FRO­NIUS Ignis 150 User manual

Operating
Instructions
Ignis 150
Ignis 180
42,0426,0512,EN 001-13112023
EN Operating Instructions

Contents
Safety rules 5
Explanation of safety notices 5
General 5
Proper use 6
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Mains connection 7
Residual current protective device 7
Protecting yourself and others 7
Noise emission values 8
Danger from toxic gases and vapours 8
Danger from flying sparks 9
Risks from mains current and welding current 9
Meandering welding currents 10
EMC Device Classifications 10
EMC measures 11
EMF measures 11
Specific hazards 11
Requirement for the shielding gas 12
Danger from shielding gas cylinders 13
Safety measures at the installation location and during transport 13
Safety measures in normal operation 14
Commissioning, maintenance and repair 14
Safety inspection 15
Disposal 15
Safety symbols 15
Data protection 16
Copyright 16
General 17
Device concept 17
Warning notices on the device 17
Application areas 18
Before commissioning 19
Safety 19
Intended use 19
Setup regulations 19
Generator-powered operation 20
Controls, connections and mechanical components 21
Safety 21
Ignis 150 controls, connections and mechanical components 22
Ignis 180 controls, connections and mechanical components 23
Control panel 24
MMA welding 26
Preparation 26
MMA welding 27
SoftStart / HotStart function 27
Arc-force dynamic 28
Pulse welding 29
TIG welding 31
General 31
Connecting the gas cylinder 31
Preparation 31
Setting the gas pressure on the welding torch with gas cut-off valve 33
TIG welding 33
TIG Comfort Stop 33
Welding process Setup menu 36
Accessing the Setup menu 36
Changing welding parameters 36
Exiting the Setup menu 36
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Parameters for MMA welding 36
Parameters for TIG welding 38
Setup menu - Level 2 39
Welding parameters in the level 2 Setup menu 39
Care, maintenance and disposal 41
Safety 41
General 41
Maintenance at every start-up 41
Maintenance every 2 months 42
Disposal 42
Troubleshooting 43
Safety 43
Indicated errors 43
Service messages 43
No function 45
Faulty operation 46
Average consumption values during welding 48
Average wire electrode consumption during MIG/MAG welding 48
Average shielding gas consumption during MIG/MAG welding 48
Average shielding gas consumption during TIG welding 48
Technical data 49
Explanation of the term "duty cycle" 49
Ignis 150 49
Ignis 180 50
Ignis 180 MV 51
Overview with critical raw materials, year of production of the device 53
4

Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
-injury or death to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the
device must:
-be suitably qualified,
-have sufficient knowledge of welding and
-read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device
-must be in a legible state,
-must not be damaged,
-must not be removed,
-must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
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Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use includes:
-carefully reading and following all the instructions given in the operating in-
structions
-studying and obeying all safety and danger notices carefully
-performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
-Thawing out pipes
-Charging batteries
-Starting engines
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic set-
ting.
The manufacturer likewise accepts no liability for inadequate or incorrect 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 shall not be held
liable for any damage arising from such usage.
Ambient temperature range:
-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)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the operator
The operator must only allow persons to work with the device who:
-are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
-have read and understood these operating instructions, especially the sec-
tion "safety rules", and have confirmed as much with their signatures
-are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
-to observe the basic instructions regarding safety at work and accident pre-
vention
-to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
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Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Mains connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number device types in terms of:
-Connection restrictions
-Criteria with regard to the maximum permissible mains impedance *)
-Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Residual current
protective
device
Local regulations and national guidelines may require a residual current protect-
ive device when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufac-
turer for the equipment is indicated in the technical data.
Protecting your-
self and others
Anyone working with the device exposes 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 us-
ing cardiac pacemakers
-Risk of electrocution from mains current and welding current
-Greater noise pollution
-Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have 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:
-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 protect-
ive 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 in-
jury
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Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi-
cinity:
-Make them aware of all the dangers (risk of dazzling by the arc, injury from
flying sparks, harmful welding fumes, noise, possible risks from mains cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
Noise emission
values
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 work-
piece, the workplace environment, etc.
Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
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. Ensure that there is a ventilation rate of
at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:
-Metals used for the workpiece
-Electrodes
-Coatings
-Cleaners, degreasers, etc.
-Welding process used
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
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Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
Danger from fly-
ing sparks
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) 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 injury 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 accord-
ance 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.
Risks from mains
current and
welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the
feed rollers and all pieces of metal that are in contact with the welding wire are
live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable,
insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
base or cover for the earth or ground potential. This base or cover must extend
over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around 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 the welding system is switched on.
Double the open circuit voltage of a welding system can occur between the weld-
ing electrodes of two welding systems. Touching the potentials of both elec-
trodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to
ensure the ground conductor is functioning properly.
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Protection class I devices require a mains supply with ground conductor and a
connector system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a
socket without ground conductor contact is only permitted if all national regula-
tions for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be
held liable for any damage arising from such usage.
If necessary, provide adequate earthing 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 plugging the mains plug back in and switching it on again.
After opening the device:
-Discharge all live components
-Ensure that all components in the device are de-energised.
If work on live parts is required, have a second person switch off the main switch
at the right moment.
Meandering
welding currents
If the following instructions are ignored, meandering welding currents can devel-
op with the following consequences:
-Fire hazard
-Overheating of parts connected to the workpiece
-Damage to ground 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 welded.
Position the device with sufficient insulation against electrically conductive envir-
onments, such as insulation against conductive floor or insulation to conductive
racks.
If power distribution boards, twin-head mounts, etc., are being used, note the fol-
lowing: 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 wirefeeder.
EMC Device
Classifications
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 mains.
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