Fronius Acerios Operating Instruction [EN]

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Operating Instructions

Acerios

EN-US

Operating instructions

42,0426,0326,EA 004-12042023

Table of contents

Safety Instructions 6

Explanation of Safety Instructions 6 General 6 Intended Use 7 Environmental Conditions 7 Obligations of the Operating Company 7 Obligations of Personnel 7 Grid Connection 8 Personal Protection and Protection of Others 8 Data regarding Noise Emission Values 8 Danger from Toxic Gases and Vapors 9 Danger from Fire 9 Hazards from Grid Current and Process Current 10 Stray currents 11 EMC Device Classifications 11 EMC Measures 11 EMF Measures 12 Particular Hazard Areas 12 Impaired Plasma Surface Treatment 13 Danger from Gas Cylinders 13 Danger due to Escaping Gas 13 Safety Measures at the Setup Location and During Transport 14 Safety Measures in Normal Operation 14 Maintenance and repair 15 Safety Inspection 15 Disposal 15 Safety symbols 16 Data backup 16 Copyright 16

EN-US

General information 17

General 19

Device Concept 19 Operating Principle 19 Application Areas 20 System Configurations 20

Operating controls and connections 21

Control Panel 23

General 23 Safety 23 Control Panel 24

Shortcut Keys - Special Functions 27

General 27 Key Lock 27 Show Software Version, Runtime, and Coolant Flow 28

Connections, Switches, and Mechanical Components 29

Acerios Connections 29

Installation and Startup 31

Before installation and initial operation 33

Safety 33 Minimum Equipment 33 Intended Use 33 Setup Regulations 33 Grid Connection 34

Installation 35

Safety 35

General 35 Installation 35

Commissioning 37

Connecting the Gas Cylinder 37 Connecting the Plasma Torch 37

Plasma Surface Treatment 39

Overloaded Electrode 41

Description of operating modes 42

2-Step Mode 42 4-Step Mode 42

Plasma Surface Treatment 43

Safety 43 Process Parameters 43 Plasma Surface Treatment 44

Special Functions and Options 45

Arc Break Monitoring Function 45 Ignition Time-Out Function 45 Plasma Pulsing 45 Hold-Function 46

Job Mode 47

General 47 Abbreviations 47 Saving a Job 48 Job Retrieval 49 Copying/Overwriting a Job 50 Deleting a Job 52

Setup Settings 53

The Setup Menu 55

General 55 Accessing the Setup Menu 55 Accessing the 2nd Level Setup Menu 55 Adjusting Parameters 55 Parameters in the Setup Menu 56 Parameters in the 2nd Level Setup Menu 57 Exiting the 2nd Level Setup Menu 60 Exiting the Setup Menu 60

Displaying Plasma System Resistance r 61

General 61 Measuring Plasma System Resistance r 61

Displaying Plasma System Inductance L 62

General Information on Plasma System Inductance L 62 Displaying Plasma System Inductance L 62

The Gas Menu 63

General 63 Accessing the Gas Menu 63 Adjusting Parameters 63 Parameters in the Gas Menu 63 Exiting the Setup Menu 64

The Job Correction Menu 65

General 65 Accessing the Job Correction Menu 65 Adjusting Parameters 65 Correctable Parameters in the Job Correction Menu 65 Exiting the Job Correction Menu 67

Troubleshooting and Maintenance 69

Troubleshooting 71

General 71

Safety 71 Displayed Service Codes 71 Power Source Troubleshooting 75

Service, maintenance and disposal 77

General 77 Safety 77 At every start-up 77 Every 2 Months 77 Every 6 Months 78 Disposal 78

Appendix 79

Technical data 81

Special Voltage 81 Acerios 81 Explanation of Footnotes 81

EN-US

Safety Instructions

Explanation of Safety Instructions

DANGER!

Indicates an immediate danger.

Death or serious injury may result if appropriate precautions are not taken.

▶

WARNING!

Indicates a possibly dangerous situation.

Death or serious injury may result if appropriate precautions are not taken.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

Minor injury or damage to property may result if appropriate precautions are

▶

not taken.

NOTE!

Indicates the possibility of ﬂawed results and damage to the equipment.

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized safety standards. If used incorrectly or misused, however, it can cause

serious or fatal injury 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.

All persons involved in the commissioning, operation, maintenance, and servicing of the device must

be suitably qualified,

have knowledge of plasma surface treatment and

have completely read and followed these Operating Instructions.

The Operating Instructions must always be kept to hand wherever the device is being used. In addition to the Operating Instructions, all applicable local rules and regulations regarding accident prevention and environmental protection must also be followed.

All safety and danger notices on the device must

be kept in a legible state

not be damaged/marked

not be removed

not be covered, pasted, or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the Operating Instructions for the device. Before switching on the device, remove any faults that could compromise safety.

Your personal safety is at stake!

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

The device is intended exclusively for the process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose". The manufacturer accepts no liability for any damage resulting from improper use.

Intended use also means

reading and adhering to all instructions in the Operating Instructions

reading and adhering to all safety instructions and danger notices

carrying out all the specified inspection and servicing work.

Never use the device for the following applications:

Thawing pipes

Charging batteries

Starting motors

The device is designed for operation in industry and business. The manufacture shall not be liable for any damage resulting from use in a living area.

The manufacturer shall also not be liable for faulty or incorrect work results.

EN-US

Environmental Conditions

Obligations of the Operating Company

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage resulting from improper use.

Temperature range of the ambient air:

During operation: -10°C to +40°C (14°F to 104°F)

During transport and storage: -20°C to +55°C (-4°F to 131°F)

Relative humidity:

Up to 50% at 40°C (104°F)

Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc. Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

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

Are familiar with the basic occupational safety and accident prevention regu-

lations and are trained in handling the device Have read and understood these Operating Instructions, especially the sec-

tion "Safety Rules," and have confirmed this with their signature Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

Obligations of Personnel

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

Grid Connection Devices with a high output can inﬂuence the energy quality of the grid due to

their current consumption.

This may affect a number of device types in terms of:

connection restrictions

criteria regarding maximum permissible grid impedance

criteria regarding the minimum required short-circuit power

both at the interface with the public grid

See technical data

In this case, the operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

Personal Protection and Protection of Others

You are exposed to numerous hazards while handling the device, for example:

Flying sparks and pieces of hot metal

Arc radiation that poses a risk of injury to the eyes and skin

Hazardous electromagnetic fields that pose a risk of death for individuals

with pacemakers Electrical risks from grid current and welding current

Increased noise exposure

Harmful fumes and gases

Wear suitable protective clothing when dealing with the device. The protective clothing must have the following properties:

Flame resistant

Insulating and dry

Covering the entire body and in good condition with no damage

Safety helmet

Cufﬂess pants

Protective clothing involves the following:

Protecting the face and eyes from UV radiation, heat, and ﬂying sparks with a

face guard featuring a regulation-compliant filter. Wearing regulation-compliant protective goggles with side protection behind

the face guard. Wearing rigid, wet-insulating footwear.

Protecting hands with appropriate gloves (featuring electrical insulation and

thermal protection). Wearing ear protection to reduce noise exposure and protect against injury.

Data regarding Noise Emission Values

Keep persons, especially children, away during the operation of the devices and during the plasma surface treatment process. However, if persons are in the vicinity:

Instruct them about all hazards (blinding hazard due to arcs, risk of injury

from ﬂying sparks, fumes hazardous to health, noise exposure, possible hazard due to grid current or process current, etc.), Provide suitable protective equipment, or

Construct suitable protective walls and curtains.

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 work station-specific emission value cannot be specified because this value depends on the process and the environmental conditions. It depends on differing parameters, such as the power range, the component geometry, the material, the resonance properties of the workpiece, the work station environment, and many other factors.

