Ignis 250 Operating instructions

Indicates the possibility of damage to property and adverse effects on work results, as well as necessary additional information, tips and tricks, recommendations, etc.

DANGER!

Indicates an immediate danger.

Could result in major injury or death.

Avoid the described danger.

WARNING!

Indicates a dangerous situation.

Could result in serious injury or death.

Avoid the dangerous situation.

CAUTION!

Indicates a harmful situation.

Could result in injury and damage to property.

Avoid the harmful situation.

NOTE!

Indicates the possibility of damage to property and adverse effects on work results, as well as necessary additional information, tips and tricks, recommendations, etc.

The operating company must only allow persons to work with the device if they

Are familiar with the basic occupational safety and accident prevention regulations and are trained in handling the device
Have read and understood these Operating Instructions, especially the section "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.

All persons who are assigned to work with the device must do the following before 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.

Devices with the CE label meet the requirements of all valid EU Directives, such as:

Directive 2014/30/EU on electromagnetic compatibility
Directive 2014/35/EU Low Voltage Directive
Directive 2014/53/EU Radio Equipment Directive
EN IEC 60974 Arc welding equipment
and others

The full text of the EU Declaration of Conformity is available at
https://www.fronius.com .

Devices bearing the CSA label satisfy the requirements of the relevant standards for Canada and the USA.

With regard to data security, the user is responsible for:

backing up any changes made to the factory settings
saving and storing personal settings.

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information on any discrepancies in the operating instructions.

The device has been manufactured in line with the state of the art and according to recognized safety standards.

The welding machine is only intended for MMA and TIG welding in conjunction with Fronius components.

Any other use shall be deemed to be not in accordance with the intended use.

Intended use also means

Carefully reading and understanding these operating instructions
Observing and obeying all safety instructions
Carrying out all the specified inspection and maintenance work

The device has been manufactured in line with the state of the art and according to recognized safety standards.

The welding machine is only intended for MMA and TIG welding in conjunction with Fronius components.

Any other use shall be deemed to be not in accordance with the intended use.

Intended use also means

Carefully reading and understanding these operating instructions
Observing and obeying all safety instructions
Carrying out all the specified inspection and maintenance work

IMPORTANT! Any use that does not comply with the intended use shall be deemed misuse.

Impermissible misuse includes the following:

Using the device to thaw pipes
Using the device to charge batteries/rechargeable batteries
Using the device to start motors
Operation or storage of the device outside the environmental conditions specified in the technical data
Operation or storage of the device outside the protection class specified in the technical data
...

The welding machine has the following characteristics:

Compact dimensions
Sturdy housing
High reliability even under tough usage conditions
Handle for easy transport even on construction sites
Protected operating elements
Current sockets with bayonet latch

In conjunction with the digital resonance inverter, during welding an electronic controller adapts the welding machine characteristic to suit the welding electrode. This provides excellent ignition and weld properties in a device that is as lightweight and compact as possible.

Additionally, the welding machine offers a "Power Factor Correction", meaning the current consumption of the welding machine adapts to the sinusoidal mains voltage. This has many advantages for the user, such as:

Low primary current
Low conductivity losses
Late tripping of the automatic circuit breaker
Improved stability during voltage fluctuations
Compatibility with long mains leads
Consistent input voltage range with multivoltage devices

When using cellulose electrodes (CEL), a specially selectable operating mode ensures perfect welding results.

TIG welding with touchdown ignition greatly extends the range of applications.

The welding machine has the following characteristics:

Compact dimensions
Sturdy housing
High reliability even under tough usage conditions
Handle for easy transport even on construction sites
Protected operating elements
Current sockets with bayonet latch

In conjunction with the digital resonance inverter, during welding an electronic controller adapts the welding machine characteristic to suit the welding electrode. This provides excellent ignition and weld properties in a device that is as lightweight and compact as possible.

Additionally, the welding machine offers a "Power Factor Correction", meaning the current consumption of the welding machine adapts to the sinusoidal mains voltage. This has many advantages for the user, such as:

Low primary current
Low conductivity losses
Late tripping of the automatic circuit breaker
Improved stability during voltage fluctuations
Compatibility with long mains leads
Consistent input voltage range with multivoltage devices

When using cellulose electrodes (CEL), a specially selectable operating mode ensures perfect welding results.

TIG welding with touchdown ignition greatly extends the range of applications.

The central control unit of the welding system controls the entire welding process.
During the welding process, actual values are continually measured and the device immediately responds to any changes. Rule algorithms ensure that the desired target state is maintained.

This results in:

A precise welding process
A high degree of reproducibility of all results
Excellent weld properties

The welding systems can be used in repair and maintenance for production and manufacturing tasks.

A rating plate and different safety symbols for the specific model are attached to the device.
The safety symbols indicate hazards during welding, which, if not observed, can lead to serious injury and damage to property.

Rating plate and safety symbols

Must be kept in a legible state
Must not be damaged
Must not be removed
Must not be covered, have anything stuck on them, or painted over

Safety symbols on the rating plate:
	Welding is dangerous. The following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Exclusion of unauthorized persons
	Do not use the functions described here until you have fully read and understood the following documents: These operating instructions All system component operating instructions, especially the safety rules

The welding machines can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

Minimum equipment for manual metal arc welding

Minimum equipment for TIG welding

Additional system components

Not shown:

Other remote controls
Other trolleys and gas cylinder holders

The welding machines can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the welding machine.

Minimum equipment for manual metal arc welding

Minimum equipment for TIG welding

Additional system components

Not shown:

