Ignis 150/180 TIG Operating Instructions

1. Safety rules

1. Safety rules

• 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.

• be suitably qualified,
• have sufficient knowledge of welding and
• read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

• must be in a legible state,
• must not be damaged,
• must not be removed,
• must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!

1. Safety rules

The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

• carefully reading and following all the instructions given in the operating instructions
• studying and obeying all safety and danger notices carefully
• performing all stipulated inspection and maintenance work.

• Thawing out pipes
• Charging batteries
• Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

1. Safety rules

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

• 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)

• up to 50% at 40 °C (104 °F)
• up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

1. Safety rules

• are familiar with the fundamental instructions regarding safety at work and accident prevention and have been instructed in how to use the device
• have read and understood these operating instructions, especially the section "safety rules", and have confirmed as much with their signatures
• are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

1. Safety rules

• to observe the basic instructions regarding safety at work and accident prevention
• to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

1. Safety rules

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

• Connection restrictions
• Criteria with regard to the maximum permissible mains impedance ^*)
• Criteria with regard to the minimum short-circuit power requirement ^*)

^*) at the interface with the public grid
see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

1. Safety rules

Local regulations and national guidelines may require a residual current protective device when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufacturer for the equipment is indicated in the technical data.

1. Safety rules

• flying sparks and hot pieces of metal
• Arc radiation, which can damage eyes and skin

• Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers

• Risk of electrocution from mains current and welding current

• Greater noise pollution

• Harmful welding fumes and gases

• Flame-resistant
• Insulating and dry
• Covers the whole body, is undamaged and in good condition
• Safety helmet
• Trousers with no turn-ups

• Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
• Wear regulation protective goggles with side protection behind the protective visor
• Wear stout footwear that provides insulation even in wet conditions
• Protect the hands with suitable gloves (electrically insulated and providing protection against heat)
• Wear ear protection to reduce the harmful effects of noise and to prevent injury

• Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.)
• Provide suitable protective equipment
• Alternatively, erect suitable safety screens/curtains.

1. Safety rules

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

1. Safety rules

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

• must not be breathed in
• must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

• Metals used for the workpiece
• Electrodes
• Coatings
• Cleaners, degreasers, etc.
• Welding process used

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

1. Safety rules

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

1. Safety rules

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

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

• never be immersed in liquid for cooling
• never be touched when the welding system is switched on.

Double the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

• Discharge all live components
• Ensure that all components in the device are de-energised.

If work on live parts is required, have a second person switch off the main switch at the right moment.

1. Safety rules

• Fire hazard
• Overheating of parts connected to the workpiece
• Damage to ground conductors
• Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

1. Safety rules

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains.

EMC device classification as per the rating plate or technical data.

1. Safety rules

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

• Safety devices
• Network, signal and data transfer lines
• IT and telecommunications devices
• Measuring and calibrating devices

1. Mains supply
   • If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)
2. Welding power-leads
   • must be kept as short as possible
   • must be laid close together (to avoid EMF problems)
   • must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
   • If necessary, establish an earth connection using suitable capacitors.
5. Shield, if necessary
   • Shield other devices nearby
   • Shield the entire welding installation

1. Safety rules

• Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
• Individuals with pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
• For safety reasons, maintain as large a distance as possible between the welding power-leads and the head/torso of the welder
• Do not carry welding power-leads and hosepacks over the shoulders or wind them around any part of the body

1. Safety rules

• Fans
• Cogs
• Rollers
• Shafts
• Wire spools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels must only be opened/removed while maintenance or repair work is being carried out.

• Ensure that all covers are closed and all side panels are fitted properly.
• Keep all covers and side panels closed.

Welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.)

Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.

Welding systems for work in areas with increased electrical risk (e.g. near boilers) must carry the ‘Safety’ sign. However, the welding system must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer’s website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

• Hook chains or ropes onto all suspension points provided on the load-carrying equipment.
• Chains and ropes must be at the smallest angle possible to the vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.

1. Safety rules

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety rules

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

1. Safety rules

• The maximum permissible tilt angle is 10°.

• Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

• Wirefeeder
• Wirespool
• Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

1. Safety rules

• injury or death to the operator or a third party
• damage to the device and other material assets belonging to the operator
• inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

1. Safety rules

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the 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 specified torque.

