FRO­NIUS TransPocket 180 RC HW User manual

Operating
Instructions
TransPocket 180 RC HW
42,0426,0267,EA 008-02112022
EN-US Operating instructions

Table of contents
Safety Instructions 5
Explanation of Safety Instructions 5
General 5
Intended Use 6
Environmental Conditions 6
Obligations of the Operating Company 6
Obligations of Personnel 6
Grid Connection 7
Residual current circuit breaker 7
Personal Protection and Protection of Others 7
Data on noise emission values 8
Danger from toxic gases and vapors 8
Danger from Flying Sparks 8
Risks from grid current and welding current 9
Stray welding currents 10
EMC Device Classifications 10
EMC measures 10
EMF measures 11
Particular hazard areas 11
Requirement for the shielding gas 12
Danger from Shielding Gas Cylinders 12
Safety Measures at the Setup Location and During Transport 13
Safety Measures in Normal Operation 14
Maintenance and repair 14
Safety Inspection 15
Disposal 15
Safety symbols 15
Data backup 15
Copyright 15
General 16
Device concept 16
Warning Notices on the Device 17
Application Example 18
Before installation 19
Safety 19
Intended Use 19
Setup Regulations 19
Generator-Powered Operation 19
Operating controls, connections and mechanical components 21
Safety 21
Operating Controls, Connections, and Mechanical Components 22
Control Panel 23
Connecting and Starting the Power Source 24
Configuring the TIG Multi Connector Plug 24
Installing the Power Source 24
Starting Pre-heating 25
Setup Menu 26
Accessing the Setup Menu 26
Adjusting Parameters 26
Exiting the Setup Menu 26
Setup Menu Parameters 27
Setup Menu 2nd Level 28
Setup Menu 2nd Level Parameters 28
Service, maintenance and disposal 30
Safety 30
General 30
During Each Start-up 30
Every Two Months 31
Disposal 31
Fault Correction 32
3
EN-US

Safety 32
Displayed Faults 32
Service messages 33
No Function 34
Average consumption values during welding 36
Average wire electrode consumption during MIG/MAG welding 36
Average shielding gas consumption during MIG/MAG welding 36
Average shielding gas consumption during TIG welding 36
Technical data 37
Explanation of the term duty cycle 37
Technical Data 38
Overview with critical raw materials, year of production of the device 38
4

Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are
not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and ac-
cording to recognized safety standards. If used incorrectly or misused, however,
it can cause
-Injury or death to the operator or a third party
-Damage to the device and other material assets belonging to the operating
company
-Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
-Be suitably qualified
-Have knowledge of welding
-Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and reg-
ulations regarding accident prevention and environmental protection must also
be followed.
All safety and danger notices on the device must
-Be kept in a legible state
-Not be damaged/marked
-Not be removed
-Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
5
EN-US

Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating
plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer is not respons-
ible for any damage resulting from improper use.
Proper use also means
-Completely reading and obeying all instructions in the Operating Instruc-
tions
-Completely reading and obeying all safety instructions and danger notices
-Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
-Thawing pipes
-Charging batteries
-Starting motors
The device is designed for operation in industry and business. The manufacture
shall not be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer accepts no liab-
ility for any damage resulting from improper use.
Temperature range of the ambient air:
-During operation: -10°C to +40°C (14°F to 104°F)
-During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
-Up to 50% at 40°C (104°F)
-Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the Operating
Company
The operating company must only allow persons to work with the device if they
-Are familiar with the basic occupational safety and accident prevention regu-
lations and are trained in handling the device
-Have read and understood these Operating Instructions, especially the sec-
tion "Safety Rules," and have confirmed this with their signature
-Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following be-
fore beginning the work:
-Follow the basic regulations for occupational safety and accident prevention
-Read these Operating Instructions, especially the section "Safety Rules," and
confirm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage
can occur in one's absence.
6

