8 tips to prevent welding spatter
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General questions
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Welding quality
- Check the welding system and all components (welding torch, wirefeeder, connections, cooling circuit, etc.) to ensure they are in good condition and free from external defects (pinched cables, leaks).
- Make sure that the gas cylinder is open and that there is sufficient pressure. Also check whether the correct gas is connected and the correct flow rate is set.
- Make sure that the gas hose is connected correctly and the gas pressure regulator is working properly.
- TIP: Formula for correct gas quantity: MIG/MAG: wire diameter in [mm] x 10 = gas quantity in [l/min] TIG: gas nozzle diameter in [mm] = gas quantity in [l/min]
- Use wearing parts of torches and feed rollers that match the wire diameter.
- Ensure that the contact pressure of the wire feed rollers of the wirefeeder is set correctly. Check them for wear. Please refer to the operation manual.
- If it has been a long time since the inner liner was last changed, we recommend replacing the wearing parts of the torch hosepack. Instructions (how-to videos) for water-cooled and gas-cooled variants can be found on YouTube. Wear part kits (BasicKits) can be obtained at any time from our sales outlets, from a Fronius Service Partner near you.
- Have you set the welding current parameter correctly? You can find helpful setting suggestions in our WeldConnect app for iPhone and Android.
- Make sure that your operating point is not in the intermediate arc. This is indicated by the following icon in the display:
Switch to a pulse characteristic curve or adjust the power up or down. - Careful workpiece preparation helps to avoid welding errors. Make sure that surfaces are free from rust and grease.
- Refer to the operating instructions and measure the welding circuit resistance. The best way to determine the welding circuit resistance [R] is by following our how-to video (YouTube) or the relevant operation manual. The operation manual for your device is available from our Download Center.
Note:
Pay attention to your safety during every activity. Wear suitable work gloves and protective goggles when working with compressed air.
- Have you set the welding current parameter correctly? You can find helpful setting suggestions in our WeldConnect app for iPhone and Android.
- Make sure that your operating point is not in the intermediate arc. This is indicated by the following icon:
Switch to a pulse characteristic curve or adjust the power up or down. - The occurrence of weld defects is related to various factors. Use WeldScript – our free training document – for your welding process. There you will find valuable tips on how to avoid errors: Link to download.
Gas problems
- Check the welding system and all components (welding torch, wirefeeder, connections, cooling circuit, etc.) to ensure they are in good condition and free from external defects (pinched cables, leaks).
- Make sure that the gas cylinder is open and that there is still sufficient pressure. Also check whether the correct gas is connected and the correct flow rate is set.
- Make sure that the gas hose is connected correctly and the gas pressure regulator is working properly.
- TIP: Formula for correct gas quantity:
MIG/MAG: wire diameter in [mm] x 10 = gas quantity in [l/min]
TIG: gas nozzle diameter in [mm] = gas quantity in [l/min] - When you press the gas test button
, you should hear a “click”. This is the sound of the gas solenoid valve opening. If you don’t hear any sound, please contact us.
Wire problems
- Check the welding system and all its components (welding torch, wirefeeder, connections, cooling circuit, etc.) to ensure they are in good condition and free from external defects (pinched cables, leaks).
- Use wearing parts of torches and feed rollers that match the wire diameter.
- Ensure that the contact pressure of the wire feed rollers of the wirefeeder is set correctly. Check them for wear. Please refer to the operation manual.
- If it has been a long time since the inner liner was last changed, we recommend replacing the wearing parts of the torch hosepack. Instructions (how-to videos) for water-cooled and gas-cooled variants can be found on YouTube. Wear part kits (BasicKits) can be obtained at any time from our sales outlets, from a Fronius Service Partner near you or from the online shop (Austria and Germany).
- Blow out the inside of the wirefeeder with compressed air (max. 6 bar). Metal dust can accumulate and cause a blockage in the inner liner.
- If your welding torch is more than 10 years old, we recommend purchasing a Fronius welding torch of the latest generation. Welding torches for all Fronius welding machines and wear part kits (BasicKits) can be obtained at any time from our sales outlets, from a Fronius Service Partner near you.
- Spare and wear parts can be found in our online spare parts catalog.
Note:
Pay attention to your safety during every activity. Wear suitable work gloves and protective goggles when working with compressed air.
Display problems
- Check the welding system and all components (welding torch, wirefeeder, connections, cooling circuit, etc.) to ensure they are in good condition and free from external defects (pinched cables, leaks).
- Ensure that the residual current circuit breaker (RCCB) is activated for the correct circuit. The correct circuit is the one that the welding machine is connected to.
- If a fuse trips, please contact our Customer Service. Our experts or Fronius Service Partner companies will be happy to take care of your welding system.
- Find service locations and Fronius Service Partners in your area with the following link: Find contacts around the world.
- When was your device last serviced or calibrated? Get in touch with us.
Welding machine maintenance
- Our blog post "8 anti-aging tips for your welding machine” provides valuable information.
- For spare or wear parts, we recommend our online spare parts catalog.
- Welding torches or wear part kits (BasicKits) can be obtained at any time from our sales outlets, from a Fronius Service Partner near you.
Note:
Pay attention to your safety during every activity. Wear suitable work gloves and protective goggles when working with compressed air.
Download App
WeldConnect free for Android and iOS:
Exento product family
How to operate your Exento welding fume extraction unit correctly.
It is not possible to give a generally valid answer, as most of these conditions are regulated by national laws.
