FRO­NIUS VW AG/VAS 821 001/MIG270i User manual

VW AG/VAS 821 001/MIG270i
EN-US
MIG/MAG Power source
Operating Instructions
VOLKSWAGEN
AKTIENGESELLSCHAFT
42,0426,0347,EA 015-18112020

Table of contents
Safety Instructions 7
Explanation of Safety Instructions 7
General 7
Intended Use 7
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 8
Residual current circuit breaker 9
Personal Protection and Protection of Others 9
Data regarding Noise Emission Values 10
Danger from toxic gases and vapors 10
Danger from Flying Sparks 10
Risks from grid current and welding current 11
Stray welding currents 12
EMC Device Classifications 12
EMC Measures 12
EMF measures 13
Particular Hazard Areas 13
Requirement for the shielding gas 14
Danger from Shielding Gas Cylinders 14
Danger Posed by Shielding Gas Leak 15
Safety Measures at the Setup Location and During Transport 15
Safety Measures in Normal Operation 16
Maintenance and repair 16
Safety Inspection 16
Disposal 17
Data backup 17
Copyright 17
General information 19
General 21
Device concept 21
Functional principle 21
Application areas 21
Warning notices on the device 22
Description of Warning Notices on the Device 24
Welding packages, welding characteristics and welding processes 26
General 26
Welding characteristics 26
Summary of MIG/MAG pulse synergic welding 28
Summary of MIG/MAG standard synergic welding 28
Summary of the PMC process 29
Summary of the LSC process 29
Summary of SynchroPulse welding 29
Summary of the CMT process 30
System components 31
General 31
Overview 31
Operating controls, connections and mechanical components 33
Control Panel 35
General 35
Safety 35
Control panel 35
Displaying plain text for parameters 40
F1/F2 special function parameters, Favourites button 41
F1 and F2 special function parameters 41
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The Favourites button 42
Connections, Switches, and Mechanical Components 45
Connections, switches and mechanical components 45
Installation and Startup 47
Minimum equipment for welding operations 49
General 49
MIG/MAG gas-cooled welding 49
Manual CMT welding 49
TIG DC welding 49
MMA welding 49
Before installation and initial operation 50
Safety 50
Intended Use 50
Setup regulations 50
Mains connection 50
Generator-Powered Operation 51
Information on system components 51
Connecting the Mains Cable 52
Safety 52
General 52
Stipulated mains cables 52
Connecting the mains cable - general 52
Commissioning 55
Safety 55
General 55
Connecting the gas cylinder 55
Establishing a ground earth connection 56
Connecting the welding torch 56
Inserting/replacing feed rollers 57
Inserting the wirespool 58
Inserting the basket-type spool 59
Feeding in the wire electrode 60
Setting the contact pressure 61
Adjusting the brake 62
Design of the Brake 62
Performing R/L alignment 63
Welding Mode 65
MIG/MAG Operating Modes 67
General 67
Symbols and their explanations 67
2-step mode 68
4-step mode 68
Special 4-step mode 68
Special 2-step mode 68
MIG/MAG and CMT welding 69
Safety 69
MIG/MAG and CMT welding – overview 69
Switching on the power source 69
Setting the welding process and operating mode 69
Retrieving the currently set filler metal 70
Selecting the filler metal 70
Setting the welding parameters 72
Setting the shielding gas flow rate 72
MIG/MAG or CMT welding 73
MIG/MAG and CMT welding parameters 74
Welding parameters for MIG/MAG pulse synergic welding, for CMT welding and PMC welding 74
Welding parameters for MIG/MAG standard synergic welding and LSC welding 75
Welding parameters for MIG/MAG standard manual welding 77
Explanation of footnotes 78
4

