with the device who:
the operator - are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the sec-
tion "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of Before using the device, all persons instructed to do so undertake:

personnel - to observe the basic instructions regarding safety at work and accident pre-
vention
- to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
6
Mains connec- Devices with a higher rating may affect the energy quality of the mains due to
EN
tion their current consumption.
This may affect a number device types in terms of:

- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance *)
- Criteria with regard to the minimum short-circuit power requirement *)
*) at
the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your- For your personal safety, take the following precautions:
self and others
Use suitable protective clothing
Protective clothing refers to a variety of different items. Operators should:

- protect their eyes with the specified protective goggles;
- wear stout footwear that provides insulation even in wet conditions;
- protect their hands by wearing suitable gloves (electrically insulated, heat-
proof, protection from cut injuries);
- wear ear protection to reduce the harmful effects of noise and to prevent in-
jury.
Keep all persons, especially children, out of the working area while any devices
are in operation or calibration is in progress. If, however, there are people in the
vicinity,
- warn them of all the dangers
- provide suitable protective equipment or
- erect suitable safety screens/curtains
Risks from mains An electric shock is potentially life threatening and can be fatal.
current and
welding current Do not touch live parts either inside or outside the device.
Make sure that you and others are protected with an adequately insulated, dry
base or cover for the earth or ground potential. This base or cover must extend
over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately di-
mensioned. Replace loose connections and scorched, damaged or inadequately
dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
Arrange for the mains cable to be checked regularly by a qualified electrician to

ensure the ground conductor is functioning properly.
7
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
If the device is operated on a grid without a ground conductor and in a socket

without a ground conductor contact, this will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to

prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:

- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
EMC Device Devices in emission class A:

Classifications - Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also
true for residential areas in which the energy is supplied from the public low-
voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for
emissions, it may affect the application area for which it was designed (e.g. when
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to recti-
fy the situation.
Check and evaluate the immunity to interference of nearby devices according to

national and international regulations. Examples of equipment that may be sus-
ceptible to interference from the device include:
- Safety devices
- Network, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:

1. Mains supply
- If electromagnetic interference arises despite the correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line filter)
2. Welding power-leads
- must be kept as short as possible
- must be laid close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
8
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
EN
5. Shield, if necessary
- Shield other devices nearby
- Shield the entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- Effects on the health of persons in the vicinity, e.g. those with pacemakers
and hearing aids
- Individuals with pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- For safety reasons, maintain as large a distance as possible between the
welding power-leads and the head/torso of the welder
- Do not carry welding power-leads and hosepacks over the shoulders or wind
them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened / removed while maintenance or re-
pair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the wire speed measuring system poses a high
risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
For this reason, always keep the wire speed measuring system away from the
head and body and wear suitable protective goggles.
Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located in
such areas.
Use only suitable load-carrying equipment supplied by the manufacturer when

transporting devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carry-
ing equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by
hand. The carrying strap is not to be used if transporting with a crane, counter-
balanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the
device or its components must be tested regularly (e.g. for mechanical damage,
9
corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Danger from Shielding gas cylinders contain gas under pressure and can explode if damaged.
shielding gas cyl- As the shielding gas cylinders are part of the welding equipment, they must be
inders handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions
to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only use
shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the
cylinder.
The manufacturer's instructions must be observed as well as applicable national

and international regulations for shielding gas cylinders and accessories.
Safety measures A device toppling over could easily kill someone. Place the device on a solid, level
at the installa- surface such that it remains stable
tion location and - The maximum permissible tilt angle is 10°.
during transport
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is
always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection
shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regard-
ing the risks arising during transport.
After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service techni-
cians before commissioning the device.
10
Safety measures Only operate the device when all safety devices are fully functional. If the safety
EN
in normal opera- devices are not fully functional, there is a risk of
tion - injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper function-
ing of safety devices.
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufac-
maintenance and tured to meet the demands made of them, or that they satisfy safety require-
repair ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown
in the Spare Parts List, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and torque to 3 Nm.
Safety inspec- The manufacturer recommends that a safety inspection of the device is per-
tion formed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician

- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international stand-
ards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may re-
quire.
Calibration of Regular calibration is required to guarantee the traceability to national or inter-

the calibration national standards of calibrations performed with this calibration system.
system Fronius recommends a 12-month calibration interval. For more information,
please contact your Fronius partner.
11
Disposal Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its imple-
mentation as national law, electrical equipment that has reached the end of its
life must be collected separately and returned to an approved recycling facility.
Any device that you no longer require must either be returned to your dealer or
given to one of the approved collection and recycling facilities in your area. Ig-
noring this European Directive may have potentially adverse affects on the envir-
onment and your health!
Safety symbol Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives. Further details can be found in the
appendix or the section headed "Technical data" in your documentation.
Data protection The user is responsible for the safekeeping of any changes made to the factory
settings. The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
12
General information
13
14
General
EN
Device concept The 2.0 calibration system is designed
for calibrating power sources.
All types of Fronius power sources can
be calibrated under static load using
this system.
Both DC and AC devices can be calib-
rated.
The calibration system is suitable for

quick and easy calibration of the power
source in situ.
The calibration system can also be
used for servicing to test or check the
power sources (e.g. after repairs,
troubleshooting, etc.).
Proper use / in- The device is only intended to be used for calibrating and testing welding systems
tended purpose and power sources.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be liable for any damage resulting from such use.
Proper use also includes

- carefully reading these Operating Instructions
- following all the instructions and safety rules in these Operating Instructions
- performing all stipulated inspection and maintenance work
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic set-
ting.
15
Crane transport
WARNING!
Risk of injury due to falling device or device parts.

▶ Do not walk under the device when it is being suspended in an elevated posi-
tion or dwell in hazardous locations
▶ Exclusively use load-carrying equipment approved by Fronius
▶ Attach 4 chains or 4 ropes to the 4 suspension points
▶ Route chains/ropes so they are at the smallest angle possible to the vertical
▶ Check and maintain load-carrying equipment to ensure it adheres to national
regulations
WARNING!
Risk of injury due to falling device or device parts.

