Cloos QINEO NexT User manual

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OPERATING
INSTRUCTIONS
QINEO NexT
-En-
This is a translation of the original operating instructions.
BA QN-NX - 04/20 - Rev.3.41
Keep for future use

Carl Cloos Schweisstechnik GmbH
Carl-Cloos-Strasse 1
35708 Haiger
GERMANY
Telephone [phone]
Telefax [phone]
E-mail [email protected]
www.cloos.de

CARL CLOOS Schweisstechnik GmbH
Carl-Cloos-Strasse 1
35708 Haiger/Germany
Tel. [phone]
Fax. [phone]
mail: [e-mail]
www.cloos.de
EU declaration of conformity No. CMM0917QNNX_01
Product description: MIG/MAG welding machine
Model name: QINEO NexT, WD
Serial number: Refer to the nameplate on the back of the device
Manufacturer: CARL CLOOS Schweisstechnik GmbH
Address:
The manufacturer bears sole responsibility for issuing the declaration of conformity.
Low Voltage Directive:
EMC Directive:
RoHS Directive:
- EN 60974-1 Arc Welding Equipment
Part 1: Welding Power Sources
- EN 60974-2 Arc Welding Equipment
Part 2: Liquid Cooling Systems
- EN 60974-5 Arc Welding Equipment
Part 5: Wire Feed Units
- EN 60974-10 Arc Welding Equipment
Part 10: Requirements of Electromagnetic Compatibility (EMC)
Signed for and in the name of:
CARL CLOOS Schweisstechnik GmbH
35708 Haiger, 08/09/17
Signature: Sieghard Thomas
Identification of signatory: Managing director
Agreement of the product stated with the regulations in the directives applied is verified with conformance to the
following standards and regulations:
Major conversions and add-ons which are not carried out by the manufacturer or the manufacturer’s authorised
representative(s) result in termination of this declaration of conformity.
Carl-Cloos-Strasse 1
35708 Haiger / GERMANY
2014/35/EU Directive of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of laws of Member States relating to the making available on the market of electrical
equipment designed for use within certain voltage limits; Official Journal of the EU L96, 29/03/2014,
Pages 357 - 374
2014/30/EU Directive of the European Parliament and of the Council of 26 February 2014 on the
harmonisation of laws of Member States relating to electromagnetic compatibility; Official Journal of the
EU L96, 29/03/2014, Pages 79 - 106
2011/65 /EU Directive of the European Parliament and of the Council of 8 June 2011 on the restriction
of use of certain hazardous substances in electrical and electronic equipment; Official Journal of the EU
L174, 01/07/2011, Pages 88 - 110
The aforementioned products covered by the declaration satisfy the relevant
statutory provisions of the Union:

Contents
Block 1 Operational Safety 11
1. Foreword .............................................................................................................12
2. Safety symbols in this document...................................................................13
3. Safety specifications for MIG/MAG welding machines .............................14
3.1 Basic safety specifications for the operation of the welding machine
..........................................................................................................................................14
3.2 Application as directed..........................................................................................15
3.3 Self protection and personal protection when MIG/MAG welding..15
3.4 Electrical danger due to mains current and welding current.............18
3.5 Particular dangers when MIG/MAG welding..............................................23
3.6 Safety precautions in daily operation.............................................................24
4. Environmental circumstances........................................................................ 25
4.1 Storage..........................................................................................................................25
4.2 Transport .....................................................................................................................26
5. Qualification of users.......................................................................................26
Block 2 Basic information Qineo NexT 27
1. Power source views........................................................................................... 28
2. Product description .......................................................................................... 30
3. Transport ............................................................................................................30
4. Commissioning.................................................................................................. 30
5. Shutdown / Recycling.......................................................................................33
6. Technical data ....................................................................................................34
Block 3 PREMIUM operating module 35
1. Main menu.........................................................................................................38
2. MAIN - Synergy ..................................................................................................38
3. MAIN - Operating modes.................................................................................39
3.1 2-cycle............................................................................................................................39
3.2 4-cycle............................................................................................................................39
3.3 Super-4-cycle..............................................................................................................40
3.4 Spot welding ..............................................................................................................40
3.5 External.........................................................................................................................40
4. MAIN - process ...................................................................................................41
4.1 Electrode ......................................................................................................................41
4.2 TIG...................................................................................................................................41
4.3 Speed Weld..................................................................................................................41
4.4 Vari Weld......................................................................................................................41
4.5 Control Weld...............................................................................................................41
4.6 Syn off............................................................................................................................41
4.7 Cold Weld.....................................................................................................................42
4.8 Rapid Weld ..................................................................................................................42
4.9 Rapid Pulse Weld ......................................................................................................43
4.10 MoTion Weld..............................................................................................................43
5. MAIN - Function.................................................................................................43
5.1 DuoPulse......................................................................................................................43