EasyJob mode 79
General 79
EasyJob mode 79
Spot welding 80
Spot welding 80
TIG welding 82
Safety 82
Preparations 82
TIG welding 82
Igniting the arc 84
Finishing welding 84
Manual Metal Arc Welding 85
Safety 85
Preparations 85
MMA welding 85
Welding parameters for manual metal arc welding 87
Setup Settings 89
Setup menu - overview 91
Entering/exiting the Setup menu 91
Setup menu - overview 92
Process parameters 93
Process parameters for start of welding/end of welding 93
Process parameters for Gas-Setup 94
Process parameters for process control 95
Penetration stabilizer 95
Arc length stabilizer 97
Combination of penetration stabilizer and arc length stabilizer 99
Process parameters for spot welding 100
Process parameters for monitoring and components 100
Process parameters for electrode setup 101
Process parameters for TIG setup 104
Process parameters for SynchroPulse 105
Process parameters for Process Mix 107
R/L alignment 109
Settings 111
General 111
Overview 111
Setting the units 111
Setting the standards 112
Setting the display brightness 112
Displaying replaced characteristics 112
Setting F1 and F2 special function parameters via the Setup menu 112
Setting the Favourites button via the Setup menu 113
Retrieving system data 113
Setting the interior lighting 114
Restoring the factory settings 115
Resetting the password for the power source website 115
Retrieving device information 115
Setting the special display for JobMaster 115
Setting the mode for spot welding 116
Setting the language 117
Setting the language 117
Keylock 118
Keylock 118
Troubleshooting and Maintenance 119
The Error menu 121
The Error menu 121
Troubleshooting 122
General 122
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Safety 122
Power Source Troubleshooting 122
Service, maintenance and disposal 126
General 126
Safety 126
At every start-up 126
If necessary 126
Every 2 months 126
Every 6 months 126
Disposal 126
Technical data 127
Average consumption values during welding 129
Average wire electrode consumption during MIG/MAG welding 129
Average shielding gas consumption during MIG/MAG welding 129
Average shielding gas consumption during TIG welding 129
Technical data 130
Explanation of the Term Duty Cycle 130
Special Voltage 130
VW AG/VAS 821 001/MIG270i 131
VW AG/VAS 821 001/MIG270i MV 133
Overview with critical raw materials, year of production of the device 134
Appendix 135
VW AG/VAS 821 001/MIG270i 136
6

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.
General The device has been manufactured using state-of-the-art technology and according to
recognized 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
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.
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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
accordance 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.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance 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.)
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
"Safety 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 con-
firm 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.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
rent consumption.
8

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!
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
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.
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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 influenced 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 environment, and many other factors.
Danger from
toxic gases and
vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that 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 that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow
rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the
measured 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
- The welding process used
Consult the corresponding material safety data sheets and manufacturer's instructions
for the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-
tected with a certified cover.
10

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 weld-
ing current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers, 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
insulation 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 dimen-
sioned 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.
Protection class I devices require a grid with a ground conductor and a connector system
with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket without a
ground conductor contact is only permitted if all national regulations for protective separ-
ation are observed.
Otherwise, this 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 neces-
sary.
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.
Position the device with sufficient insulation against electrically conductive environments,
e.g., insulation against electrically conductive floors or electrically conductive mounts.
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
holder 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
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 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
12

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
immediate 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
protected.
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.
13
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Power sources for work in areas with increased electrical hazard (e.g. boilers) must be
labeled with the symbol (Safety). However, the power source may not be located in such
areas.
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 manufac-
turer’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting
devices 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
transport 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
device or its components, must be checked regularly (e.g. for mechanical damage, cor-
rosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national stand-
ards 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.
Requirement for
the shielding gas
Especially with ring lines, contaminated shielding gas can cause damage to equipment
and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
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
impact, 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.
14

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 cylin-
ders 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 connec-
ted.
Follow the manufacturer's instructions and applicable national and international provi-
sions 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 cylin-
der 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
leakage before each start-up.
Safety Measures
at the Setup Loc-
ation 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 work-
place 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
prevention regulations are observed when transporting the device, especially guidelines
concerning 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 ser-
vice technicians before commissioning the device.
15
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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 manu-
facturer 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
certain 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 manufac-
turer’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 manu-
facturer'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
interval.
16

A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your
service center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as
national law, electrical equipment that has reached the end of its life must be collected
separately and returned to an approved recycling facility. Any device that you no longer
require must be returned to your dealer, or you must locate the approved collection and
recycling facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!
Data backup The user is responsible for backing up any changes made to the factory settings. The
manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the right to
make changes. The contents of the Operating Instructions shall not provide the basis for
any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the Operating
Instructions, we will be most grateful for your comments.
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EN-US

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General information
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