EN-US

Danger from Toxic Gases and Vapors

The fumes produced during plasma surface treatment contain toxic gases and vapors.

The fumes produced contain substances that may cause birth defects and cancer in some circumstances.

Use at-source extraction source and a room extraction system. If possible, use integrated extraction devices.

The operator of the plasma system is obliged to maintain the values for the maximum allowable concentrations (MAC).

Ensure that there is sufficient fresh air!

Arrange the extraction capacity so that at least 3 times the gas used can be

extracted per plasma torch.

Keep your head out of the fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

Do not breathe them in

Extract them from the work area using appropriate equipment.

Use breathing apparatus with air supply if there is insufficient ventilation.

When no work is taking place, close the valve of the gas cylinder or the main gas supply.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.

The following components are factors that determine how toxic the fumes are:

The materials used for the workpiece

Electrodes

Coatings

Cleaning agents, degreasers, and the like

The type and amount of component contamination

Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.

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

Danger from Fire Flying sparks can cause fires and explosions.

Never perform the plasma surface treatment near ﬂammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Only ever perform the plasma surface treatment in areas at risk of fire and explosion, on sealed tanks, drums, or pipes if these have been prepared in accordance with corresponding national and international standards.

Do not perform the plasma surface treatment on containers in which gases, fuels, mineral oils, and the like are/were stored. Residues pose a risk of explosion.

Do not perform plasma surface treatments on materials or contamination which could cause a fire when the plasma arc is operated.

Hazards from Grid Current and Process Current

An electric shock is life-threatening and may be deadly.

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

Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the 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. Before every use, check power connections for secure fit by hand. In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the longitudinal axis and pretension.

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

The electrode

never immerse it in liquids to cool it

never touch it when the power source is switched on.

The open circuit voltage of a device may double, for example, between two voltage-carrying electrodes. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.

Only operate the device on a grid with a ground conductor and a socket with a ground conductor contact.

Operating the device on a grid without a ground conductor and on a socket without a ground conductor contact is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.

Switch off unused devices.

Before working on the device, switch off the device and remove the mains plug.

Secure the device to prevent the mains plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

After opening the device:

Discharge all electrically charged components

Ensure that all components are disconnected from the power supply.

If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.

Stray currents If the following instructions are not observed, stray currents may occur, which

pose a risk of the following:

Fire

Overheating of components connected to the workpiece

Irreparable damage to ground conductors

Damage to the device and other electrical equipment

Ensure a tight connection between the hosepack and the power source.

Ensure a tight connection between the plasma nozzle and the plasma welding torch.

If the ﬂoor is electrically conductive, ensure that there is sufficient insulation between the device and the ﬂoor.

EN-US

EMC Device Classifications

EMC Measures In certain cases, even though a device complies with the standard limit values for

Devices in emission class A:

Are only designed for use in industrial settings

Can cause line-bound and radiated interference in other areas

Devices in emission class B:

Satisfy the emissions criteria for residential and industrial areas. This is also

true for residential areas in which the energy is supplied from the public lowvoltage grid.

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

emissions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.

Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interferenceprone equipment that could be affected by the device:

Safety devices

Grid power lines, signal lines, and data transfer lines

IT and telecommunications equipment

Devices for measuring and calibrating

Supporting measures to avoid EMC problems:

Grid power supply

1. If electromagnetic interference occurs despite a grid connection that

complies with regulations, take additional measures (e.g., use a suitable grid filter).

Route the hosepack far away from other lines

Equipotential bonding

Workpiece grounding

4. If necessary, establish grounding using suitable capacitors.

Shield, if necessary

5. Shield other devices in the vicinity

Shield the complete system

EMF Measures Electromagnetic fields may cause health problems that are not yet known:

Effects on the health of persons close by, e.g., those with pacemakers and

hearing aids Persons with pacemakers must seek advice from their doctor before staying

in the immediate vicinity of the device and the plasma process Keep distances between hosepacks and the head/torso of the operator as

great as possible for safety reasons Do not carry hosepacks over your shoulder or wrap them around your body

or body parts

Particular Hazard Areas

Keep hands, hair, loose clothing, and tools away from moving parts, such as:

fans

Covers and side parts must only be opened/removed during maintenance and repair work.

During operation:

Ensure that all covers are closed, and all side parts have been mounted prop-

erly. Keep all covers and side parts closed.

Always keep the plasma torch away from your body and wear suitable protective goggles.

Do not touch the workpiece during or after the plasma surface treatment - burning hazard.

Material or other residues may ﬂy off cooling workpieces. Therefore, also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected.

Leave the plasma torch and other parts with a high operating temperature to cool before working on them.

Special regulations apply in areas at risk of fire or explosion

- follow the appropriate national and international regulations.

Power sources for work in areas where electrical hazards pose a greater risk (e.g. the boiler room) must be marked with a (Safety) sign. However, the power source may not be located in such areas.

Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.

When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufacturer's homepage.

Only use suitable load-carrying equipment from the manufacturer when transporting devices by crane.

Attach chains or ropes to all designated suspension points on suitable load-

carrying equipment. Chains or ropes must be as close to perpendicular as possible.

Remove the gas cylinder.

If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The handle and carrier belt are not suitable for transport by crane, counterbalanced lift truck or other mechanical lifting tools.

All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g. for mechanic-

al damage, corrosion, or changes due to other environmental inﬂuences). The test interval and scope must at least comply with the respective valid national standards and guidelines.

There is a risk of colorless, odorless gas escaping unnoticed if an adapter is used for the gas connection. Use suitable Teﬂon tape to seal the thread of the gas connection adapter on the device side before installation.

EN-US

Impaired Plasma Surface Treatment

Danger from Gas Cylinders

The following specifications concerning gas quality must be met in order to ensure the safe and proper function of the plasma system:

Solid particle size < 40 µm

Pressure condensation point < -20 °C

Max. oil content < 25 mg/m³

Use filters if necessary.

IMPORTANT! Ring lines in particular pose a risk of contamination.

Gas cylinders contain compressed gas and may explode if damaged. Gas cylinders are an integral part of the plasma system, so they must be handled very carefully.

Protect gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open ﬂames, sparks, and arcs.

Mount the gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.

Keep gas cylinders away from electrical circuits.

Ensure that when handling a plasma torch, you never:

Hang it on a gas cylinder

Point it at or place it on a gas cylinder

Danger due to Escaping Gas

Never touch a gas cylinder with an electrode.

Risk of explosion - never perform a plasma surface treatment on a compressed gas cylinder.

Always use suitable gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.). Only use gas cylinders and accessories that are in good condition.

If a valve on a gas cylinder is open, turn your face away from the outlet.

If no plasma surface treatment is being performed, close the valve of the gas cylinder.

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

Follow the manufacturer's instructions and applicable national and international provisions for gas cylinders and accessories.

Risk of suffocation due to uncontrolled gas leakage

In the event of leaks, the escaping colorless and odorless gas may displace the oxygen in the ambient air.

Ensure there is a sufficient supply of fresh air with a ventilation ﬂow rate of

at least 20 m³ per hour Observe the safety and maintenance information on the gas cylinder or the

main gas supply When no plasma surface treatment is being performed, close the valve of

the gas cylinder or the main gas supply. Check the gas cylinder or main gas supply for uncontrolled gas leakage be-

fore each start-up.

Safety Measures at the Setup Location and During Transport

A toppling device can be deadly! Set up the device securely on an even, solid surface

A tilt angle of no more than 10° is permitted.

Special regulations apply in areas at risk of fire or explosion

Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the area around the work station is always clean and organized.

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

When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Do not lift or transport any active devices. Switch off devices before transport or lifting.

Before transporting the device, completely drain the coolant and remove the gas cylinder.