Grid Connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
-connection restrictions
-criteria regarding maximum permissible grid impedance *)
-criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Residual current
circuit breaker
Local regulations and national guidelines may mean that a residual current cir-
cuit breaker is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manu-
facturer can be found in the technical data.
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
-Flying sparks and pieces of hot metal
-Arc radiation that poses a risk of injury to the eyes and skin
-Hazardous electromagnetic fields that pose a risk of death for individuals
with pacemakers
-Electrical risks from grid current and welding current
-Increased noise exposure
-Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective
clothing must have the following properties:
-Flame resistant
-Insulating and dry
-Covering the entire body and in good condition with no damage
-Safety helmet
-Cuffless pants
Protective clothing involves the following:
-Protecting the face and eyes from UV radiation, heat and flying sparks with a
face guard featuring a regulation-compliant filter
-Wearing regulation-compliant protective goggles with side protection behind
the face guard
-Wearing rigid, wet-insulating footwear
-Protecting hands with appropriate gloves (featuring electrical insulation and
thermal protection)
-Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and
during the welding process. If persons are in the vicinity, however:
-Instruct them about all hazards (blinding hazard due to arcs, risk of injury
from flying sparks, welding fumes hazardous to health, noise exposure, pos-
sible hazard due to grid current or welding current, etc.)
-Provide suitable protective equipment or
-Construct suitable protective walls and curtains.
7
EN-US

Data on noise
emission values
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation in relation to the maximum permit-
ted operating point at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be spe-
cified because this value depends on the welding process and the environmental
conditions. It is influenced by a wide range of parameters, such as the welding
process itself (MIG/MAG, TIG welding), the selected current type (direct cur-
rent, alternating current), the power range, the type of weld metal, the resonance
properties of the workpiece, the workplace environment, and many other factors.
Danger from tox-
ic gases and va-
pors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph
118 from the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
-Do not breathe them in.
-Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventila-
tion flow rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, com-
pare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding
fumes are:
-The metals used for the workpiece
-Electrodes
-Coatings
-Cleaning agents, degreasers, and the like
-The welding process used
Consult the corresponding material safety data sheets and manufacturer's in-
structions for the components listed above.
Recommendations for exposure scenarios, risk management measures and
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or
the main gas supply.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the
arc or protected with a certified cover.
8

Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with cor-
responding national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and
the like are/were stored. Residues pose a risk of explosion.
Risks from grid
current and
welding current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the
feed rollers, as well as all pieces of metal that are in contact with the welding
wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable in-
sulating wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with
sufficient insulation against the ground potential. The temporary backing or cov-
er must completely cover the entire area between the body and the ground po-
tential.
All cables and leads must be secured, undamaged, insulated, and adequately di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at
least 180° around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
-Never immerse it in liquids to cool it
-Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between
the electrodes of two welding systems. Touching the potentials of both elec-
trodes at the same time may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to en-
sure that the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a grid without a ground conductor and on a socket
without a ground conductor contact is only permitted if all national regulations
for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no li-
ability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if
necessary.
Switch off unused devices.
9
EN-US

When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched
on again by applying a clearly legible and understandable warning sign.
After opening the device:
-Discharge all electrically charged components
-Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will
switch off the main switch at the correct time.
Stray welding
currents
If the following instructions are not observed, stray welding currents may occur,
which pose a risk of the following:
-Fire
-Overheating of parts connected to the workpiece
-Irreparable damage to ground conductors
-Damage to the device and other electrical equipment
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
Position the device with sufficient insulation against electrically conductive envir-
onments, e.g., insulation against electrically conductive floors or electrically con-
ductive mounts.
Observe the following when using power distribution boards, twin-head mounts,
etc.: Even the electrode of the welding torch/electrode holder not in use carries
electric potential. Ensure that there is sufficient insulation when the unused
welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the
welding wire drum, large spool, or wirespool to the wirefeeder with insulation.
EMC Device
Classifications
Devices in emission class A:
-Are only designed for use in industrial settings
-Can cause line-bound and radiated interference in other areas
Devices in emission class B:
-Satisfy the emissions criteria for residential and industrial areas. This is also
true for residential areas in which the energy is supplied from the public low-
voltage grid.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for
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 operating company is obliged to take appropriate ac-
tion to rectify the situation.
10