When transporting by crane, make sure that:
▶ There are no objects on the shelf or in the storage compartments
▶ All accessory drawers are closed and locked
4 suspension points for transporting by crane
16
Accessories and options
EN
Interface and
trolley
Interface calibration system Trolley calibration system

4,050,211 4,077,022
Accessories
(1) (2) (3) (4) (5) (6) (7) (8)
(17) (16) (15) (14) (13) (12) (11) (10) (9)
17
Item Description
Item no.
(1) 1 x mains cable, 5 m

43,0004,2862
(2) 1 x Euro/central connector adapter with Tuchel socket

44,0350,5407
(3) 1 x Fronius/central connector adapter

44,0350,4504
(4) 1 x (+) power cable with sense lead (red)

43,0004,5883
(5) 1 x LocalNet passive splitter

4,100,261
(6) 1 x (-) power cable with sense lead (blue)

43,0004,5882
(7) 1 x cooling unit bridging hose

for use with the Euro/central connector adapter
44,0001,1204
(8) 1 x gas hose 1.5 m, 2 x 1/4“

44,0001,0538
(9) Adapter ZA Euro/FSC

44,0350,3329
(10) 1 x USB connection cable to PC/laptop

43,0004,5963
(11) Socket splitter 70/95 DIX KAB

43,0003,0704
(12) 2 x high-current socket to bayonet adapter

42,0001,4482
(13) 1 x LocalNet/USB converter

4,101,026
(14) 2 x bayonet adapter 25 mm2 to 50 mm2

4,001,549
(15) 1 x Tuchel adapter cable

43,0004,5884
(16) Adapter ZA FSC-S-G/Euro STD

44,0350,3565
(17) 1 x welding wire calibration system

4,050,210
+
Connecting cable 5 m
43,0004,5997
18
Further accessories (not pictured)
EN
Description Item no.
1 x power adapter 4051091
1 x connection cable for gas sensor, 5 43,0004,5914
m
1 x 1.6 m SpeedNet cable 4051021
2 x 5 m SpeedNet cable 4051022
2 x insulating sleeve adapter 42,0100,1411
1 x 2.5 m 8-pin data cable, PUR 43,0004,4361
1 x LocalNet 6-pin cable with Molex 43,0004,4850
Microfit socket
2 x USB Ethernet adapter EU 4306 43,0004,5688
Options Designation Item no.

Signotec signature pad 41,0006,0126
1.5 m gas hose, 2 x 1/4" 44,0001,0538
5 m gas hose, 2 x 1/4" 44,0001,0695
10 m gas hose, 2 x 1/4" 44,0001,3423
Double nipple 1/4" 42,0401,0874
Gas fitting connection, 1/4" 44,0450,0281
Gas hosepack adapter, external 1/4" - 42,0001,3540
internal 5/8-18 UNF
Gas fitting 5 /8" - 8400 + 8411 42,0001,6601
Removable cable tie, 180 mm 42,0407,0558
Calibration system trolley 4,077,022
TU Car 4 Basic trolley 4,077,009
19
Required for calibration
Computer & - Computer, laptop

software - Calibration software
The calibration software can be downloaded from:
https://downloadcenter.myfronius.com
Software/Firmware
Firmware
„Calibration“
Fronius internal:
https://collaboration.fronius.com
Collaboration Perfect Welding / Products & Services PW
General Topics / Services
Securing Services
Categories / Calibration
04_cal_software_releases
Hardware & ac- - Calibration system 2.0

cessories - Interface calibration system
- Welding wire calibration system
- Accessories calibration system
- Trolley calibration system
Required for cal- For the calibration of WeldCube Connector U/I and WeldCube Connector Ad-
ibration of the vanced:
WeldCube Con- - PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
nector - M12-X / RJ45 network cable, 5 m (42.0411.0232)
- TPS 500i power source
For the calibration of WeldCube Connector U/I/WFS WSM and WeldCube Con-
nector Advanced + WSM:
- PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
- M12-X / RJ45 network cable, 5 m (42.0411.0232)
- Existing TransSteel system components
- 70/95 DIX KAB socket splitter (43,0003,0704)
20
For the calibration of WeldCube Connector U/I/WFS Euro and WeldCube Con-
nector Advanced + Euro:
EN
- PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
- M12-X / RJ45 network cable, 5 m (42.0411.0232)
- TPS 500i power source
- WF 25i / WF 30i wirefeeder with Euro central connection
alternatively
WF 25i / WF 30i wirefeeder with adapter ZA FSC-S-G/Euro STD
(44,0350,3565)
- 70/95 DIX KAB socket splitter (43,0003,0704)
21
22
Controls, connections and mechan-
ical components
23
24
Controls and connections on calibration system
EN
Front of device
(11)
(10)
(9) (12)
(13)
(8)
(14)
(7)
(6) (15)
(5)
(4) (16)
(3) (17)
(2) (18)
(1)
Calibration system 2.0 with interface calibration system
Item Description
(1) (+) power connection (red)
(2) (+) sense lead connection socket (red)
(3) (-) sense lead connection socket (blue)
(4) (-) power connection (blue)
(5) USB port computer/laptop
(6) USB port for adapter
(7) USB port for adapter
(8) SpeedNet connection socket
(9) Welding wire calibration system connection socket
(10) Status indicator
Lights up green
Device is ready
Lights up red
An error has occurred
A description of the error is displayed by the software during the calibra-
tion process.
(11) Gas calibration system connection socket
25
(16) Gas IN connection socket (option)
(17) Gas OUT connection socket (option)
(18) Data connection socket (option of connecting to the calibration system)
Rear of device Item Designation

(without trolley) (5) (6) (7)
(1) F5 fuse (2 A slow-blow)
24 V PLC fuse protection

24 V PLC fuse protection
(3) Mains cable connection

(4) (8)
(3) (9) (4) Main fuse for the device F1
(2) (4 A slow-blow)
(10)
(5) Mains switch
(1) (11)
(6) 230 V socket
(for 230 V power supply)
(7) 230 V socket

(for 230 V power supply)

AC voltage measurement fuse protection

AC voltage measurement fuse protection

Automatic start/stop fuse protection

24 V fan fuse protection
26
Mechanical components on trolley
EN
Calibration sys- Item Designation
tem trolley (4)
(1) Calibration system trolley
(3)
(option)
(2) Accessory drawers
(3) Cable hanger

(5) (2)
(4) Tray
(5) Storage trays
(1)
27
28
Installation
29
30
Installing the calibration system
EN
General NOTE!
Installation of the calibration system was created based on Windows7 and may
differ on other operating systems.
1 Unzip the software package provided onto your PC:

WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI.zip
TwinCat Prerequisite:
The USB cable is not connected.
NOTE!
If a version of TwinCat is already present on your PC (TwinCat 2 or TwinCat 3),
installation is not mandatory.
However, Fronius recommends that the version of TwinCat provided is used.
1 Open the path:

\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\twincat
2 Install the file located there and follow the setup instructions
3 Restart the PC
(only if prompted to do so at the end of installation)
USB to LAN NOTE!

driver
(Windows® 7) The USB to LAN driver is already installed in Windows® 10.
1 Connect the PC to the calibration system via USB and switch on the calibra-
tion system (green LED lights up)
2 Open the Device Manager
If no driver is yet installed, the device will appear as unknown
Unknown
LAN9500
3 Install the required driver software from the unzipped software package:
Right click on LAN9500
4 Update driver software
5 Find the driver software on the computer
6 Open the path:
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\USB-
TOLAN\
31
7 Depending on the operating system, select the subfolder (win / win_64) and
follow the instructions
After successful installation, the driver can be found under the network ad-
apters:
Network adapters
Microsoft Virtual WiFi Miniport Adapter
8 If a driver is already installed,

ensure that it is the latest version and if necessary update it
Also use the connected USB port for future work with the calibration system.
TPS/i Smart- NOTE!