1. Safety rules

The manufacturer recommends that a safety inspection of the device be performed at least once every 12 months.

The manufacturer recommends that the welding system be calibrated during the same 12-month period.

• after any changes are made
• after any additional parts are installed, or after any conversions
• after repair, care and maintenance are carried out
• at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you with any documents you may require, on request.

1. Safety rules

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Proper disposal of the old device promotes sustainable recycling of material resources. Ignoring this may lead to potential health/environmental impacts.

Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume of the box.

1. Safety rules

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety rules

The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal settings.

1. Safety rules

Copyright of these operating instructions remains with the manufacturer.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

The welding system has the following properties:

• Compact dimensions
• Robust plastic housing
• Extremely reliable even under harsh operating conditions
• Carrying strap for easy transport on construction sites, etc.
• Protected controls
• Current sockets with bayonet latch

In conjunction with the digital resonance inverter, an electronic regulator adapts the welding system characteristic to suit the welding electrode during welding. The result is a lightweight and compact device with excellent ignition and weld properties.

• Low primary current
• Low conduction losses
• Late tripping of the automatic circuit breaker
• Improved stability in the event of voltage fluctuations
• Long mains leads can be used
• In the case of multivoltage devices, a continuous input voltage range.

When using cellulose electrodes (CEL), a dedicated operating mode can be chosen for perfect welding results.

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

1. General

The welding system has the following properties:

• Compact dimensions
• Robust plastic housing
• Extremely reliable even under harsh operating conditions
• Carrying strap for easy transport on construction sites, etc.
• Protected controls
• Current sockets with bayonet latch

In conjunction with the digital resonance inverter, an electronic regulator adapts the welding system characteristic to suit the welding electrode during welding. The result is a lightweight and compact device with excellent ignition and weld properties.

• Low primary current
• Low conduction losses
• Late tripping of the automatic circuit breaker
• Improved stability in the event of voltage fluctuations
• Long mains leads can be used
• In the case of multivoltage devices, a continuous input voltage range.

When using cellulose electrodes (CEL), a dedicated operating mode can be chosen for perfect welding results.

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

1. General

The warning notices and safety symbols on the welding system must not be removed or painted over. They warn against incorrect operation which can lead to serious injury and damage.

Meaning of safety symbols on the device:

	Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly: Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must be kept at a safe distance 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 the Operating Instructions for the system components of the welding system, especially the safety rules
	Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

1. General

MMA welding

TIG welding, welding torch with torch trigger and TIG Multi Connector plug

1. Before commissioning

1. Before commissioning

The welding system is intended exclusively for MMA welding and TIG welding in conjunction with system components from the manufacturer.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such usage.

• Carefully reading these Operating Instructions
• Following all the instructions and safety rules in these Operating Instructions
• Performing all stipulated inspection and maintenance work

1. Before commissioning

• Protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49 in.)
• Protected against spraywater at any angle up to 60° to the vertical

Cooling air
The device must be set up in such a way that cooling air can flow freely through the slots in the front and rear panels.

Dust
Ensure that metallic dust is not sucked into the system by the fan, when carrying out grinding for example.

Outdoor operation
The device can be set up and operated outdoors in accordance with IP23 degree of protection. Avoid direct wetting (e.g. from rain).

1. Before commissioning

The welding system is generator-compatible.

In order to dimension the required generator output, the maximum apparent power S_1max of the welding system is required.

The maximum apparent power S_1max of the welding system can be calculated as follows:
S_1max = I_1max x U₁

See device rating plate or technical data for I_1max and U₁ values

The generator apparent power S_GEN needed is calculated using the following rule of thumb:
S_GEN = S_1max x 1.35

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

IMPORTANT! The generator apparent power S_GEN must always be higher than the maximum apparent power S_1max of the welding system.

When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the single-phase power of the generator from the generator manufacturer.

