FRO­NIUS MIG/MAG User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0219,EN 014-06082020
TPS/i Robotics Pull welding system
TPS/i Robotics PushPull CMT
welding system
Operating Instructions
MIG/MAG robot welding system
EN

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EN
Contents
Safety rules ................................................................................................................................................ 9
Explanation of safety notices ................................................................................................................ 9
General ................................................................................................................................................. 9
Intended use ......................................................................................................................................... 10
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 10
Mains connection.................................................................................................................................. 10
Protecting yourself and others .............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from flying sparks ..................................................................................................................... 12
Risks from mains current and welding current...................................................................................... 12
Meandering welding currents................................................................................................................ 13
EMC Device Classifications .................................................................................................................. 14
EMC measures ..................................................................................................................................... 14
EMF measures...................................................................................................................................... 14
Specific hazards.................................................................................................................................... 15
Requirement for the shielding gas ........................................................................................................ 16
Danger from shielding gas cylinders..................................................................................................... 16
Danger from escaping shielding gas..................................................................................................... 16
Safety measures at the installation location and during transport ........................................................ 17
Safety measures in normal operation ................................................................................................... 17
Commissioning, maintenance and repair.............................................................................................. 18
Safety inspection................................................................................................................................... 18
Disposal ................................................................................................................................................ 18
Safety symbols...................................................................................................................................... 18
Data protection...................................................................................................................................... 19
Copyright............................................................................................................................................... 19
Description of Warning Notices on the Device...................................................................................... 20
General information 23
System configurations - conventional robot ............................................................................................... 25
PowerDrive with wire drum ................................................................................................................... 25
PowerDrive with wire drum and external wirefeeding hose .................................................................. 26
PushPull with 4-roller unreeling wirefeeder and wire drum................................................................... 27
PushPull with 4-roller unreeling wirefeeder and wirespool .................................................................. 28
PushPull with SB 60i, 4-roller unreeling wirefeeder and wirespool....................................................... 29
PushPull with 2-roller unreeling wirefeeder, wire drum and external wirefeeding hose........................ 30
CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum............................................................. 31
CMT with SB 500i, 4-roller unreeling wirefeeder, wire drum and external wirefeeding hose................ 32
CMT with SB 60i, 4-roller unreeling wirefeeder and wirespool ............................................................. 33
System configurations - PAP ..................................................................................................................... 34
PowerDrive with wire drum ................................................................................................................... 34
PushPull with 4-roller unreeling wirefeeder and wire drum................................................................... 35
PushPull with 4-roller unreeling wirefeeder and wirespool ................................................................... 36
PushPull with 2-roller unreeling wirefeeder and wire drum................................................................... 37
PushPull with wire buffer, 4-roller unreeling wirefeeder and wire drum................................................ 38
PushPull with wire buffer, 4-roller unreeling wirefeeder and wirespool................................................. 39
PushPull with SB 500i, 4-roller unreeling wirefeeder and wire drum ................................................... 40
CMT with SB 60i, 4-roller unreeling wirefeeder and wire drum............................................................. 41
CMT with SB 500i, 4-roller unreeling wirefeeder and wire drum .......................................................... 42
CMT with SB 500i, 4-roller unreeling wirefeeder and wirespool ........................................................... 43
Interconnecting hosepack .......................................................................................................................... 44
General remarks ................................................................................................................................... 44
General ................................................................................................................................................. 44
PowerLiner................................................................................................................................................. 45
General ................................................................................................................................................. 45
WF 25i REEL R /4R, WF 30i REEL R /2R ................................................................................................. 46
Safety.................................................................................................................................................... 46