5.2 CleanStart...............................................................................................................44
5.3 Blow through........................................................................................................44
5.4 Threading (only in connection with MoTion Equipment)................44
5.5 Wire forward.........................................................................................................44
5.6 Wire backward .....................................................................................................44
5.7 Gas manually........................................................................................................44
5.8 Start manually .....................................................................................................45
5.9 Off / Re-start..........................................................................................................45
6. MAIN - Programming ...................................................................................45
6.1 Parameters in the operating modes 2-cycle and 4-cycle...................46
6.2 Parameters in the operating mode Super-4-cycle ...............................47
6.3 Parameters in operating mode Spot Welding / Interval ...................48
6.4 MAIN - Programming - Setting ranges......................................................49
6.4.1 Input of setting ranges.....................................................................................49
6.4.2 Prerequisite to use the setting ranges......................................................50
6.4.3 Deactivating the setting ranges...................................................................51
6.5 MAIN - Programming - Tandem....................................................................52
6.6 MAIN - Programming - Pulse synchronisation......................................52
6.7 MAIN - Programming - Expert Mode .........................................................52
6.7.1 Expert Mode - Reset to synergy values......................................................53
6.7.2 Main parameters in the "Expert Mode"....................................................53
6.7.3 Secondary parameters in the "Expert Mode" .........................................54
6.7.4 "DuoPulse parameters" in the "Expert Mode"........................................54
6.8 Main - Programming - Active QWD............................................................55
6.9 Main - Programming - Welding circuit (from x.02).............................55
7. MAIN - Measured values..............................................................................55
7.1 Operating data.....................................................................................................56
7.1.1 Data set switching 1/2 .....................................................................................57
7.1.2 Seam counter Setup ..........................................................................................57
7.1.3 Consumption costs ............................................................................................58
8. MAIN - Display ...............................................................................................58
9. MAIN (2) - Config (Configuration)..............................................................60
9.1 Config - General...................................................................................................60
9.1.1 Display brightness..............................................................................................61
9.1.2 MHW x10 Master................................................................................................61
9.1.3 Control coolant pump and fan .....................................................................61
9.1.4 Config - General - Basic settings...................................................................62
9.1.5 Config - General - Basic settings (2)............................................................63
9.1.6 Config - General - Sense technology...........................................................64
9.1.7 Config - General - QWD ....................................................................................64
9.1.8 Config - General - SD module ........................................................................66
9.1.9 Config - General - Options...............................................................................66
9.2 Config - Water monitoring..............................................................................68
9.3 Config - Compensation.....................................................................................69
9.4 Access rights..........................................................................................................70
9.4.1 Config - Access management........................................................................70
9.4.2 Config - User management and PAK (option)........................................72
9.5 Config - Ethernet .................................................................................................77
9.6 Config - Clock ........................................................................................................78
9.7 Config - Process monitoring...........................................................................78
9.8 Config - General (2) ............................................................................................79
9.9 Config - General (3) ............................................................................................80
10. MAIN (2) - Diagnostics..................................................................................80
10.1 Diagnostics - Software versions ...................................................................81
10.2 Diagnostics - System logbook........................................................................81

