FRO­NIUS TPS 320i User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0114,EN 025-11012018
TPS 320i / 400i / 500i / 600i
TPS 400i LSC ADV
Operating Instructions
MIG/MAG Power source
EN

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

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EN
Contents
Safety rules ................................................................................................................................................ 11
Explanation of safety symbols .............................................................................................................. 11
General ................................................................................................................................................. 11
Proper use ............................................................................................................................................ 12
Mains connection.................................................................................................................................. 12
Environmental conditions...................................................................................................................... 12
Obligations of the operator.................................................................................................................... 13
Obligations of personnel ....................................................................................................................... 13
Residual current protective device........................................................................................................ 13
Protecting yourself and others .............................................................................................................. 13
Noise emission values .......................................................................................................................... 14
Danger from toxic gases and vapours .................................................................................................. 14
Danger from flying sparks..................................................................................................................... 15
Risks from mains current and welding current...................................................................................... 15
Meandering welding currents................................................................................................................ 16
EMC Device Classifications.................................................................................................................. 16
EMC measures ..................................................................................................................................... 17
EMF measures...................................................................................................................................... 17
Specific hazards.................................................................................................................................... 17
Factors affecting welding results........................................................................................................... 19
Danger from shielding gas cylinders..................................................................................................... 19
Danger from escaping shielding gas..................................................................................................... 19
Safety measures at the installation location and during transport ........................................................ 20
Safety measures in normal operation ................................................................................................... 20
Commissioning, maintenance and repair.............................................................................................. 21
Safety inspection................................................................................................................................... 21
Disposal ................................................................................................................................................ 21
Safety symbols...................................................................................................................................... 22
Data protection...................................................................................................................................... 22
Copyright............................................................................................................................................... 22
General information 23
General ...................................................................................................................................................... 25
Device concept ..................................................................................................................................... 25
Functional principle............................................................................................................................... 25
Application areas .................................................................................................................................. 25
FCC Compliance................................................................................................................................... 26
Warning notices on the device.............................................................................................................. 26
Welding processes, procedures and welding characteristics for MIG/MAG welding ................................. 28
General ................................................................................................................................................. 28
Welding characteristics......................................................................................................................... 28
Summary of MIG/MAG pulse synergic welding .................................................................................... 29
Summary of MIG/MAG standard synergic welding............................................................................... 29
Summary of the PMC process.............................................................................................................. 30
Summary of the LSC / LSC Advanced process.................................................................................... 30
Summary of SynchroPulse welding ...................................................................................................... 30
Summary of the CMT process .............................................................................................................. 30
System components .................................................................................................................................. 31
General ................................................................................................................................................. 31
Overview............................................................................................................................................... 31
Options.................................................................................................................................................. 31
OPT/i Safety Stop PL d option.............................................................................................................. 32
Controls, connections and mechanical components 35
Control panel.............................................................................................................................................. 37
General ................................................................................................................................................. 37
Safety.................................................................................................................................................... 37
Control panel......................................................................................................................................... 37

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Connections, switches and mechanical components ................................................................................39
TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV power source.......................................................... 39
Operating concept 41
Input options .............................................................................................................................................. 43
General ................................................................................................................................................. 43
Turning/pressing the adjusting dial ....................................................................................................... 43
Pressing buttons ................................................................................................................................... 44
Pressing on the display......................................................................................................................... 44
Display and status line ............................................................................................................................... 45
Display .................................................................................................................................................. 45
Status bar.............................................................................................................................................. 46
Status bar – Current limit reached ........................................................................................................ 46
Installation and commissioning 47
Minimum equipment needed for welding task............................................................................................ 49
General ................................................................................................................................................. 49
MIG/MAG gas-cooled welding .............................................................................................................. 49
MIG/MAG water-cooled welding ........................................................................................................... 49
MIG/MAG automated welding............................................................................................................... 49
Manual CMT welding ............................................................................................................................ 49
Automated CMT welding....................................................................................................................... 50
TIG DC welding..................................................................................................................................... 50
MMA welding ........................................................................................................................................ 50
Before installation and commissioning....................................................................................................... 51
Safety.................................................................................................................................................... 51
Proper use ............................................................................................................................................ 51
Setup regulations.................................................................................................................................. 51
Mains connection.................................................................................................................................. 51
Generator-powered operation............................................................................................................... 52
Information on system components...................................................................................................... 52
Connecting the mains cable....................................................................................................................... 53
General ................................................................................................................................................. 53
Stipulated mains cables........................................................................................................................ 53
Connecting the mains cable - general .................................................................................................. 54
Commissioning the TPS 320i / 400i / 500i / 600i, TPS 400i LSC ADV ...................................................... 56
Safety.................................................................................................................................................... 56
General ................................................................................................................................................. 56
TPS 320i / 400i / 500i / 600i: Fitting the system components (overview) ............................................. 57
TPS 400i LSC ADV: Fitting the system components (overview) .......................................................... 58
Fixing the strain-relief device for the interconnecting hosepack ........................................................... 59
Connecting the interconnecting hosepack............................................................................................ 59
Correct arrangement of the interconnecting hosepack......................................................................... 60
Connecting the gas cylinder.................................................................................................................. 61
Establishing a ground earth connection................................................................................................ 61
Connecting MIG/MAG welding torches to the wire-feed unit ................................................................ 62
Other tasks............................................................................................................................................ 63
Locking and unlocking the power source using the NFC key .................................................................... 64
General remarks ................................................................................................................................... 64
Locking and unlocking the power source using the NFC key ............................................................... 64
Welding 65
MIG/MAG 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