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Device concept ..................................................................................................................................... 46
Application area .................................................................................................................................... 46
Proper use ............................................................................................................................................ 46
Warning notices on the device.............................................................................................................. 47
SplitBox SB 500i R..................................................................................................................................... 49
Device concept ..................................................................................................................................... 49
Proper use ............................................................................................................................................ 49
Safety.................................................................................................................................................... 49
Warning notices on the device.............................................................................................................. 50
SplitBox SB 60i R....................................................................................................................................... 52
Device concept ..................................................................................................................................... 52
Proper use ............................................................................................................................................ 52
Safety.................................................................................................................................................... 52
Warning notices on the device.............................................................................................................. 53
PushPull hosepack .................................................................................................................................... 55
General ................................................................................................................................................. 55
Scope of supply .................................................................................................................................... 55
WF Robacta Drive...................................................................................................................................... 56
General ................................................................................................................................................. 56
Warning notices on the device.............................................................................................................. 56
CrashBox /i ................................................................................................................................................ 57
General ................................................................................................................................................. 57
Also required for installation.................................................................................................................. 57
Device concept ..................................................................................................................................... 58
Areas of utilisation................................................................................................................................. 58
Scope of supply .................................................................................................................................... 58
Robot welding torch ................................................................................................................................... 59
Safety.................................................................................................................................................... 59
General ................................................................................................................................................. 59
TPSi wire buffer ......................................................................................................................................... 60
General ................................................................................................................................................. 60
WireSense ................................................................................................................................................. 61
General ................................................................................................................................................. 61
Requirements........................................................................................................................................ 61
How it works.......................................................................................................................................... 61
WireSense - edge detection.................................................................................................................. 62
WireSense - contour detection.............................................................................................................. 63
Technical details ................................................................................................................................... 64
Controls, connections and mechanical components 65
SplitBox...................................................................................................................................................... 67
Safety.................................................................................................................................................... 67
General ................................................................................................................................................. 67
Gas test/wire threading control panel (optional) ................................................................................... 67
Control elements, connections and mechanical components of the SplitBox............................................ 69
Safety.................................................................................................................................................... 69
Control elements, connections and mechanical components............................................................... 69
SB 60i R:control elements, connections and mechanical components ................................................ 70
SB 60i R /L:control elements, connections and mechanical components ............................................ 71
SB 500i R PAP control elements, connections and mechanical components ........................................... 73
Safety.................................................................................................................................................... 73
Control elements, connections and mechanical components............................................................... 73
WF 25i Robacta Drive control panel / WF 60i Robacta Drive CMT ........................................................... 75
WF 25i Robacta Drive / WF 60i Robacta Drive CMT control panel ...................................................... 75
WF 25i REEL R /4R, WF 30i REEL R /2R ................................................................................................. 77
Safety.................................................................................................................................................... 77
Controls, connections and mechanical components............................................................................. 77
Control panel......................................................................................................................................... 79
Installation - conventional robot 81
Fitting the welding system to a conventional robot .................................................................................... 83
Safety.................................................................................................................................................... 83

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Fitting the TPS/i welding system to a conventional robot ..................................................................... 83
Optimum hosepack arrangement.......................................................................................................... 84
Fitting the SplitBox ..................................................................................................................................... 85
Fitting the wirefeeder holder ................................................................................................................. 85
Fitting the SB 500i R............................................................................................................................. 85
Fitting the SB 500i R (left variant)......................................................................................................... 85
Fitting the SB 60i R to the robot............................................................................................................ 86
Fitting the SB 60i R to the balancer ...................................................................................................... 86
Mounting the SB 60i R on the wall........................................................................................................ 87
Fitting the TPSi wire buffer......................................................................................................................... 88
Fitting the TPSi wire buffer.................................................................................................................... 88
Fitting the CrashBox /i to the robot ............................................................................................................ 89
Fitting the CrashBox /i to the robot ....................................................................................................... 89
Installing the CrashBox/i Dummy on the robot...................................................................................... 90
Preparing the WF Robacta Drive and fitting to a conventional robot ......................................................... 92
Fitting the gas-saver nozzle.................................................................................................................. 92
Fitting the hosepack to the WF Robacta Drive (conventional).............................................................. 93
Fitting the WF Robacta Drive to the CrashBox (conventional) ............................................................. 94
Fitting the inner liner inside the torch body ........................................................................................... 94
Fitting the welding torch to the WF Robacta Drive (conventional)........................................................ 96
Fitting the interconnecting hosepack ......................................................................................................... 97
Fitting the standard interconnecting hosepack to the robot .................................................................. 97
Connecting the extension hosepack..................................................................................................... 97
Connecting the SplitBox to the system components.................................................................................. 99
Safety.................................................................................................................................................... 99
General ................................................................................................................................................. 99
Connecting the SplitBox to the system components............................................................................. 99
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 100
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 101
Fitting the inner liner (unreeling wirefeeder- WF Robacta Drive with external wirefeeding hose) ........ 102
Fitting the inner liner (wire buffer - WF Robacta Drive with external wirefeeding hose) ....................... 102
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 103
Fitting the inner liner (unreeling wirefeeder - SplitBox SB60i) .............................................................. 104
Fitting the inner liner inside the torch hosepack.................................................................................... 105
Connecting the torch hosepack to the SplitBox SB 60i R..................................................................... 106
Connecting the control line to the wire buffer........................................................................................ 107
Fitting the unreeling wirefeeder.................................................................................................................. 108
Fitting the unreeling wirefeeder............................................................................................................. 108
Installation - PAP 109
Fitting the welding system to a PAP robot ................................................................................................. 111
Safety.................................................................................................................................................... 111
Fitting the TPS/i welding system to a PAP robot .................................................................................. 111
Maximum axis rotation .......................................................................................................................... 112
Fitting the SplitBox ..................................................................................................................................... 113
Fitting the SB 500i R PAP..................................................................................................................... 113
Fitting the TPSi wire buffer......................................................................................................................... 114
Fitting the TPSi wire buffer.................................................................................................................... 114
Installing the CrashBox Drive /i PAP on the robot ..................................................................................... 115
Installing the CrashBox on the robot..................................................................................................... 115
Installing the CrashBox/i Dummy on the robot...................................................................................... 116
WF Robacta Drive...................................................................................................................................... 118
Fitting the gas-saver nozzle.................................................................................................................. 118
Fitting the hosepack to the WF Robacta Drive ..................................................................................... 118
Fitting the WF Robacta Drive to the robot............................................................................................. 119
Fitting the inner liner inside the torch body ........................................................................................... 121
Fitting the welding torch to the WF Robacta Drive................................................................................ 122
Fitting the interconnecting hosepack ......................................................................................................... 124
Fitting the PAP interconnecting hosepack to the robot......................................................................... 124
Connecting the extension hosepack..................................................................................................... 125
Connecting the SplitBox to the system components.................................................................................. 126
Safety.................................................................................................................................................... 126
General ................................................................................................................................................. 126