10.3 Diagnostics - Control.........................................................................................82
10.3.1 Diagnostics - Control - Ethernet...................................................................83
10.3.2 Diagnostics - Control - I / O (inputs and outputs)...............................83
10.3.3 Diagnostics VBC module..................................................................................85
10.3.4 Diagnostics - Control - LED..............................................................................86
10.3.5 Diagnostics - Control - Tandem.....................................................................87
10.4 Diagnostics - Process control.........................................................................87
10.4.1 Diagnostics - Process control - Pulse synchronisation .......................88
10.4.2 Diagnostics - Process control - Current characteristic curve...........89
10.4.3 Diagnostics - Process control - Data set info ..........................................89
10.5 Diagnostics - Power unit..................................................................................90
10.5.1 Diagnostics - Power unit - Mains.................................................................90
10.5.2 Diagnostics - Power unit - Temperature...................................................91
10.5.3 Diagnostics - Power unit - Calibration ......................................................91
10.5.4 Diagnostics - Power unit - Inverter .............................................................92
10.5.5 Diagnostics - Power unit - Fan ......................................................................93
10.5.6 Diagnostics - Power unit - LED ......................................................................94
10.6 Diagnostics - Wire drive unit.........................................................................95
10.6.1 Diagnostics - Wire drive unit - MD..............................................................95
10.6.2 Diagnostics - Wire drive unit - QWD-MD / QWD-A.............................96
10.6.3 Diagnostics - Wire drive unit - QWD-B......................................................97
10.7 Diagnostics - Cooling module.......................................................................97
10.7.1 Diagnostics - cooling module - LED ............................................................98
10.8 Diagnostics - Robot ............................................................................................99
11. MAIN (2) - Language .................................................................................. 100
12. MAIN (2) - Data backup............................................................................. 101
12.1 Data backup Job ............................................................................................... 101
12.1.1 Save job to storage medium ....................................................................... 102
12.1.2 Load job from storage medium.................................................................103
12.2 Data backup Config......................................................................................... 104
12.2.1 Save configuration data to the storage medium.............................. 104
12.2.2 Load configuration data from storage medium................................ 105
12.3 Data backup Synergy...................................................................................... 105
12.3.1 Save characteristic curve to the storage medium.............................105
12.3.2 Load characteristic curve data from storage medium.................... 106
13. User log on/off ............................................................................................ 106
13.1 MAIN (2) - Log on..............................................................................................106
13.2 MAIN (2) - Log off .............................................................................................106
14. Job mode...................................................................................................... 107
14.1 Save job................................................................................................................. 107
14.2 Overwrite an existing job............................................................................. 108
14.3 Copy a job ............................................................................................................ 108
14.4 Activate job ......................................................................................................... 109
15. Main (3) - Weld data monitoring ............................................................ 109
Block 3 MasterPlus / Compact operating
module 111
1. Operating controls..................................................................................... 113
1.1 Display ..................................................................................................................113
2. Welding processes...................................................................................... 114
2.1 Definition arc length ...................................................................................... 114
2.2 Definition Dynamics....................................................................................... 114
2.3 Hold value display............................................................................................114
2.4 TIG welding......................................................................................................... 114
2.5 Electrode Welding............................................................................................ 115
2.6 Description of processes in MIG/MAG process...................................115