Card driver
The TPS/i SmartCard driver is already installed in Windows® 10.
1 Open the path:

\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\OMNIKEY
\
2 Depending on the operating system, select the subfolder, install the file loc-
ated there and follow the instructions
Win7 / Win8:
Successful installation will be displayed in the Device Manager as follows:
Smart card readers

OMNIKEY 6121
NOTE!
If several SmartCard readers appear in the Device Manager, select the correct
one:
1 Right-click on the existing SmartCard reader and select "Properties"
Under General / Storage location, a port is specified

e.g..:
Port_#0002.Hub_#0002
This device must be activated!
If under Properties / General / Storage location NO port is specified for a Smart-

Card reader, it must be deactivated:
1 Right-click on the affected SmartCard reader and select "Disable Device"
32
LocalNet FTDI Connect the power source with LocalNet to the calibration system via USB
EN
1
driver and switch on both components
2 Open the Device Manager
If no driver is yet installed, the device will appear as unknown (USB Serial
Port, USB-RS232 cable, etc.)
Unknown
Unknown
3 Install the required driver software from the unzipped software package:
Right click on USB Serial Port
4 Update driver software
5 Find the driver software on the computer
6 Open the path:
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\FTDI\
7 Confirm and follow the instructions
After successful installation of the driver, the COM Port can be found under
Ports:
Ports (COM & LPT)
8 Restart the PC
(only if prompted to do so at the end of installation)
9 If a driver is already installed,
ensure that it is the latest version and if necessary update it
If the device still appears as unknown after installation, repeat the process.
Desktop soft- Requirements:

ware installation - Windows 7 or higher
- Local admin rights
- Screen resolution higher than 1024 * 768
- .net Framework 4.7.2
If this .net Framework version is not yet installed on the computer, a mes-
sage is displayed to this effect.
The appropriate .net Framework version can be downloaded and installed
from the following link:
https://dotnet.microsoft.com/download/dotnet-framework-runtime/net472
1 Open the path:

\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\application
2 Install the file located there and follow the setup instructions
33
Changing net- 1 Setting network settings
work settings
a) via the calibration software:
or
b) under the network settings (TCP/IPv4) of the adapter:
Internet protocol, version 4 (TCP/IPv4) Properties
Changing the IMPORTANT! Prerequisites for USB calibration:

network settings - DHCP server, which starts automatically when the program starts.
for USB calibra- - .net Framework, at least version 4.7.2
tion
1 Specify network settings for USB calibration
a) Via the calibration software:

Settings / Configure network adapter / SpeedNet / Ethernet ...
or
b) From the network settings (TCP/IPv4) of the adapter:

Use the following IP address: 192.168.125.200
2 Check if the IP address 192.168.125.1 is displayed on the power source
34
Action if the IP address 192.168.125.1 is not displayed on the power source:
- Check if the DHCP server is running (icon!)
EN
If the DHCP server is not running, restart the software.
- Disconnect the USB briefly from the power source and reconnect it again
- Only connect the USB Ethernet adapter to the calibration system, not to the
computer/laptop
Setting a Twin- 1 Click on the TwinCat symbol in the lower bar of your PC and select "Edit
Cat route routes"
2 Add a new route by going to "Add" and then "Broadcast Search"
The calibration system is then normally displayed.
3 Implement the following settings:
35
4 Deactivate "Encrypt password (Twincat 3 only)"
If connection is successful, an X is displayed in the overview.

5 Close the window by clicking "Close"
Possible errors/points to check if the route cannot be set as described above in-
clude:
a) Check network settings:

The calibration station must be accessible in the Windows command prompt
(CMD) at the IP address 192.168.120.50 with the ping command.
b) Various security programmes (e.g. F-Secure, etc.) may block the network
connection.
If necessary, allow network traffic
c) Reset the calibration station and ensure that the green LED is on
d) Remove the USB cable for a short time, then reconnect it and try again
e) Restart the PC
36
Setting the language, system information
EN
Setting the lan-
guage
After the calibration software has been installed, the language can be set for the
user interface:
The system switches to the chosen language when the program is restarted.
NOTE!
Only the user interface of the calibration software is displayed in the chosen
language. The language for the calibration report must be set separately!
Retrieving sys- Clicking on the ? displays the following

tem information system information:
- Software version of the calibration
software installed
- Software version of the Beckhoff
elements installed in the calibra-
tion system
37
38
Calibrating welding systems
39
40
General information
EN
Mains voltage With single-phase machines, the mains voltage must be measured manually us-
measurement ing a FLUKE measuring device.
for single-phase
power sources 1 Enter the measured mains voltage in the box
2 [ ] Enable In Use
3 Under external measuring equipment, enter the FLUKE measuring device
used
Correcting set If the values specified by the calibration software are not achieved, the set value
values and load or load resistance may need to be modified.
resistances
Examples:
AccuPocket 150 / 400 Tig

Current calibration (M1: Set value [A] = 60 A / RLoad [mOhm] = 240 mOhm)
TransTig 2200 Job

Current calibration (M5: RLoad [mOhm] = 96 mOhm)
VarioSynergic 3400
Read the measured value for the respective level in the calibration program and
enter it in the "set value" box.
41
Calibrating welding systems with LocalNet (TPS,
TSt, MW, TT)
Overview - Loc- Welding systems with external wirefeeder

alNet - TS 4000 / 5000
- TPS 3200 / 4000 / 5000
- TIME 5000 Digital
- CMT 4000 Advanced
- TSt 3500/5000
- TSt 3500 / 5000 Rob
- TSt 3500 / 5000 Syn
- TSt 4000 / 5000 Pulse
Welding systems with integrated wire drive

- TPS 2700
- TSt 2200c (cable harness 43,0004,4850 also required)
- TSt 2500c / 2700c / 3000 c Pulse / 3500c
TIG welding systems

- TT 800 / 2200 / 2500 / 3000 / 4000 / 5000
- TT 800 / 2200 / 2500 / 3000 / 4000 / 5000 Job
- TT 2200 / 2500 / 3000 / 4000 / 5000 Comfort
- MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000
- MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000 Job
- MW 2200 / 2500 / 3000 / 4000 / 5000 Comfort
Manual metal arc welding systems

- TP 4000 / 5000 CEL
The power sources listed above have a LocalNet port and are calibrated using the
following calibration process.
Connecting the 1 Plug in the mains cable

power source Switch on the mains switch
2
and calibration
system
42
3 Connect the (+) power cable to the
calibration system and the power
EN
source
4 Connect the sense lead (red) to the
calibration system
4
3
3
5 Connect the (-) power cable to the
calibration system and the power
source
6 Connect the sense lead (blue) to
the calibration system
5
6
5
7 Connect the LocalNet/USB con-

verter to the calibration system
and to a free LocalNet port on the
7
welding system
If there is no LocalNet port avail-

7 able, use the LocalNet passive dis-
tributor (4,100,261)
e.g. for TSt 5000
8 Switch on the power source

9 Start calibration
For TransSteel TSt 2200c only:
A cable harness (item number 43,0004,4850) is also required when calibrating a

TSt 2200c power source.
The calibration process is performed with an open power source housing.
43
WARNING!
An electric shock can be fatal.