Test and assess the immunity of equipment in the vicinity of the device in ac-
cordance with national and international provisions. Examples of interference-
prone equipment that could be affected by the device:
-Safety devices
-Grid power lines, signal lines, and data transfer lines
-IT and telecommunications equipment
-Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1.Grid power supply
-If electromagnetic interference occurs despite a grid connection that
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
2.Welding power-leads
-Keep them as short as possible
-Route them close together (also to avoid EMF problems)
-Route them far from other lines
3.Equipotential bonding
4.Workpiece grounding
-If necessary, establish grounding using suitable capacitors.
5.Shield, if necessary
-Shield other devices in the vicinity
-Shield the entire welding installation
EMF measures Electromagnetic fields may cause health problems that are not yet known:
-Effects on the health of persons close by, e.g., those with pacemakers and
hearing aids
-Persons with pacemakers must seek advice from their doctor before staying
in the immediate vicinity of the device and the welding process
-Keep distances between welding power-leads and the head/torso of the
welder as great as possible for safety reasons
-Do not carry welding power-leads and hosepacks over your shoulder or wrap
them around your body or body parts
Particular haz-
ard areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
-Fans
-Gears
-Rollers
-Shafts
-Wirespools and welding wires
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side panels must only be opened/removed during maintenance and
repair work.
During operation
-Ensure that all covers are closed, and all side parts have been mounted prop-
erly.
-Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of
injury (cuts to the hand, facial and eye injuries, etc.).
Therefore, always hold the welding torch away from the body (devices with
wirefeeder) and use suitable protective goggles.
Do not touch the workpiece during or after welding – risk of burns.
11
EN-US

Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant
protective equipment when reworking workpieces and ensure that other persons
are sufficiently protected.
Leave the welding torch and other parts with a high operating temperature to
cool before working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g., boilers)
must be labeled with the symbol (Safety). However, the power source may not be
located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before discon-
necting connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data
sheet. The coolant safety data sheet can be obtained from your service center or
via the manufacturer's website.
Only use suitable load-carrying equipment from the manufacturer to transport
devices by crane.
-Attach chains or ropes to all designated attachments of the suitable load-
carrying equipment.
-Chains or ropes must be the smallest angle possible from vertical.
-Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
In the event of crane attachment of the wirefeeder during welding, always use a
suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclus-
ively for transport by hand. The carrier belt is not suitable for transport by crane,
counterbalanced lift truck, or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association
with the device or its components, must be checked regularly (e.g., for mechanic-
al damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid nation-
al standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an
adapter is used for the shielding gas connection. Use suitable Teflon tape to seal
the thread of the shielding gas connection adapter on the device side before in-
stallation.
Requirement for
the shielding gas
Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
-Solid particle size < 40 µm
-Pressure condensation point < -20 °C
-Max. oil content < 25 mg/m³
Use filters if necessary.
Danger from
Shielding Gas
Cylinders
Shielding gas cylinders contain compressed gas and may explode if damaged.
Shielding gas cylinders are an integral part of the welding equipment, so they
must be handled very carefully.
12

Protect shielding gas cylinders with compressed gas from excessive heat, mech-
anical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with
instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the
correct matching accessories (controller, hoses, and fittings, etc.) Only use
shielding gas cylinders and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not
connected.
Follow the manufacturer's instructions and applicable national and international
provisions for shielding gas cylinders and accessories.
Safety Measures
at the Setup
Location and
During Transport
A toppling device can be deadly! Set up the device securely on an even, solid sur-
face
-The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
-Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the
workplace is always clean and organized.
Only set up and operate the device in accordance with the protection class
shown on the rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m
(1 ft. 7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and acci-
dent prevention regulations are observed when transporting the device, espe-
cially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or
lifting.
Before transporting the device, completely drain the coolant and dismantle the
following components:
-wirefeeder
-wirespool
-shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage
after it has been transported but before commissioning. Have any damage re-
paired by trained service technicians before commissioning the device.
13
EN-US

Safety Measures
in Normal Oper-
ation
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a danger of:
-Injury or death to the operator or a third party
-Damage to the device and other material assets belonging to the operating
company
-Inefficient operation of the device
Safety devices that are not fully functional must be repaired before the device is
switched on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable dam-
age and functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by
crane.
Only the original coolant from the manufacturer is suitable for use in our devices
due to its properties (electrical conductivity, anti-freeze, material compatibility,
flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit cir-
cuit.
If there is damage due to use of other system components or other coolants, the
manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flam-
mable in certain conditions. Only transport the coolant in closed original contain-
ers and keep away from sources of ignition.
Properly dispose of used coolant according to national and international regula-
tions. The coolant safety data sheet can be obtained from your service center or
via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
Maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
-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
manufacturer'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 spe-
cified torque.
14