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

1. Controls, connections and mechanical components

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

1. Controls, connections and mechanical components

• (+) current socket for electrode holder or grounding cable
• (-) current socket for electrode holder or grounding cable

• (+) current socket for grounding cable
• (-) current socket for welding torch

1. Controls, connections and mechanical components

• (+) current socket for electrode holder or grounding cable
• (-) current socket for electrode holder or grounding cable

• (+) current socket for grounding cable
• (-) current socket for welding torch

1. Controls, connections and mechanical components

(1)	Setting value indicator shows which setting value is selected:
	Arc-force dynamic
	Welding current
	SoftStart / HotStart function
	Pulse welding
(2)	Unit indicator shows the unit of the value that is currently being changed with the adjusting dial (7):
	Time (seconds)
	Percent
	Frequency (Hertz)
(3)	Setting value button for selecting the desired setting value (1)
(4)	Display shows the current figure of the selected setting value
(5)	Welding process indicator shows which welding process is selected:
	MMA welding
	MMA welding with Cel electrode
	TIG welding
(6)	Welding process button for selecting the welding process
(7)	Adjusting dial for continuous adjustment of the selected setting value (1)
(8)	Status indicators display various operating modes of the welding system:
	VRD lights up when the safety device for voltage reduction is activated (VRD devices only)
	Setup lights up in Setup mode
	Temperature lights up when the device is outside the permissible temperature range
	Fault lights up in the event of a fault, also see section ‘Troubleshooting’
	TAC lights up when the tacking function is activated (only possible on TIG devices with the TIG welding process)

1. MMA welding

1

2

3

4

5

1. MMA welding

1Use the welding process button to select one of the following processes:
	MMA welding - the MMA welding indicator lights up after selection
	MMA welding with Cel electrode - the MMA welding with Cel electrode indicator lights up after selection
2Press the setting value button until
	the welding current indicator lights up
3Adjust the welding current using the adjusting dial Welding system is ready for welding

1. MMA welding

This function is used to set the starting current.

Setting range: 1 - 200 %

Operating principle:
At the start of the welding process, the welding current is reduced (SoftStart) or increased (HotStart) for 0.5 seconds, depending on the setting.
The change is shown as a percentage from the set welding current.

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

Setting the starting current:

1Press the setting value button until
	the SoftStart / HotStart indicator lights up
2Turn the adjusting dial until the desired value is reached power source is ready for welding

• Ignis 150 to 160 A
• Ignis 180 to 200 A

Example of HotStart function

Features of SoftStart function:

• Reduced pore formation with certain electrode types

Features of HotStart function:

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of the base material during the start-up phase, meaning fewer cold-shut defects
• Largely prevents slag inclusions

1. MMA welding

To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic.

Setting range: 0 - 100 (corresponds to 0 - 200 A current increase)

Operating principle:
At the moment of droplet transfer or in the event of a short circuit, the amperage is briefly increased in order to obtain a stable arc.
If the rod electrode is at risk of sinking into the weld pool, this measure prevents the weld pool from solidifying, as well as preventing a prolonged short-circuit of the arc. This largely prevents the rod electrode from sticking.

Setting the arc-force dynamic:

1Press the setting value button until
	the arc-force dynamic indicator lights up
2Turn the adjusting dial until the desired correction value is reached Welding system is ready for welding

• Ignis 150 to 180 A
• Ignis 180 to 220 A

• Arc-force dynamic = 0
  • arc-force dynamic deactivated
  • soft, low-spatter arc
• Arc-force dynamic = 20
  • arc-force dynamic with 40 A current increase
  • harder, more stable arc
• Arc-force dynamic = 60, set welding current = 100 A
  • for the Ignis 150: actual increase is just 80 A as the maximum current limit is reached!
  • for Ignis 180: arc-force dynamic with 120 A current increase

1. MMA welding

Pulse welding is welding with a pulsing welding current. It is used for out-of-position welding of steel pipes or when welding thin sheets.

• if the amperage is too low, the base material will not melt sufficiently
• if overheating occurs, the liquid weld pool may drip.

Setting range: 0.2 - 990 Hz

• 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 can be set on the welding system.
• This results in an average current that is lower than the set pulse current I-P.
• During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.

The welding system controls the Duty cycle dcY parameter and base current I-G according to the set pulse current and pulse frequency.