All work on the power source may only be carried out in a de-energised state.
Before opening the device
▶ Move the mains switch to the "O" position
▶ Unplug the device from the mains
▶ Ensure the device cannot be switched back on
▶ Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have been discharged
7 Connect the LocalNet/USB con-

verter to the calibration system
8 Remove the right side panel from
9
the power source
9 Connect the cable harness
43,0004,4850 to the 6-pin con-
nector on the PC board LST-
MAG20 as shown in the illustration
10 Connect the cable harness and
LocalNet/USB converter
WARNING!
An electric shock can be fatal!

The calibration process is performed with an open housing.
After switching on the power source
▶ Do not touch any parts in the housing interior!
▶ Use only suitable measuring or test probes to touch parts inside the device!
▶ Keep people away from the open power source when carrying out the calibra-
tion!
11 Connect the power source to the mains and switch it on

12 Start calibration
44
Connecting the
EN
NOTE!
welding wire cal-
ibration system The power cables are not relevant for calibration of the welding wire!
Establish data communication between the following:
▶ power source and calibration system (LocalNet, SpeedNet, USB, etc.)
▶ power source and wirefeeder (LocalNet, SpeedNet, USB, etc.)
▶ welding wire calibration system and calibration system
1 Connect the connection cable to

the welding wire calibration system
1 IMPORTANT! A maximum of 3
connection cables (max. 15 m) can
be used to connect the welding
wire calibration system and the cal-
ibration system!
2 Connect the connection cable to

2 3 (+) Disconnect power cable from
welding system
4 Connect the welding torch to the
welding system
5 Remove the gas nozzle from the
welding torch
6 Thread the wire
The welding wire should protrude
approx. 200 mm from the contact
tip.
7 Thread the welding wire into the in-

take part of the sensor
45
8 Secure the welding torch in the
welding wire calibration system at
the contact tip
9 Make sure that the torch hosepack
is arranged as straight as possible
NOTE!
When calibrating robot welding systems, the welding wire calibration system is
usually attached to the contact tip of the robot welding torch.
If, in this case, it is not possible to attach it properly, the following longer contact
tips may be used on the robot welding torch:
- 42,0001,0056
contact tip 1.6/M6/ø8x33 mm
- 42,0001,3485
contact tip 1.6/M8/ø8x35 mm/CB4.8
- 42,0001,5413
contact tip 3.2/M10/ø10x40 mm
Connecting the 1 Connect the USB connection cable

computer to the to the calibration system and the
calibration sys- computer / laptop
tem and signa-
ture pad 1
16
46
2 Connect the Signotec signature
pad to the calibration system
EN
2
47
Preparing the IMPORTANT! If a shielding gas supply is to be calibrated, it must be connected
gas calibration to the calibration system before starting the calibration process.
system The welding system and calibration system must be connected to each other.
1 Connect the gas hose to the pres-

sure regulator and to the Gas IN
connection on the calibration sys-
tem
1 max. supply pressure: 5 bar
2 Connect the gas hose to the

wirefeeder or the power source
and to the Gas OUT connection on
2
2
3 Connect the gas and data connec-

tions to each other
48
Calibrating the IMPORTANT! Before starting the calibration process:
EN
welding system - All devices to be calibrated must be connected to the calibration system:
power source, wirefeeder, shielding gas supply; etc.
- The power source to be calibrated must be switched on at least 5 minutes
before the calibration process starts.
The calibration process is started from the calibration software on the com-
puter / laptop.
1 Start the calibration program
2 Click [New calibration]
The preliminary settings / contractor data are displayed.
3 Enter the details for a new contractor (= Person performing calibration):

- Name
- Address
- Postcode
- Calibration technician
4 Click on [Add]
or
select current contractor from the list shown
5 Enter the serial numbers of the measuring equipment:

- Calibration system
- Gas measurement system
6 Click [Next >]
The preliminary settings / customer data are displayed.
7 Enter the details for a new client:

- Name
- Address
- Postcode
- Customer number
8 Click on [Add]
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be

entered.
9 Click [Next >]
The preliminary settings / device selection are displayed.
49
10 Under Settings, select the connection to the power source:
o LocalNet
11 Click on [Establish connection]
If the connection is established successfully, a message to this effect is dis-

played and the data from the power source and wirefeeder is automatically
read in.
Welding current, welding voltage and wire speed are pre-selected. To

deselect them, click on the respective check box.
If a gas flow calibration is to be performed, click on the check box.
12 Click [Next >]
The preliminary settings / calibration parameters are displayed:

five measured values M1 - M5 for each power source and wirefeeder
- Welding current [A]
- Welding voltage [V]
- Wire speed
13 Click [Next >]
The preliminary settings / general measurement data are displayed:

- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage US [V]
If no data is displayed, it can be found by clicking on [Start measuring pro-

cess].
If there is still no data displayed, check the F2 and F3 fuses on the back of
the calibration system.
14 Carry out a visual inspection of the welding system and the calibration sys-
tem, according to the calibration instructions
15 If the visual inspection does not reveal any defects, select [Click here]
16 Click [Next >]
The summary of the calibration process is displayed.
17 Define the calibration class:

o Precision
o Standard
50
18 Click [Start automatic calibration]
EN
The calibration process starts.
When a calibration process is active:

- A corresponding notification is displayed
- The [Interrupt calibration] button is available
- All measuring points are checked one after the other
- Current measured values are displayed
- A progress bar with the remaining time is displayed
If the calibration process is interrupted before the welding wire has been cal-
ibrated, a corresponding notification is displayed.
19 Change over the welding system for calibration of the welding wire:
(see page 45 onwards)
- Connect welding wire calibration system and calibration system
- (+) Disconnect power cable from welding system
- Connect the welding torch to the welding system
- Remove the gas nozzle from the welding torch
- Thread the wire
- Thread the welding wire into the sensor
- Secure the welding torch in the welding wire calibration system
CAUTION!
Risk of injury from emerging welding wire.