Safety Inspec-
tion
The manufacturer recommends that a safety inspection of the device be per-
formed at least every 12 months.
The manufacturer recommends calibrating power sources within the same 12-
month interval.
A safety inspection by a certified electrician is recommended:
-After changes
-After alterations
-After repair, care, and maintenance
-At least every 12 months
For the safety inspection, follow the appropriate national and international
standards and guidelines.
You can obtain more information about the safety inspection and calibration
from your service center. The service center will provide the necessary docu-
ments upon request.
Disposal To comply with European directives and national law, waste electrical and elec-
tronic equipment must be collected separately and sent for environmentally-
friendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices pro-
motes the sustainable recycling of material resources. Ignoring this may have po-
tentially adverse effects on the environment and your health.
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directive (e.g., relevant product standards of
the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive
2014/53/EU. The full text of the EU Declaration of Conformity is available on the
following website: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing. Fronius reserves the
right to make changes. The contents of the Operating Instructions shall not
provide the basis for any claims whatsoever on the part of the purchaser. If you
have any suggestions for improvement, or can point out any mistakes that you
have found in the Operating Instructions, we will be most grateful for your com-
ments.
15
EN-US

General
Device concept
The power source is specifically designed to pre-heat welding wires during TIG
hot-wire welding and has the following characteristics:
-Compact dimensions
-Robust plastic housing
-High reliability even under tough usage conditions
-Carrier belt for easy transport even on construction sites
-Securely attached operating elements
-Current sockets with bayonet latch
Additionally, the power source offers Power Factor Correction, meaning the cur-
rent consumption of the power source is adapted to the sinusoidal grid voltage.
This has many advantages for the user, such as:
-Low primary current
-Low conductivity losses
-Late tripping of the power circuit breaker
-Improved stability during voltage fluctuations
-Compatibility with long grid leads
16

Warning Notices
on the Device
The warning notices and safety symbols located on the power source must not be
removed or painted over. They warn against incorrect operation, which may result
in serious injury and damage.
Meaning of the safety symbols on the device:
Welding is dangerous. To ensure that this device can be used cor-
rectly and safely, the following basic requirements must be met:
-Adequate welding qualifications
-Appropriate protective equipment
-Keep unauthorized people away from the welding process
Do not use the functions described here until you have fully read
and understood the following documents:
-These Operating Instructions
-All operating instructions for the system components of the
power source, especially the safety rules
Dispose of old devices in accordance with safety rules and not in
normal domestic waste.
17
EN-US

Application Ex-
ample
(9)
(5)
(1) Robot
(2) Workpiece
(3) Welding torch
(4) Wirefeeder
(5) Power cable (positive pole)
(6) Power source
(7) Robot control/power source connection cable
(8) Robot control
(9) Grounding cable (negative pole)
(10) Robot control/robot connection cable
18

Before installation
Safety WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
▶Read and understand this document in full.
▶Read and understand all safety rules and user documentation for this equip-
ment and all system components.
Intended Use The power source is intended exclusively for pre-heating welding wires during
TIG hot-wire welding in combination with the manufacturer's system compon-
ents.
Any other use does not constitute proper use.
The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
-Reading these Operating Instructions in their entirety
-Following all instructions and safety rules in these Operating Instructions
-Carrying out all the specified inspection and servicing work
Setup Regula-
tions WARNING!
Danger from machines falling or toppling over.
This can result in severe personal injury and damage to property.
▶Securely set up the devices on a level and stable surface.
The device has been tested according to degree of protection IP23. This means:
-Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
-Protection against spraywater up to an inclined angle of 60°
Cooling air
The device must be set up so that cooling air can flow through the air vents on
the front and back unhindered.
Dust
Ensure that any metallic dust is not sucked into the device fan during grinding
work, for example.
Operation outdoors
The device can be installed and operated outdoors in accordance with degree of
protection IP23. Avoid the effects of direct moisture (from rain, for example).
Generator-
Powered Opera-
tion
The power source is generator-compatible.
The maximum apparent power S1max of the power source is required for dimen-
sioning the necessary generator output.
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EN-US

The maximum apparent power S1max of the power source is calculated as follows:
S1max = I1max x U1
I1max and U1according to the device rating plate and technical data
The generator apparent power SGEN needed is calculated using the following rule
of thumb:
SGEN = S1max x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power SGEN must not be less than the
maximum apparent power S1max of the power source!
When single phase devices are being operated with a 3-phase generator, note
that the stated apparent power of the generator is often just the total that can
be present across all three phases of the generator. If necessary, obtain further
information about the single-phase power of the generator from the generator
manufacturer.
NOTE!
The voltage delivered by the generator must never fall outside of the mains
voltage tolerance range.
The mains voltage tolerance is specified in the "Technical Data" section.
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