FRO­NIUS TransSynergic 5000 Guide

/ Battery Charging Systems / Welding Technology / Solar Electronics
42,0426,0001,EN 006-04092012
TransSynergic 4000/5000
TransPuls Synergic 2700
TransPuls Synergic 3200/4000/5000
TIME 5000 Digital
CMT 4000 Advanced
Operating Instructions
Spare parts list
MIG/MAG Power source
EN

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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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EN
Contents
Safety rules ................................................................................................................................................ 9
Explanation of safety symbols .............................................................................................................. 9
General ................................................................................................................................................. 9
Intended purpose .................................................................................................................................. 10
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 11
Mains connection .................................................................................................................................. 11
Protecting yourself and others .............................................................................................................. 11
Noise emission values .......................................................................................................................... 12
Danger from toxic gases and vapours .................................................................................................. 12
Danger from flying sparks ..................................................................................................................... 13
Risks from mains current and welding current...................................................................................... 13
Meandering welding currents................................................................................................................ 15
EMC device classifications ................................................................................................................... 15
EMC measures ..................................................................................................................................... 15
EMF measures...................................................................................................................................... 16
Specific hazards.................................................................................................................................... 16
Danger from shielding gas cylinders..................................................................................................... 18
Safety measures at the installation location and during transport ........................................................ 18
Safety measures in normal operation ................................................................................................... 19
Maintenance and repair ........................................................................................................................ 20
Safety inspection................................................................................................................................... 20
Disposal ................................................................................................................................................ 20
Safety symbols...................................................................................................................................... 20
Data protection...................................................................................................................................... 21
Copyright............................................................................................................................................... 21
General information 23
General ...................................................................................................................................................... 25
Device concept ..................................................................................................................................... 25
Functional principle ............................................................................................................................... 25
Application areas .................................................................................................................................. 25
Warning notices on the device.............................................................................................................. 25
Special versions......................................................................................................................................... 27
General ................................................................................................................................................. 27
Alu edition ............................................................................................................................................. 27
CrNi edition ........................................................................................................................................... 27
CMT Variants ........................................................................................................................................ 27
CMT 4000 Advanced ............................................................................................................................ 27
TIME 5000 Digital ................................................................................................................................. 28
Yard edition........................................................................................................................................... 28
Steel edition .......................................................................................................................................... 28
System components .................................................................................................................................. 29
General ................................................................................................................................................. 29
Overview ............................................................................................................................................... 29
Control elements and connections 31
Description of the control panels................................................................................................................ 33
General ................................................................................................................................................. 33
Safety.................................................................................................................................................... 33
Overview ............................................................................................................................................... 33
Standard control panel............................................................................................................................... 34
General ................................................................................................................................................. 34
Standard control panel.......................................................................................................................... 34
Key combinations - special functions.................................................................................................... 36
Displaying the feeder inching speed ..................................................................................................... 36
Displaying the gas pre-flow and gas post-flow time..............................................................................36