3. Description of the additional functions................................................ 117
3.1 DuoPulse.............................................................................................................. 117
3.2 CleanStart............................................................................................................117
3.3 QWD.......................................................................................................................117
3.4 Functions - System logbook ........................................................................ 118
3.5 Functions - Diagnostics................................................................................. 118
3.5.1 Diagnostics - Software versions ................................................................ 118
3.5.2 Diagnostics - Power unit...............................................................................118
3.5.3 Diagnostics - Cooling module.................................................................... 119
3.5.4 Diagnostics - Process control......................................................................119
3.6 Functions - Information................................................................................ 119
3.7 Functions - Loading Saving.......................................................................... 120
4. Operation..................................................................................................... 121
4.1 Operating concept for the operating modes ...................................... 121
4.1.1 Operating mode 2-cycle................................................................................121
4.1.2 Operating mode 4-cycle................................................................................122
4.1.3 Operating mode Super-4-cycle.................................................................. 123
4.1.4 Operating mode Spot welding/Interval ................................................124
4.2 Configuration of characteristic curve..................................................... 124
4.2.1 Adjusting secondary parameters ............................................................. 124
4.2.2 Restore the original state of the secondary parameters................125
4.2.3 Parameters of operating modes "2-cycle" and "4-cycle"................. 125
4.2.4 Additional parameters of operating mode "Super-4-cycle"..........126
4.2.5 Additional parameters of operating mode "Spot Welding/Interval"
.................................................................................................................................. 126
4.2.6 Parameter setting ranges (optional).......................................................126
4.3 Save and load job ............................................................................................. 128
4.3.1 Quick memory access..................................................................................... 128
4.3.2 Storage management.................................................................................... 129
5. Configuration menu.................................................................................. 132
5.1 Language .............................................................................................................132
5.2 Basic settings .....................................................................................................133
5.2.1 Basic screen ........................................................................................................ 133
5.2.2 2-cycle start and end crater program..................................................... 133
5.2.3 Fine adjustment ...............................................................................................133
5.2.4 Control voltage mode.....................................................................................134
5.2.5 External selection of process ......................................................................134
5.2.6 Reset to factory setting..................................................................................134
5.2.7 Polarity "+/-" connection...............................................................................134
5.2.8 Application range of power source.......................................................... 134
5.3 Config - General................................................................................................ 135
5.3.1 Automatic Hold display................................................................................. 135
5.3.2 MHW X10 Master............................................................................................. 135
5.3.3 Cooling water pump....................................................................................... 135
5.3.4 Job continuation...............................................................................................135
5.4 Config - General (2) ......................................................................................... 136
5.4.1 Wire speed in..................................................................................................... 136
5.4.2 V-display shows ................................................................................................ 136
5.4.3 Gas flow - min/max ........................................................................................136
5.4.4 TIG - pot setting range - min/max........................................................... 136
5.5 Compensation of the external welding circuit ..................................136
5.6 Process monitoring......................................................................................... 138
5.7 Cooling water monitoring ........................................................................... 138
5.8 Sense technology ............................................................................................. 139
5.9 QWD.......................................................................................................................140
5.9.1 QWD PushPull ................................................................................................... 140
5.9.2 Wire end control............................................................................................... 140
5.10 Locking/unlocking functions...................................................................... 140
5.10.1 Access management ......................................................................................141

