FRO­NIUS TPS/i Push User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
TPS/i Robotics welding system
Push
EN
Operating instructions
MIG/MAG robot welding system
42,0426,0183,EN 019-31032021

Contents
Safety rules 7
Explanation of safety notices 7
General 7
Intended use 8
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 8
Protecting yourself and others 9
Danger from toxic gases and vapours 9
Danger from flying sparks 10
Risks from mains current and welding current 10
Meandering welding currents 11
EMC Device Classifications 12
EMC measures 12
EMF measures 12
Specific hazards 13
Requirement for the shielding gas 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 14
Safety measures at the installation location and during transport 15
Safety measures in normal operation 15
Commissioning, maintenance and repair 16
Safety inspection 16
Disposal 16
Safety symbols 17
Data protection 17
Copyright 17
Description of the warning notices on the device 18
System configurations 21
System configurations - conventional robot 23
Push with wire drum 23
Push with wirespool 24
Push with 4-roller unreeling wirefeeder and wire drum 25
System configurations - PAP 26
Push with wire drum 26
Push with wirespool 27
Push with 4-roller unreeling wirefeeder and wire drum 28
System components 29
WF wire-feed unit 31
Device concept 31
Proper use 31
Safety 31
Warning notices on the device 32
WF 25i REEL R /4R, WF 30i REEL R /2R 34
Safety 34
Device concept 34
Application area 34
Proper use 34
Warning notices on the device 34
Interconnecting hosepack 37
General 37
Torch hosepack 38
General remarks 38
Scope of supply 38
Buttons on the Robacta MHP hosepack 38
CrashBox /i 39
3
EN

General remarks 39
Also required for installation 39
Device concept 39
Application areas 40
Information on repairing CrashBoxes 40
Scope of supply 40
Clamp system scope of supply and options 41
Robot welding torch 42
Safety 42
General 42
Controls, connections and mechanical components 43
Control elements and mechanical components 45
Safety 45
Control elements and mechanical components 45
Gas test/wire threading control panel (optional) 45
WF 15i / 25i / 30i R 48
WF 15i R, WF 30i R connections 48
WF 30i R / L connections 48
WF 25i R connections 49
WF 25i R / L connections 50
WF 15i / 25i / 30i R PAP 51
WF 15i R PAP, WF 30i R PAP connections 51
WF 25i R PAP connections 51
WF 25i R / L PAP connections 52
WF 25i REEL R /4R, WF 30i REEL R /2R 53
Safety 53
Controls, connections and mechanical components 53
Control panel 55
Installation - conventional robot 59
Fitting the welding system to a conventional robot 61
Safety 61
Fitting the TPS/i welding system to a conventional robot 61
Fitting the wire-feed unit 62
Fitting the wirefeeder holder 62
Fitting the wirefeeder 62
Fitting the CrashBox /i to the robot 64
Fitting the CrashBox /i to the robot 64
Installing the CrashBox/i Dummy on the robot 65
Fitting the clamp system 67
Special tilt angle for the welding torch 67
Fitting the clamp system 68
Fitting the clamp system with extension 68
Fitting the MHP G / W hosepack 69
Fitting the MHP G / W conventional hosepack - Standard 69
Optimum hosepack arrangement 69
Fitting the TPS/i torch neck 70
Safety 70
Fitting the TPS/i torch body - Standard 70
“OPT / i MHP WireBrake” option 70
Fitting the inner liner inside the torch hosepack 71
Fitting the interconnecting hosepack 73
Fitting the Standard interconnecting hosepack to the robot 73
Connecting the extension hosepack 73
Connecting the MHP W hosepack 75
Connecting the MHP W hosepack 75
Connecting wire-feed unit to system components 78
Safety 78
General 78
Connecting the wirefeeder to the system components 78
4