Pulse welding - welding current curve

• F-P: Pulse frequency (1/F-P = time interval between two pulses)
• I-P:  Pulse current
• SoftStart/HotStart

• I-G: Base current
• dcY: Duty cycle

To use pulse welding:

1Press the setting value button until
	the pulse welding indicator lights up
2Turn the adjusting dial until the desired frequency value (Hz) is reached Welding system is ready for welding

	Pull back and hold the torch trigger
	Release the torch trigger forwards
	Push forward and hold the torch trigger
	Release the torch trigger backwards

• GPo: Gas post-flow time
• I-S: Starting-current phase - the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly
• I-E: Final current phase - to prevent crater cracks or cavitations
• I-1: Main current phase (welding-current phase) - uniform thermal input into the base material, whose temperature is raised by the continuous heat
• I-2:  Reduced current phase - intermediate lowering of the welding current in order to prevent any local overheating of the base material

• GPr: Gas pre-flow time
• t_up: UpSlope phase - the welding current is continually increased
  Duration = 0.5 seconds
• t_down: DownSlope phase - the welding current is continually decreased
  Duration = 0.5 seconds
• t_S: Starting current duration
• t_E: Final current duration

1. TIG modes

	Pull back and hold the torch trigger
	Release the torch trigger forwards
	Push forward and hold the torch trigger
	Release the torch trigger backwards

• GPo: Gas post-flow time
• I-S: Starting-current phase - the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly
• I-E: Final current phase - to prevent crater cracks or cavitations
• I-1: Main current phase (welding-current phase) - uniform thermal input into the base material, whose temperature is raised by the continuous heat
• I-2:  Reduced current phase - intermediate lowering of the welding current in order to prevent any local overheating of the base material

• GPr: Gas pre-flow time
• t_up: UpSlope phase - the welding current is continually increased
  Duration = 0.5 seconds
• t_down: DownSlope phase - the welding current is continually decreased
  Duration = 0.5 seconds
• t_S: Starting current duration
• t_E: Final current duration

1. TIG modes

See the description Parameters for TIG welding on page (→) for details on how to activate 2-step mode.

1. TIG modes

See the description Parameters for TIG welding on page (→) for details on how to activate 4-step mode.

4-step mode with intermediate lowering I-2

Intermediate lowering means that the welder uses the torch trigger during the main current phase to lower the welding current to the specified reduced current I-2 .

1. TIG welding

1. TIG welding

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2

1. TIG welding

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2

CAUTION!

Danger from electric shocks. As soon as the welding system is switched on, the electrode in the welding torch is live.

This can result in injury and damage to property.

Ensure the electrode does not touch any persons or electrically conductive or earthed parts (the housing, etc.)

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4

1. TIG welding

Welding torch with torch trigger
(and TIG Multi Connector plug)

Welding torch with torch trigger (and TIG Multi Connector plug):

1Press the torch trigger

- shielding gas flows

2Set the desired gas flow rate on the pressure regulator

3Release the torch trigger

1. TIG welding

1Select TIG welding with the welding process button
	the TIG welding indicator lights up
2Press the setting value button until
	the welding current indicator lights up
3Adjust the welding current using the adjusting dial
When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting): 4Place the gas nozzle down on the ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece 5Gradually tilt the welding torch up until the tungsten electrode touches the workpiece 6Pull back and hold the torch trigger - shielding gas flows 7Raise the welding torch and rotate it into its normal position - the arc ignites 8Carry out welding

1. TIG welding

To activate and set the TIG Comfort Stop function, see the description Parameters for TIG welding starting on page (→).

Operating principle and use of the TIG Comfort Stop:

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

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

Gas post-flow:
The gas post-flow can be changed in the Setup menu via the "Gas post-flow time" parameter (Gas Post flow).

1. TIG welding

Pulse welding is welding with a pulsing welding current. It is used for out-of-position welding of steel pipes or when welding thin sheets.

• if the amperage is too low, the base material will not melt sufficiently
• if overheating occurs, the liquid weld pool may drip.

Setting range: 0.5 - 100 Hz

• 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 can be set on the welding system.
• This results in an average current that is lower than the set pulse current I-P.
• During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.

The welding system controls the Duty cycle dcY parameter and base current I-G according to the set pulse current and pulse frequency.