As soon as the calibration process resumes, the welding wirefeed starts and the
welding wire emerges.
▶ Keep the welding wire calibration system away from the head and body and
wear suitable protective goggles.
▶ Make sure that when the welding wire emerges, it does not touch any elec-
trically conducting, earthed or live parts.
▶ Make sure that there is sufficient space for the emerging welding wire (ap-
prox. 10 m).
▶ Make sure that no one is endangered by the emerging welding wire.
20 Click on [OK] to start calibration of the wirefeeder system
When the calibration process is complete, a corresponding notification is dis-

played and the [Print calibration report] button is available.
21 Click [Print calibration report]
Calibration system / create report is displayed.
22 Enter the details to create the calibration report:

Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the cal-
ibration system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration
system and then click on [Reconnect].
23 Sign the Signotec signature pad with the corresponding digital pen
51
24 Press [OK] on the Signotec signature pad
The signature is sent to the calibration software.
x ... Cancel signature

Refresh ... new signature
A corresponding notification is displayed after the signature has been re-

ceived successfully.
25 Click [Create PDF]
IMPORTANT! Only after the confirmation "PDF created successfully!" is dis-

played, will the calibration report be saved.
52
Calibrating welding systems with SpeedNet
(TPS /i, iWave 300i - 500i)
EN
Overview - MIG/MAG welding systems with external wirefeeder
SpeedNet - TPS 320i / 400i / 500i / 600i
- TPS 400i LSC ADV
MIG/MAG welding systems with integrated wire drive

- TPS 270i C
- TPS 320i C
TIG welding systems

- iWave 300i - 500 DC
- iWave 300i - 500i AC/DC
The power sources listed above have a SpeedNet port and are calibrated using
the following calibration process.
Connecting the 1 Plug the mains cable into the calibration system
power source Plug the mains cable into the grid
2
and calibration
system 3 Switch on the mains switch
NOTE!
If there is a power connector for the high current socket on the power source,
use the adapter for the high current sockets to bayonet (42,0001,4482).
4 Connect the (+) power cable to the calibration system and the power source
5 Connect the sense lead (red) to the calibration system
6 Connect the (-) power cable to the calibration system and the power source
7 Connect the sense lead (blue) to the calibration system
9 Connect the SpeedNet cable to the calibration system and to a free Speed-
Net connection socket on the welding system
Connecting the NOTE!

welding wire cal-
1 Connect the connection cable to the welding wire calibration system
IMPORTANT! A maximum of 3 connection cables (max. 15 m) can be used to

connect the welding wire calibration system and the calibration system!
2 Connect the connection cable to the calibration system
53
3 Connect the welding torch to the welding system
4 Remove the gas nozzle from the welding torch
5 Thread the wire
The welding wire should protrude approx. 200 mm from the contact tip.
6 Thread the welding wire into the intake part of the sensor
7 Use clamps to secure the welding torch in the welding wire calibration system
at the contact tip
8 Make sure that the torch hosepack is arranged as straight as possible
Connecting the 1 Connect the USB connection cable to the calibration system and the com-
computer to the puter / laptop
calibration sys- Connect the Signotec signature pad to the calibration system
2
tem and signa-
ture pad 3 Switch on the power source


tem

2
2
54
tions to each other
EN
3

puter / laptop.

- Name
- Address
- Postcode
4 Click on [Add]
or

6 Click [Next >]
55
- Name
- Address
- Postcode
- Customer number
8 Click on [Add]
or

entered.
9 Click [Next >]

o SpeedNet

read in.

12 Click [Next >]

five measured values M1 - M5 for each power source
For the wirefeeder, enter five wire speed measured values M1 - M5 [m/min]:
The measured value M5 is the maximum value for the wirefeeder.

Press the Tab key to enter the other measured values.
56
13 Click [Next >]
EN
- Mains voltage [V]

cess].
16 Click [Next >]

o Precision
o Standard
18 Click [Start automatic calibration process]
When a calibration process is active

- Thread the wire
57
CAUTION!

prox. 10 m).





58
Calibrating welding systems with USB / SpeedNet
EN
Overview - USB Software version 1.0.28 and higher:
TIG welding systems

- iWave 230i DC
- iWave 190i / 230i AC/DC
MIG/MAG welding systems with external wirefeeder

- TPS 320i / 400i / 500i / 600i
- TPS 400i LSC ADV

- TPS 270i C
- TPS 320i C
The TPS /i power sources can be calibrated via both the SpeedNet port and the
USB port.
The power sources listed above have a USB port and are calibrated using the fol-
lowing calibration process.
Connecting the Also required:

power source - 2 USB Ethernet adapters (supplied with the calibration system)
and calibration - 1 Ethernet cable with RJ45 plug connectors
system
1 Plug the mains cable into the calibration system
2 Plug the mains cable into the grid
3 Switch on the mains switch
NOTE!
9 Only when calibrating iWave 230i DC and iWave 190i / 230i AC/DC:
In the power source setup menu under Ignition and mode settings, set the
HF ignition parameter to "off".
10 Connect the USB Ethernet adapter to the calibration system

11 Connect the USB Ethernet adapter to the USB port of the welding system
12 Connect the USB Ethernet adapter using the Ethernet cable
59
welding wire cal-


5 Thread the wire
at the contact tip
2
tem and signa-


tem
60
EN
2
2

tions to each other

- Check/specify the network settings for USB calibration (see page 34).
puter / laptop.

- Name
- Address
- Postcode
61
4 Click on [Add]
or

6 Click [Next >]

- Name
- Address
- Postcode
- Customer number
8 Click on [Add]
or

entered.
9 Click [Next >]

o SpeedNet
11 [ ] Activate USB

read in.
If the connection is not established successfully, proceed as follows:

- Check if the DHCP server is running (icon in the task bar!)
If the DHCP server is not running, restart the software and check the
network settings.
- Disconnect the USB briefly from the power source and reconnect it again

62
13 Click [Next >]
EN
The measured value M5 is the maximum value for the wirefeeder.

Press the Tab key to enter the other measured values.
14 Click [Next >]

- Mains voltage [V]

cess].
17 Click [Next >]

o Precision
o Standard

63
- Thread the wire
CAUTION!

prox. 10 m).