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Connecting the SplitBox to the system components............................................................................. 126
Fitting the inner liner (unreeling wirefeeder - SplitBox SB 500i R)........................................................ 127
Fitting the inner liner (SplitBox - WF 25i with internal inner liner) ......................................................... 128
Fitting the inner liner (unreeling wirefeeder - wire buffer) ..................................................................... 129
Fitting the inner liner (wire buffer - WF Robacta Drive with internal wirefeeding hose) ........................ 130
Connecting the control line to the wire buffer........................................................................................ 130
Start-up 133
Inserting/replacing feed rollers................................................................................................................... 135
General ................................................................................................................................................. 135
4-roller drive: Inserting/replacing feed rollers........................................................................................ 135
2-roller drive: Inserting/replacing feed rollers........................................................................................ 136
Inserting/replacing the WF 25i Robacta Drive feed rollers.................................................................... 137
Inserting/replacing the WF 60i Robacta Drive CMT feed rollers........................................................... 139
Feeding in the wire electrode..................................................................................................................... 142
Insulated routing of wire electrode to wirefeeder .................................................................................. 142
Feeding in the wire electrode................................................................................................................ 142
Setting the contact pressure for the WF 25i Robacta Drive.................................................................. 143
Setting the contact pressure for the WF 60i Robacta Drive CMT......................................................... 144
Start-up ...................................................................................................................................................... 145
Requirements........................................................................................................................................ 145
General ................................................................................................................................................. 145
Troubleshooting, maintenance and disposal 147
Troubleshooting ......................................................................................................................................... 149
Safety.................................................................................................................................................... 149
Fault diagnosis...................................................................................................................................... 149
Care, maintenance and disposal ............................................................................................................... 153
General ................................................................................................................................................. 153
Safety.................................................................................................................................................... 153
Every start-up........................................................................................................................................ 153
Special care of O-rings ......................................................................................................................... 154
Whenever the welding torch or torch hosepack is changed ................................................................. 154
Changing the torch hosepack, changing the interconnecting hosepack............................................... 154
Every 6 months ..................................................................................................................................... 154
Recognising faulty wearing parts.......................................................................................................... 155
Replacing the WF 25i Robacta Drive clamping lever............................................................................ 155
Replacing the WF 60i Robacta Drive CMT clamping lever................................................................... 156
Replacing the WF Robacta Drive gas-saver nozzle ............................................................................. 156
Replacing the SB 60i R inner liner........................................................................................................ 157
Replacing the TPSi wire buffer wire guide............................................................................................ 159
Changing the direction of operation of the TPSi wire buffer ................................................................. 160
Replacing the TPSi wire buffer lever..................................................................................................... 161
Fitting wearing parts to the torch body.................................................................................................. 162
Fitting wearing parts to the torch body - MTW 700 i ............................................................................. 162
Removing the CrashBox PAP from the robot ....................................................................................... 163
Disposal ................................................................................................................................................ 164
Technical data 165
SB 500i R, R left variant, PAP ................................................................................................................... 167
SB 500i R, R left variant, PAP .............................................................................................................. 167
SB 60i R..................................................................................................................................................... 168
SB 60i R................................................................................................................................................ 168
CrashBox /i ................................................................................................................................................ 169
CrashBox /i ........................................................................................................................................... 169
PushPull hosepack .................................................................................................................................... 171
General ................................................................................................................................................. 171
Gas-cooled PushPull hosepacks .......................................................................................................... 171
Water-cooled PushPull hosepacks ....................................................................................................... 172
WF 25i Robacta Drive................................................................................................................................ 174
WF 25i Robacta Drive /G ...................................................................................................................... 174

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WF 25i Robacta Drive /W ..................................................................................................................... 174
WF 60i Robacta Drive CMT ...................................................................................................................... 175
WF 60i Robacta Drive CMT /G ............................................................................................................. 175
WF 25i Robacta Drive /W ..................................................................................................................... 175
Robot welding torch ................................................................................................................................... 176
Gas-cooled robot welding torches ........................................................................................................ 176
Water-cooled robot welding torches ..................................................................................................... 177
Interconnecting hosepacks ........................................................................................................................ 179
HP 70i ................................................................................................................................................... 179
HP 95i ................................................................................................................................................... 179
HP 120i ................................................................................................................................................. 179
HP 70i, HP PC Cable HD 70................................................................................................................. 179

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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 automated welding, and
- read and carefully follow these operating instructions as well as the operating instruc-
tions for all system components.
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 applica-
ble and local regulations regarding accident prevention and environmental 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 section headed
"General" in the operating instructions for the device.
Before commissioning the device, rectify any faults that could compromise safety.
This is for your personal safety!

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Intended use The devices and components described in these Operating Instructions are intended ex-
clusively for automated MIG/MAG applications in conjunction with Fronius components.
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 also includes:
- Carefully reading and following all the instructions given in the Operating Instructions
- Studying and obeying all safety instructions and danger notices carefully
- Performing all stipulated inspection and servicing work
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 ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age 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 section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
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 prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection 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 *)

11
EN
*) 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 matter with the power sup-
ply company.
IMPORTANT! Ensure that the mains connection is earthed properly
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 using cardi-
ac 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 reg-
ulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Keep all persons, especially children, out of the working area while any devices are in op-
eration or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from toxic
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.

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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 Association website under
Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation 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 al-
ternatively 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 accordance 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 weld-
ing 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 wirespool, 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 cov-
er 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 dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.

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EN
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 touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding elec-
trodes of two power sources. Touching the potentials of both electrodes 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.
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 with-
out ground conductor contact is only permitted if all national regulations for protective sep-
aration 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 any-
one 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, appoint a second person to switch off the main switch at
the right moment.
Meandering weld-
ing currents
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable 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 environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode 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.

14
In the case of automated MIG/MAG applications, ensure that only an insulated wire elec-
trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wire-
feeder.
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 mains.
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 operator is obliged to take appropriate action to rectify the situ-
ation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interfer-
ence from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the de-
vice or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body

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EN
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with wire-feed unit)
and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting cool-
ant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The cool-
ant safety data sheet may be obtained from your service centre or downloaded from the
manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or chang-
es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.

16
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
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 cyl-
inders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan-
ical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylin-
ders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Danger from es-
caping shielding
gas
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox-
ygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage be-
fore every start-up.

17
EN
Safety measures
at the installation
location and dur-
ing transport
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before com-
missioning the device.
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 risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its prop-
erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system com-
ponents or a different coolant. In addition, all warranty claims will be forfeited.

18
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
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 is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-
month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and di-
rectives.
Further details on safety inspection and calibration can be obtained from your service cen-
tre. They will provide you on request with any documents you may require.
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
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 se-
ries).

19
EN
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of 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.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba-
sis 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 instructions, we will
be most grateful for your comments.

20
Description of
Warning Notices
on the Device
On certain device versions, warning notices are attached to the device.
The arrangement of the symbols may vary.
Warning! Watch Out!
There are possible hazards as shown by the symbols.
A Drive rolls can injure fingers.
B Welding wire and drive parts are at welding voltage during operation
Keep hands and metal objects away.
1. Electric shock can kill.
1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear
wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating yourself from work and ground.
1.3 Disconnect input plug or power before working on machine
2. Breathing welding fumes can be hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.
AB