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Displaying the software version ............................................................................................................ 36
Comfort / CrNi / Steel control panel ........................................................................................................... 38
Difference between Comfort, CrNi and Steel control panels ................................................................ 38
Comfort control panel............................................................................................................................ 38
Key combinations - special functions.................................................................................................... 41
Displaying the feeder inching speed ..................................................................................................... 41
Displaying the gas pre-flow and gas post-flow time..............................................................................42
Displaying the software version ............................................................................................................ 42
US control panel ........................................................................................................................................ 43
US control panel ................................................................................................................................... 43
Key combinations - special functions.................................................................................................... 46
Displaying the feeder inching speed ..................................................................................................... 46
Displaying the gas pre-flow and gas post-flow time..............................................................................46
Displaying the software version ............................................................................................................ 47
TIME 5000 Digital control panel................................................................................................................. 48
TIME 5000 Digital control panel............................................................................................................ 48
Key combinations - special functions.................................................................................................... 51
Displaying the feeder inching speed ..................................................................................................... 51
Displaying the gas pre-flow and gas post-flow time..............................................................................52
Displaying the software version ............................................................................................................ 52
CMT control panel...................................................................................................................................... 53
CMT control panel................................................................................................................................. 53
Key combinations - special functions.................................................................................................... 56
Displaying the feeder inching speed ..................................................................................................... 56
Displaying the gas pre-flow and gas post-flow time..............................................................................56
Displaying the software version ............................................................................................................ 56
Yard control panel...................................................................................................................................... 58
Yard control panel................................................................................................................................. 58
Key combinations - special functions.................................................................................................... 61
Displaying the feeder inching speed ..................................................................................................... 61
Displaying the gas pre-flow and gas post-flow time..............................................................................61
Displaying the software version ............................................................................................................ 62
“Remote” control panel .............................................................................................................................. 63
General ................................................................................................................................................. 63
Remote control panel............................................................................................................................ 63
CMT Remote control panel ........................................................................................................................ 64
General ................................................................................................................................................. 64
CMT Remote and CMT Advanced control panel .................................................................................. 64
Connections, switches and mechanical components ................................................................................ 65
TPS 2700 power source ....................................................................................................................... 65
TPS 2700 CMT power source............................................................................................................... 66
TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital power sources ...................................... 67
CMT 4000 Advanced power source...................................................................................................... 68
Installation and commissioning 71
Minimum equipment needed for welding task............................................................................................ 73
General ................................................................................................................................................. 73
MIG/MAG gas-cooled welding .............................................................................................................. 73
MIG/MAG water-cooled welding ........................................................................................................... 73
MIG/MAG automated welding............................................................................................................... 73
CMT manual welding ............................................................................................................................ 73
CMT automated welding ....................................................................................................................... 74
CMT Advanced welding ........................................................................................................................ 74
TIG DC welding..................................................................................................................................... 74
Manual metal arc welding ..................................................................................................................... 74
Before installation and commissioning....................................................................................................... 75
Safety.................................................................................................................................................... 75
Proper use ............................................................................................................................................ 75
Setup regulations .................................................................................................................................. 75
Mains connection .................................................................................................................................. 75
Connecting up the mains cable on US power sources .............................................................................. 76
General ................................................................................................................................................. 76
Stipulated mains cables and strain-relief devices ................................................................................. 76

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Safety.................................................................................................................................................... 76
Connecting the mains cable.................................................................................................................. 76
Replacing the strain-relief device.......................................................................................................... 77
Start-up ...................................................................................................................................................... 79
Safety.................................................................................................................................................... 79
Remarks on the cooling unit ................................................................................................................. 79
Information on system components ...................................................................................................... 79
Overview ............................................................................................................................................... 79
Commissioning the TPS 2700 ................................................................................................................... 80
General ................................................................................................................................................. 80
Recommendation for water-cooled applications ................................................................................... 80
Connecting the gas cylinder.................................................................................................................. 80
Establishing a ground (earth) connection ............................................................................................. 81
Connecting the welding torch................................................................................................................ 81
Inserting/replacing feed rollers.............................................................................................................. 81
Inserting the wirespool .......................................................................................................................... 82
Inserting the basket-type spool ............................................................................................................. 82
Feeding in the wire electrode................................................................................................................ 83
Setting the contact pressure ................................................................................................................. 84
Adjusting the brake ............................................................................................................................... 84
Design of the brake............................................................................................................................... 85
Commissioning the TS 4000 / 5000, TPS 3200 / 4000 / 5000, TIME 5000 Digital .................................... 86
General ................................................................................................................................................. 86
Fitting the system components (overview)............................................................................................ 86
Fixing the strain-relief device in place................................................................................................... 87
Connecting the interconnecting hosepack ............................................................................................ 87
Connecting the gas cylinder.................................................................................................................. 88
Establishing a ground (earth) connection ............................................................................................. 89
Connecting the welding torch................................................................................................................ 89
Other tasks............................................................................................................................................ 89
Commissioning the CMT4000 Advanced................................................................................................... 90
Fitting the system components (overview)............................................................................................ 90
Connecting the interconnecting hosepack, CMT welding torch and wire buffer ................................... 90
Other tasks............................................................................................................................................ 90
Preparing the wire-feed unit.................................................................................................................. 91
Welding 93
MIG/MAG modes ....................................................................................................................................... 95
General ................................................................................................................................................. 95
Symbols and their explanations ............................................................................................................ 95
2-step mode .......................................................................................................................................... 96
4-step mode .......................................................................................................................................... 96
Special 4-step mode ............................................................................................................................. 97
Spot welding ......................................................................................................................................... 97
MIG/MAG welding...................................................................................................................................... 98
Safety.................................................................................................................................................... 98
General tasks before MIG/MAG welding .............................................................................................. 98
Overview ............................................................................................................................................... 98
MIG/MAG synergic welding ....................................................................................................................... 99
General ................................................................................................................................................. 99
MIG/MAG synergic welding .................................................................................................................. 99
Corrections during welding ................................................................................................................... 100
Adjusting parameters for correction ...................................................................................................... 100
Remarks on the Standard control panel ............................................................................................... 100
MIG/MAG standard manual welding .......................................................................................................... 101
General ................................................................................................................................................. 101
Available parameters ............................................................................................................................ 101
MIG/MAG standard manual welding ..................................................................................................... 101
Corrections during welding ................................................................................................................... 102
Adjusting parameters for correction ...................................................................................................... 102
CMT welding .............................................................................................................................................. 103
General ................................................................................................................................................. 103
CMT welding ......................................................................................................................................... 103