64
Calibrating other Fronius welding systems
EN
Overview - other MIG/MAG welding systems with external wirefeeder
Fronius devices - VarioSynergic 3400 / 4000 / 5000

- VarioStar 1500 / 2500 / 3100
- VarioSynergic 3400 / 4000 / 5000
TIG welding systems

- MagicWave 2600 / 2600 CEL / 3000
- TransTig 2600 / 2600 CEL / 3000
- TransTig 1750 Puls
- TransTig 170 / 210
Manual metal arc welding systems

- TransPocket 125 VRD / 150 / 180
- TransPocket 1100 / 1200 / 1400 / 1500 / 2000
- TransPocket 2500 / 3500 - RC, TIG, Comfort
- AccuPocket 150
The Fronius power sources listed above do not have a SpeedNet or LocalNet port
and are calibrated using the following calibration process.
power source Plug the mains cable into the grid
2
and calibration
system 3 Switch on the mains switch
NOTE!
Use the corresponding adapters depending on the size of the current sockets on
the power source.
If there is a Tuchel connection on the power source:
8 Connect the Tuchel adapter cable to the power source and to the calibration
system
65
welding wire cal-
▶ power source and calibration system
▶ power source and wirefeeder


5 Thread the wire
at the contact tip
2
tem and signa-

1 Connect the gas hose to the pressure regulator and to the Gas IN connection
on the calibration system
max. supply pressure: 5 bar
2 Connect the gas hose to the wirefeeder or the power source and to the Gas
OUT connection on the calibration system
3 Connect the gas and data connections to each other
66
EN
TransPocket - The power source to be calibrated must be connected to the calibration sys-
welding system tem.
puter / laptop.
1 Set manual metal arc welding mode on the power source

- Name
- Address
- Postcode
5 Click on [Add]
or

7 Click [Next >]

- Name
- Address
- Postcode
- Customer number
9 Click on [Add]
or

entered.
67
10 Click [Next >]
11 Under Settings, select:

o Fronius devices
12 Select the respective TransPocket variant
13 Enter the serial number and name of the power source
14 Click [Next >]

15 Click [Next >]
The preliminary settings / general measurement data are displayed.
16 Click [Start measuring process]
The following data is displayed:

- Mains voltage [V]
IMPORTANT! The mains voltage displayed is incorrect!

With single-phase machines, the mains voltage must be measured manually
using a FLUKE measuring device, and entered!
17 Measure the mains voltage
18 Enter the mains voltage measured
19 [ ] Enable In Use and enter the measuring device used under External meas-
uring equipment
22 Click [Next >]

o Precision
o Standard
24 Set the specified measured value M1 on the power source
68
25 Click [ Start measuring process ]
EN
26 Enter the value displayed on the power source in the Display [A] box
27 Click [Next >]
28 Repeat steps 24 - 27 for the measured values M2 - M5 - M1

(10 measurements)





69
Calibrating Tran- IMPORTANT! Before starting the calibration process:
sTig 1750 Puls - All devices to be calibrated must be connected to the calibration system:
power source, shielding gas supply, etc.
system
This enables the calibration process to be started from the calibration software
on the computer/laptop.
2 Set manual metal arc welding mode on the power source and in the Rod elec-
trode setup menu, specify the welding parameter Hti = 0

- Name
- Address
- Postcode
6 Click on [Add]
or

70
8 Click [Next >]
EN

- Name
- Address
- Postcode
- Customer number
10 Click on [Add]
or

entered.
11 Click [Next >]

o Fronius devices
13 Select TransTig 1750 Puls
14 Click [External start with calibration system]
15 Enter the serial number of the TT 1750 Puls in the box
16 Click [Next >]

- Mains voltage [V]

uring equipment
71
23 Click [Next >]

o Precision
o Standard
28 Click [Next >]
29 Repeat steps 25 - 28 for the measured values M2 - M5 - M1

(10 measurements)




72
EN
73
Calibrating Vari- IMPORTANT! Before starting the calibration process:
oSynergic 3400 - The power source to be calibrated must be connected to the calibration sys-
tem (if possible, connect the relevant adapters).
1 Open the clamping lever on the wirefeeder

2 Thread the welding wire back again and attach to the wirespool
system
This enables the calibration process to be started from the calibration software
on the computer/laptop.


- Name
- Address
- Postcode
7 Click on [Add]
or

9 Click [Next >]

- Name
- Address
- Postcode
- Customer number
11 Click on [Add]
or

entered.
74
12 Click [Next >]
EN

o Fronius devices
14 Select VarioSynergic 3400
[Display available] and [External start with calibration system] have been pre-
selected
15 Enter the serial number of the VarioSynergic in the box
Welding current, welding voltage and wire speed have been pre-selected. To
16 Click [Next >]

The measured value M5 is the maximum value for the wirefeeder (= 18 m/min
for VS 3400).
Enter the other measured values by pressing the Tab key.
17 Click [Next >]
18 Specify the following settings on the power source:
Move the welding program selector switch to the For the US measurement, set the coarse stage
MANUAL position switch to B and the fine stage switch to 7
75
Set the toggle switch to A (current) Set the selector switch on the interior of the
device to 2-step mode.

22 Click [Next >]

o Precision
o Standard
NOTE!
In the case of step-switched machines, the set values can be adapted manually
in the calibration program.
24 Set the stage switch on the power source as specified in the calibration pro-
gram for measuring point M1 (e.g. stage A1)
25 Click [Start calibration process]
26 Read the measured value for the respective level in the calibration program
and enter it in the Set value [A] box
27 Click [Start calibration process]
29 Click [Next >]
30 Repeat steps 24 - 29 for measuring points M2 - M5
For the subsequent measurement of M5 to M1, the set values entered are
saved by the calibration program.
76
31 Repeat steps 24 - 29 for the welding voltage
EN
At the end of the current and voltage calibration, the message [Start calibra-
tion feed system 1!] is displayed
32 To calibrate the welding wire on the power source, specify the following set-
tings:
Set the toggle switch to wirefeeder. Depending on the measurement, set the wire
Set the wirefeeder controller on the interior of speed controller to the relevant measured value
the device under MANUAL to 100 %. according to the table.
Set the wire diameter for the welding wire used.
33 Disconnect the +/- current cables from the calibration station on the power
source
34 Connect the welding torch and Tuchel plug to the power source
35 Remove the gas nozzle
36 Thread the wire
37 Close the clamping lever on the wirefeeder
38 Thread the wire until it protrudes approx. 200 mm from the contact tip
at the contact tip
41 Click on [Start calibration wirefeeder 1!]
42 Set the respective measured value on the power source wire speed controller.
(e.g.: M1 = 1 m)
CAUTION!

prox. 10 m).
43 Press and hold the torch trigger to start the wirefeeder
77
44 After about 3 seconds of wirefeeder running time, click on "Start measuring
process" in the calibration program and release the torch trigger
45 Enter the value displayed on the power source under "Display" and click on
[Next >]
46 Repeat steps 43 - 45 for the measurement of M2 to M5 and M1
When the calibration process is complete, a notification is displayed to this

effect and the [Print calibration report] button is available.