It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before start-up. Have any damage repaired by trained service technicians before starting up the device.

Safety Measures in Normal Operation

Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of

serious or fatal injury to the operator or a third party,

damage to the device and other material assets belonging to the operating

company, inefficient operation of the device.

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

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

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

Always secure the gas cylinder well and remove it before transporting by crane.

Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, ﬂammability, etc.).

Only use appropriate original coolant from the manufacturer.

Do not mix original coolant from the manufacturer with other coolants.

Only connect system components from the manufacturer to the cooling unit circuit.

If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.

Cooling Liquid FCL 10/20 is not ﬂammable. The ethanol-based coolant is ﬂam- mable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.

Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or via the manufacturer's homepage.

When the system is cool, always check the coolant level before starting a plasma surface treatment.

EN-US

Maintenance and repair

Safety Inspection

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.

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

A safety inspection by a certified electrician is recommended

after changes

after alterations

after repair, care, and maintenance

at least every 12 months.

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection from your service center. The service center will provide the necessary documents upon request.

Disposal Do not dispose of this device with normal domestic waste! To comply with the

European Directive on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its

life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must be returned to your dealer, or you must locate the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage

and electromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).

Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com

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

Data backup The user is responsible for backing up any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your comments.

General information

General

Device Concept The fully digitized and microprocessor-

controlled Acerios plasma power source is used for Hot Active Plasma (HAP) surface treatments on metallic materials.

The modular design makes it easy to upgrade the system and allows great ﬂexibility. The devices can be adapted to practically any conditions.

The plasma power source has a LocalNet interface to make it easy to connect digital system add-ons. The extensive robot and system interfaces simplify networking and control.

All key functions can be quickly viewed and adjusted. Job Mode allows differing process parameters to be saved and retrieved and can be used for pre-setting.

EN-US

Operating Principle

The plasma pulsed arc function with a wide frequency range provides additional process-stabilizing options.

The Acerios plasma power source has an optimized high-frequency ignition process for short cycle times and high repeatability.

NOTE!

The plasma surface treatment process will simply be referred to as the plasma process in the rest of these instructions.

The central control and regulation unit of the plasma power source is coupled with a digital signal processor. Together, the central control and regulation unit and signal processor control the entire plasma process. During the plasma process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired status is maintained.

This results in:

a precise plasma process,

an exact degree of reproducibility for all process parameters,

excellent surface treatment properties.

The energy yield can be individually tailored by distance and speed.

It is possible to achieve high plasma process speeds, thanks to stable and precise arc control and the regulated supply of process gas (argon).

Another gas can be introduced via an additional gas connection, e.g. as a shielding gas or as a reactive gas.

Application Areas

The devices are used commercially in automated applications with various metals, non-ferrous metals, and various heat-resistant materials.

The devices achieve excellent results, for example in cleaning applications involving:

Dry lubricant on aluminum

Oil on steel

System Configurations

Plasma power source and cooling unit installed on an upright console

(1) Acerios plasma power source

+ Robot interface

(2) FK 9000 R cooling unit

(3) TU Podium upright console

(4) Gas control 5 - 30 l

digital, external gas regulator

(5) PCT 2000 plasma torch

(6) Robot

(7) Robot control system

Plasma power source and gas cylinder on trolley, separate cooling unit

(1) Acerios plasma power source

+ Robot interface

(2) CU 1800 or CU 4700 cooling unit

+ OPT/i CU 1800 / 4700 Interface FC

(3) TU Car 4 Pro trolley

(4) Gas control 5 - 30 l

digital, external gas regulator

(5) PCT 2000 plasma torch

(6) Robot

(7) Robot control system

Operating controls and connec-

tions

Control Panel

General The key feature of the control panel is the logical arrangement of the controls.

All parameters essential for day-to-day work can be easily

selected with buttons

changed using the selection dial

shown on the digital display during the plasma process.

NOTE!

Because of software updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa.

In addition, individual figures may also differ slightly from the operating elements of your device. However, the function of these operating elements is identical.

EN-US

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

Control Panel

(1)

(2)

(3)

(4)

(5) (6) (7)

(15)

(14)

(13)

(12)

(11)

(10)

(8)

(9)

No. Function

(1) Left parameter selection button

(2) Right parameter selection button

Buttons (1) and (2) are used to select the following process parameters:

Starting current for the plasma process

UpSlope

Period of time it takes to rise from the starting current I cified main current I

during the plasma process.

main

to the spe-

start

Main current for the plasma process

DownSlope

Period of time it takes to fall from the specified main current I final current I

Final current for the plasma process

during the plasma process.

end

main

to the

Job number

In job mode, for retrieving saved parameter sets by job numbers.

Diameter of electrode For entering the diameter of the tungsten electrode for the plasma process

When a parameter is selected, the LED at the corresponding parameter symbol illuminates.

(3) Special indicators

Pulsing indicator

Illuminates when the F-P setup parameter has been set to a pulse frequency

Electrode overloaded indicator

Illuminates when the tungsten electrode is overloaded

Further information on the electrode overloaded indicator can be found in the section headed "Overloaded Electrode" on page 41 of the "Plasma Surface Treatment" chapter.

Key lock indicator

Illuminates when the key lock is activated

Inch indicator

Illuminates when the SEt setup parameter is set to US

(4) Overtemperature indicator

Illuminates when the power source heats up excessively Refer to the "Troubleshooting" section for further information.

(5) Left digital display

(6) Process current display

For displaying the current value for the parameters starting current I main current I

, and final current I

main

The left digital display shows the set value before the start of the plasma process. For I

start

and I

end

amount of the main current I The parameter I

is automatically selected after the start of the

main

plasma process. The left digital display shows the current actual value of the main current. The corresponding position in the plasma process is shown for the process parameters by illuminated LEDs.

end

, the right digital display also shows the %

main

EN-US

start,

(7) Voltage indicator

Illuminates when the selected parameter is I During the plasma process, the current actual voltage value is indicated

on the right digital display.

(8) Right digital display

(9) Unit indicators

Job no. indicator Illuminates in Job Mode

kHz indicator Illuminates if the F-P setup parameter is selected when the value entered for the pulse frequency is >/= 1000 Hz

Hz indicator Illuminates if the F-P setup parameter is selected when the value entered for pulse frequency is < 1000 Hz

main

mm indicator Illuminates when the electrode diameter setup parameter has been selected

s indicator Illuminates when parameters tup and t

the following setup parameters: GPr / G-L / G-H / t-S / t-E / C-t / HFt / Ito / Arc

% indicator Illuminates when parameters I

setup parameters dcY and I-G

A indicator

(10) LocalNet connection

Standardized connection socket for system add-ons

(11) Torch control connection

Input for the collision protection signal if connecting a robot interface or fieldbus coupler

(12) Operating mode button

For selecting the operating mode

2-step mode

4-step mode

Job Mode

start

down

and I

have been selected, along with

end

When a mode is selected, the LED illuminates at the corresponding symbol.

(13) Gas-test button

For setting the required gas volume on the pressure regulator After pressing the gas-test button, process gas is released for 30 s. Press the button again to stop the gas ﬂow prematurely.

(14) Selection dial

for changing parameters. When the indicator on the selection dial illuminates, the selected parameter can be changed.

(15) Store button

For saving jobs and accessing the Setup menu

Shortcut Keys - Special Functions

General Pressing buttons on the control panel simultaneously or repeatedly can access

the functions described below.

EN-US

Key Lock

Activate key lock:

Keeping the store button pressed, press the right parameter selection button.

The lock message "CLo|SEd" appears brieﬂy on the digital displays.

The key lock special indicator illuminates on the control panel

Now if a button is pressed, the lock message "CLo|SEd" will appear on the control panel. The selection dial can only be used to change the parameter selected when the keys were locked.