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MIG/MAG and CMT welding – overview............................................................................................... 69
Switching on the power source............................................................................................................. 69
Setting the welding process and operating mode.................................................................................70
Selecting the filler metal and shielding gas........................................................................................... 71
Setting the welding parameters ............................................................................................................ 72
Setting the shielding gas flow rate ........................................................................................................ 73
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............................................................... 76
Explanation of footnotes ....................................................................................................................... 76
EasyJob mode ........................................................................................................................................... 77
General ................................................................................................................................................. 77
Activating EasyJob mode...................................................................................................................... 77
Storing EasyJob operating points ......................................................................................................... 78
Retrieving EasyJob operating points .................................................................................................... 78
Deleting EasyJob operating points ....................................................................................................... 79
Job mode ................................................................................................................................................... 80
General ................................................................................................................................................. 80
Storing settings as a job........................................................................................................................ 80
Job welding - retrieving a job ................................................................................................................ 81
Renaming a job..................................................................................................................................... 82
Deleting a job........................................................................................................................................ 83
Loading a job ........................................................................................................................................ 84
Optimising a job .................................................................................................................................... 85
Setting correction limits for a job........................................................................................................... 86
Pre-settings for "Save as Job" .............................................................................................................. 88
TIG welding................................................................................................................................................ 90
Safety.................................................................................................................................................... 90
Preparations.......................................................................................................................................... 90
TIG welding........................................................................................................................................... 91
Igniting the arc ...................................................................................................................................... 93
Finishing welding .................................................................................................................................. 94
MMA welding ............................................................................................................................................. 95
Safety.................................................................................................................................................... 95
Preparations.......................................................................................................................................... 95
MMA welding ........................................................................................................................................ 96
Welding parameters for manual metal arc welding............................................................................... 98
Process parameters................................................................................................................................... 99
Overview - Process parameters, Common........................................................................................... 99
Overview – components and monitoring process parameters.............................................................. 99
Overview – Process parameters, Job................................................................................................... 99
Process parameters, General .................................................................................................................... 100
Process parameters for start of welding/end of welding ....................................................................... 100
Process parameters for gas setup........................................................................................................ 102
Process parameters for process control ............................................................................................... 103
Penetration stabiliser ............................................................................................................................ 103
Arc length stabilizer............................................................................................................................... 105
Combination of penetration stabiliser and arc length stabiliser............................................................. 106
R/L-check / alignment ........................................................................................................................... 107
Process parameters for TIG / MMA/SMAW Setup................................................................................ 108
Process parameters for SynchroPulse ................................................................................................. 112
Process parameters for Process mix.................................................................................................... 114
Components and monitoring process parameters ..................................................................................... 117
Process parameters for components.................................................................................................... 117
System calibration................................................................................................................................. 118
Setting process parameters for arc break monitoring........................................................................... 119
Process parameters for wire stick contact tip ....................................................................................... 121
Process parameters for wire stick work piece....................................................................................... 122
Process parameter for wire end monitoring.......................................................................................... 123
Process parameters, Job ........................................................................................................................... 125
Optimising job process parameters ...................................................................................................... 125
Process parameters for correction limits............................................................................................... 127