Fitting the OPT / i MHP WireBrake and torch body 81
Safety 81
Prerequisites for operation 81
Compressed air supply specifications 81
Remedying the clamping marks on the wire electrode 81
Technical data 82
Fitting the OPT/i MHP WireBrake 82
Removing the OPT / i MHP WireBrake and torch body 84
Safety 84
Removing the OPT / i MHP WireBrake and torch body 84
Fitting the unreeling wirefeeder 85
Fitting the unreeling wirefeeder 85
Installation - PAP 87
Fitting the welding system to a PAP robot 89
Safety 89
Fitting the TPS/i welding system to a PAP robot 89
Maximum axis rotation 89
Fitting the wire-feed unit 91
Fitting the WF 15i/25i/30i R PAP 91
Installing the CrashBox /i PAP on the robot 92
Installing the CrashBox /i PAP on the robot 92
Installing the CrashBox/i Dummy on the robot 93
Fitting the MHPi/MHP S G/W PAP hosepack 95
Fitting the Robacta MHP G/W PAP hosepack 95
“OPT / i MHP WireBrake” option 96
Fitting the inner liner inside the torch hosepack 97
Fitting the MHPi/MHP S G/W PAP SM hosepack 99
Fitting the Robacta MHP G/W PAP SM hosepack 99
“OPT / i MHP WireBrake” option 100
Fitting the inner liner inside the torch hosepack 101
Fitting the interconnecting hosepack 103
Fitting the PAP interconnecting hosepack to the robot 103
Connecting the extension hosepack 104
Connecting the interconnecting hosepack 105
Connecting wire-feed unit to system components 106
Safety 106
General 106
Connecting the WF 15i/25i/30i R PAP to the system components 106
Start-up 109
Inserting/replacing feed rollers 111
General 111
WF 25i Reel 4R: inserting/replacing feed rollers for the 4-roller drive 111
WF 30i Reel 2R: inserting/replacing feed rollers for the 2-roller drive 112
Inserting/replacing feed rollers 113
Feeding in the wire electrode 115
Insulated routing of wire electrode to wirefeeder 115
Feeding in the wire electrode 115
Setting the contact pressure 117
Start-up 118
Requirements 118
General 118
Troubleshooting, maintenance and disposal 119
Troubleshooting 121
Safety 121
Fault diagnosis 121
Care, maintenance and disposal 124
General 124
Safety 124
5
EN

Every start-up 124
Special care of O-rings 125
Whenever the welding torch or torch hosepack is changed 125
Every 6 months 125
Preparing the WF 15i/25i/30i R PAP for replacement of the welding torch inner liner 125
Recognising faulty wearing parts 126
MTG d, MTW d - Fitting wearing parts to the torch body 127
Fitting wearing parts to the torch body - MTW 700 i 128
Removing the CrashBox PAP from the robot (without mounting key) 128
Removing the CrashBox PAP from the robot (with mounting key) 130
Changing the torch hosepack, changing the interconnecting hosepack 132
Cleaning the welding torch 133
Disposal 133
Technical data 135
WF wire-feed unit 137
WF 15i R, WF 15i R PAP 137
WF 25i R, WF 25i R PAP, WF 25i R / L 137
WF 30i R, WF 30i R PAP, WF 30i R / L 138
Unreeling wirefeeder WF REEL 139
WF 25i REEL R /4R/G/W 139
WF 30i REEL R /2R/G/W 139
CrashBox /i 140
Technical data, triggering torques and weight/distance diagram 140
Torch hosepack 143
MHP 400i G / R 143
MHP 400i G / R / PAP 143
MHP 700i W / R (0.95 - 2.25 m / 3.12 - 7.38 ft.) 144
MHP 700i W / R (3.25 - 4.25 m / 10.66 - 13.12 ft.) 145
MHP 700i W / R / PAP 146
Robot welding torch 147
Gas-cooled robot welding torches 147
Water-cooled robot welding torches 148
Interconnecting hosepacks 150
HP 70i 150
HP 95i 150
HP 120i 150
HP 70i, HP PC Cable HD 70 150
6