5.10.2 User management and PAK ........................................................................ 142
5.11 PC adaptation.................................................................................................... 146
5.12 Options .................................................................................................................146
5.13 Activation code..................................................................................................147
5.14 Time .......................................................................................................................147
5.15 Off / Re-start.......................................................................................................147
5.16 Torch remote control ......................................................................................147
Block 4 Additional information 149
1. RC Plus (Remote Control) .......................................................................... 150
2. Multi-button torch..................................................................................... 151
3. SD module ................................................................................................... 152
3.1 Monitoring channels......................................................................................152
3.2 Submenus ...........................................................................................................156
3.3 Configure monitoring channel.................................................................. 157
3.4 Logbook.................................................................................................................159
3.5 Combine the application example SD monitoring with QIROX
controller..............................................................................................................162
Block 5 Qineo Wire Drive 165
1. Technical data ............................................................................................. 166
1.1 Weight...................................................................................................................166
1.2 Dimensions......................................................................................................... 166
1.3 Ambient conditions ........................................................................................166
1.4 Compatibility list.............................................................................................. 166
2. QINEO Wire Drive P5.................................................................................. 167
2.1 Connection overview P5................................................................................ 168
3. QINEO Wire Drive M4 ................................................................................ 169
3.1 Connection overview M4.............................................................................. 170
4. QINEO Wire Drive M5 ................................................................................ 171
4.1 Connection overview M5.............................................................................. 172
4.2 Connection instructions cable assembly.............................................. 173
4.2.1 Preparations on QWD-M5............................................................................173
4.2.2 Attach the protective hose........................................................................... 174
4.2.3 Attach the corrugated tube ........................................................................174
4.2.4 Recommended laying of connector cables...........................................174
4.2.5 Final tasks on QWD-M5.................................................................................174
5. QINEO Wire Drive A4 ................................................................................. 175
5.1 Structure and function A4...........................................................................176
6. QINEO Wire Drive AR4 ............................................................................... 177
6.1 Connection overview AR4............................................................................. 178
7. Function ....................................................................................................... 179
7.1 Button "Gas manually"..................................................................................179
7.1.1 Adjustment of the gas flow rate ...............................................................179
7.2 Button "Wire forward" or "Wire backward".......................................... 180
8. General commissioning............................................................................ 181
8.1 Safety instructions for commissioning.................................................. 181
8.1.1 Risks due to mechanical hazards.............................................................. 181
8.1.2 Risks due to electrical hazards................................................................... 181
8.2 Disassembly reducing insert ...................................................................... 182
8.3 Installation/change of the wire drive rollers.......................................183

8.3.1 QWD-M4 ..............................................................................................................183
8.3.2 QWD-P5 / QWD-M5........................................................................................ 184
8.4 Inserting the welding wire.......................................................................... 185
8.4.1 QWD-M4 ..............................................................................................................185
8.4.2 QWD-P5 / QWD-M5........................................................................................ 186
8.5 Adjustment of the pressure clamps........................................................ 187
9. Maintenance............................................................................................... 188
10. Error list........................................................................................................ 189
11. Disposal and Recycling.............................................................................. 190
Block 6a Error messages 191
1. Error messages............................................................................................ 192
Block 6b General maintenance instructions
207
1. Maintenance and Care.............................................................................. 208
1.1 Regular testing.................................................................................................. 209
1.2 Semi-annual testing....................................................................................... 210
1.3 Annual testing...................................................................................................210
1.4 Special testing................................................................................................... 211
1.4.1 Optional filter mat in the cooling unit...................................................211
1.4.2 Lifting eyes at the wire drive unit.............................................................211
1.4.3 Electrolytic capacitors of the transistor cascades.............................211
Block 7 Automation 213
1. Interfaces ..................................................................................................... 214
1.1 QOMI Module (Open Machine Interface)..............................................214
1.2 Profibus Module (Process Field Bus)........................................................ 214
1.3 ProfiNet Module ...............................................................................................215
1.4 DeviceNet Module........................................................................................... 215
1.5 Ethernet-IP Module .........................................................................................215
2. QIROX Technology Interface (QTI)............................................................ 216
2.1 Software compatibility..................................................................................216
2.2 Assignment of protocol type for Tandem operation........................ 216
2.3 Additional welding processes protocol type 2.................................... 216
2.4 Control of communication between welding power source and
robot ......................................................................................................................216
3. Basic configuration Operating mode "Tandem".................................. 217
3.1 Connection diagram.......................................................................................217
3.2 Conditions........................................................................................................... 217
3.3 Pre-adjustments............................................................................................... 218
3.3.1 QIROX robots...................................................................................................... 218
3.3.2 QINEO welding power sources ..................................................................218
3.4 Job programming QINEO welding power sources............................220
3.4.1 Select operating mode "Tandem" ............................................................. 220
3.4.2 Adjustment of the synergy variant.......................................................... 222
3.4.3 "Active QWD" setting...................................................................................... 223
4. Pulse synchronisation ............................................................................... 226
4.1 Configuration ....................................................................................................226
4.1.1 Synchronisation mode................................................................................... 227
4.1.2 Phase shift........................................................................................................... 228
5. Job allocation .............................................................................................. 230