Pulse welding - welding current curve

• I-S = starting current
• I-E = final current
• F-P = pulse frequency (1/F-P = time interval between two pulses)
• I-P = pulse current

• t_up = UpSlope
• t_Down = DownSlope
• dcY = duty cycle
• I-G = base current

To use pulse welding:

1Press the setting value button until
	the pulse welding indicator lights up
2Turn the adjusting dial until the desired frequency value (Hz) is reached Welding system is ready for welding

1. TIG welding

To activate and set the tacking function, see the description Parameters for TIG welding starting on page (→).

• 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 is done with a pulse current that makes the weld pool run together better when two components are being tacked.

Welding current curve

• tAC = duration of the pulse current for the tacking process
• I-E = final current
• I-S = starting current
• I-1 = main flow

• t_up = UpSlope
• t_Down = DownSlope
• I-P = pulse current
• dcY = duty cycle
• F-P = pulse frequency
• I-G = base current

The welding system controls the pulse frequency F-P, pulse current I-P, duty cycle dcY and base current I-G parameters according to the set main current I-1.

• 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.

1. Welding process Setup menu

1Use the Welding Process button to select the process whose Setup parameters are to be changed:
	MMA welding
	MMA welding with Cel electrode
	TIG welding
2Press the Setting Value and Welding Process buttons at the same time The code for the first parameter in the Setup menu is displayed on the control panel

1. Welding process Setup menu

1Turn the adjusting dial to select the required parameter
2Press the adjusting dial to display the preset value of the parameter
3Turn the adjusting dial to change the value - the new value becomes effective immediately - exception: when restoring the factory settings, press the adjusting dial after changing the value to activate the new value.
4Press the adjusting dial to return to the list of parameters

1. Welding process Setup menu

1Press the Setting Value or Welding Process button to exit the Setup menu

1. Welding process Setup menu

Parameter	Description		Range	Unit
	Starting current duration For the SoftStart / HotStart function Factory setting: 0.5 seconds		0.1 - 2.0	Seconds
	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) Factory setting: ON (activated)		On OFF
	Start ramp To activate/deactivate grinding mode Factory setting: ON (activated)		On OFF
	Break voltage (Voltage cut off) Used to specify at which arc length the welding process is to be completed. The welding voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here Factory setting: 45 volts		25 - 90	Volts
	Factory setting (FACtory) This can be used to reset the device to its factory settings
	cancel reset		no
	reset the parameters for the selected welding process to their factory settings		YES
	reset the parameters for all welding processes to their factory settings		ALL
		Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.
	Level 2 Setup menu To set general welding parameters For details, see the "Level 2 Setup menu" section

1. Welding process Setup menu

Parameter	Description		Range	Unit
	Operating mode (trigger mode)
	Operation using welding torch without a torch trigger		OFF
	2-step mode		2t
	4-step mode Factory setting: 2t		4t
	Starting current (I-Start) This parameter is only available in 4-step mode (tri = 4t) Factory setting: 35%		1 - 200	Percent
	Reduced current This parameter is only available in 4-step mode (tri = 4t) Factory setting: 50%		1 - 200	Percent
	Final current (I-End) This parameter is only available in 4-step mode (tri = 4t) Factory setting: 30%		1 - 100	Percent
	Gas pre-flow time (Gas Pre flow) Duration of gas pre-flow Factory setting: 0.0 seconds		0.0 - 9.9	Seconds
	Gas post-flow (Gas Post flow) Specified period during which gas flows at the end of welding Factory setting: AUt		AUt 0.2 - 25	Seconds
	Gas purging (gas purging) Purging of the protective gas shield begins as soon as GPU is allocated a value. For safety reasons, purging of the protective gas shield cannot be restarted until a new GPU value is entered. IMPORTANT! Purging the shielding gas is necessary if condensation forms when the device is left unused in a cold environment for a prolonged period. Long hosepacks are most affected. Factory setting: off		0.1 - 9.9	Minutes
	Comfort Stop Sensitivity This parameter is only available when the tri parameter is set to OFF Factory setting: 1.5 V For details, see TIG Comfort Stop starting at page (→)		0.6 - 3.5	Volts
	Break voltage (Voltage cut off) Used to specify at which arc length the welding process is to be completed. The welding voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here. Factory setting: 35 volts (for 2-step mode, 4-step mode and pedal remote control) Factory setting: 25 V (for the trigger = oFF mode)		10 - 45	Volts
	Tacking function (tACking) Factory setting: OFF For details, see description of the "Tacking function"		OFF 0.1 - 9.9	Seconds
	Factory setting (FACtory) This can be used to reset the device to its factory settings
	cancel reset		no
	reset the parameters for the selected welding process to their factory settings		YES
	reset the parameters for all welding processes to their factory settings		ALL
		Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.
	Level 2 Setup menu To set general welding parameters For details, see the "Level 2 Setup menu" chapter