Calibrating Tran- Requirement:

sTig 170 / 210 - TransTig 170 / 210 firmware version: at least 4.1.7 or higher
- Start with external ignition aid (EHF) activated:

TIG setup menu - Level 2 / IGn / EHF
After calibration, deactivate EHF again or reset it to the original value.
- Break voltage UCo set to a value > 30 V:

TIG setup menu - Level 2 / UCo > 30 V (factory setting = 35 V)
IMPORTANT! Before starting the calibration process:

- All devices to be calibrated must be connected to the calibration system:
power source, shielding gas supply, etc.
78
Notes on voltage calibration:
- The maximum voltage during calibration is 30 V.
EN
- The same resistance of 480 mOhm is used for all measuring points.
- The calibration software automatically specifies the measuring points to be
measured.
- The voltage is regulated by the current;
the predefined current values are standard values and may have to be adjus-
ted to achieve the specified voltages.
Recommended points for calibration:
Voltage [V] Resistance [mOhm] Current on the device

[A]
10 480 20
15 480 29
20 480 39
25 480 49
30 480 59
Calibration procedure

- Name
- Address
- Postcode
4 Click on [Add]
or

6 Click [Next >]

- Name
- Address
- Postcode
- Customer number
79
8 Click on [Add]
or

entered.
9 Click [Next >]

o Fronius devices
11 Select TransTig 170 / 210
12 Click [External start with calibration system]
13 Enter the serial number of the TT 170 / 210 in the box
14 Click [Next >]

- Mains voltage [V]

18 Measure the open circuit voltage, key in

, click
[Start measurement]
uring equipment
80
22 Click [Next >]
EN

o Precision
o Standard
27 Click [Next >]
28 Repeat steps 25 - 28 for the measured values M2 - M5

(5 measurements)





81
Calibrating WeldCube Connector
Overview WeldCube Connector with current/voltage measurement:

- WeldCube Connector U/I
- WeldCube Connector Advanced
A TPS 500i power source is used when calibrating the WeldCube Connector.
System layout as shown in the figure on page 83 with the following exceptions:
- no wirefeeder
- no WCC Euro wire sensor
- no Euro/central connector adapter with Tuchel socket
- the (+) power cable from the calibration system is connected directly to the
(+) current socket on the power source.
WeldCube Connector with current/voltage measurement and wire speed meas-

urement (Euro):
- WeldCube Connector U/I/WFS Euro
- WeldCube Connector Advanced + OPT/WCC Wire Sensor EUR
The WeldCube Connector is calibrated using a

TPS 500i power source + WF 25i / 30i with Euro connection
or
TPS 500i power source + WF 25i / 30i + adapter ZA FSC-S-G/Euro STD
WeldCube Connector with current/voltage measurement and wire speed meas-

urement (TSt c, VR 5000):
- WeldCube Connector U/I/WFS WSM
- WeldCube Connector Advanced + OPT/WCC Wire Sensor WSM
The WeldCube Connector is calibrated with the existing TransSteel system com-
ponents.
System layout as shown in the figure on page 83 with the following exceptions:
- TSt + VR 5000 instead of TPS 500i + WF 25i / 30i
or
TSt c with integrated wire drive
- no WCC Euro wire sensor, wire sensor installed in VR 5000 or in TSt c
- no Euro/central connector adapter with Tuchel socket
TPS /i power Plug the mains cable into the grid
2
source, Weld-
Cube Connector 3 Switch on the mains switch
and calibration
system
82
CALSYS
EN
+
WF 15i / 25i / 30i Euro
WCC
+
+ +
TPS 500i
CALSYS = calibration system 2.0, WCC = WeldCube Connector, PoE = Power over Ethernet
* = Euro/central connector adapter with Tuchel socket
NOTE!
4 Connect the wirefeeder to the (+) socket on the power source (for example,
using the interconnecting hosepack power cable)
5 Connect the WCC Euro wire sensor to the wirefeeder
6 Connect the Euro/central connector with Tuchel socket to the WCC Euro
wire sensor
7 Connect the (+) power cable to the calibration system and the Euro/central
connector adapter with Tuchel socket
9 Connect the (-) power cable to the calibration system and the WeldCube
Connector
11 Connect the WeldCube Connector grounding cable to the (-) socket on the
power source
12 Connect the WCC Euro wire sensor to the WeldCube Connector
13 Connect the laptop, WeldCube Premium Server and PoE to the WeldCube
Connector
15 Connect the SpeedNet cable to the calibration system and to a free Speed-
Net connection socket on the welding system
83
welding wire cal-
ibration system In conjunction with the WeldCube Connector, wire calibration takes place in the
course of the system calibration.
Following the first current-voltage calibration, a prompt to start wire calibration
appears in the calibration software.
Before confirming the prompt:
▶ Establish data communication between the power source and the calibration
system (LocalNet, SpeedNet, USB, etc.)
▶ Establish data communication between the power source and wirefeeder
(LocalNet, SpeedNet, USB, etc.)
▶ Establish data communication between the welding wire calibration system
and the calibration system
▶ Change over the welding system as follows:


3 Disconnect the (+) power cable from the Euro/central connector adapter
with Tuchel socket
4 Disconnect the Euro/central connector adapter with Tuchel socket from the
WCC Euro wire sensor
5 Connect the welding torch to the WCC Euro wire sensor
7 Thread the wire
at the contact tip
2
tem and signa-

84
EN
tem

2
2

tions to each other
Calibrating IMPORTANT! Before starting the calibration process:

WeldCube Con- - All devices to be calibrated must be connected to the calibration system:
nector power source, wirefeeder, shielding gas supply; etc.
puter / laptop.
85

- Name
- Address
- Postcode
4 Click on [Add]
or

6 Click [Next >]

- Name
- Address
- Postcode
- Customer number
8 Click on [Add]
or

entered.
9 Click [Next >]

o SpeedNet
Establish connection to the WeldCube Connector

(for details, see WeldCube Connector Operating Instructions
42,0426,0363,xx)
11 Determine the welding circuit resistance of the welding system incl. Weld-
Cube Connector
12 Start WeldConnect app and open menu
86
13 Select WeldCube Connector Setup
14 Take smartphone to the WeldCube Connector
EN
15 Follow the instructions in the installation wizard (Setup 1 - 6)
Following the 6 setup steps, the WeldCube Connector will be ready to con-
nect to the calibration software.
16 Click on [Establish connection] in the calibration software

read in.