11
Block 1 Operational Safety

12
Foreword
Dear customer,
You have decided to purchase a CLOOS shielding gas welding machine from
the QINEO series. This is a brand-name product which will meet your highest
quality requirements.
Messrs. CLOOS Schweisstechnik GmbH are a company certified to DIN ISO
9001 and who put great emphasis on development, manufacture and
quality of their products.
The power sources and the accessories in the QINEO series have been
developed, designed and manufactured according to the generally accepted
safety regulations. This is confirmed by the declaration of conformity and CE
marking.
The technical design, texts and photographs of the welding machines
correspond to the development status at the date of the printing of this
documentation.
The contents of the documentation will be adapted to technical
developments.
Subject to alterations.
The copyright law for the complete documentation remains with the
manufacturer.
1. Foreword

13
INFO!
Practical tips and other useful information!
ATTENTION!
The signal word indicates a hazard without risk of a physical impairment,
which, if not avoided, can lead to property damage.
CAUTION!
Describes a probably dangerous situation which may result in minor injury
or damage to property.
WARNING!
Describes a probably dangerous situation which may result in severe injury
or even death.
DANGER!
Describes an imminent danger which may result in severest injury or even
death.
May cause damage to organs through prolonged or repeated exposure.
2. Safety symbols in this
document
INFO!
ATTENTION!
CAUTION!
WARNING!
DANGER!

14
Safety specifications for MIG/MAG welding machines
Connection, service and repair works must only be carried out by qualified
personnel who have the appropriate professional training and sufficient
experience and knowledge of the power source and who are able to perform
the required works in accordance with the relevant safety specifications.
(Electrician as per BGV A3, Electrical plants and operating equipment).
The design and construction of the welding machine corresponds to
DIN EN 60 974 - 1. (Arc welding equipment, part 1, Welding power sources).
It corresponds to the latest state-of-the-art in technology and the recognised
rules of safety engineering. It must be operated by trained personnel or
users who have been familiarized with the machine to prevent danger due
to inappropriate handling or operation which is not in accordance with the
specifications.
For the use in Germany the following regulations have to be considered!
• Safety regulations BGV D1
• Safety regulations BGV A3
• National and regional fire protection rules
• Works on supply voltage, repairs and maintenance must be carried out by
qualified personnel only (electricians as defined in BGV A3).
• Movable mains supply and welding lines must be protected against dam-
age.
• Do not install the power source in a working area where welding with
increased electrical hazard takes place.
• The machine must be switched off and disconnected for all maintenance
work.
• All labels and danger signs on the welding machine must be kept easily
legible and must not be covered, coated, pasted over or removed.
• The operating manual must always be available near the welding ma-
chine. In addition, the regional rules for prevention of accidents and envi-
ronment must be available and be adhered to.
If repair work is carried out by unauthorised persons and safety regulations
are not adhered to, any guarantee and warranty claims become invalid.
3. Safety specifications for MIG/MAG welding machines
WARNING!
3.1 Basic safety
specifications for
the operation of the
welding machine
INFO!