Other remote controls
Other trolleys and gas cylinder holders

Item	Name
(1)	Special indicators Spot welding indicator Lights up when the "SPt" setup parameter has been set to a spot welding time Trigger indicator Lights up when the "tri" setup parameter has been set to "off" Remote control indicator Lights up when a remote control is connected Pulsing indicator Lights up when a pulse frequency has been set in the welding parameters
(2)	Welding current indicator To display the welding current for the parameters: Starting current I_S Welding current I₁ Before the start of welding, the left digital display shows the set value. For I_S, the right digital display also indicates the % amount of the welding current I₁. After the start of welding, the left digital display shows the current actual value of the welding current. The relevant parameters in the welding process are shown by the illuminated segment in the welding parameter overview (11)
(3)	Left digital display
(4)	Special indicators Single-phase power supply indicator Lights up when the welding machine has a single-phase power supply Electrode overloaded indicator Lights up when the tungsten electrode is overloaded Further information related to the "Electrode overloaded" indicator can be found in the "TIG welding" section of the "Welding mode" chapter HOLD indicator At the end of welding, the current actual values for the welding current and welding voltage are saved—the "HOLD" indicator lights up. The "HOLD" indicator relates to the last main current I₁ to be reached. Any further interaction with the welding machine will cause the "HOLD" indicator to go out. IMPORTANT! No hold values are output if the main current phase has never been reached. VRD indicator Lights up when the VRD safety function is active
(5)	Right digital display
(6)	Welding voltage indicator Lights up when parameter "I₁" is selected. During welding, the current actual value of the welding voltage is shown on the right digital display. Before welding, the right digital display shows the current value of the open circuit voltage when operating modes for TIG welding are selected and when the "tri" setup parameter is set to "off", or when the manual metal arc welding operating mode is selected (after a delay of 3 seconds; 93 V is approximately the average value of the pulsed open circuit voltage).
(7)	Unit indicators SF indicator Lights up when a special function is activated Hz indicator Lights up when the "Pulse frequency" welding parameter has been selected s indicator Lights up when the "t_up" and "t_down" parameters have been selected, as well as the following setup parameters: tAC % indicator Lights up when the "I_S" and "HCU" parameters have been selected mm indicator Lights up when the "ELd" setup parameter is set
(8)	Selection dial with rotary/push button function For selecting elements, setting values, and scrolling through lists
(9)	Welding process button For selecting the operating mode Manual metal arc welding CEL welding TIG welding When an operating mode is selected, the corresponding LED lights up.
(10)	EasyJob buttons For saving and retrieving EasyJobs More information can be found from page (→) onwards.
(11)	Welding parameter overview The welding parameter overview contains the most important welding parameters for welding. The welding parameter sequence is depicted by a "washing line" structure. Navigation within the welding parameter overview is carried out by turning the selection dial. The welding parameter overview contains the following welding parameters: Starting current I_S For manual metal arc welding Main current (welding current) I₁ For manual metal arc welding For TIG welding Arc-force dynamic *) For influencing the short-circuiting dynamic at the instant of droplet transfer. 0-100 Factory setting: 20 Pulse frequency Pulse frequency for electrode and TIG pulsing
(12)	Favorite button For saving and retrieving preferred settings More information can be found from page (→) onwards.

Item	Name
(1)	Special indicators Spot welding indicator Lights up when the "SPt" setup parameter has been set to a spot welding time Trigger indicator Lights up when the "tri" setup parameter has been set to "off" Remote control indicator Lights up when a remote control is connected Pulsing indicator Lights up when a pulse frequency has been set in the welding parameters
(2)	Welding current indicator To display the welding current for the parameters: Starting current I_S Welding current I₁ Before the start of welding, the left digital display shows the set value. For I_S, the right digital display also indicates the % amount of the welding current I₁. After the start of welding, the left digital display shows the current actual value of the welding current. The relevant parameters in the welding process are shown by the illuminated segment in the welding parameter overview (11)
(3)	Left digital display
(4)	Special indicators Single-phase power supply indicator Lights up when the welding machine has a single-phase power supply Electrode overloaded indicator Lights up when the tungsten electrode is overloaded Further information related to the "Electrode overloaded" indicator can be found in the "TIG welding" section of the "Welding mode" chapter HOLD indicator At the end of welding, the current actual values for the welding current and welding voltage are saved—the "HOLD" indicator lights up. The "HOLD" indicator relates to the last main current I₁ to be reached. Any further interaction with the welding machine will cause the "HOLD" indicator to go out. IMPORTANT! No hold values are output if the main current phase has never been reached. VRD indicator Lights up when the VRD safety function is active
(5)	Right digital display
(6)	Welding voltage indicator Lights up when parameter "I₁" is selected. During welding, the current actual value of the welding voltage is shown on the right digital display. Before welding, the right digital display shows the current value of the open circuit voltage when operating modes for TIG welding are selected and when the "tri" setup parameter is set to "off", or when the manual metal arc welding operating mode is selected (after a delay of 3 seconds; 93 V is approximately the average value of the pulsed open circuit voltage).
(7)	Unit indicators SF indicator Lights up when a special function is activated Hz indicator Lights up when the "Pulse frequency" welding parameter has been selected s indicator Lights up when the "t_up" and "t_down" parameters have been selected, as well as the following setup parameters: tAC % indicator Lights up when the "I_S" and "HCU" parameters have been selected mm indicator Lights up when the "ELd" setup parameter is set
(8)	Selection dial with rotary/push button function For selecting elements, setting values, and scrolling through lists
(9)	Welding process button For selecting the operating mode Manual metal arc welding CEL welding TIG welding When an operating mode is selected, the corresponding LED lights up.
(10)	EasyJob buttons For saving and retrieving EasyJobs More information can be found from page (→) onwards.
(11)	Welding parameter overview The welding parameter overview contains the most important welding parameters for welding. The welding parameter sequence is depicted by a "washing line" structure. Navigation within the welding parameter overview is carried out by turning the selection dial. The welding parameter overview contains the following welding parameters: Starting current I_S For manual metal arc welding Main current (welding current) I₁ For manual metal arc welding For TIG welding Arc-force dynamic *) For influencing the short-circuiting dynamic at the instant of droplet transfer. 0-100 Factory setting: 20 Pulse frequency Pulse frequency for electrode and TIG pulsing
(12)	Favorite button For saving and retrieving preferred settings More information can be found from page (→) onwards.

A keylock can be selected to prevent the settings from being inadvertently changed on the control panel. As long as the keylock is active:

Settings cannot be adjusted on the control panel
Only parameter settings can be retrieved
Any assigned "Save" button can be retrieved provided that an assigned "Save" button was selected when the keylock was enabled

Activating the keylock:

1Press the EasyJob 1 button and the operating mode button simultaneously until "CLO | SEd" appears on the digital displays.

The keylock is activated, the welding machine is locked.

Deactivating the keylock:

1Press the EasyJob 1 button and the operating mode button simultaneously until "OP | En" appears on the digital displays.

The keylock is deactivated.

(1)	Control panel
(2)	(-) Current socket with bayonet latch
(3)	TMC connection (TIG Multi Connector) for connecting a remote control After connecting a remote control to the welding machine "rc" is displayed on the welding machine display the welding current can only be adjusted using the remote control
(4)	(+) Current socket with bayonet latch
(5)	Strain-relief device for mains cable connection For XT devices: mains cable to plug in (see "Connecting the mains cable to the welding machine" on page (→))
(6)	Power switch
(7)	Air filter

Using the power connections for manual metal arc welding (depending on the type of electrode used):

(+) Current socket for electrode holder or return lead cable
(-) Current socket for electrode holder or return lead cable

Using the power connections for TIG welding:

(+) Current socket for return lead cable
(-) Current socket for welding torch

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from falling or falling devices.

Serious personal injury and property damage can be the result.

Place the device securely on a flat, solid surface.

After installation, check all screw connections for tightness.

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).

The welding machine is generator-compatible.

The maximum apparent power S_1max of the welding machine must be known in order to select the correct generator output.
The maximum apparent power S_1max of the welding machine is calculated as follows:

Three-phase devices: S_1max = I_1max x U₁ x √3

Single-phase devices: S_1max = I_1max x U₁

I_1max and U₁ according to the device rating plate and technical data

The generator apparent power S_GENneeded is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GENmust not be less than the maximum apparent power S_1maxof the welding machine!