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Corrections during welding ................................................................................................................... 104
Adjusting parameters for correction ...................................................................................................... 106
Special functions and options .................................................................................................................... 107
Arc break watchdog function................................................................................................................. 107
Ignition time-out function....................................................................................................................... 107
Spatter-free ignition option.................................................................................................................... 107
SynchroPulse option ............................................................................................................................. 108
Robot welding ............................................................................................................................................ 110
Prerequisite........................................................................................................................................... 110
General ................................................................................................................................................. 110
Special 2-step mode for robot interface ................................................................................................ 110
Wire-stick control function..................................................................................................................... 111
Changing the welding process during CMT Advanced welding............................................................ 111
TIG welding................................................................................................................................................ 112
Safety.................................................................................................................................................... 112
Prerequisite........................................................................................................................................... 112
Preparation ........................................................................................................................................... 112
TIG welding........................................................................................................................................... 112
Igniting the arc ...................................................................................................................................... 113
Finishing welding .................................................................................................................................. 114
TIG Comfort Stop option ....................................................................................................................... 114
TIG welding with TIG Comfort Stop ...................................................................................................... 116
MMA welding ............................................................................................................................................. 117
Safety.................................................................................................................................................... 117
Prerequisite........................................................................................................................................... 117
Preparation ........................................................................................................................................... 117
Manual metal arc welding ..................................................................................................................... 117
Corrections during welding ................................................................................................................... 118
Adjusting parameters for correction ...................................................................................................... 118
HotStart function ................................................................................................................................... 118
SoftStart function .................................................................................................................................. 119
Anti-stick function.................................................................................................................................. 119
Job mode ................................................................................................................................................... 120
General ................................................................................................................................................. 120
Prerequisites ......................................................................................................................................... 120
Restrictions ........................................................................................................................................... 120
Job mode displays on the left-hand digital display................................................................................ 120
Selecting job mode as the process ....................................................................................................... 120
Creating a job........................................................................................................................................ 120
Retrieving a job ..................................................................................................................................... 121
Copying/overwriting a job...................................................................................................................... 122
Deleting a job ........................................................................................................................................ 123
Setup settings 125
Job correction ............................................................................................................................................ 127
General ................................................................................................................................................. 127
Opening the Job correction menu......................................................................................................... 127
Changing welding parameters .............................................................................................................. 127
Exiting the Job correction menu............................................................................................................ 127
Parameters in the job correction menu ................................................................................................. 128
Permanently settable parameters ......................................................................................................... 128
Parameters that can be corrected at a later time.................................................................................. 130
Shielding gas setup menu.......................................................................................................................... 133
General ................................................................................................................................................. 133
Protective gas shield setup menu for the standard control panel ......................................................... 133
Protective gas shield setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ... 133
Welding parameters in the Protective gas shield setup menu .............................................................. 133
Setup menu for the standard control panel................................................................................................ 135
General ................................................................................................................................................. 135
Setup menu for the standard control panel........................................................................................... 135
Parameters in the Setup menu for the Standard control panel............................................................. 135
Process setup menu .................................................................................................................................. 138
General ................................................................................................................................................. 138