NOTE!

The key lock also remains activated after the power source has been switched off and back on again.

Deactivate key lock:

Keeping the store button pressed, press the right parameter selection button

The unlock message "‑OP|En‑"

appears brieﬂy on the digital displays. The key lock special indicator turns off

Show Software Version, Runtime, and Coolant Flow

Show software version:

Keeping the store button pressed, press the left parameter selection button. The software version appears on the digital displays.

Show runtime:

Press the left parameter selection button again

The runtime records the actual plasma time since starting for the first time. Example: "654 | 32.1" = 65,432.1 hours= 65,432 hours 6 mins

NOTE!

The runtime indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.

Show coolant ﬂow:

(Only in conjunction with a cooling unit with the optional ﬂow sensor fitted): Press the left parameter selection button again

The current coolant ﬂow of the cooling unit is shown in l/min (CFL = Coolant Flow) If the coolant ﬂow is < 0.7 l/min, the power source switches off after the period of time set in parameter C-t, the error message "no | H2O" is output.

Exit:

by pressing the store button.

Connections, Switches, and Mechanical Compon-

(1)

(4)

(5)

(8)

(7)

(6)

(2)

(3)

ents

Acerios Connections

EN-US

No. Function

(1) (+) Current socket with bayonet latch

Connect the plasma torch here

(2) LocalNet connection

Standardized connection socket for system add-ons

(3) Torch control connection

Input for the collision protection signal if connecting a robot interface or fieldbus coupler

(4) (-) Current socket with bayonet latch and gas outlet

Connect the plasma torch here

(5) Power switch

For switching the power source on and off

(6) Dummy cover

(7) Mains cable with strain relief

(8) Gas connection

For using an additional shielding gas

Depending on the configuration, a robot interface is fitted to the plasma power source.

Installation and Startup

Before installation and initial operation

EN-US

Safety

Danger from incorrect operation and work that is not carried out properly.

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

▶ ▶

▶

Minimum Equipment

Intended Use The plasma power source is intended exclusively for automated plasma surface

treatment in conjunction with Fronius components. Any other use does not constitute proper use. The manufacturer accepts no responsibility for any damage resulting from improper use.

WARNING!

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

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

Acerios plasma power source Robot interface or fieldbus coupler Plasma torch Cooling unit Process gas connection (process gas supply of 5 - 6 bar) Digital, external gas regulator

Setup Regulations

Intended use also means:

Following all instructions in these Operating Instructions

Reading the Operating Instructions of all the other system components, es-

pecially the safety rules in the aforementioned documents Carrying out all the specified inspection and servicing work

The device has been tested according to degree of protection IP 23. This means:

Protection against penetration by solid foreign bodies with diameters > 12.5

mm (0.49 in.) Protection against spraywater at any angle up to 60° from the vertical

The device can be set up and operated outdoors in accordance with degree of protection IP 23. Direct moisture (e.g., from rain) must be avoided.

WARNING!

Danger from machines toppling over or falling.

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

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through

the vents on the front and back. Any electrically conductive dust (e.g. from grinding work) must not be allowed to be sucked directly into the device.

Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the

mains cable or mains plug has not been attached to your version of the appliance, these must be installed according to national standards. Fuse protection for the grid lead can be found in the technical data.

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.

Installation

EN-US

Safety

Danger from electrical current.

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

▶ ▶ ▶

Danger of electrical current due to electrically conductive dust in the device.

This can result in severe personal injury and damage to property.

▶

General A standard configuration is used to describe the installation and start-up of the

plasma system.

WARNING!

Before starting work, switch off all devices and components involved, and disconnect them from the grid. Secure all devices and components involved 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.

WARNING!

Only operate the device if an air filter is fitted. The air filter is a very important safety device for achieving IP 23 protection.

Installation

The standard configuration consists of the following system components:

Acerios plasma power source (including robot interface)

FK 9000 R cooling unit

PCT 2000 plasma torch

Gas pressure regulator

Gas cylinder with process gas

Upright console

Gas control 5 - 30 l

The following steps should provide an overview of plasma system installation and start-up. For detailed information about the individual steps, please refer to the corresponding Operating Instructions for the system components.

WARNING!

Danger due to incorrect operation.

Serious personal injury and damage to property may result.

All the functions described may only be used by trained specialist personnel.

▶

Read and understand this document in full.

▶

Read and understand all the Operating Instructions for the system compon-

▶

ents, especially the safety rules, in full.

Requirement:

The components for an automated application (e.g. robot, robot control sys-

tem, longitudinal chassis, rotary tables, etc.) must be present and ready for use.

Anchor the upright console to the surface

Fit the cooling unit on the upright console

IMPORTANT! To mount the cooling unit, follow the "FK 9000 R in Conjunc-

tion with a Power Source" chapter in the Operating Instructions for the cooling unit.

Connect and secure the plasma power source to the cooling unit

Set up the plasma torch (on the robot, for example)

Connect the plasma torch to the plasma power source and the cooling unit

Connect the plasma torch to the external gas regulator

Use a LocalNet cable to join the external gas regulator to the plasma power

source

Connect the process gas supply to the external gas regulator

IMPORTANT! A ﬂow controller must not be fitted upstream of the external

gas regulator.

Connect the robot interface to the robot control system

Equip the plasma torch with the correct wearing parts

NOTE!

Do not use pure tungsten electrodes for the Acerios plasma power source (color code: green).

Commissioning

EN-US

Connecting the Gas Cylinder

WARNING!

Danger of severe injury and damage to property if gas cylinders fall over.

Place gas cylinders on a solid, level surface in such a way that they remain

▶

stable. Secure the gas cylinders to prevent them from falling over: the retaining

▶

strap must be attached at the height of the upper part of the gas cylinder. Never secure a retaining strap to the neck of the cylinder!

▶

Observe the safety rules of the gas cylinder manufacturer!

▶

Secure the gas cylinder

Remove the safety cap from the gas cylinder

Brieﬂy open the gas cylinder valve to remove surrounding dirt

Inspect the seal on the gas pressure regulator

Screw the gas pressure regulator to the gas cylinder and tighten the connec-

tion

Use a gas hose to join the gas pressure regulator and the GAS IN connection

at the external gas regulator

Tighten the gas hose union nut

Connecting the Plasma Torch

Set the power switch to - O -

Insert the power cable from the plasma torch hose pack into the current

sockets of the plasma power source and twist clockwise to lock in place

IMPORTANT! (-) = current socket / power cable with gas through-hole!

Connect the plasma torch gas hose to the GAS OUT connection on the ex-

ternal gas regulator

Fit parts to the plasma torch according to the plasma torch's Operating In-

structions

Connect the plasma torch coolant connections to the cooling unit according

to the color markings for coolant supply and coolant return (red)

Plasma Surface Treatment

Overloaded Electrode

EN-US

Overloaded Electrode

If the electrode is overloaded, there is a risk that an oversized cap could form on the tungsten electrode. An oversized cap has a negative effect on the ignition properties.

If the electrode is overloaded, the "electrode overloaded" indicator illuminates on the control panel.

Possible causes of an overloaded electrode:

Diameter of the tungsten electrode is too small

Main current I

Remedy:

Use a tungsten electrode with a larger diameter

Reduce the main current

NOTE!

The "electrode overloaded" indicator is tailored for use with ceriated tungsten electrodes.