15
The welding machine is exclusively intended for application as directed.
The welding machine must only be used for welding processes and working
ranges scheduled on the power sign.
Every other use is regarded as
not directed.
The manufacturer is not liable for damages occurred hereof.
The power source must never be used for the following works:
• Thawing of pipe lines
• Charging batteries/accumulators
• Starting of motors
The machine is intended for industrial use and must not be used in
residential buildings. The manufacturer is not liable for damages due to
use in residential buildings. The power source is subject to the standards
IEC 61000-3-4 or EN 61000-3-2.
• When welding, dry and flame resistant protective clothing, apron, helmet
and gloves as well as solid, well-insulated work shoes should be worn.
3.3.1. Danger due to electromagnetic fields (EMF)
According to the Accident Prevention Regulations BGV B11 "Electro-magnetic
fields" the permissible values of electric and magnetic fields will not be
exceeded with arc welding systems in the environment of the power source,
the feed lines and the torch.
However, the safety values for persons with active implants (cardiac
pacemakers, defibrillators and similar) might be exceeded in the
environment of welding machines.
Due to the low magnetic fields of arc welding systems, a safety distance
of 1 m to the live parts such as cable assemblies, cables and torch/arc is
recommended. During MIG/MAG welding, the danger is due to magnetic
fields and during TIG welding due to the high voltage pulses of arc ignition
units.
In practice, various models of active implants are used, the threshold values
of which depend on different parameters (type of implant, operating mode,
programming of the implant).
As far as the occupational safety is concerned, an individual risk assessment
is recommended in each individual case. If this is not possible, the generally
valid safety values - which are based on the most sensible implants - can
be applied, according to standard EN DIN VDE 0848-3-1 "Safety in electric,
magnetic and electromagnetic fields - Protection of persons with active
physical aids".
3.2 Application as directed
CAUTION!
3.3 Self protection and
personal protection
when MIG/MAG
welding
INFO!

16
Safety specifications for MIG/MAG welding machines
3.3.2. High frequency electromagnetic compatibility
EMC machine classification in accordance with standard EN 60974-10 (see
type plate or the specification of technical data).
Class B machines meet the EMC requirements in industrial and residential
areas, including residential areas connected to the public low voltage supply
network.
Class A machines are not intended for use in residential areas where electric
energy is drawn from the public low voltage supply network. It is difficult
to guarantee electromagnetic compatibility for class A machines due to
conducted emissions and radiated interferences in these areas.
3.3.3. Radiation
Ultraviolet and infrared radiation are released during welding.
• Protect skin and particularly the eyes. Keep eye drops and skin cream with
a high sun protection factor available.
• Always use safety glasses according to DIN EN 166 and DIN EN 379 in your
welder’s protective shield or helmet.
• Protect other persons in the vicinity of the welding area from UV rays and
spatter by suitable, non-flammable partition walls.
• Always wear safety glasses with side protection when you are in an area
where welding takes place or where slag is removed.

17
3.3.4. Gases and vapours
• All metal vapours are harmful to health!
• Be careful with alloys which contain lead, cadmium, copper, zinc, nickel,
chrome and beryllium.
• Chloric cleaning and degreasing agents can lead to the formation of the
toxic gas phosgene due to the decomposition in the arc (risk of suffoca-
tion!).
• Risk of poisoning in narrow places!
• If shielding gas hoses are not tight or the shielding gas valve gets caught
unintentionally, shielding gas may escape to such an extent that the oxy-
gen content of the inhaled air decreases, symptoms of poisoning appear
which may lead to unconsciousness and suffocation. (Argon and CO2are
heavier than air).
• Sufficient fresh air must be provided! Please check the gas supplying parts
in regular intervals.
• Use fume extraction systems. Pay attention to the national and regional
safety regulations.
3.3.5. Fire prevention (explosion)
• Remove all flammable materials around the welding place or cover these
with a non-flammable or at least hardly combustible material.
• Hot slag or spatter might cause fires if in contact with flammable materi-
als.
• Only use shielding gas mixtures suitable for welding consisting of e. g.
Argon, Helium, CO2and O2.
Never use flammable gases such as acetylene, propane or pure hydrogen.
Never weld on drums, tanks, pipes or similar containers unless they have
been thoroughly cleaned and prepared according to the relevant national
and international standards.
Make sure that no toxic, flammable or explosive vapours can develop.
Ensure that suitable fire-fighting equipment such as water, sand or fire
extinguishers are within easy reach.
Confined spaces must have a free passage allowing escape in case of danger.
Please observe the weld area and its surroundings when welding has
finished. Fire may break out later due to smouldering.
CAUTION!
WARNING!
WARNING!
WARNING!
WARNING!
DANGER!
CAUTION!