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Process setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ....................... 138
Parameters for MIG/MAG welding in the Process setup menu ............................................................ 138
Parameters for TIG welding in the Process setup menu ...................................................................... 141
Parameters for MMA welding in the Process setup menu .................................................................... 141
Mode setup menu ...................................................................................................................................... 142
General ................................................................................................................................................. 142
Mode setup menu for the Comfort, US, TIME 5000 Digital and CMT control panels ........................... 142
Welding parameters for "Special 2-step mode" in the Mode setup menu............................................. 142
Welding parameters for "Special 4-step mode" in the Mode setup menu............................................. 143
Parameters for spot welding in the Mode setup menu.......................................................................... 143
Setup menu - Level 2................................................................................................................................. 144
General ................................................................................................................................................. 144
Setup menulevel 2 for the Standard control panel................................................................................144
Setup menu level 2 for the Comfort, US, TIME 5000 Digital and CMT control panels ......................... 145
Parameters for MIG/MAG welding in the Setup menu level 2 .............................................................. 145
Parameters for operating power sources in parallel in the Setup menu level2..................................... 148
Parameters for TimeTwin Digital in the Setup menu level2 .................................................................. 148
Parameters for TIG welding in the Setup menu level2 ......................................................................... 148
Parameters for rod electrode (MMA) welding in the Setup menu level 2.............................................. 150
Notes on the use of the FAC parameter ............................................................................................... 152
Calibrating push-pull unit ........................................................................................................................... 153
General ................................................................................................................................................. 153
Calibrating the push-pull unit - overview ............................................................................................... 153
Calibrating the push-pull unit ................................................................................................................ 153
Service codes for push-pull calibration ...................................................................................................... 157
Safety.................................................................................................................................................... 157
Service codes when the drive units are disengaged ("open-circuit" calibration)................................... 157
Service codes when the drive units are engaged ("engaged" calibration)............................................ 158
Measuring welding circuit resistance r ....................................................................................................... 160
General ................................................................................................................................................. 160
Measuring welding circuit resistance r .................................................................................................. 160
Displaying welding circuit inductivity L ....................................................................................................... 162
General ................................................................................................................................................. 162
Displaying welding circuit inductivity L .................................................................................................. 162
Arranging the interconnecting hosepack correctly ................................................................................162
Troubleshooting and maintenance 163
Troubleshooting ......................................................................................................................................... 165
General ................................................................................................................................................. 165
Safety.................................................................................................................................................... 165
Displayed service codes ....................................................................................................................... 165
Power source - troubleshooting ............................................................................................................ 173
Care, maintenance and disposal ............................................................................................................... 177
General ................................................................................................................................................. 177
Safety.................................................................................................................................................... 177
At every start-up.................................................................................................................................... 177
Every 2 months ..................................................................................................................................... 177
Every 6 months ..................................................................................................................................... 177
Disposal ................................................................................................................................................ 177
Appendix 179
Technical data............................................................................................................................................ 181
Special voltages.................................................................................................................................... 181
TPS 2700 .............................................................................................................................................. 181
TPS 2700 MV........................................................................................................................................ 182
TPS 3200 .............................................................................................................................................. 183
TPS 3200 MV........................................................................................................................................ 184
TPS 3200 460VAC............................................................................................................................... 185
TS/TPS 4000 ........................................................................................................................................ 186
TS/TPS 4000 MV .................................................................................................................................. 187
TS/TPS 5000 ........................................................................................................................................ 187
TS/TPS 5000 MV .................................................................................................................................. 188

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Technical data - US devices ................................................................................................................. 189
Technical data - Alu edition, CrNi edition, Yard edition and CMT variants ........................................... 189
TIME 5000 Digital ................................................................................................................................. 189
CMT 4000 Advanced ............................................................................................................................ 190
CMT 4000 Advanced MV...................................................................................................................... 191
Welding program databases ...................................................................................................................... 193
Explanation of symbols ......................................................................................................................... 193
Setting up a welding program database - example............................................................................... 193
Terms and abbreviations used................................................................................................................... 194
General ................................................................................................................................................. 194
Terms and abbreviations A - C ............................................................................................................. 194
Terms and abbreviations D - F ............................................................................................................. 194
Terms and abbreviations G - I .............................................................................................................. 195
Terms and abbreviations J - R.............................................................................................................. 195
Terms and abbreviations S ................................................................................................................... 196
Terms and abbreviations T - 2nd .......................................................................................................... 196
Spare parts list 199
Spare parts list: TransPuls Synergic 2700................................................................................................. 200
Spare parts list: TS/TPS 3200/4000/5000, TIME 5000..............................................................................203
Spare parts list: CMT 4000 Advanced ....................................................................................................... 206

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Safety rules
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules", special care is required.
General
DANGER! indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
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 operat-
ing 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
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be kept in a legible state
- must not be damaged/marked
- 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
section headed "General remarks" in the operating instructions for the device.
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!

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Intended purpose
Environmental
conditions
Obligations of the
operator
The device is to be used exclusively for its intended purpose.
The device is intended for the welding process described on the rating plate
only.
Any use above and beyond this purpose is deemed improper. The manufac-
turer shall not be liable for any damage resulting from such improper use.
Utilisation in accordance with the "intended purpose" also comprises
- reading carefully and following all operating instructions to the letter
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries/accumulators
- Starting engines
The device is designed for use in industry and the workshop. The manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for unexpected or incorrect re-
sults.
Operation or storage of the device outside the stipulated area will be deemed
as "not in accordance with the intended purpose". The manufacturer shall not
be liable for any damage resulting from such improper use.
Ambient temperature:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Ambient air: free from dust, acids, corrosive gases and substances, etc.
For use at altitudes above sea level: up to 2000 m (6500 ft)
The operator undertakes only to allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety and acci-
dent prevention, and have been instructed how to use the device
- have read and understood these operating instructions, especially the
section “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.

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EN
Obligations of
personnel
Mains connection
Protecting your-
self and others
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- 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 work area, ensure that people or property cannot come to
any harm in your absence.
Devices with a higher rating may affect the energy quality of the mains due to
their current input.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)
*)at the interface with the public mains network
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
matter with the power supply company.
Persons involved with welding expose themselves to numerous risks, e.g.:
- flying sparks and hot pieces of metal
- arc radiation, which can damage eyes and skin
- hazardous electromagnetic fields, which can endanger the lives of those
using cardiac pacemakers
- risk of electrocution from mains current and welding current
- greater noise pollution
- harmful welding fumes and gases
Anyone working on the workpiece while welding is in progress must wear suit-
able protective clothing with the following properties:
- flame-resistant
- insulating and dry
- covers the whole body, is undamaged and in good condition
- safety helmet
- trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:

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Noise emission
values
Danger from toxic
gases and va-
pours
- protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation filter.
- wear regulation protective goggles with side protection behind the safety
visor.
- wear stout footwear that provides insulation even in wet conditions.
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
- wear ear protection to reduce the harmful effects of noise and to prevent
injury.
Keep all persons, especially children, out of the working area while any devic-
es are in operation or welding is in progress. If, however, there are people in
the vicinity,
- make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible danger from
mains or welding current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases,
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air.
If this cannot be provided, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or central gas supply if no welding is tak-
ing place.

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EN
Danger from fly-
ing sparks
Risks from mains
current and weld-
ing current
If there is any doubt about whether the extraction system is powerful enough,
then the measured toxic emission values should be compared with the permis-
sible limit values.
The following components are responsible, amongst other things, for the de-
gree of toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (35 ft) away from the arc, or
alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of in-
jury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in ac-
cordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
An electric shock is life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG or TIG welding, the welding wire, the wirespool, the drive
rollers and all metal parts that are in contact with the welding wire are live.
Always set the wire-feed unit up on a sufficiently insulated surface or use a
suitable, insulated wire-feed unit mount.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.

14
All cables and leads must be complete, undamaged, insulated and adequately
dimensioned. Loose connections, scorched, damaged or inadequately dimen-
sioned cables and leads must be repaired/replaced immediately.
Do not sling cables or leads around either the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc) must
- never be immersed in liquid for cooling
- never be touched when current is flowing.
Double the open circuit voltage of a welding machine can occur between the
welding electrodes of two welding machines. Touching the potentials of both
electrodes at the same time may under certain circumstances be fatal.
Arrange for the mains and device supply to be checked regularly by a qualified
electrician to ensure the PE conductor is functioning properly.
The device must only be operated on a mains supply with a PE conductor and
a socket with an earth contact.
If the device is operated on a mains without a PE conductor and in a socket
without an earth contact, this will be deemed gross negligence. The manufac-
turer shall not be liable for any damage resulting from such improper use.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
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 reconnecting it to the mains and switching it on again.
After opening the device:
- discharge all components holding an electric charge
- ensure that all components in the device are de-energised.
If work on live parts cannot be avoided, appoint a second person to switch off
the main switch at the right moment.

15
EN
Meandering weld-
ing currents
EMC device clas-
sifications
EMC measures
If the following instructions are ignored, meandering welding currents can de-
velop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to PE conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be weld-
ed.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
Devices with emission class A:
- are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.
Devices with emission class B:
- satisfy the emissions criteria for residential and industrial areas.
This also applies to residential areas in which power is supplied
from the public low-voltage grid.
EMC device classification according to the rating plate or the techni-
cal data.
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 rec-
tify the situation.

16
EMF measures
Specific hazards
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international require-
ments:
- Safety features
- power, signal and data transfer lines
- IT and telecommunications devices
- measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
a) Mains supply
- if electromagnetic interference arises despite correct mains connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
b) Welding leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
c) Equipotential bonding
d) Earthing the workpiece
- if necessary, establish an earth connection using suitable capacitors.
e) Shielding, if necessary
- shield off other nearby devices
- shield off entire welding installation
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
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
repair 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.

17
EN
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Always keep the welding torch away from the body (devices with wire-feed
unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources that are to be used 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.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains and/or ropes onto the suspension points provided on the
load-carrying equipment.
- Chains/ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wire-feed unit holder (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, forklift
truck or other mechanical hoist.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the device-
side thread of the adapter for the shielding gas connection using suitable Te-
flon tape.

18
Danger from
shielding gas cyl-
inders
Safety measures
at the installation
location and dur-
ing transport
Shielding gas cylinders contain gas under pressure and can explode if dam-
aged. As the shielding gas cylinders are part of the welding equipment, they
must be 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 instruc-
tions 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 na-
tional and international regulations for shielding gas cylinders and accesso-
ries.
A device that topples over can easily kill someone. Place the device on a solid,
level surface in such a way that it remains stable
- The maximum permissible slope is 10°.
Special regulations apply in rooms at risk of fire or explosion
- observe relevant national and international requirements.
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 protec-
tion shown on the rating plate.
When setting up the device, ensure there is a gap of 0.5 m (1 ft. 7.69 in.) all
round so that cooling air can enter and exit unhindered.