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 recog-
nised 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 com-
pany,
- 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
instructions 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 applic-
able 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!
7
EN

Intended use The devices and components described in these Operating Instructions are intended
exclusively for automated MIG/MAG applications in conjunction with Fronius compon-
ents.
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
accordance with the intended purpose. The manufacturer shall not be held liable for any
damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the 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 cur-
rent 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 *)
8

*) 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.
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 car-
diac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective visor and
regulation filter
- Wear regulation protective goggles with side protection behind the 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
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
- Alternatively, erect suitable safety screens/curtains.
Danger from
toxic gases and
vapours
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.
9
EN

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 tox-
icity 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 identify-
ing 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
alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near
sealed tanks, vessels or pipes unless these have been prepared in 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, insu-
lated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or
cover for the earth or ground potential. This base or cover must extend over the entire
area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimen-
sioned. Replace loose connections and scorched, damaged, or inadequately dimen-
sioned cables and leads immediately.
10

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
without ground conductor contact is only permitted if all national regulations for protective
separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent
anyone from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised.
If work on live parts is required, 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
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.
11
EN

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
wirefeeder.
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
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 rectify 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 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, addi-
tional 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 hear-
ing aids
- wearers of pacemakers must seek advice from their doctor before approaching 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
12

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
coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. 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 transport-
ing 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
changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
13
EN

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, mech-
anical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to pre-
vent 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 cor-
rect 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 cylin-
der.
The manufacturer's instructions must be observed as well as applicable national and
international regulations for shielding gas cylinders and accessories.
Danger from
escaping shield-
ing 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
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 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
before every start-up.
14

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 sur-
face 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
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 follow-
ing 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
commissioning 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
properties (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.
15
EN

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.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under
certain 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 ser-
vice 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 manu-
facturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety inspection The manufacturer recommends that a safety inspection of the device 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
directives.
Further details on safety inspection and calibration can be obtained from your service
centre. 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 poten-
tially adverse affects on the environment and your health!
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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
series).
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 follow-
ing address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant stand-
ards 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
basis for any claims whatsoever on the part of the purchaser. If you have any sugges-
tions for improvement, or can point out any mistakes that you have found in the instruc-
tions, we will be most grateful for your comments.
17
EN

Description of the
warning notices
on the device
For certain device versions, warning notices are affixed to the device.
The arrangement of the symbols may vary.
AB
!Warning! Attention!
The symbols represent possible dangers.
A Drive rollers can injure fingers.
B The welding wire and drive parts are live during operation.
Keep hands and metal objects away!
1. An electric shock can be fatal.
1.1 Wear dry, insulating gloves. Do not touch the wire electrode with bare hands. Do
not wear wet or damaged gloves.
1.2 Use a base that is insulated from the floor and work area to protect against elec-
tric shock.
1.3 Before working on the device, switch off the device and pull out the mains plug or
disconnect it from the power supply.
2. Inhalation of welding fumes can be harmful to health.
2.1 Keep your face away from any welding fumes.
2.2 Use forced-air ventilation or a local extraction system to remove welding fumes.
2.3 Remove welding fumes with a fan.
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3 Welding sparks can cause an explosion or fire.
3.1 Keep flammable materials away from the welding process. Never weld close to
flammable materials.
3.2 Welding sparks can cause a fire. Have fire extinguishers to hand. If necessary,
have a supervisor ready who can operate the fire extinguisher.
3.3 Do not weld on drums or closed containers.
4. Arc rays can burn the eyes and injure the skin.
4.1 Wear headgear and protective goggles. Use ear protection and a shirt collar with
button. Use a welding helmet with the correct tinting. Wear suitable protective
clothing over the entire body.
xx,xxxx,xxxx *
5. Before working on the system or welding:
undertake training on the device and read the instructions!
6. Do not remove or paint over the warning sticker.
* Manufacturer order number of the sticker
19
EN

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