When single-phase devices are being operated with a three-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.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

The devices are designed for the mains voltage stated on the rating plate.
Devices with a rated welding voltage of 3 x 575 V and XT devices operated with 3 x 575 V must be operated on three-phase grids grounded at the neutral point.
If the mains cable or mains plug has not been attached to your version of the appliance, these must be installed by qualified personnel according to national standards.
The fuse protection of the mains lead is specified in the technical data.

WARNING!

Danger of electric shock due to insufficient mains connection.

Could result in serious injury or death.

Only connect the device to a grid with a ground conductor.

Only connect the device to the grid via a plug-in system with a ground conductor contact.

If operating the device on a grid without a ground conductor and on a socket without a ground conductor contact, observe all national regulations for protection by electrical separation.

CAUTION!

Danger due inadequately dimensioned electrical installations.

This can lead to serious damage

The grid lead and its fuse protection should be designed to suit the existing power supply.
The technical data on the rating plate should be followed.

NOTE!

Devices with a high output can influence the energy quality of the grid due to their current consumption.

Before connecting the device to the mains, check with the grid operator whether or not the device is allowed to be connected.

The maximum permissible grid impedance that is decisive for a mains connection is stated in the technical data.

IMPORTANT! Ensure secure grounding of the mains connection.

Due to local regulations and national guidelines, a residual-current circuit breaker may be required when connecting a device to the public grid. The residual-current circuit breaker recommended for the device can be found in the technical data.

In the case of /nc and /XT welding machines, no mains cable is connected when delivered.
Before commissioning, a mains cable corresponding to the connection voltage must be installed with a minimum cross-section according to the following table.

Welding machine	Mains cable
Ignis 250 nc	4G2.5
Ignis 250 XT/nc 1 ~ 3 ~	3x AWG8 (3G6) 4x AWG12 (4G2.5)
Ignis 250 /600 V /nc	4x AWG12 (4G2.5)

If a welding machine is delivered without a mains cable installed, a mains cable corresponding to the welding machine's connection voltage must be connected before commissioning.

IMPORTANT! The ground conductor should be approx. 20 - 25 mm (0.8 - 1 in.) longer than the phase conductors.

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If a welding machine is delivered without a mains cable installed, a mains cable corresponding to the welding machine's connection voltage must be connected before commissioning.

IMPORTANT! The ground conductor should be approx. 20 - 25 mm (0.8 - 1 in.) longer than the phase conductors.

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WARNING!

Danger from incorrect operation or misuse.

This can result in serious personal injury - including injury to third parties, damage to property, and impaired welding results.

All persons involved in the commissioning, operation, maintenance, and servicing of the device must be appropriately qualified and have knowledge of welding.

Read these operating instructions in full and follow them carefully and precisely.

The operating instructions must always be kept to hand wherever the device is being used.

Observe generally applicable and regional regulations regarding accident prevention and environmental protection.

WARNING!

Danger from incorrect operation or misuse.

This can result in serious personal injury - including injury to third parties, damage to property, and impaired welding results.

All persons involved in the commissioning, operation, maintenance, and servicing of the device must be appropriately qualified and have knowledge of welding.

Read these operating instructions in full and follow them carefully and precisely.

The operating instructions must always be kept to hand wherever the device is being used.

Observe generally applicable and regional regulations regarding accident prevention and environmental protection.

WARNING!

Danger of electric shock.

Could result in serious injury or death.

Do not touch voltage-carrying parts inside or outside the device.

Use a dry backing bar or cover with sufficient insulation against the ground potential.
The backing bar or cover must completely cover the entire area between the body and the ground potential.

Only use undamaged, insulated, and adequately dimensioned cables and leads.

Do not wrap cables or leads around your body or parts of the body.

Never touch the welding wire, tungsten electrode, or the stick electrode when the welding machine is switched on.

Ground the workpiece.

Switch off unused devices.

Before working on the device, switch off the device, remove the mains plug, and attach a clearly legible and understandable warning sign to prevent the mains plug from being connected and switched on again.

After opening the device, ensure that all components are disconnected from the power supply – especially all electrically charged components.

WARNING!

Danger due to electromagnetic fields.

This can result in damage to health and effects on the health of persons close by, e.g., those with pacemakers and hearing aids.

Keep distances between welding power-leads and the head/torso of the welder as great as possible.

Do not carry welding power-leads and hosepacks over your shoulder or wrap them around your body or body parts.

Persons with pacemakers must seek advice from their doctor before standing in the immediate vicinity of the device and the welding process.

CAUTION!

Danger due to stray welding currents.

Overheating of components, fire, destruction of ground conductors, and damage to the device and other electrical equipment may result.

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 environments, e.g., insulation against electrically conductive floors or electrically conductive mounts.

Ensure that the unused welding torch / electrode holder is adequately insulated when using power distribution boards, twin-head mounts, etc.

Electromagnetic compatibility (EMC) describes the unwanted mutual influence of electrical/electronic devices.

The EMC device classification is shown on the rating plate of the device or in the technical data.

Despite compliance with the standardized emission limit values, electrical devices can, in certain cases, influence each other in the intended application area.

Interference-prone equipment that could be affected by the device includes:

Safety devices
Grid leads, signal lines, and data transfer lines
IT and telecommunications equipment
Measuring and calibrating devices
Medical devices
etc.

CAUTION!

Danger due to electromagnetic emissions.

Operational disruptions and malfunctions as well as resulting damage may result.

Use suitable grid filters.

Keep welding power-leads as short as possible, route them close together and far from other lines.

Perform equipotential bonding.

Ground the workpiece, e.g., using suitable capacitors.

Shield the entire welding system.

Shield other devices in the vicinity.

WARNING!

Danger from flying sparks.

Could result in 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 using a certified cover.

Keep suitable, certified fire extinguishers on hand.

Take appropriate measures to ensure that sparks and hot metal particles do not get into surrounding areas through small cracks and openings.

Only undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums, or pipes, if these have been prepared in accordance with corresponding national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, etc. are/were stored.

Keep flammable vapors (such as solvent vapors) out of the arc radiation range.

WARNING!

Danger from flying sparks and flying hot metal particles.

Could result in injury.

Wear suitable protective clothing when working with the device.
The protective clothing must be flame retardant, insulating, dry, and undamaged, must cover the whole body, and the pants must be cuffless.

Wear rigid, wet-insulating footwear.

Wear appropriate, electrically insulating, and heat protective gloves.

Wear a safety helmet.

WARNING!

Danger from arc radiation, UV radiation, heat, and flying sparks that pose a risk of injury to the eyes and skin

Could result in injury.

Use a face guard with a regulation-compliant filter insert.

Wear regulation-compliant protective goggles with side protection behind the face guard.

CAUTION!

Danger due to increased noise exposure.

Could result in hearing damage.

Use hearing protection during welding.

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 permitted operating point at standard loading in accordance with EN 60974-1.

A workplace-specific emission value for welding cannot be specified 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, the selected current type, the power range, the type of weld metal, the resonance properties of the component, the workplace environment, and many other factors.

WARNING!

Danger from welding operation (blinding hazard, flying sparks, harmful welding fume, noise, etc.)

Personal injury may result.

Keep unauthorized people away during the operation of the devices and during the welding process.