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Process parameters for "Save as Job" pre-settings ............................................................................. 128
Defaults 131
Defaults...................................................................................................................................................... 133
General remarks ................................................................................................................................... 133
Overview............................................................................................................................................... 133
Defaults - view ........................................................................................................................................... 134
Setting the language............................................................................................................................. 134
Setting Units/Standards ........................................................................................................................ 135
Setting the date and time...................................................................................................................... 136
Retrieving system data ......................................................................................................................... 137
Displaying characteristics ..................................................................................................................... 139
Defaults - System....................................................................................................................................... 140
Retrieving device information................................................................................................................ 140
Restoring factory settings ..................................................................................................................... 140
Restoring the website password........................................................................................................... 141
Mode Setup: Activating the special 4-step mode "Guntrigger", special display for JobMaster and torch
trigger job selection............................................................................................................................... 142
Setting network parameters manually................................................................................................... 144
Power source configurations................................................................................................................. 145
Defaults - Documentation .......................................................................................................................... 147
Setting the sampling rate ...................................................................................................................... 147
Viewing the logbook.............................................................................................................................. 148
Activate/deactivate limit value monitoring............................................................................................. 149
Defaults - Administration............................................................................................................................ 150
General remarks ................................................................................................................................... 150
Explanation of terms used .................................................................................................................... 150
Pre-defined roles and users.................................................................................................................. 150
Overview............................................................................................................................................... 151
Administrator and creating roles ................................................................................................................ 152
Recommendation for creating roles and users ..................................................................................... 152
Create administrator key....................................................................................................................... 152
Creating roles........................................................................................................................................ 154
Copy roles............................................................................................................................................. 157
Creating a user .......................................................................................................................................... 159
Creating a user ..................................................................................................................................... 159
Copying users....................................................................................................................................... 160
Editing roles / users, deactivating user management ................................................................................ 162
Editing roles .......................................................................................................................................... 162
Deleting roles........................................................................................................................................ 163
Editing users ......................................................................................................................................... 164
Deleting users....................................................................................................................................... 166
Deactivating user management ............................................................................................................ 167
SmartManager - The power source website 169
SmartManager - The power source website .............................................................................................. 171
General remarks ................................................................................................................................... 171
Calling up the power source SmartManager......................................................................................... 171
Logging on - unlocking function, forgotten password............................................................................ 172
Changing password / logging off........................................................................................................... 172
Settings................................................................................................................................................. 173
Language selection............................................................................................................................... 173
Status indicator ..................................................................................................................................... 174
Fronius.................................................................................................................................................. 174
Current system data................................................................................................................................... 175
Current system data.............................................................................................................................. 175
Documentation........................................................................................................................................... 176
Documentation...................................................................................................................................... 176
Job-Data .................................................................................................................................................... 177
Job data ................................................................................................................................................ 177
Job overview......................................................................................................................................... 177
Editing a job .......................................................................................................................................... 177

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EN
Importing a job ...................................................................................................................................... 178
Exporting a job...................................................................................................................................... 178
Exporting job(s) as… ............................................................................................................................ 178
Power source settings................................................................................................................................ 179
Power source settings........................................................................................................................... 179
Backup & Restore ...................................................................................................................................... 180
General remarks ................................................................................................................................... 180
Backup & Restore................................................................................................................................. 180
Automatic backup ................................................................................................................................. 181
User management ..................................................................................................................................... 182
User management ................................................................................................................................ 182
Signal visualisation .................................................................................................................................... 183
Signal visualisation ............................................................................................................................... 183
Overview .................................................................................................................................................... 184
Overview............................................................................................................................................... 184
Expand all groups / Reduce all groups ................................................................................................. 184
Save as XML-file................................................................................................................................... 184
Update ....................................................................................................................................................... 185
Update .................................................................................................................................................. 185
Searching for an update file (performing the update) ........................................................................... 185
Fronius WeldConnect ........................................................................................................................... 186
Function Packages .................................................................................................................................... 187
Function Packages ............................................................................................................................... 187
Welding Packages ................................................................................................................................ 187
Special characteristics .......................................................................................................................... 187
Options.................................................................................................................................................. 187
Installing a function package................................................................................................................. 187
Synergic lines overview ............................................................................................................................. 188
Characteristics overview....................................................................................................................... 188
Show /hide filter .................................................................................................................................... 188
Screenshot................................................................................................................................................. 189
Screenshot............................................................................................................................................ 189
Interface ..................................................................................................................................................... 190
Interface................................................................................................................................................ 190
Troubleshooting and maintenance 191
Troubleshooting ......................................................................................................................................... 193
General ................................................................................................................................................. 193
Safety.................................................................................................................................................... 193
MIG/MAG welding – Current limit ......................................................................................................... 193
Power source troubleshooting .............................................................................................................. 193
Care, maintenance and disposal ............................................................................................................... 197
General ................................................................................................................................................. 197
Safety.................................................................................................................................................... 197
At every start-up.................................................................................................................................... 197
Every 2 months..................................................................................................................................... 197
Every 6 months..................................................................................................................................... 197
Updating firmware................................................................................................................................. 197
Disposal ................................................................................................................................................ 197
Appendix 199
Technical data............................................................................................................................................ 201
Explanation of the term "duty cycle" ..................................................................................................... 201
Special voltages.................................................................................................................................... 201
TPS 320i ............................................................................................................................................... 202
TPS 320i /nc ......................................................................................................................................... 203
TPS 320i /600V/nc................................................................................................................................ 204
TPS 320i /MV/nc................................................................................................................................... 205
TPS 400i ............................................................................................................................................... 206
TPS 400i /nc ......................................................................................................................................... 207
TPS 400i /600V/nc................................................................................................................................ 208
TPS 400i /MV/nc................................................................................................................................... 209