For all other electrodes, the "electrode overloaded" indicator can be used as a guide.

value is set too high

main

Description of operating modes

0 ... 1

1 ... 0

main

GPr

start

down

end

t-S t-E

0 ... 1

1 ... 0

0 ... 1

1 ... 0

main

GPr

start

down

end

0 ... 1 1 ... 01 ... 0 0 ... 1

2-Step Mode

Trigger signal (from the robot control system)

Reset trigger signal

GPr = gas pre-ﬂow time, I main current, t

= DownSlope, I

down

= starting current, t-S = starting current time, tup = UpSlope, I

start

= final current, t-E = final current time

end

main

4-Step Mode

Trigger signal (from the robot control system)

Reset trigger signal

Start with starting current I

UpSlope and working with main current I

Lowering to final current I

End (trigger signal not active)

In 4-step mode, the starting current time and the final current time are defined by the length of time for which the trigger signal is active.

(trigger signal active)

start

main

(trigger signal active)

end

(trigger signal not active)

GPr = gas pre-ﬂow time, I DownSlope, I

= final current,

end

= starting current, tup = UpSlope, I

start

= main current, t

main

down

Plasma Surface Treatment

EN-US

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all the devices and components involved and

▶

disconnect them from the grid. Secure all devices and components involved 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.

Process Parameters

start

main

down

end

Starting current

0 - 200% (of main current I Factory setting: 50%

UpSlope

0.0 - 9.9 s Factory setting: 0.5 s

Main current

35 - 200 A Factory setting: -

DownSlope

0.0 - 9.9 s Factory setting: 1.0 s

Final current

0 - 100% (of main current I Factory setting: 30%

Electrode diameter

OFF - max. mm / in. Factory setting: 4.8 mm/0.189 in.

main

)

Plasma Surface Treatment

Insert mains plug

CAUTION!

Danger of injury and damage from electric shock.

When the power switch is set to position - I -, the tungsten electrode of the plasma torch is live.

Ensure that the tungsten electrode is not touching any people or electrically

▶

conductive or grounded parts (housing, etc.).

Set the power switch to position - I -

All indicators on the control panel brieﬂy illuminate.

Press the operating mode button to select the desired operating mode:

2-step mode

4-step mode

Use the left or right parameter selection button to select the corresponding

process parameters

Set the selected parameters to the desired value with the selection dial

All parameter set values that are set using the selection dial are saved until their next alteration. This is still true if the power source has been turned off and back on again in the meantime.

Check whether the "COr" parameter in the 2nd level Setup menu is set to

"Aut"

Set the process gas cylinder pressure regulator to 5 - 6 bar or open the valve

of the main gas supply

If hosepacks are long and condensate has built up after longer periods of

downtime in the cold: Pre-purge the gas - set a time for setup parameter GPU

The plasma power source is now ready.

Plasma surface treatment is triggered by a corresponding signal from the robot control system.

Special Functions and Options

EN-US

Arc Break Monitoring Function

Ignition TimeOut Function

Plasma Pulsing The current set at the start of a plasma surface treatment may not always be op-

If the arc breaks and no current ﬂow takes place during the time set in the Setup menu, the plasma power source automatically switches off. The control panel displays the service code "no | Arc".

Press any button on the control panel to resume the plasma process.

The "2nd Level Setup Menu" section describing how to set the arc break monitoring (Arc) setup parameters begins on page 58.

The plasma power source has an ignition time-out function.

If the plasma process is started, gas pre-ﬂow begins immediately. Then the ignition procedure is initiated. If no plasma arc emerges during the period of time set in the Setup menu, the plasma power source automatically switches off. The control panel displays the service code "no | IGn".

The "2nd Level Setup Menu" section describes how to set the ignition time-out function (ito) parameter.

timum for the entire plasma process.

If the amperage is too low, this can reduce the effect of the plasma arc. If the amperage is too high, this can cause distortion in thin-walled components. Low treatment distances and treatment speeds can cause thermal damage to components.

With plasma pulsing (plasma process with a pulse current), a low base current IG rises steeply to the significantly higher pulse current I

the base current I-G after the set dcY (duty cycle) time. Higher pulse frequencies are generally used in automated applications and mainly serve to stabilize the plasma arc.

Plasma pulsing allows the heat input to be tailored to each component and restricted, if necessary, to achieve the best-possible results.

and drops back to

main

Current ﬂow during plasma pulsing

1/F-P

I-G

down

start

end

dcY

main

= starting current, I

start

quency, dcY = duty cycle, IG = base current, I

= final current, tup = UpSlope, t

end

main

*) (1/F-P = Time between two impulses)

= main current

down

= DownSlope, F-P = pulse fre-

Hold-Function The current actual process current and process voltage values are saved each

time a process ends. The hold-function relates to the last main current I

to be reached.

main

If other parameters are selected, the set values will be displayed again. If the I

parameter is selected again, the hold values will still be available.

main

The hold values are cleared when:

a process starts again

the process current I

the operating mode is changed

main

is set

NOTE!

No hold values are output if the main current phase has never been reached.

Job Mode

General Job Mode raises quality and simplifies operation in automated plasma applica-

tions. Up to 100 proven jobs (operating points) can be reproduced in Job Mode, with no need to manually document the parameters. Different jobs are preprogrammed, depending on the configuration.

Another advantage is that because jobs are preprogrammed, the plasma power source is ready for use immediately. The jobs can be grouped or lined up in accordance with the production process.

The result is minimal downtime at fully reproducible quality, as well as easy operation and adjustment.

Abbreviations The following messages can be displayed when working with jobs:

- -

- .....

nPG ....No job assigned to the program location (saving a job)

No job assigned to the program location (job retrieval)

EN-US

PrG .... Job assigned to the program location

Pro ..... Brieﬂy displayed while saving

dEL .... Brieﬂy displayed while deleting

Saving a Job

NOTE!

Jobs cannot be created in Job Mode.

Creating a new job:

Set the desired process parameters to be saved as a job

NOTE!

Apart from specific settings in the 2nd level Setup menu, all the currently made settings are saved.

Brieﬂy press the store button to switch to the Job menu.

The first free program location for the job is displayed.

Use the selection dial to select the desired program location, or leave the

suggested program location.

Press and hold the store button

NOTE!

If the selected program location already has a job assigned to it, the existing job will be overwritten by the new job.

This action cannot be undone.

"Pro" shows on the left digital display - the job is saved to the preset program location.

If "PrG" appears on the left digital display, saving has finished.

Release the store button

Brieﬂy press the store button to exit the Job menu.

The power source switches to the setting requested before the job was saved.

Job Retrieval

NOTE!

Before retrieving a job, make sure that the plasma power source is set up and installed in accordance with the job.

Press the operating mode button to select Job Mode

The last used job is displayed.

Use the selection dial to select the desired job

Use the left and right parameter selection buttons to view the settings programmed in the job. It is not possible to change these settings.

EN-US

It is not possible to select unassigned program locations (indicated by "- - -") either, when retrieving a job on the plasma power source.

Start the plasma process

The plasma surface treatment is performed with the parameters saved in the job. During the plasma process, it is possible to switch to a different job without interruption.

Switching to a different operating mode ends Job Mode.

Copying/Overwriting a Job

In Job Mode, it is possible to copy a job already saved to a program location to any other program location:

Press the operating mode button to select Job Mode

The last used job is displayed.

Use the selection dial to select the desired job

Brieﬂy press the store button to switch to the Job menu.

The first free program location is suggested for the job being copied

Use the selection dial to select the desired program location, or leave the

suggested program location.

Press and hold the store button

NOTE!

If the selected program location already has a job assigned to it, the existing job will be overwritten by the new job.

This action cannot be undone.

"Pro" shows on the left digital display - the job is copied to the preset program location.

When "PrG" appears on the left digital display, copying has finished.

Release the store button

Brieﬂy press the store button to exit the Job menu

The power source switches to the setting requested before the job was copied.

EN-US

Deleting a Job

In Job Mode, brieﬂy press the store button to switch to the Job menu.

The first free program location is displayed.

Use the selection dial to select the job to delete

The "DEL" symbol illuminates on the gas-test button.