Inform people in the vicinity about all the dangers of the welding operation.

Provide suitable protective equipment.

Construct suitable protective walls and curtains.

WARNING!

Danger from toxic gases and vapors.

Fumes produced during welding contain substances that cause cancer, as stated in monograph 118 from the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.

If possible, use a welding torch with an integrated extraction device.

Keep your face out of the welding fume and gases produced.

Do not breathe in fume or harmful gases.

Ensure that there is a sufficient supply of fresh air.
A ventilation flow rate of at least 20 m³/h (11.77 cfm) must be provided at all times.

Use a welding helmet with air supply if there is insufficient ventilation.

WARNING!

Danger due to missing, defective or circumvented safety equipment.

This can result in serious personal injury - including injury to third parties, damage to property, and undesired welding results.

Only operate the device when all safety equipment is fully functional.

Any safety equipment that is not fully functional must be repaired by an authorized specialist before the device is switched on.

Never bypass or disable safety equipment.

Before switching on the device, ensure that no one can be put in danger.

CAUTION!

Danger due to missing or opened covers.

Personal injury may result.

Before operation, ensure that all covers and side panels are present and have been correctly fitted.

Ensure that all covers and side panels are closed during operation.

Only open covers and side panels for the duration of assembly and maintenance activities.

WARNING!

Danger from pressurized shielding gas cylinders.

Serious personal injury and damage to property can result from explosions.

Protect pressurized shielding gas cylinders from high heat, mechanical impact, slag, open flames, sparks, and arcs.

Do not weld pressurized shielding gas cylinders.

Keep shielding gas cylinders away from welding or other circuits.

Do not hang the welding torch on a shielding gas cylinder.

Leave the protective cap on the valve of the shielding gas cylinder when the cylinder is not connected.

Mount shielding gas cylinders vertically and secure them from falling in accordance with the instructions.

Observe and follow the manufacturer's instructions and national and international provisions for shielding gas cylinders and accessories.

Remove the shielding gas cylinder before transporting a welding system with trolley by crane.

Observe the safety and maintenance information on the shielding gas cylinder or a central gas supply.

WARNING!

Danger from shielding gas escaping without notice.
Shielding gas is colorless and odorless and, in the event of leaks, may replace the oxygen in the ambient air.

Could result in serious injury or death due to suffocation.

Ensure that there is a sufficient supply of fresh air.
There must be a ventilation flow rate of at least 20 m³ per hour.

Close the valve of the shielding gas cylinder or a central gas supply when no welding is taking place.

Turn your face away from the outlet when a valve on a shielding gas cylinder is being opened.

Check the shielding gas cylinder or central gas supply for uncontrolled gas leakage before each start-up.

If an adapter is being used, use suitable Teflon tape to seal the thread of the shielding gas connection on the device side before installation.

CAUTION!

Danger due to contaminated shielding gas.

This can result in damage to property and undesired weld results.

The quality of the shielding gas must meet the following specifications:
Solid particle size < 40 μm
Pressure condensation point < -20 °C
Max. oil content < 25mg/m³

CAUTION!

Danger due to hot components, parts, and liquids.

Could result in burns and injury.

Do not touch the workpiece during and after welding.

Allow hot components, hot parts, and hot liquids to cool before touching (e.g., the welding torch).

If a cooling unit is being used, switch it off before disconnecting coolant hoses.

CAUTION!

Danger due to slag flying off cooling workpieces.

Could result in burns and injury.

Also wear protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.

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CAUTION!

Danger from live stick electrode when welding machine is switched on.

Personal injury and damage to property may result.

Ensure that the stick electrode is not touching any people or electrically conductive or grounded parts (housing, etc.).

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CAUTION!

Danger from live stick electrode when welding machine is switched on.

Personal injury and damage to property may result.

Ensure that the stick electrode is not touching any people or electrically conductive or grounded parts (housing, etc.).

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1Use the welding process button to select the desired welding process for manual metal arc welding.

IMPORTANT! If the manual metal arc welding operating mode is selected, the welding voltage is only available after a delay of 3 seconds.

2Turn the selection dial to select the welding parameters:
Starting current I_S, Welding current I₁, Arc-force dynamic*, Pulse frequency*

* Arc-force dynamic and Pulse frequency depending on the application

3Press the selection dial to change the welding parameter.

4Turn the selection dial to set the value.

5Press the selection dial to go back to the list of parameters.

6To obtain optimum welding results, adjust the arc-force dynamic.

0 ... soft and low-spatter arc
100 ... harder and more stable arc

The welding current is reduced or increased at the start of the welding process depending on the setting.
The change is shown as a percentage of the set welding current.
I_S > 100% ... HotStart
I_S < 100% ... SoftStart

Setting range: 1-200%

The duration of the starting current can be changed in the Setup menu using the "Starting current duration" (Hti) parameter.

Setting the starting current I_S:

1Turn the selection dial to select the "Starting current I_s" parameter.

2Press the selection dial to change the "Starting current I_s" parameter.

3Turn the selection dial to set the "Starting current I_s" parameter.

4Press the selection dial to go back to the list of parameters.

Examples (set welding current = 100 A)
100%	= 100 A starting current = function deactivated
80%	= 80 A starting current = SoftStart
135%	= 135 A starting current = HotStart
200%	= 200 A starting current = HotStart

Example of HotStart

SoftStart properties:

Reduced pore formation for certain electrode types

HotStart properties:

Improved ignition properties, even when using electrodes with poor ignition properties
Better fusion of the parent material during the start-up phase, therefore less neutralization
Slag inclusions largely avoided

Electrode pulsing is manual metal arc welding with a pulsing welding current. It is used to weld steel pipes out-of-position or to weld thin sheet metal.

In these applications, the welding current set at the start of welding is not always optimum for the entire welding process:

If the amperage is too low, the base material will not be sufficiently melted
If overheating occurs, there is a risk that the liquid weld pool may drip

Operating principle:

A low base current I-G rises steeply to the significantly higher pulse current I-P and drops back to the base current I-G after the Duty cycle dcY time. The pulse current I-P matches the welding current set on the welding machine.
This results in an average current that is lower than the set pulse current I-P.
During electrode pulsing, small sections of the welding location melt quickly and then rapidly re-solidify.

The welding machine controls the "Duty cycle dcY" and "Base current I-G" parameters according to the set welding current and pulse frequency.

The pulse frequency is set on the control panel in the welding parameters.
Setting range: 0.2-990 Hz

Welding current progression curve

F-P = Pulse frequency, I-P = Pulse current, I-G = Base current, dcY = Duty cycle

Adjustable parameters:

Pulse frequency (1/F-P = Time between two pulses)
Pulse current (corresponds to the set welding current)
Starting current (SoftStart / HotStart)

Parameters specified by the welding machine:

Base current I-G
Duty cycle

Setting electrode pulsing:

1Set the STICK or CEL welding process

2Turn the selection dial and select the pulse frequency

3Press the selection dial to set the pulse frequency

The pulse frequency is shown on the right digital display, the Hz unit indicator lights up.