17 Enter the DHCP IP address of the WeldCube Connector
18 After the network settings message is displayed, briefly disconnect and re-
connect the Ethernet cable between the WeldCube Connector and the
laptop.
If connection is successful, a message to this effect will be displayed.
19 Click [Next >]

five measured values M5 - M1 for each
- power source / welding current [A]
- power source / welding voltage [V]
- Wirefeeder / wire speed [m/min]
The measured value M5 corresponds to the maximum value for the
wirefeeder.
20 Click [Next >]

- Mains voltage [V]

cess].
23 Click [Next >]
87
o Precision
o Standard

26 Change over welding system for wire calibration

(see page 84)
CAUTION!

prox. 10 m).
27 click [OK] to start calibrating the wirefeeder system
When wire calibration is complete, a message to reverse the polarity of the

WeldCube Connector is displayed.
88
28 Change over the welding system as shown below:
EN
WF 15i / 25i / 30i Euro
WCC
+ +
CALSYS
TPS 500i
CALSYS = calibration system 2.0, WCC = WeldCube Connector, PoE = Power over Ethernet
* = Euro/central connector adapter with Tuchel socket
29 Confirm the prompt to change the polarity of the WeldCube Connector with
OK.
The calibration process resumes.
When the calibration process is complete, a notification to this effect is dis-

played and the [Print calibration record] button is available.




89
90
Troubleshooting
91
92
Troubleshooting
EN
The status indic- No power supply
ator is not lit up
Cause: Mains cable not connected
Remedy: Connect the mains cable
Cause: Faulty mains cable

Remedy: Check the mains cable and replace if necessary
Cause: Fuses F1 / F4 / F5 have tripped

Remedy: Switch off the device, disconnect it from the mains, and check fuses,
e.g.:
using a multimeter
or
visual inspection (burnt-through metal strips)
The status indic- An error has occurred during the calibration process
ator lights up red
A description of the error is displayed by the calibration software.
Cause: Various
Remedy: Follow the instructions in the calibration software
Contact our After-Sales Service team if the error is constantly

present.
No connection No connection between power source and calibration software

Cause: Error during installation
Remedy: Check that all cables are connected.
Check whether the TwinCat Route has been set properly.
Check whether the network adapter has been configured correctly.
Check the Firewall settings.
Check that all drivers are installed.
Check all installation steps in general
93
No USB/Speed- No USB/SpeedNet connection between power source and calibration software
Net connection
Cause: USB connection error
Remedy: Check that the USB Ethernet adapters are properly plugged into the
power source and calibration system.
Check the Ethernet connection cable for any possible damage and
for functionality.
Check that the Ethernet connection cable is connected correctly to
the USB Ethernet adapters.
Check that the DHCP server is running (icon in the task bar!). If the
DHCP server is not running, restart the software and check the net-
work settings.
Disconnect the USB briefly from the power source and reconnect it
again.
94
Technical data
95
96
Technical data
EN
Calibration sys- Mains voltage 100 - 240 V AC
tem 2.0
Mains voltage tolerance +15 / -10 %
Mains frequency 50/60 Hz
Mains fuse protection (slow-blow) 4A
Primary current 3 A @ 100 V AC
1.5 A @ 240 V AC
cos phi power factor 0.99
Internal power supply 24 V DC +/- 1%
Output current 10 A (-25 °C - +55 °C)
Max. permissible loading of the sock- 8A
ets
Degree of protection IP 20
Type of cooling AF
Max. permissible current of the load 600 A
Max. permissible loading of the load 24 kW for 20 s
Max. permissible voltage of the load 113 V peak
EMC device class EN 61010 -1:2010
Safety symbols CE
Dimensions l x w x h 686 x 304 x 497 mm
Total dimensions (with trolley) 1103 x 738 x 1017 mm
Weight 31.5 kg
Total weight (with trolley) 120 kg
Ambient temperature 0 – 40 °C
Load resistance 8 x 480 mOhm parallel
Wire speed Operating voltage 5 - 30 V DC

measuring sys-
tem Open-circuit current 55 mA
Wire speed 0 - max. 30 m/min
Safety symbols CE
Weight 1.5 kg
Fuse protection T2A
97
Interface box Operating voltage 24 V DC
Safety symbols CE
Dimensions l x w x h 466 x 355 x 85 mm
Weight (incl. gas measurement I-kit) 3.85 kg
Gas measure- Operating voltage 18 - 30 V DC

ment option
Max. current consumption 100 mA
Max. operating pressure 11 bar
Measuring range 0 - 60 l/min
Gas temperature 0 – 50 °C
Fuse protection T2A
98
EN
99
spareparts.fronius.com
SPAREPARTS
ONLINE
Fronius International GmbH

Froniusstraße 1
4643 Pettenbach
Austria
contact@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the adresses

of all Fronius Sales & Service Partners and locations.

42,0426,0270, en

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Operating

Controls, connections and mechanical components 23

Calibrating welding systems 39

Indicates a potentially hazardous situation.

Indicates a situation where damage or injury could occur.

General The device is manufactured using state-of-the-art technology and according to

All persons involved in commissioning, operating, maintaining and servicing the

All safety and danger notices on the device

This is for your personal safety!

Proper use includes:

The manufacturer likewise accepts no liability for unexpected or incorrect res-

Ambient air temperature range:

Obligations of Before using the device, all persons instructed to do so undertake:

This may affect a number device types in terms of:

IMPORTANT! Ensure that the mains connection is earthed properly

Protective clothing refers to a variety of different items. Operators should:

Arrange for the mains cable to be checked regularly by a qualified electrician to

If the device is operated on a grid without a ground conductor and in a socket

If necessary, provide an adequate earth connection for the workpiece.

Switch off unused devices.

Attach a clearly legible and easy-to-understand warning sign to the device to

After opening the device:

EMC Device Devices in emission class A:

Devices in emission class B:

EMC device classification as per the rating plate or technical data.

Check and evaluate the immunity to interference of nearby devices according to

Supporting measures for avoidance of EMC problems:

Special provisions apply in areas at risk of fire or explosion

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

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

The manufacturer's instructions must be observed as well as applicable national

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

A safety inspection should be carried out by a qualified electrician

Calibration of Regular calibration is required to guarantee the traceability to national or inter-

Copyright Copyright of these operating instructions remains with the manufacturer.

The calibration system is suitable for

Proper use also includes

Risk of injury due to falling device or device parts.

Risk of injury due to falling device or device parts.

4 suspension points for transporting by crane

Interface calibration system Trolley calibration system

(17) (16) (15) (14) (13) (12) (11) (10) (9)

(1) 1 x mains cable, 5 m

(2) 1 x Euro/central connector adapter with Tuchel socket

(3) 1 x Fronius/central connector adapter

(4) 1 x (+) power cable with sense lead (red)

(5) 1 x LocalNet passive splitter

(6) 1 x (-) power cable with sense lead (blue)

(7) 1 x cooling unit bridging hose

(8) 1 x gas hose 1.5 m, 2 x 1/4“

(9) Adapter ZA Euro/FSC

(10) 1 x USB connection cable to PC/laptop

(11) Socket splitter 70/95 DIX KAB

(12) 2 x high-current socket to bayonet adapter

(13) 1 x LocalNet/USB converter