Press and hold the gas-test button

"dEL" shows on the left digital display - the job is deleted.

When "nPG" appears on the left digital display, deleting has finished.

Release the gas-test button

Brieﬂy press the store button to exit the Job menu.

The power source switches to the setting requested before the job was deleted

Setup Settings

The Setup Menu

General The Setup menu offers easy access to expert knowledge related to the plasma

power source, as well as additional functions. The Setup menu makes it possible to easily adjust the parameters for various tasks.

All setup parameters that directly affect the plasma process are located in

the Setup menu. All setup parameters for presetting the plasma system are located in the 2nd

level Setup menu.

The parameters are arranged in logical groups. The individual groups can be accessed through their own shortcut keys.

EN-US

Accessing the Setup Menu

Accessing the 2nd Level Setup Menu

Press the operating mode button to select 2-step mode

Press and hold the store button

Press the operating mode button

The power source is now located in the Setup menu. The last selected parameter is displayed.

Accessing the Setup Menu

Select the "2nd" parameter

Press and hold the store button

Adjusting Parameters

Press the operating mode button

The power source is now located in the 2nd level Setup menu. The last selected parameter is displayed

Use the left or right parameter selection button to select the parameter to

adjust

Use the selection dial to change the parameter value

Parameters in

main

GPr

start

tupt

down

end

t-S t-E

0 ... 1

1 ... 0

the Setup Menu

F-P Pulse frequency

OFF / 0, 20 Hz - 2.00 kHz) Factory setting: OFF

IMPORTANT! If F-P is set to "OFF", Setup parameters dcY and I-G cannot be selected.

The pulsing special display illuminates on the control panel if a value for

the pulse frequency has been entered. Selecting pulse frequency F-P:

0.2 Hz to 5 Hz ... Thermal pulsing 1 kHz to 2 kHz ... Arc-stabilizing pulsing (stabilizing the arc at a low process current)

dCY Duty cycle

Relationship between pulse duration and base current duration at the set pulse frequency 10 - 90% Factory setting: 50%

I-G Base current

0 - 100% (of main current I Factory setting: 50%

main

)

t-S Starting current time (for 2-step mode)

OFF / 0.01 - 9.9 s Factory setting: OFF

The starting current time t-S indicates the duration of the starting-current phase I

start

t-E Final current time (for 2-step mode)

OFF / 0.01 - 9.9 s Factory setting: OFF

The final current time t-E indicates the duration of the final current phase I

end

2-step mode: Starting current and final current time GPr = gas pre-ﬂow time, I

time, tup = UpSlope, I

main

= starting current, t-S = starting current

start

= main current, t

current, t-E = final current time 0 ... 1 = trigger signal (from the robot control system) 1 ... 0 = trigger signal reset

FAC Factory

Resetting the plasma power source to the factory setting

= DownSlope, I

down

= final

end

Keep the store button pressed for 2 s, to restore the factory setting. If "PrG" shows on the digital display, the plasma power source is reset.

IMPORTANT! If the plasma power source is reset, all the personal settings in the Setup menu are lost. The jobs and parameter settings in the 2nd level Setup menu are not deleted when the plasma power source is reset.

2nd 2nd level Setup menu

EN-US

Parameters in the 2nd Level Setup Menu

C-C Cooling unit controls

Aut / ON / OFF Factory setting: Aut

Aut ... The cooling unit cuts out 2 minutes after the end of the plasma process ON ... The cooling unit remains permanently ON OFF ... The cooling unit remains permanently OFF

IMPORTANT! If the cooling unit has the "Thermostat" option fitted, the

return-ﬂow temperature of the coolant is constantly checked. If the re- turn-ﬂow temperature is less than 50 °C, the cooling unit cuts out auto-

matically.

C-t Cooling time

Time from when the ﬂow sensor is triggered until the "no | H2O" service code is output For example, if there are air bubbles in the cooling system, the cooling unit will not cut out until the end of this preset time.

5 - 25 s Factory setting: 10 s

IMPORTANT! Every time the plasma power source is switched on, the cooling unit carries out a test run for 180 seconds.

HFt High frequency time

High frequency ignition: Time between HF impulses

0.01 - 0.4 s / EHF (starting with external ignition tool) Factory setting: 0.01 s

IMPORTANT! If there are problems with sensitive equipment in the immediate vicinity, increase the HFt parameter up to as much as 0.4 s.

PrI Delayed ignition for immediate high frequency start

OFF / 0.1 - 1 s Factory setting; OFF

If a time is entered for the PrI parameter, arc ignition is delayed by this amount of time: trigger signal - high frequency applied for the period of time - arc ignition

r Plasma system resistance

mOhm

See the "Displaying Plasma System Resistance r" section starting on page

61.

L Plasma system inductance

Microhenry See the "Displaying Plasma System Inductance L" section starting on page 62.

Ito Ignition time-out

Period of time until the safety cut-out following failed ignition

0.1 - 9.9 s Factory setting: 5 s

IMPORTANT! The ignition time-out function is a safety function and cannot be deactivated. The ignition time-out function is described on page

45.

Arc Arc break monitoring

Period of time until the safety cut-out following an arc break

0.1 - 9.9 s Factory setting: 2 s

IMPORTANT! Arc break monitoring is a safety function and cannot be deactivated. The arc break monitoring function is described on page 45.

SEt Country-specific setting

Std/US (Standard/USA) Factory setting: Std (metric units)

E-P External parameter

A freely selectable parameter for the robot interface A freely selectable parameter is available for the robot interface. If "E-P" is selected, use the selection dial to choose between the following for this freely definable parameter:

OFF ... The freely definable parameter is not assigned (factory setting) ELd ... Diameter of electrode I-S ... Starting current UPS ... UpSlope dsl ... DownSlope I-E ... Final current F-P ... Pulse frequency dcY ... Duty cycle I-G ... Base current The number of freely selectable parameters depends on the configuration and the set operating mode.

ACS Automatic changeover to main current

ON/OFF Factory setting: ON

ON After the plasma process has started, the parameter I

(main current)

main

is automatically selected. The main current I

OFF The last selected parameter remains selected during the plasma process. The last selected parameter can be adjusted immediately. The main current I

is not automatically selected.

main

COr Gas correction

For entering a gas correction factor for the process gas (only in conjunction with the "digital gas control" or "external gas regulator" options)

Aut / 1.0 - 10.0 Factory setting: Aut

IMPORTANT! More detailed explanations of the "COr" parameter can be found in the "Digital Gas Control" Operating Instructions.

can be adjusted immediately.

main

EN-US

Exiting the 2nd Level Setup Menu

Press the store button

The power source is now located in the Setup menu

Press the store button again to exit the Setup menu

Exiting the Setup Menu

Press the store button

Displaying Plasma System Resistance r

General Measuring the plasma system resistance provides information on the total resist-

ance of the plasma torch hosepack and the plasma torch.

For example, if the plasma system resistance increases after the plasma torch is replaced, the following components may be faulty:

Plasma torch hosepack

Plasma torch

Plasma torch wearing parts

Current sockets

The plasma system resistance is displayed on the right digital display after measuring.

r ... Plasma system resistance (in mOhm)

EN-US

Measuring Plasma System Resistance r

In Gas Setup, set the GAS parameter to "OFF"

Establish contact between the electrode and the plasma nozzle

Access the 2nd level Setup menu

Use the left or right parameter selection button to select the "r" parameter

NOTE!

Ensure that there is contact between the electrode and the plasma nozzle with new wearing parts.

The cooling unit is deactivated during the measurement.