Yes, there is a solution. Please contact our Customer Service.
Choose the 3-phase configuration of the Exento HighVac for such exhaust air solutions. This ensures sufficient reserve capacity when the filter gradually becomes saturated. For further information, please contact your Fronius consultant at the Technical Competence Center (TCC). We will be glad to help you with the setup.
The filter elements must be disposed of in accordance with the legal requirements of your country or waste disposal region. Please clarify this in advance with your local waste disposal service.
Exento LowVac:
The filter must be replaced. Washing or cleaning with compressed air is not permitted.
The cleaning intervals depend on use and the amount of soiling.
Both Exento products have a built-in filter alarm. As soon as the filter is full, it must be replaced (Exento LowVac) or cleaned (Exento HighVac).
The main filter of the Exento LowVac must be replaced at regular intervals. If the 42 m2 filter is used, the replacement intervals are extended.
Clean the filter of the Exento HighVac daily (compressed air at 6 bar).
If a layer of oil and metal particles has already formed inside the hose, we recommend replacing the hose due to the increased risk of fire.
The intake filter for the motor should be checked monthly and replaced if necessary.
Protective equipment
There is no need to worry. Your eyes are protected by the permanent UV and infrared filter.
Our recommendation for the default setting:
Set the control to “Autopilot”
If the helmet does not darken sufficiently, increase the degree of darkening with the “Sensitivity” control. The setting goes up to “super high”.
Do you have a Vizor Connect? First charge the helmet via the USB-C connector. If you have a different Fronius helmet, please insert new batteries (CR XXXX).
Note: When changing batteries, remove the plastic film from the battery.
The sensor slider can be set to two different positions. The angle for detecting ambient light is reduced or increased depending on the position.
If you have any further questions or if the error persists, please contact one of our teams or a Fronius Service Partner near you. Find your Fronius Service Partner here.
The grind mode button serves as an on/off switch for the connect mode.
In the off position, the welding helmet works conventionally (no LED indicator).
In the on position, the welding helmet reacts by wireless control via the welding machine (after successful pairing, the blue LED indicator lights up continuously).
Pairing is possible with the following systems:
- TPS 320i C / TPS 320i / TPS 400i / TPS 500i / TPS 600i from serial number 29200502 and 4,067,101 NFC/BLE/WIFI24 Inside (firmware version 2.0.1)
- MW 230i / TT 230i from start of series (firmware version 1.5.0)
- iWave series
There is no need to worry. Your eyes are protected by the permanent UV and infrared filter.
Our recommendation for the default setting:
Slider to Autopilot
Recommendation for TIG DC low ampere welding
Recommendation for pulse welding
Recommendation for tack welding
Recommended for welding outdoors or in strong ambient light
If the darkness level is already at maximum due to your welding application, additional shades are available that can be attached to the inside of the auto-darkening filter cartridge. The additional shades increase the darkness by one or two darkness levels, depending on the desired strength. Additional shades are available through our extensive sales network with outlets in your area.
Spare parts and other accessories are available through our extensive sales network with outlets in your area.
For more information, see our spare parts and accessories catalog.
MagicCleaner
Learn how to operate your MagicCleaner correctly.
Cleaning power standard values (POWER):
- Cleaning electrode 10 mm / 0.39 inch: 1 - 2
- Cleaning electrode 22 mm / 0.87 inch: 1 - 3
- Cleaning electrode 45 mm / 1.77 inch: 3 - 4
- Large cleaning brush: 1 - 3
As the cleaning power increases, higher cleaning speeds are possible.
Further information is available from our DownloadCenter.
If the operating mode (MODE) is set to ”Small cleaning torch”, the blow-off function of the blow-off torch and the pump are deactivated.
Cleaning power standard values (POWER):
- Cleaning electrode 10 mm / 0.39 inch: 1 - 2
- Cleaning electrode 22 mm / 0.87 inch: 1 - 3
- Cleaning electrode 35 mm / 1.38 inch: 3 - 4
- Small cleaning brush: 1 - 3
As the cleaning power increases, higher cleaning speeds are possible.
The printing process is similar to the cleaning process. On each device there is a separate print mode that uses special printing fluids (black/white). A suitable cleaning torch with interchangeable components is available to prevent contamination of the printing and cleaning fluids.
The MagicCleaner is also suitable for aluminum, but please note that the cleaning behavior may vary due to the large number of metal alloys. The effectiveness of the cleaning depends not only on the metal itself, but also on its “degradation”. As the metal gets older, natural oxidation increases, which leads to a change in the cleaning effect.
To polish, place a new cleaning felt on the cleaning electrode. Fill the tank with the red cleaning electrolyte.
Polishing power standard values (POWER):
- Cleaning electrode 10 mm / 0.39 inch: 1 - 2
- Cleaning electrode 22 mm / 0.87 inch: 1 - 3
IMPORTANT! The 45 mm / 1.77 inch cleaning electrode is not suitable for polishing.
If the operating mode (MODE) is set to ”No cleaning torch”, the blow-off function of the blow-off torch and the pump are deactivated.
Cleaning power standard values (POWER):
- Cleaning electrode 10 mm / 0.39 inch: 1 - 2
- Cleaning electrode 22 mm / 0.87 inch: 1 - 3
- Cleaning electrode 35 mm / 1.38 inch: 3 - 4
To clean not only TIG welds but also MMA or GMAW welds effectively, you may need to increase the cleaning intensity. This could increase the cleaning time.