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TPS 400i LSC ADV............................................................................................................................... 210
TPS 400i LSC ADV /nc....................................................................................................................... 211
TPS 400i LSC ADV /600V/nc.............................................................................................................. 212
TPS 400i LSC ADV /MV/nc................................................................................................................. 213
TPS 500i ............................................................................................................................................... 214
TPS 500i /nc ......................................................................................................................................... 215
TPS 500i /600V/nc................................................................................................................................ 216
TPS 500i /MV/nc................................................................................................................................... 217
TPS 600i ............................................................................................................................................... 218
TPS 600i /nc ......................................................................................................................................... 219
TPS 600i /600V/nc................................................................................................................................ 220
Spare parts list: TPS 320i / 400i / 500i / 600i............................................................................................ 221

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EN
Safety rules
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
General
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operat-
ing company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be 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 switching on the device, rectify any faults that could compromise safe-
ty.
This is for your personal safety!

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Proper use
Mains connection
Environmental
conditions
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 manufac-
turer 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
instructions
- 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 manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device 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
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
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 sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

13
EN
Obligations of the
operator
Obligations of
personnel
Residual current
protective device
Protecting your-
self and others
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.
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.
Local regulations and national guidelines may require a residual current pro-
tective 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.
RCD
Persons involved with welding expose themselves to numerous risks, e.g.:
- flying sparks and hot pieces of metal
- arc radiation, which can damage eyes and skin
- hazardous electromagnetic fields, which can endanger the lives of those
using cardiac pacemakers
- risk of electrocution from mains current and welding current
- greater noise pollution
- harmful welding fumes and gases
Anyone working on the workpiece while welding is in progress must wear suit-
able protective clothing with the following properties:
- flame-resistant
- insulating and dry
- covers the whole body, is undamaged and in good condition
- safety helmet
- trousers with no turn-ups

14
Noise emission
values
Danger from toxic
gases and va-
pours
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 protec-
tive visor.
- wear stout footwear that provides insulation even in wet conditions.
- protect the hands with suitable gloves (electrically insulated and providing
protection against heat).
- wear ear protection to reduce the harmful effects of noise and to prevent
injury.
Keep all persons, especially children, out of the working area while any devic-
es are in operation or welding is in progress. If, however, there are people in
the vicinity,
- make them aware of all the dangers (risk of dazzling by the arc, injury
from flying sparks, harmful welding fumes, noise, possible risks from
mains current and welding current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/
hour.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
ing place.
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.
Amongst others, the following components are responsible for the degree of
toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.

15
EN
Danger from fly-
ing sparks
Risks from mains
current and weld-
ing current
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (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 in-
jury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in ac-
cordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
An electric shock is 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 suit-
able, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Replace loose connections and scorched, damaged or inade-
quately 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 pre-load.
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 electrodes of two power sources. 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.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.

16
Meandering weld-
ing currents
EMC Device Clas-
sifications
Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from 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.
If the following instructions are ignored, meandering welding currents can de-
velop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to 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 weld-
ed.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
Devices 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 sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.

17
EN
EMC measures
EMF measures
Specific hazards
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rec-
tify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference 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 connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
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
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.

18
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 al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources 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 discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling cool-
ant. The coolant 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 de-
vices).
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, coun-
terbalanced 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 changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
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 Tef-
lon tape.

19
EN
Factors affecting
welding results
Danger from
shielding gas cyl-
inders
Danger from es-
caping shielding
gas
The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Shielding gas cylinders contain gas under pressure and can explode if dam-
aged. As the shielding gas cylinders are part of the welding equipment, they
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instruc-
tions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only
use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.
The manufacturer's instructions must be observed as well as applicable na-
tional and international regulations for shielding gas cylinders and accesso-
ries.
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place the oxygen 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 cylin-
der 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 before every start-up.

20
Safety measures
at the installation
location and dur-
ing transport
Safety measures
in normal opera-
tion
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 protec-
tion 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 guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising 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 dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safe-
ty 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 func-
tioning 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 properties (electrical conductibility, anti-freeze agent, material com-
patibility, 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 components or a different coolant. In addition, all warranty claims will
be forfeited.