Brieﬂy press the gas-test button

The plasma system resistance is calculated, the right digital display shows "run" during the measurement

The measurement is finished when the right digital display shows the plasma system resistance (e.g. 11.4 milliohm)

In the gas setup menu, set the GAS parameter to the desired value

Displaying Plasma System Inductance L

General Information on Plasma System Inductance L

The way that the hosepack is arranged has a significant effect on the properties of the plasma arc. Depending on the length and arrangement of the hosepack, a high plasma system inductance can be produced, especially during pulsing. The increase in current is limited.

Plasma stability can be optimized by modifying the hosepack arrangement. The hosepack must always be arranged as shown in the diagram.

Correct hosepack arrangement

Displaying Plasma System Inductance L

Measure plasma system resistance r

Use the left or right parameter selection button to select setup parameter "L"

The right digital display shows the plasma system inductance (e.g. 5 microhenry).

The Gas Menu

minImax

G-H

G-L

(1)

(2)

General The gas menu gives easy access to the gas settings.

EN-US

Accessing the Gas Menu

Adjusting Parameters

Parameters in the Gas Menu

Press and hold the store button

Press the gas-test button

The power source in now located in the gas menu; the last selected parameter is displayed.

Use the left or right parameter selection button to select the parameter to

adjust

Use the selection dial to change the parameter value

GPr Gas pre-ﬂow time

0.0 - 9.9 s Factory setting: 0.4 s

G-L Gas post-ﬂow time increase at minimum process current

0 - 25 s Factory setting: 5 s

G-H Gas post-ﬂow time increase at maximum process current

0 - 40 s / Aut Factory setting: Aut

The setting for G-H only applies if the maximum process current is actually set. The actual value results from the process current at that moment. With a medium process current, the actual value is half the setting for G-H, for example.

IMPORTANT! The settings for setup parameters G-L and G-H are added together. For example, if both parameters are at their maximum (25 s / 40 s), the gas post-ﬂow time lasts for 25 s at minimum process current 65 s at maximum process current 45 s if the process current is exactly halfway between the minimum and maximum current values.

In the Aut setting, the gas post-ﬂow time G-H is calculated automatically.

Gas post-ﬂow time subject to the process current: (1) = present gas post-ﬂow time, (2) = present process current, G-H = post-ﬂow at I

, G-L = post-ﬂow at I

max

min

GAS Set value for the ﬂow of process gas

("Digital Gas Control" option)

OFF / 5.0 - max l/min (OFF / 10.71 - max. cfh) Factory setting: 15 l/min (32.14 cfh)

IMPORTANT! More detailed explanations of the "GAS" parameter can be found in the "Digital Gas Control" Operating Instructions.

GPU Gas pre-purging

OFF / 0.1 - 10.0 min Factory setting: OFF

Gas pre-purging starts as soon as a value is set for GPU. For safety reasons, it is necessary to re-enter a value for GPU in order to re-start gas pre-purging.

IMPORTANT! Gas pre-purging is mainly required if condensate has built up after longer periods of downtime in the cold. Long hosepacks in particular may be affected by this.

Exiting the Setup Menu

Press the store button

The Job Correction Menu

General Setup parameters can be adapted to meet the specific requirements of individual

jobs in the job correction menu.

EN-US

Accessing the Job Correction Menu

Adjusting Parameters

Correctable Parameters in the Job Correction Menu

Press the operating mode button to select "Job Mode"

Press and hold the store button

Press the operating mode button

The power source is now located in the job correction menu. The first "Job" parameter is displayed. The "Job" parameter is used to select the job for which the parameters are to be adapted.

Use the selection dial to select the job with parameters to be adjusted

Use the left or right parameter selection button to select the parameter to be

corrected

Use the selection dial to change the parameter value

IMPORTANT! The adjusted parameters are immediately saved and applied to

the plasma process.

NOTE!

Some parameters are specific to the job correction menu and relate, for example, to changing settings that were affected the first time the job was saved on the control panel.

The list below contains the corresponding explanation and details of the adjustment ranges for these parameters.

The following parameters can be adjusted for each saved job:

Eld Electrode diameter

OFF - max. mm (OFF - max. in.) Factory setting: 4.8 mm (0.189 in.)

I-S Starting current I

0 - 200% (of main current I

start

main

)

Factory setting: 35%

UPS UpSlope t

Transition time from starting current I

to main current I

start

OFF / 0.01 - 9.9 s Factory setting: 0.5 s

I-1 Main current I

main

35 - 200 A Factory setting: -

main

dSL DownSlope t

Transition time from main current I OFF / 0.01 - 9.9 s

Factory setting: 1.0 s

down

to final current I

main

end

I-E Final current I

0 - 100% (of main current I

end

main

)

Factory setting: 30%

GAS Set value for the ﬂow of process gas

("Digital Gas Control" option) OFF / 5.0 - max l/min (OFF / 10.71 - max. cfh) Factory setting: 15 l/min (32.14 cfh)

Cor Gas correction

For entering a gas correction factor for the process gas (only in conjunction with the "digital gas control" or "external gas regulator" options) Aut / 1.0 - 10.0 Factory setting: Aut

JSL Job slope

Time for a smooth transition of the process current from the job in question to the job next in line

OFF / 0.1 - 9.9 s Factory setting: OFF

IMPORTANT! "JSL" job slope can be adjusted separately for each saved job.

It is only possible to progress from one job to the next without interrupting the plasma process with a robot interface or a fieldbus.

GPr Gas pre-ﬂow time

0.0 - 9.9 s Factory setting: 0.4 s

G-L Gas post-ﬂow time increase at minimum process current

0 - 25 s Factory setting: 5 s

G-H Gas post-ﬂow time increase at maximum process current

0 - 40 s / Aut Factory setting: Aut

More information about the G-H parameter can be found on page 63.

F-P Pulse frequency

OFF / 0, 20 Hz - 2.00 kHz Factory setting: OFF

More information about the F-P parameter can be found on page 45.

dCY Duty cycle

Relationship between pulse duration and base current duration at the set pulse frequency 10 - 90% Factory setting: 50%

I-G Base current

0 - 100% (of main current I Factory setting: 50%

tri Operating mode selection

2t / 4t

2t = operating mode is 2-step mode 4t = operating mode is 4-step mode

t-S Starting current time

OFF / 0.01 - 9.9 s Factory setting: OFF

More information about the t-S parameter can be found on page 56.

t-E Final current time

OFF / 0.01 - 9.9 s Factory setting: OFF

main

EN-US

)

Exiting the Job Correction Menu

More information on the t-E parameter can be found on page 56.

I-c I

correction range for job retrieval

main

OFF / 1 - 100% Factory setting: OFF

All the settings in the jobs are fixed and saved. Parameter I-c, however, allows the main current I

Example Setup parameter I-c was set to 30%. Main current I

IMPORTANT! Each subsequent correction to the main current I set when the plasma power source is switched off.

Press the store button

to be subsequently corrected.

main

can be reduced or increased by up to 30%.

main

is re-

Troubleshooting and Maintenance

Troubleshooting

General Digital power sources are equipped with an intelligent safety system, which com-

pletely negates the need for fuses (except for the coolant pump fuse). After correcting a possible error, the power source can be properly operated again without having to change any fuses.

EN-US

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid. Secure all devices and components involved 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.

WARNING!

Displayed Service Codes

Danger due to insufficient ground conductor connection.