1. Setup menu - Level 2

Parameter	Description	Range	Unit
	Software version The full version number of the currently installed software is spread across a number of displays and can be retrieved by turning the adjusting dial.
	Automatic switch-off (time Shut down) If the device is not used or operated for a specified period of time, it automatically switches itself into Standby mode Pressing any button on the control panel will cancel Standby mode and the device will be ready to resume welding Factory setting: OFF	5 - 60 OFF	Minutes
	Fuse For displaying/setting the fuse used Factory setting: for mains voltage 230 V = 16 A for mains voltage 120 V = 20 A If a fuse is set on the welding system, the welding system limits the power drawn from the mains. This prevents the automatic circuit breaker from tripping immediately	At 230 V: 10 / 13 / 16 / OFF (TP 180 MV only) At 120 V: 15 / 16 / 20 / OFF (TP 180 MV only)	Ampere

Parameter	Description	Range	Unit
	Operating time (System on time) For displaying the operating time (begins to count as soon as the device is switched on) The full operating time is spread across a number of displays and can be retrieved by turning the adjusting dial		Hours, minutes, seconds
	Welding time (System Active time) For displaying how long the system has been active for (only shows the time during which welding was in progress) The full system active time is spread across a number of displays and can be retrieved by turning the adjusting dial		Hours, minutes, seconds

1. Care, maintenance and disposal

1. Care, maintenance and disposal

Under normal operating conditions, the device requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the device remains in a usable condition for many years.

1. Care, maintenance and disposal

• Ensure that the mains plug and mains cable as well as the welding torch / electrode holder are undamaged. Replace any damaged components.
• Make sure that the welding torch / electrode holder and the grounding cable are properly connected to the welding system and screwed / locked as described in this document
• Ensure that a proper ground earth connection has been established to the workpiece.
• Check that there is an all-round clearance of 0.5 m (1 ft 8 in.) around the device to ensure that cooling air can flow in and out freely. Air inlets and outlets must never be covered, not even partially.

1. Care, maintenance and disposal

Clean air filter:

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1. Care, maintenance and disposal

Dispose of in accordance with the applicable national and local regulations.

1. Troubleshooting

1. Troubleshooting

Overtemperature

"hot" appears on the display, the temperature indicator lights up
  

Cause:	Operating temperature too high
Remedy:	Allow device to cool (do not switch off the device - the fan will cool it down)

1. Troubleshooting

When E and a 2-digit error number appear on the display (e.g. E02) and the ‘Error’ indicator lights up, this is an internal welding system source service code.
Example:

It is also possible that several error numbers are present. These appear when turning the adjusting dial.

Make a note of the error numbers shown on the display, and of the serial number and configuration of the welding system, and contact our after-sales service team with a detailed description of the error.

1. Troubleshooting

1. Troubleshooting

1. Average consumption values during welding

1. Average consumption values during welding

1. Average consumption values during welding

Duty cycle (ED) is the proportion of time in a 10-minute cycle at which the device may be operated at its rated output without overheating.

Example: Welding at 150 A at 60% ED

• Welding phase = 60% of 10 minutes = 6 minutes
• Cooling phase = remaining time = 4 minutes
• After the cooling phase, the cycle begins again.

If the device is to be continuously operated without stopping:

1. Technical data

Duty cycle (ED) is the proportion of time in a 10-minute cycle at which the device may be operated at its rated output without overheating.

Example: Welding at 150 A at 60% ED

• Welding phase = 60% of 10 minutes = 6 minutes
• Cooling phase = remaining time = 4 minutes
• After the cooling phase, the cycle begins again.

If the device is to be continuously operated without stopping:

1. Technical data

1. Technical data

1. Technical data

1. Technical data

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.
www.fronius.com/en/about-fronius/sustainability.

• 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