4Turn the dial and adjust the value for the pulse frequency

5Press the selection dial to confirm the set pulse frequency

NOTE!

Do not use pure tungsten electrodes (color-coded green) if the TIG welding process has been selected.

NOTE!

Do not use pure tungsten electrodes (color-coded green) if the TIG welding process has been selected.

WARNING!

Danger from falling gas cylinders.

Serious personal injury and damage to property may result.

Place gas cylinders on a solid, level surface so that they remain stable. Secure gas cylinders to prevent them from falling over.

Observe the safety rules of the gas cylinder manufacturer.

1

2

3

CAUTION!

Danger of electric shock. As soon as the welding machine is switched on, the electrode in the welding torch is live.

Personal injury and damage to property may result.

Make sure the electrode does not touch any persons or electrically conducting or grounded parts (e.g., the housing, etc.).

4

TIG gas-valve welding torch

1Open the gas cut-off valve

- Shielding gas flows

2Set the desired gas flow rate on the pressure regulator

3Close the gas cut-off valve

1Select TIG welding with the welding process button.

2Turn the selection dial to set the welding current.

3Press the selection dial to go back to the list of parameters.

4Position the gas nozzle at the ignition point so that there is a gap of approximately 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece. A gap exists.

5Open the gas cut-off valve.

6Gradually tilt the welding torch up until the tungsten electrode touches the workpiece.

7When the arc ignites, raise the welding torch and tilt it into the normal position.

8Carry out welding.

For details on how to activate and set the TIG Comfort Stop function, see the description Parameters for TIG welding from page (→) onwards.

How TIG Comfort Stop works and is used:

1Welding

2During welding, raise the welding torch

The arc length is increased significantly

3Lower the welding torch

The arc length is decreased significantly
TIG Comfort Stop function is triggered

4Maintain height of the welding torch

The welding current continually decreases (DownSlope) until the arc goes out

5Wait for the gas post-flow time to finish and lift the welding torch away from the workpiece

Welding current and gas flow curve with TIG Comfort Stop function activated

(1)	Gas pre-flow
(2)	Gas post-flow

DownSlope:
The DownSlope time t_down is 0.5 seconds and cannot be adjusted.

Gas post-flow:
The gas post-flow must be carried out manually.

TIG pulsing is TIG welding with a pulsing welding current. It is used to weld steel pipes out-of-position or to weld thin sheet metal.

In these applications, the welding current set at the start of welding is not always optimum for the entire welding process:

If the amperage is too low, the base material will not be sufficiently melted
If overheating occurs, there is a risk that the liquid weld pool may drip

Operating principle:

A low base current I-G rises steeply to the significantly higher pulse current I-P and drops back to the base current I-G after the Duty cycle dcY time. The pulse current I-P matches the welding current set on the welding machine.
This results in an average current that is lower than the set pulse current I-P.
During TIG pulsing, small sections of the welding location melt quickly and then rapidly re-solidify.

The welding machine controls the "Duty cycle dcY" and "Base current I-G" parameters according to the set welding current and pulse frequency.

The pulse frequency is set on the control panel in the welding parameters.
Setting range: 0.2-990 Hz

Welding current progression curve

Adjustable parameters:

Pulse frequency (1/F-P = Time between two pulses)
Pulse current (corresponds to the set welding current)
Starting current I_S

Parameters specified by the welding machine:

t_up = UpSlope
t_down = DownSlope
dcY = Duty cycle
I-G = Base current
I-E = Final current

Setting the TIG pulses:

1Set the TIG welding process

2Turn the selection dial and select the pulse frequency.

3Press the selection dial to set the pulse frequency

The pulse frequency is shown on the right digital display, the Hz unit indicator lights up.

4Turn the dial and adjust the value for the pulse frequency

5Press the selection dial to confirm the set pulse frequency.

For details on how to activate and set the tacking function, see the description Parameters for manual metal arc welding from page (→) onwards.

When a time period is specified for the "tAC" (tacking) setup parameter, the tacking function is assigned to all operating modes
The basic operating sequence of each of these modes remains unchanged
During the specified period, welding takes place with a pulse current that makes the weld pool run together better when two components are being tacked

Welding current progression curve

Adjustable parameters:

tAC = Duration of the pulse current for the tacking process
I₁ = main current

Parameters specified by the welding machine:

t_up = UpSlope
t_down = DownSlope
I-P = Pulse current
dcY = Duty cycle
F-P = Pulse frequency
I-G = Base current

The welding machine regulates the "Pulse frequency F-P", "Pulse current I-P", Duty cycle dcY", and "Base current I-G" parameters according to the set "Main current I₁".

The pulse current starts

After the end of the starting-current phase I_S
With the UpSlope phase t_up

After the tAC time has elapsed, welding continues at a constant welding current, and any pulse parameters that may have been set are available.

The "EasyJob" buttons allow up to five EasyJob operating points to be saved. Each operating point corresponds to the settings made on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

The "EasyJob" buttons allow up to five EasyJob operating points to be saved. Each operating point corresponds to the settings made on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

1Press and hold one of the "EasyJob" buttons until "Pro" appears on the left digital display.
e.g.:

After a short time, the left display switches to the original value

2Release the "EasyJob" button

The EasyJob is saved and active, the LED on the "EasyJob" button lights up.

1Press the corresponding "Save" button briefly
e.g.:

The saved settings are shown on the digital displays.
The EasyJob is active, the LED on the "EasyJob" button lights up.

1Press and hold the corresponding "EasyJob" button until first "Pro" and then "CLr" appear on the left digital display
e.g.:

After a short time, the left display switches to the original value

2Keep the "EasyJob" button held down until "---" appears on both digital displays.

3Release the "EasyJob" button

The Favorites feature can be used to save and retrieve setup parameters directly on the control panel.

1Select the desired parameter in the Setup menu
For more details about the Setup menu, see page (→) onwards.

2Press and hold the "Favorite" button for approx. 3 seconds until "PrG" appears on the left digital display.
e.g.:

3Release "Favorite" button

The setup parameter is saved and can be retrieved directly on the control panel by briefly pressing the "Favorite" button.

IMPORTANT! If a setup parameter is retrieved by pressing the "Favorite" button, its value can be changed immediately by turning the selection dial.
Finally, press the selection dial to apply the value change.

A parameter saved under the "Favorites" button cannot be deleted, but can only be overwritten by another parameter.

The Favorites feature can be used to save and retrieve setup parameters directly on the control panel.

1Select the desired parameter in the Setup menu
For more details about the Setup menu, see page (→) onwards.

2Press and hold the "Favorite" button for approx. 3 seconds until "PrG" appears on the left digital display.
e.g.:

3Release "Favorite" button

The setup parameter is saved and can be retrieved directly on the control panel by briefly pressing the "Favorite" button.

IMPORTANT! If a setup parameter is retrieved by pressing the "Favorite" button, its value can be changed immediately by turning the selection dial.
Finally, press the selection dial to apply the value change.

A parameter saved under the "Favorites" button cannot be deleted, but can only be overwritten by another parameter.

1Use the welding process button to select the desired welding process for manual metal arc welding.

2Press the welding process button and Favorite button at the same time.

1Use the welding process button to select the desired welding process for manual metal arc welding.

2Press the welding process button and Favorite button at the same time.

1Turn the selection dial to select the desired parameter

2Press the selection dial to display the set value of the parameter

3Press the selection dial to change the value

The set value is immediately active.Exception:
When resetting to the factory settings, the selection dial needs to be pressed after changing the value in order to activate the change.

4Press the selection dial to go back to the list of parameters

1Press the welding process button to exit the Setup menu.

Starting current duration
For the SoftStart / HotStart function

0.1-2.0 s
Factory setting: 0.5 s

Anti-stick
When the anti-stick function is active, the arc is extinguished after 1.5 seconds in the event of a short circuit (sticking of the electrode)

ON / OFF
Factory setting: ON (activated)

Start ramp
To activate / deactivate the start ramp

ON / OFF
Factory setting: ON (activated)

Break voltage
For setting a voltage value at which the welding process may be ended by a slight raise of the stick electrode.

25-90 V
Factory setting: 45 V

The arc length depends on the welding voltage. To end the welding process, a significant lifting of the stick electrode is usually required.
The break voltage parameter allows the welding voltage to be limited to a value that permits the welding process to be ended by only slightly lifting the stick electrode.

IMPORTANT! If the welding process regularly comes to an unintentional end, set the break voltage to a higher value.

Factory settings
Reset the welding machine to its factory settings

no / yES / ALL

no	Cancel reset
yES	Reset the parameters for the set welding process to the factory settings
ALL	Reset the parameters for all welding processes to the factory settings

Confirm selection by pressing the selection dial

2nd level setup menu
For setting general parameters

For details see the Setup Menu 2nd Level section from page (→) onwards

Comfort Stop Sensitivity

OFF / 0.6-3.5 V
Factory setting: 1.5 V
Factory setting: 35 V (for 2-step and 4-step mode and operation with a foot-operated remote control)

For details see the TIG Comfort Stop section from page (→) onwards

Break voltage
For setting a voltage value at which the welding process may be ended by a slight raise of the TIG welding torch.

10.0-45.0 V
Factory setting: 35 V (for 2-step and 4-step mode and operation with a foot-operated remote control)
Factory setting: 25 V (for trigger = oFF operation)

Tacking
Tacking function—duration of the pulsed welding current at the start of the tacking process

off / 0.1-9.9 s / on
Factory setting: off

on
The pulsed welding current remains present until the end of the tacking process

0.1-9.9 s
The selected time begins with the UpSlope phase. After the set time has elapsed, further welding is carried out at a constant welding current. Set pulse parameters are available if applicable.

off
Tacking function is switched off

The SF special indicator lights up on the control panel if a value has been set.

Factory settings
Reset the welding machine to its factory settings

no / yES / ALL

no	Cancel reset
yES	Reset the parameters for the set welding process to the factory settings
ALL	Reset the parameters for all welding processes to the factory settings

Confirm selection by pressing the selection dial

2nd level setup menu
For setting general parameters

For details see the Setup menu 2nd level parameters section from page (→) onwards

Welding duration
For displaying the welding duration
(only shows the time during which welding has taken place)

hh:mm:ss

The complete welding duration is divided across several displays and can be viewed by turning the selection dial

Operating duration
For displaying the operating duration
(count begins as soon as the device is switched on)

hh:mm:ss

The complete operating duration is divided across several displays and can be accessed by turning the selection dial.

Fuse
To display / set the fuse being used on XT devices

At 230 V: 10, 13, 16 A / off
Factory setting: off

If a fuse is set on the welding machine, the welding machine will limit the current drawn from the grid, which prevents an immediate tripping of the automatic circuit breaker.

Software version

The complete version number of the current firmware is divided across several displays and can be viewed by turning the selection dial.

Automatic shutdown

off / 5-60 s
Factory setting: OFF

If the device is not used or operated within a set period of time, it automatically switches into Standby mode.
Pressing a button on the control panel switches off Standby mode—the device is now ready for welding.

Welding duration
For displaying the welding duration
(only shows the time during which welding has taken place)

hh:mm:ss

The complete welding duration is divided across several displays and can be viewed by turning the selection dial

Operating duration
For displaying the operating duration
(count begins as soon as the device is switched on)

hh:mm:ss

The complete operating duration is divided across several displays and can be accessed by turning the selection dial.

Fuse
To display / set the fuse being used on XT devices

At 230 V: 10, 13, 16 A / off
Factory setting: off

If a fuse is set on the welding machine, the welding machine will limit the current drawn from the grid, which prevents an immediate tripping of the automatic circuit breaker.

Software version

The complete version number of the current firmware is divided across several displays and can be viewed by turning the selection dial.

Automatic shutdown

off / 5-60 s
Factory setting: OFF

If the device is not used or operated within a set period of time, it automatically switches into Standby mode.
Pressing a button on the control panel switches off Standby mode—the device is now ready for welding.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

This may result in serious personal injury and damage to property.

Before starting any maintenance or servicing work, switch off all the devices and components involved and disconnect them from the grid.

Secure all these devices and components so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

CAUTION!

Danger due to insufficient ground conductor connection.

This can result in personal injury and damage to property.

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

This may result in serious personal injury and damage to property.

Before starting any maintenance or servicing work, switch off all the devices and components involved and disconnect them from the grid.

Secure all these devices and components so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

CAUTION!

Danger due to insufficient ground conductor connection.

This can result in personal injury and damage to property.

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

If "Err" and a two-digit error code appear on the display and the fault indicator lights up, this is an internal service code for the welding machine, e.g.:
Err | 002

Take note of all displayed error codes as well as the serial number and configuration of the welding machine, and then contact the service team with a detailed error description.

Err | 001-003, Err | 011, Err | 015, Err | 021, Err | 033-035, Err | 037-040,
Err| 042-044, Err | 046-052

Cause:	Power module error
Remedy:	Contact service team

Err | 004

Cause:	Open circuit voltage has not been reached: Electrode is in contact with the component/hardware defect
Remedy:	Remove the electrode support from the component. If the service code continues to be displayed, contact service team

Err | 005, Err | 006, Err | 012

Cause:	System start failure
Remedy:	Turn device off and on again. If this happens multiple times, inform service team

Err | 010

Cause:	Overvoltage at the current socket (> 113 V_DC)
Remedy:	Contact service team

Err | 16

Cause:	Memory error
Remedy:	Press selection dial to acknowledge service message
OR:	Turn device off and on again. If this happens multiple times, inform service team

Err | 17, Err | 18

Cause:	Memory error / faulty firmware update
Remedy:	Perform firmware update. If this happens multiple times, inform service team

Err | 019

Cause:	Overtemperature or undertemperature
Remedy:	Operate device at permitted ambient temperature. For more information about environmental conditions see "Environmental conditions" in the "Safety rules" section

Err | 020

Cause:	Improper use of the device
Remedy:	Only use the device in accordance with the intended purpose

Err | 022

Cause:	Welding current set too high
Remedy:	Ensure that the welding machine is being operated at the correct mains voltage; ensure the correct fuse is set; set a lower welding current

Err | 037

Cause:	Mains voltage exceeds admissible limits
Remedy:	Immediately pull out the mains plug and ensure that the welding machine is being operated at the correct mains voltage

Err | 036, Err | 041, Err | 045

Cause:	Mains voltage is outside of the tolerance or mains output is insufficient for the connected device(s)
Remedy:	Ensure that the welding machine is being operated at the correct mains voltage; ensure the correct fuse is set

Err | 065-075

Cause:	Error in communicating with the display
Remedy:	Turn device off and on again / inform service team if this happens multiple times

Overtemperature

"hot" is shown on the display

Cause:	Operating temperature is too high
Remedy:	Leave the device to cool (Do not switch off the device - the fan will cool the device)

Device cannot be switched on

Cause:	Defective power switch
Remedy:	Inform service team

No welding current

The welding system is switched on, display for selected process illuminates

Cause:	Welding power-lead connections interrupted
Remedy:	Correctly establish welding power-lead connections
Cause:	Poor grounding or no grounding at all
Remedy:	Establish a connection with the workpiece
Cause:	Power cable in the welding torch or electrode holder interrupted
Remedy:	Replace welding torch or electrode holder

No welding current

Switch on device, display illuminates for selected process, overtemperature display illuminates

Cause:	Duty cycle exceeded - device overloaded - fan running
Remedy:	Observe duty cycle
Cause:	Thermal automatic circuit breaker has shut down the device
Remedy:	Wait for device to cool down (do not switch off the device - the fan will cool the device); the welding system will switch on again automatically after a short time
Cause:	Fan in the welding system defective
Remedy:	Contact After-Sales Service
Cause:	Cooling air supply is insufficient
Remedy:	Ensure there is a sufficient air supply
Cause:	Air filter is dirty
Remedy:	Clean air filter
Cause:	Power module error
Remedy:	Switch the device off and then on again If this error persists, inform service team

Poor ignition properties during manual metal arc welding

Cause:	The wrong process has been selected
Remedy:	Select "manual metal arc welding" or "manual metal arc welding with Cel electrodes" process
Cause:	Starting current too low; electrode remains stuck during ignition process
Remedy:	Increase starting current
Cause:	Starting current too high; electrode burns too quickly during ignition process or spatters strongly
Remedy:	Decrease starting current

Arc occasionally breaks during the welding process

Cause:	Break voltage (Uco) is set too low
Remedy:	Raise the break voltage (Uco) in the Setup menu
Cause:	Voltage of the electrode too high (e.g. grooved electrode)
Remedy:	Use alternative electrode if possible or use power source with higher welding power

Rod electrode tends to stick to the workpiece

Cause:	Value for dynamic parameter (manual metal arc welding) set too low
Remedy:	Set a higher value for dynamic parameter

Poor-quality weld property

(strong spattering)

Cause:	Incorrect polarity of the electrode
Remedy:	Reverse the polarity of the electrode (observe manufacturer guidelines)
Cause:	Poor ground earth connection
Remedy:	Attach earthing clamps directly to the workpiece
Cause:	Non-viable setup setting for the selected process
Remedy:	Optimize the setting for the selected process in the Setup menu

Tungsten electrode melts

Tungsten inclusions in the base material during the ignition phase

Cause:	Incorrect polarity of the tungsten electrode
Remedy:	Connect TIG welding torch to the (-) current socket
Cause:	Incorrect shielding gas, no shielding gas
Remedy:	Use inert shielding gas (argon)

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

This may result in serious personal injury and damage to property.

Before starting any maintenance or servicing work, switch off all the devices and components involved and disconnect them from the grid.

Secure all these devices and components so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

CAUTION!

Danger due to insufficient ground conductor connection.

This can result in personal injury and damage to property.

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

WARNING!

Danger due to incorrect operation and work not carried out correctly.

This may result in serious personal injury and damage to property.

All the work and functions described in this document must be carried out by technically trained and qualified personnel only.

Read and understand this document in full.

Read and understand all safety rules and user documentation for this equipment and all system components.

WARNING!

Danger from electrical current.

This may result in serious personal injury and damage to property.

Before starting any maintenance or servicing work, switch off all the devices and components involved and disconnect them from the grid.

Secure all these devices and components so they cannot be switched back on.

After opening the device, use a suitable measuring instrument to check that electrically charged components (such as capacitors) have been discharged.

CAUTION!

Danger due to insufficient ground conductor connection.

This can result in personal injury and damage to property.

The housing screws provide a suitable ground conductor connection for grounding the housing.

The housing screws must not under any circumstances be replaced by other screws without a reliable ground conductor connection.

The device only requires a minimum of service and maintenance under normal operating conditions. However, several points must be observed in order for the device to remain operational for years to come.

Ensure that the mains plug and mains cable as well as the welding torch / electrode holder are undamaged. Replace any damaged components.
Ensure that the welding torch/electrode holder and the return lead cable are properly connected to the welding machine and screwed/locked in place as described in this document
Ensure a proper ground earth connection to the workpiece.
Ensure that the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that cooling air can circulate unimpeded. Air inlet and outlet openings must not be blocked or even partially covered.

Clean air filter:

1

2

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally sound manner in accordance with the European Directive and national law. Used equipment must be returned to the distributor or through a local authorized collection and disposal system. Proper disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

Packaging materials

Collect separately
Observe local regulations
Crush cardboard boxes

The duty cycle (ED) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.

NOTE!

The ED values cited on the rating plate relate to an ambient temperature of 40 °C.

If the ambient temperature is higher, the ED or power must be lowered accordingly.

Example: Welding with 150 A at 60% ED

Welding phase = 60% of 10 mins = 6 mins
Cool-down phase = rest time = 4 mins
Following the cool-down phase, the cycle begins again.

To use the device without interruptions:

1Search for a 100% ED value in the technical data, which corresponds to the existing ambient temperature.

2Reduce the power or amperage value correspondingly so that the device can operate without a cool-down phase.

The duty cycle (ED) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.

NOTE!

The ED values cited on the rating plate relate to an ambient temperature of 40 °C.

If the ambient temperature is higher, the ED or power must be lowered accordingly.

Example: Welding with 150 A at 60% ED

Welding phase = 60% of 10 mins = 6 mins
Cool-down phase = rest time = 4 mins
Following the cool-down phase, the cycle begins again.

To use the device without interruptions:

1Search for a 100% ED value in the technical data, which corresponds to the existing ambient temperature.

2Reduce the power or amperage value correspondingly so that the device can operate without a cool-down phase.

Overview with critical raw materials:
An overview of which critical raw materials are contained in this device can be found at the following Internet address:
https://www.fronius.com/welding-technology/downloads
Find downloads: critical

To calculate the year of production of the device:

Each device is provided with a serial number
The serial number consists of 8 digits - for example 28020099
The first two digits give the number from which the year of production of the device can be calculated
This figure minus 11 gives the year of production
- For example: Serial number = 28020065, calculation of the year of production = 28 - 11 = 17, year of production = 2017

Temperature range of ambient air:
during operation during transport and storage	-10 °C to + 40 °C / 14 °F to 104 °F -20 °C to +55 °C / -4 °F to 131 °F

Relative humidity of ambient air:
at 40 °C / 104 °F at 20 °C / 68 °F	max. 50% max. 90%

Mains voltage U₁	3 x 400 V
Max. effective primary current (I_1eff)	10.3 A
Max. primary current (I_1max)	14.7 A
Mains voltage tolerance	- 10% / +10%
Mains frequency	50/60 Hz
Mains fuse	16 A slow-blow
Cos phi	0.99
Max. permitted grid impedance Z_max on PCC ¹⁾	127 mOhm
Recommended residual-current circuit breaker	Type B
Welding current range
MMA	10 - 250 A
TIG	10 - 300 A
Welding current at 10 min / 40 °C (104 °F)
MMA	40% ED²⁾ / 250 A
	60% ED ²⁾ / 220 A
	100% ED ²⁾ / 180 A
TIG	40% ED²⁾ / 300 A
	60% ED ²⁾ / 260 A
	100% ED ²⁾ / 210 A
Open circuit voltage (pulsed)
MMA	101 V
TIG	39 V
Working voltage
MMA	20.4 - 30.0 V
TIG	10.3 - 22.0 V
Protection class	IP 23
EMC emission class (according to EN/IEC 60974-10)	A ³⁾
Dimensions l x w x h	488 x 210 x 369 mm 19.2 x 8.3 x 14.5 in.
Weight	18.00 kg 39.68 lb.
Noise emissions (L_WA)	< 80 dB(A)
Idle state power consumption at 400 V	15 W
Welding machine efficiency at 250 A / 30.0 V	88%

¹⁾	Interface to the public grid (230/400 V and 50 Hz)
²⁾	ED = duty cycle
³⁾	A device in emission class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.

Mains voltage (U₁)	3 x 200/230/400/460/575 V 1 x 230 V
Max. effective primary current (I_1eff)
3 x 200 V	16.5 A
3 x 230 V	14.4 A
3 x 400 V	8.4 A
3 x 460 V	7.4 A
3 x 575 V	8.0 A
1 x 230 V	24.0 A
Max. primary current (I_1max)
3 x 200 V	25.5 A
3 x 230 V	22.1 A
3 x 400 V	12.6 A
3 x 460 V	11.1 A
3 x 575 V	11.6 A
1 x 230 V	37.5 A
Mains voltage tolerance	- 10% / +10%
Mains frequency	50/60 Hz
Mains fuse 3 x 200 - 230 V 3 x 400 - 575 V 1 x 230 V	32 A slow-blow 16 A slow-blow 30 A slow-blow
Cos phi	0.99
Max. permitted grid impedance Z_max on PCC ¹⁾	119 mOhm
Recommended residual-current circuit breaker	Type B
Welding current range
MMA	10 - 250 A
TIG	10 - 300 A
Welding current at 10 min / 40 °C (104 °F)
MMA	40% ED²⁾ / 250 A
	60% ED²⁾ / 220 A
	100% ED²⁾ / 180 A
TIG	40% ED ²⁾ / 300 A
	60% ED ²⁾ / 260 A
	100% ED ²⁾ / 230 A
Open circuit voltage (pulsed)
MMA	101 V
TIG	39 V
Working voltage
MMA	20.4 - 30.0 V
TIG	10.3 - 22.0 V
Protection class	IP 23
EMC emission class (according to EN/IEC 60974-10)	A ³⁾
Dimensions l x w x h	488 x 210 x 369 mm 19.2 x 8.3 x 14.5 in.
Weight	16.0 kg 35.27 lb.
Noise emissions (L_WA)	< 80 dB(A)
Idle state power consumption at 400 V	17.3 W 38.14 lb.
Welding machine efficiency at 250 A / 30.0 V	90%

/XT	Extended (larger voltage range, single-phase usage, CEL welding)
/nc	Welding machine without mains cable
¹⁾	Interface to the public grid (230/400 V and 50 Hz)
²⁾	ED = duty cycle
³⁾	A device in emission class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.

Mains voltage (U₁)	3 x 575 V
Max. effective primary current (I_1eff)	7.8 A
Max. primary current (I_1max)	11.3 A
Mains voltage tolerance	- 10% / +10%
Mains frequency	50/60 Hz
Mains fuse	16 A slow-blow
Cos phi	0.99
Recommended residual-current circuit breaker	Type B
Welding current range
MMA	10 - 250 A
TIG	10 - 300 A
Welding current at 10 min / 40 °C (104 °F)
MMA	40% ED¹⁾ / 250 A
	60% ED¹⁾ / 220 A
	100% ED¹⁾ / 180 A
TIG	40% ED ¹⁾ / 300 A
	60% ED ¹⁾ / 260 A
	100% ED ¹⁾ / 210 A
Open circuit voltage (pulsed)
MMA	101 V
TIG	39 V
Working voltage
MMA	20.4 - 30.0 V
TIG	10.3 - 22.0 V
Protection class	IP 23
EMC emission class (according to EN/IEC 60974-10)	A ²⁾
Dimensions l x w x h	488 x 210 x 369 mm 19.2 x 8.3 x 14.5 in.
Weight	16.0 kg 35.27 lb.
Noise emissions (L_WA)	< 80 dB(A)

¹⁾	ED = duty cycle
²⁾	A device in emission class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies.

Ignis 250

General

Explanation of safety instructions

DANGER!

WARNING!

CAUTION!

NOTE!

Explanation of safety instructions

DANGER!

WARNING!

CAUTION!

NOTE!

Obligations of the Operating Company

Obligations of Personnel

Safety symbols

Data security

Copyright

Utilization in accordance with "intended purpose"

Intended use

Intended use

Foreseeable misuse

Information about the device

Device concept

Device concept

Operating principle

Application areas

Notes on the device

System components

System components

System components

Operating controls, connections and mechanical components

Control panel

Control panel

Keylock

Operating controls, connections, and mechanical components

Before installation

Safety

WARNING!

Safety

WARNING!

Setup Regulations

WARNING!

Generator-powered operation

NOTE!

Connecting the mains cable to the welding machine

Safety

WARNING!

Safety

WARNING!

Mains connection

WARNING!

CAUTION!

NOTE!

Specified mains cables

Connecting the mains cable (3‑phase)

Connecting the mains cable (1‑phase)

Dangers when welding

Danger from incorrect operation and misuse

WARNING!

Danger from incorrect operation and misuse

WARNING!

Danger from grid current and welding current

WARNING!

WARNING!

CAUTION!

Danger due to electromagnetic emissions

CAUTION!

Danger from flying sparks

WARNING!

WARNING!

Danger from arc radiation

WARNING!

Danger due to noise

CAUTION!

Danger from welding operation

WARNING!

Danger from toxic gases and vapors

WARNING!

Danger due to missing safety equipment

WARNING!

Setting the starting current I_S