18
Safety specifications for MIG/MAG welding machines
3.3.6. Noise
• Noise may cause permanent damage to your hearing. During welding the
admissible noise level might be exceeded under unfavourable conditions.
• Please make sure that the admissible maximum values are not exceeded
(Security Administrator).
• If the maximum values are exceeded, a suitable ear protection (earplugs
or earmuffs) has to be used.
3.4 Electrical danger due to mains current and welding current
3.4.1. General information
An electric shock can prove fatal. Basically, every electric shock is extremely
dangerous.
• Do not touch live parts within or outside the power source!
• During MIG/MAG welding, the welding wire, the wire coil, the drive rollers
as well as all metal parts which touch the welding wire, are live.
• All cables must be tight, undamaged, insulated and sufficiently dimen-
sioned. The negative cable (earth cable) and the positive cable are locked
by turning to the right. Loose plugs affect the arc and thus the welding
behaviour of the power source to a considerable extent.
• Switch the welding machine off when not in use to prevent any electrical
risk.
• Avoid contact with metal parts, wear dry, insulating clothing and safety
shoes.
• Power sources may only be used when all covers are available and correctly
installed.
3.4.2. Mains connection
The power supply must be installed by qualified personnel only!
Please ensure that the mains voltage to be used is identical to the operating
voltage indicated on the machine type plate.
According to the connection regulations the machine has to be fused and
connected by means of a mains cable. You will find the connection rules
inside the power source after removal of the cover or side panel. The cross
section of the connection cable must be adequate.
The machine must be connected to a three-phase four-wire system with
earth conductor and operated.
WARNING!
INFO!
CAUTION!

19
Connection to ungrounded networks (e.g. IT networks) or asymmetrically
grounded networks is only permitted with an appropriate isolating
transformer
Position Designation Colour
L1 Phase conductor 1 brown
L2 Phase conductor 2 black
L3 Phase conductor 3 grey
N Earth conductor blue
PE Protective conductor green-yellow
The terminal voltage of the power source can be up to 113 V DC or 48 V AC !
Although the power source is "marked S" for welding in environments with
increased electrical hazard, the power source itself must not be installed in
such places (mains voltage 400V).
Only the welding torch and wire drive unit may be installed and operated in
such places.
ATTENTION!
L1
L2
L3
N
PE
CAUTION!
ATTENTION!

20
Safety specifications for MIG/MAG welding machines
Depending on the process used, it may happen that there is an addition of
the two open circuit voltages between the welding electrodes of two power
sources. There is possibly the risk of danger to life if both potentials are
touched at the same time, see Figure 3.
Electric shocks can be caused when touching the point of the torch (wire)
when the open circuit voltage is more than 48 V and simultaneous skin
contact with metal parts at the mass potential of the welding machine.
Protective measures by a suitable insulation are absolutely necessary. The
open circuit voltage is indicated on the type plate of the welding machine.
3.4.3. Protective conductor
Danger of severe personal injury because of improper mains connection
In the case of improper mains connection of the machine severe shock
currents may arise.
In connection with the welding power source the protective conductor may
be destroyed by faulty mass connections with earthed welding systems.
• Make sure that the protective conductor connection is correct and tight!
(VDE rules).
• The functioning of the protective conductors, the supply network and
machine cables must be checked before commissioning and in regular
intervals by a skilled electrician.
It is regarded as gross negligent to operate a power source on a supply
network without protective conductor. The manufacturer is not liable for
damages occurred hereof.
Before working on the power source, switch off the machine and disconnect
the mains plug. Please use a warning sign as protection against unintended
restart.
A second person should be present for safety reasons if working on voltage-
carrying parts is required.
Figure 3. Added open circuit voltages
WARNING!
DANGER!