This can result in serious 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 an error message that is not listed here appears on the displays, the error can only be corrected by service personnel. Please note the displayed error message, as well as the serial number and configuration of the power source, and contact the After-Sales Service team with a detailed description of the error.

no | Prg

Cause: Remedy:

No preconfigured program has been selected Select a configured program

tP1 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tP2 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tP3 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tP4 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tP5 | xxx

Note: xxx stands for a temperature value

Overtemperature in the primary circuit of the power source Leave power source to cool

Cause: Remedy:

tP6 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tS1 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tS2 | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

tS3 | xxx

Note: xxx stands for a temperature value

Overtemperature in the primary circuit of the power source Leave power source to cool

Overtemperature in the secondary circuit of the power source Leave power source to cool

Cause: Remedy:

Overtemperature in the secondary circuit of the power source Leave power source to cool

tSt | xxx

Note: xxx stands for a temperature value

Cause: Remedy:

Err | 049

Cause: Remedy:

Err | 050

Cause: Remedy:

Err | 051

Cause:

Remedy:

Err | 052

Cause:

Remedy:

no | IGn

Cause:

Remedy:

Overtemperature in the control circuit of the power source

EN-US

Leave power source to cool

Phase error in the power supply Check the mains fuse, the grid lead and the mains plug

Indirect symmetry error Contact After-Sales Service

Mains undervoltage: Mains voltage has fallen below the tolerance range (see "Technical Data" section)

Check the mains voltage

Mains overvoltage: Mains voltage has exceeded the tolerance range (see "Technical Data" section)

Check the mains voltage

The ignition time-out function is active; current did not start ﬂowing within the time specified in the Setup menu. The power source safety cut-out has tripped

Check the plasma torch wearing parts; if necessary, increase the period of time in the "2nd Level Setup Menu" to the safety cut-out

Err | PE

Cause:

Remedy:

Err | IP

Cause: Remedy:

Err | bPS

Cause: Remedy:

dSP | Axx

Cause: Remedy:

dSP | Cxx

Cause: Remedy:

The earth current watchdog has triggered the safety cut-out of the power source.

Switch off the power source, wait for 10 seconds and then switch it back on again; if the error occurs again despite numerous attempts to eliminate it - contact After-Sales Service

Primary overcurrent Contact After-Sales Service

Power module error Contact After-Sales Service

Error in the central control and regulation unit Contact After-Sales Service

dSP | Exx

Cause: Remedy:

Error in the central control and regulation unit Contact After-Sales Service

dSP | Sy

Cause: Remedy:

dSP | nSy

Cause: Remedy:

r | E30

Cause:

Remedy:

r | E31

Cause:

Remedy:

r | E33

Cause:

Remedy:

Error in the central control and regulation unit Contact After-Sales Service

r adjustment: There is no contact between the electrode and the plasma nozzle

Establish a proper connection between the electrode and the plasma nozzle

r adjustment: Process was interrupted by repeatedly pressing the gas-test button

Establish a proper connection between the electrode and the plasma nozzle Press the gas-test button once

r adjustment: Poor contact between the electrode and the plasma nozzle

Check the plasma torch wearing parts

r | E34

Cause:

Remedy:

no | Arc

Cause: Remedy:

no | H2O

Cause: Remedy:

hot | H2O

Cause: Remedy:

-St | oP-

When operating the power source with a robot interface or field coupler

r adjustment: Poor contact between the electrode and the plasma nozzle

Check the plasma torch wearing parts

Plasma arc break Check plasma torch wearing parts, check process parameters and

gas ﬂow rate

Cooling unit ﬂow sensor trips Check the cooling unit; if necessary, top-up with coolant or vent the

coolant supply, as per the "Starting up the Cooling Unit" section

Cooling unit thermostat trips Wait until the end of the cooling phase, when "Hot | H2O" is no longer

displayed. ROB 5000 or fieldbus coupler for robot control: Before resuming the plasma process, set the "Source error reset" signal.

Cause: Remedy:

Robot not ready Set the "Robot ready" signal, set the "Source error reset" signal

("Source error reset" only for ROB 5000 and fieldbus coupler for robot control)

Power Source Troubleshooting

Power source not working

Power source switched on; displays and indicators do not illuminate

EN-US

Cause: Remedy:

No plasma arc

Power switch ON, overtemperature indicator illuminates

Cause: Remedy:

Grid lead damaged or broken, mains plug not inserted Check grid lead, insert mains plug if necessary

Grid socket or mains plug faulty Replace faulty parts

Mains fuse protection Replace mains fuse

Overloading Take duty cycle into account

Automatic thermal circuit breaker has tripped Wait until the power source automatically comes back on after the

end of the cooling phase

Fan in the power source is faulty Contact After-Sales Service

No gas

All other functions are OK

Cause: Remedy:

Poor plasma qualities

Cause: Remedy:

Gas cylinder empty Replace gas cylinder

Faulty gas pressure regulator Replace the gas pressure regulator

Gas hose is not fitted or is damaged Fit or replace gas hose

Faulty plasma torch Replace the plasma torch

Faulty gas solenoid valve Contact After-Sales Service

Incorrect process parameters Check settings

Plasma torch gets very hot

Cause: Remedy:

Plasma torch is under-dimensioned Observe duty cycle and load limits

Cause: Remedy:

Coolant ﬂow too low Check coolant level, coolant ﬂow rate, water contamination, etc. If

coolant pump blocked: use a screwdriver to turn on the shaft of the coolant pump at the gland

Parameter C-C is set to "OFF". In the Setup menu, set parameter C-C to "Aut" or "ON".

Service, maintenance and disposal

General The plasma power source only requires minimal care and maintenance under nor-

mal operating conditions. However, several points must be observed in order for the plasma power source to remain operational for years to come.

EN-US

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

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

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-

▶

ment and all system components.

WARNING!

Danger from electrical current.

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

Before starting work, switch off all devices and components involved, and

▶

disconnect them from the grid. Secure all devices and components involved 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.

WARNING!

At every startup

Every 2 Months

Danger due to insufficient ground conductor connection.

This can result in serious 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.

Check for damage to the mains plug and mains cable, as well as the plasma

torch and hosepack Check if the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that

cooling air can circulate unimpeded

NOTE!

Air intake and exhaust openings must also not be blocked or even partially covered.

If present: clean air filter

Every 6 Months

Danger due to the effect of compressed air.

This can result in damage to property.

▶

Danger of electric shock due to grounding cable and device grounding points not being connected properly.

An electric shock can be fatal.

▶

Disposal Materials should be disposed of according to valid local and national regulations.

CAUTION!

Do not bring the air nozzle too close to electronic parts.

Dismantle device side panels and blow the inside of the device clean with dry,

reduced compressed air

Also clean the cooling air ducts if there is a large accumulation of dust

WARNING!

When refitting the side panels, ensure that the grounding cable and device grounding points are properly connected.

Appendix

Technical data

EN-US

Special Voltage

Acerios

CAUTION!

An inadequately dimensioned electrical installation can lead to serious damage.

The grid lead and its fuse protection should be designed accordingly.

▶

The technical data on the rating plate should be followed.

▶

Mains voltage 3 x 400 V

Mains voltage tolerance ±15%

Grid frequency 50 / 60 Hz

Slow-blow mains fuse protection 35 A

Max. permitted grid impedance Z

Primary continuous power (100% D.C.3))

Cos phi 0.99

Process current range 35 - 200 A

Process current at 10 min/40°C (104°F) 100%

D.C.

max

on PCC

Possible connection

restrictions

10.8 kVA

200 A

Explanation of Footnotes

Open circuit voltage 97 V

Working voltage 11.4 - 33.0 V

Striking voltage (Up) 9.5 kV

Protection class IP 23

Type of cooling AF

Insulation class F

EMC device class (according to EN/IEC 60974-10)

Dimensions l/w/h (with handle) 625/290/475 mm

24.6/11.4/18.7 in.

Weight 40.3 kg

Marks of conformity S, CE

PCC = interface to a 230/400 V, 50 Hz public grid

Consult the grid operator before connecting the device to the public grid!

D.C. = duty cycle

A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid. The electromagnetic compatibility may be inﬂuenced by conducted or radiated radio frequencies.

88.85 lb.

EN-US

Fronius Acerios Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual