FRO­NIUS TransSteel 2200 User manual

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42,0426,0241,EA 005-06062019
TransSteel 2200 Operating Instructions
MIG/MAG Power source
EN-US

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EN-US
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 familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advan-
tages.
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.
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and 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.
If you see any of the symbols depicted in the "Safety Rules," special care is required.

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EN-US
Contents
Safety 9
Safety Instructions ..................................................................................................................................... 11
Explanation of Safety Instructions......................................................................................................... 11
General ................................................................................................................................................. 11
Intended Use......................................................................................................................................... 12
Grid Connection .................................................................................................................................... 12
Environmental Conditions ..................................................................................................................... 12
Obligations of the Operating Company................................................................................................. 13
Obligations of Personnel....................................................................................................................... 13
Residual current circuit breaker ............................................................................................................ 13
Personal Protection and Protection of Others....................................................................................... 13
Data regarding Noise Emission Values ................................................................................................ 14
Danger from Toxic Gases and Vapors.................................................................................................. 14
Danger from Flying Sparks ................................................................................................................... 14
Risks from Grid Current and Welding Current ...................................................................................... 15
Stray Welding Currents......................................................................................................................... 16
EMC Device Classifications .................................................................................................................. 16
EMC Measures ..................................................................................................................................... 16
EMF measures...................................................................................................................................... 17
Particular Hazard Areas........................................................................................................................ 17
Undesired Welding Results................................................................................................................... 18
Danger from Shielding Gas Cylinders................................................................................................... 18
Danger Posed by Shielding Gas Leak .................................................................................................. 19
Safety Measures at the Setup Location and During Transport ............................................................. 19
Safety Measures in Normal Operation.................................................................................................. 20
Maintenance and repair ........................................................................................................................ 20
Safety Inspection .................................................................................................................................. 20
Disposal ................................................................................................................................................ 21
Safety Symbols ..................................................................................................................................... 21
Backup .................................................................................................................................................. 21
Copyright............................................................................................................................................... 21
General Information 23
General ...................................................................................................................................................... 25
Device concept ..................................................................................................................................... 25
"Power limitation" function .................................................................................................................... 25
Application areas .................................................................................................................................. 26
Warning notices on the device.............................................................................................................. 27
Description of Warning Notices on the Device...................................................................................... 29
Operating controls and connections 31
Control Panel ............................................................................................................................................. 33
General ................................................................................................................................................. 33
Safety.................................................................................................................................................... 33
Control panel......................................................................................................................................... 33
Keylock ................................................................................................................................................. 38
Connections, Switches, and Mechanical Components .............................................................................. 40
Safety.................................................................................................................................................... 40
Front and rear of the power source....................................................................................................... 40
Side view............................................................................................................................................... 41
Before installation and initial operation 43
General ...................................................................................................................................................... 45
Safety.................................................................................................................................................... 45
Intended use ......................................................................................................................................... 45

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Setup regulations .................................................................................................................................. 45
Grid Connection .................................................................................................................................... 46
Generator-Powered Operation................................................................................................................... 47
Generator-powered operation............................................................................................................... 47
Mains Fuse Protection ............................................................................................................................... 48
Adjustable mains fuse protection .......................................................................................................... 48
Carrying Strap Option 51
Fitting the Carrying Strap ........................................................................................................................... 53
Fitting the carrying strap to the power source....................................................................................... 53
MIG/MAG 55
Commissioning .......................................................................................................................................... 57
Connecting a MIG/MAG welding torch.................................................................................................. 57
Inserting the feed rollers ....................................................................................................................... 58
Inserting the D100 wirespool ................................................................................................................ 59
Inserting the D200 wirespool ................................................................................................................ 59
Feeding in the wire electrode................................................................................................................ 60
Setting the contact pressure ................................................................................................................. 61
Connecting the gas cylinder.................................................................................................................. 62
Connecting the polarity reverser and establishing a grounding (earthing) connection ........................ 63
Adjusting the Brake of the Wirespool Holders ........................................................................................... 64
General ................................................................................................................................................. 64
Adjusting the brake of the D200 wirespool holder ................................................................................ 65
Adjusting the brake of the D100 wirespool holder ................................................................................ 65
Description of MIG/MAG Operating Modes ............................................................................................... 66
2-step mode .......................................................................................................................................... 66
4-step mode .......................................................................................................................................... 66
Special 4-step mode ............................................................................................................................. 67
Spot welding ......................................................................................................................................... 68
2-step stitch welding ............................................................................................................................. 69
4-step stitch welding ............................................................................................................................. 69
MIG/MAG Standard Manual Welding......................................................................................................... 71
General ................................................................................................................................................. 71
Available parameters ............................................................................................................................ 71
MIG/MAG standard manual welding ..................................................................................................... 71
Corrections during welding ................................................................................................................... 71
MIG/MAG Standard Synergic Welding ...................................................................................................... 72
MIG/MAG standard synergic welding ................................................................................................... 72
Corrections during welding ................................................................................................................... 72
Spot and Stitch Welding............................................................................................................................. 73
General ................................................................................................................................................. 73
Spot welding ......................................................................................................................................... 73
Stitch welding........................................................................................................................................ 73
TIG 75
Commissioning .......................................................................................................................................... 77
Start-Up................................................................................................................................................. 77
TIG welding........................................................................................................................................... 78
Description of TIG Operating Modes ......................................................................................................... 80
2-step mode .......................................................................................................................................... 80
4-Step Mode ......................................................................................................................................... 81
Pulse Welding ............................................................................................................................................ 83
Applications........................................................................................................................................... 83
Operating Principle ............................................................................................................................... 83
Activating Pulse Welding ...................................................................................................................... 84
Rod Electrode 85
Commissioning .......................................................................................................................................... 87
Preparation ........................................................................................................................................... 87

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EN-US
Manual metal arc welding ..................................................................................................................... 88
Functions for Optimizing the Welding Process .......................................................................................... 89
Arc-Force Dynamic ............................................................................................................................... 89
HotStart (Hti) Function .......................................................................................................................... 89
Anti-stick (Ast) Function ........................................................................................................................ 89
EasyJobs 91
Saving and Retrieving EasyJobs ............................................................................................................... 93
General ................................................................................................................................................. 93
Saving an EasyJob ............................................................................................................................... 93
Retrieving an EasyJob .......................................................................................................................... 93
Deleting an EasyJob ............................................................................................................................. 93
Setup Menu 95
Setup Menu Level 1 ................................................................................................................................... 97
Operation .............................................................................................................................................. 97
Parameters for MIG/MAG Standard Manual Welding........................................................................... 98
Parameters for MIG/MAG Standard Synergic Welding......................................................................... 99
Parameters for TIG Welding ................................................................................................................. 101
Parameters for MMA Welding............................................................................................................... 102
Setup Menu 2nd Level ............................................................................................................................... 103
Operation .............................................................................................................................................. 103
Parameters for MIG/MAG welding ........................................................................................................ 104
Parameters for MIG/MAG welding ........................................................................................................ 105
Parameters for TIG Welding (Setup Menu 2nd Level).......................................................................... 107
Parameters for Manual Metal Arc Welding (Setup Menu 2nd Level).................................................... 108
Optimizing Weld Quality 109
Measuring the Welding Circuit Resistance r .............................................................................................. 111
General ................................................................................................................................................. 111
Measuring the Welding Circuit Resistance r ......................................................................................... 111
Displaying the Welding Circuit Inductivity L ............................................................................................... 112
General ................................................................................................................................................. 112
Displaying the Welding Circuit Inductivity L .......................................................................................... 112
Laying the Hosepacks Correctly ........................................................................................................... 112
Troubleshooting and Maintenance 113
Displaying Service Parameters.................................................................................................................. 115
Service parameters............................................................................................................................... 115
Troubleshooting ......................................................................................................................................... 116
Safety.................................................................................................................................................... 116
Troubleshooting .................................................................................................................................... 116
Displayed Service Codes...................................................................................................................... 119
Service, maintenance and disposal ........................................................................................................... 123
General ................................................................................................................................................. 123
Safety.................................................................................................................................................... 123
At every start-up.................................................................................................................................... 123
As required, at least every two months................................................................................................. 124
Every 6 Months ..................................................................................................................................... 124
Disposal ................................................................................................................................................ 124
Removing Stiff Drive Rollers ...................................................................................................................... 125
Removing a stiff drive roller .................................................................................................................. 125
Technical Data 127
General ...................................................................................................................................................... 129

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Special voltage...................................................................................................................................... 129
Explanation of the Term Duty Cycle ..................................................................................................... 129
Technical Data ........................................................................................................................................... 130
TSt 2200 ............................................................................................................................................... 130
TSt 2200 MV ......................................................................................................................................... 131

Safety

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EN-US
Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and 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.
If you see any of the symbols depicted in the "Safety Rules," special care is required.
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized safety standards. If used incorrectly or misused, however, it can cause
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over

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For the location of the safety and danger notices on the device, refer to the section headed
"General" 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!
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in ac-
cordance with the intended purpose." The manufacturer is not responsible for any damage
resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current
consumption.
This may affect a number of device types in terms of:
- connection restrictions
- criteria regarding maximum permissible grid impedance *)
- criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°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 of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

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EN-US
Obligations of the
Operating Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safe-
ty Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
Residual current
circuit breaker
Local regulations and national guidelines may mean that a residual current circuit breaker
is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manufacturer can
be found in the technical data.
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pace-
makers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury

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Keep persons, especially children, away during the operation of the devices and during the
welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
Data regarding
Noise Emission
Values
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in
the cooling phase following operation in relation to the maximum permitted operating point
at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified because
this value depends on the welding process and the environmental conditions. It is influ-
enced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG
welding), the selected current type (direct current, alternating current), the power range,
the type of weld metal, the resonance properties of the workpiece, the workplace environ-
ment, and many other factors.
Danger from Tox-
ic Gases and Va-
pors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that can cause cancer, as stated in monograph 118
from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in
- Extract them from the work area using appropriate equipment
Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³
per hour.
Use breathing apparatus with air supply if there is insufficient ventilation.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the mea-
sured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.

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EN-US
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-
tected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums,
or pipes if these have not been prepared in accordance with corresponding national and
international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/
were stored. Residues pose a risk of explosion.
Risks from Grid
Current and
Welding Current
An electric shock is life-threatening and may be deadly.
Do not touch voltage-carrying parts inside or outside of the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed roll-
ers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient in-
sulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180°
around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- never immerse it in liquids to cool it
- never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the elec-
trodes of two welding systems. Touching the potentials of both electrodes at the same time
may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a ground con-
ductor contact.
Operating the device on a grid without a ground conductor and on a socket without a
ground conductor contact is considered gross negligence. The manufacturer accepts no
liability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.

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Secure the device to prevent the grid plug from being connected and switched on again by
applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply
If work is needed on voltage-carrying parts, bring in a second person who will switch off the
main switch at the correct time.
Stray Welding
Currents
If the following instructions are not observed, stray welding currents may occur, which pose
a risk of the following:
- Fire
- Overheating of components connected to the workpiece
- Destruction of ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece terminal is securely connected to the workpiece.
Secure the workpiece terminal as close to the spot to be welded as possible.
If the floor is electrically conductive, ensure that there is sufficient insulation between the
device and the floor.
Observe the following when using electrical distributors, double-headed retainers, etc.:
Even the electrode of the welding torch/electrode holder not in use carries electric poten-
tial. Ensure that there is sufficient insulation when the unused welding torch/electrode hold-
er is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire
drum, large spool or wirespool to the wirefeeder with insulation.
EMC Device Clas-
sifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage grid.
EMC device classification as per the rating plate or technical data.
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g., when there is sen-
sitive 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 operating company is obliged to take appropriate action to rectify
the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance with
national and international provisions. Examples of interference-prone equipment that could
be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating

17
EN-US
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the im-
mediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Particular Hazard
Areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- fans
- gears
- rollers
- shafts
- wirespools and welding wires.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury (cuts
to the hand, facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder) and
use suitable protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective
equipment when reworking workpieces and ensure that other persons are sufficiently pro-
tected.
Leave the welding torch and other parts with a high operating temperature to cool before
working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.

18
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be la-
beled with the symbol (Safety). However, the power source may not be located in such ar-
eas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting
connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The
coolant safety data sheet can be obtained from your service center or via the manufactur-
er’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting devic-
es by crane.
- Attach chains or ropes to all designated attachments of the suitable load-carrying
equipment.
- Chains or ropes must be the smallest angle possible from vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
In the event of crane attachment of the wirefeeder during welding, always use a suitable,
insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for trans-
port by hand. The carrier belt is not suitable for transport by crane, counterbalanced lift
truck or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the de-
vice or its components, must be checked regularly (e.g. for mechanical damage, corrosion,
or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national stan-
dards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is
used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the
shielding gas connection adapter on the device side before installation.
Undesired Weld-
ing Results
The following specifications concerning shielding gas quality must be met in order to en-
sure the safe and proper function of the welding system:
- Solid particle size < 40 μm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
IMPORTANT! Ring lines in particular pose a risk of contamination.
Danger from
Shielding Gas
Cylinders
Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding
gas cylinders are an integral part of the welding equipment, so they must be handled very
carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical im-
pact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instruc-
tions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.

19
EN-US
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct
matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders
and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.
Follow the manufacturer's instructions and applicable national and international provisions
for shielding gas cylinders and accessories.
Danger Posed by
Shielding Gas
Leak
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in
the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least
20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylinder
or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the
main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas leak-
age before each start-up.
Safety Measures
at the Setup Loca-
tion and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Only set up and operate the device in accordance with the protection class shown on the
rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident pre-
vention regulations are observed when transporting the device, especially guidelines con-
cerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Before transporting the device, completely drain the coolant and dismantle the following
components:
- wirefeeder
- wirespool
- shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before commissioning. Have any damage repaired by trained service
technicians before commissioning the device.

20
Safety Measures
in Normal Opera-
tion
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by crane.
Only the original coolant from the manufacturer is suitable for use in our devices due to its
properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manufac-
turer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in cer-
tain conditions. Only transport the coolant in closed original containers and keep away from
sources of ignition.
Properly dispose of used coolant according to national and international regulations. The
coolant safety data sheet can be obtained from your service center or via the manufactur-
er’s website.
When the system is cool, always check the coolant level before starting welding.
Maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac-
turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
every 12 months.
The manufacturer recommends calibrating power sources within the same 12-month inter-
val.