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Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
Calibration system 2.0
Operating Instructions
EN
Miscellaneous
42,0426,0270,EN 008-29052019
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
Explanation of
safety notices
DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
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Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 8
Risks from mains current and welding current...................................................................................... 9
EMC Device Classifications .................................................................................................................. 9
EMC measures ..................................................................................................................................... 9
EMF measures...................................................................................................................................... 10
Specific hazards.................................................................................................................................... 10
Danger from shielding gas cylinders..................................................................................................... 11
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 12
Commissioning, maintenance and repair.............................................................................................. 12
Safety inspection................................................................................................................................... 12
Calibration of the calibration system ..................................................................................................... 13
Disposal ................................................................................................................................................ 13
Safety symbol ....................................................................................................................................... 13
Data protection...................................................................................................................................... 13
Copyright............................................................................................................................................... 13
EN
General information 15
General ...................................................................................................................................................... 17
Device concept ..................................................................................................................................... 17
Proper use / intended purpose.............................................................................................................. 17
Crane transport ..................................................................................................................................... 18
Required for calibration......................................................................................................................... 18
Accessories and options ............................................................................................................................ 19
Accessories........................................................................................................................................... 19
Options.................................................................................................................................................. 20
Controls, connections and mechanical components 21
Controls and connections on calibration system........................................................................................ 23
Front of device ...................................................................................................................................... 23
Rear of device (without trolley) ............................................................................................................. 24
Mechanical components on trolley............................................................................................................. 25
Calibration system trolley...................................................................................................................... 25
Installation 27
Installing the calibration system ................................................................................................................. 29
General ................................................................................................................................................. 29
TwinCat................................................................................................................................................. 29
USB to LAN driver................................................................................................................................. 29
TPS/i SmartCard driver......................................................................................................................... 30
LocalNet FTDI driver............................................................................................................................. 32
Desktop software installation ................................................................................................................ 32
Changing network settings.................................................................................................................... 33
Changing the network settings for USB calibration............................................................................... 33
Setting a TwinCat route ........................................................................................................................ 34
Setting the language, system information.................................................................................................. 36
Setting the language ............................................................................................................................. 36
Retrieving system information............................................................................................................... 36
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Calibrating welding systems 37
General information ................................................................................................................................... 39
Mains voltage measurement for single-phase power sources.............................................................. 39
Correcting set values and load resistances .......................................................................................... 39
Calibrating welding systems with LocalNet (TPS, TSt, MW, TT) ............................................................... 40
Overview - LocalNet.............................................................................................................................. 40
Connecting the power source and calibration system .......................................................................... 40
Connecting the welding wire calibration system ................................................................................... 43
Connecting the computer to the calibration system and signature pad ................................................ 44
Preparing the gas calibration system.................................................................................................... 45
Calibrating the welding system ............................................................................................................. 46
Calibrating welding systems with SpeedNet (TPSi)................................................................................... 49
Overview - SpeedNet............................................................................................................................ 49
Connecting the power source and calibration system .......................................................................... 49
Connecting the welding wire calibration system ................................................................................... 49
Connecting the computer to the calibration system and signature pad ................................................ 50
Preparing the gas calibration system.................................................................................................... 50
Calibrating the welding system ............................................................................................................. 51
Calibrating welding systems with USB / SpeedNet.................................................................................... 55
Overview - USB .................................................................................................................................... 55
Connecting the power source and calibration system .......................................................................... 55
Connecting the welding wire calibration system ................................................................................... 56
Connecting the computer to the calibration system and signature pad ................................................ 56
Preparing the gas calibration system.................................................................................................... 56
Calibrating the welding system ............................................................................................................. 57
Calibrating other Fronius welding systems ................................................................................................ 61
Overview - other Fronius devices ......................................................................................................... 61
Connecting the power source and calibration system .......................................................................... 61
Connecting the welding wire calibration system ................................................................................... 62
Connecting the computer to the calibration system and signature pad ................................................ 62
Preparing the gas calibration system.................................................................................................... 62
Calibrating the TransPocket welding system ........................................................................................ 62
Calibrating TransTig 1750 Puls............................................................................................................. 66
Calibrating VarioSynergic 3400 ............................................................................................................ 69
Troubleshooting 75
Troubleshooting ......................................................................................................................................... 77
The status indicator is not lit up ............................................................................................................ 77
The status indicator lights up red .......................................................................................................... 77
No connection ....................................................................................................................................... 77
No USB/SpeedNet connection.............................................................................................................. 77
Technical data 79
Technical data............................................................................................................................................ 81
Calibration system 2.0 .......................................................................................................................... 81
Wire speed measuring system.............................................................................................................. 81
Interface box ......................................................................................................................................... 82
Gas measurement option...................................................................................................................... 82
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Safety rules
General The device is manufactured using state-of-the-art technology and according to recognised
safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
EN
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for unexpected or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient air temperature range:
- during operation: 0 °C to + 40 °C (32 °F to 104 °F)
- during transport and storage: 0 °C to + 40 °C (32 °F to 104 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
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The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
Protecting yourself and others
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance
- Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
For your personal safety, take the following precautions:
Use suitable protective clothing
Protective clothing refers to a variety of different items. Operators should:
- protect their eyes with the specified protective goggles;
- wear stout footwear that provides insulation even in wet conditions;
- protect their hands by wearing suitable gloves (electrically insulated, heat-proof, protection from cut injuries);
- wear ear protection to reduce the harmful effects of noise and to prevent injury.
Keep all persons, especially children, out of the working area while any devices are in operation or calibration is in progress. If, however, there are people in the vicinity,
- warn them of all the dangers
- provide suitable protective equipment or
- erect suitable safety screens/curtains
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Risks from mains
current and welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area
between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
If the device is operated on a grid without a ground conductor and in a socket without a
ground conductor contact, this will be deemed gross negligence. The manufacturer shall
not be held liable for any damage arising from such usage.
EN
EMC Device Classifications
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
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Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened / removed while maintenance or repair work
is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
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The welding wire emerging from the wire speed measuring system poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
For this reason, always keep the wire speed measuring system away from the head and
body and wear suitable protective goggles.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
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Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Danger from
shielding gas cylinders
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
EN
Safety measures
at the installation
location and during transport
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.
A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
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Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Safety measures
in normal operation
Commissioning,
maintenance and
repair
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
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 torque to 3 Nm.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
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Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.
EN
Calibration of the
calibration system
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
either be returned to your dealer or given to one of 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 symbol Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives. Further details can be found in the appendix or the
section headed "Technical data" in your documentation.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Regular calibration is required to guarantee the traceability to national or international standards of calibrations performed with this calibration system.
Fronius recommends a 12-month calibration interval. For more information,
please contact your Fronius partner.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
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General information
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General
EN
Device concept
Proper use / intended purpose
The calibration system 2.0 is designed for
calibrating power sources.
All types of power sources, regardless of
manufacturer, can be calibrated under
static load using this system.
Both DC and AC devices can be calibrated.
The calibration system is suitable for quick
and easy calibration of the power source in
situ.
The calibration system can also be used for
servicing to test or check the power sources
(e.g. after repairs, troubleshooting, etc.).
The device is only intended to be used for calibrating and testing welding systems and
power sources.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be liable for any damage resulting from such use.
Proper use also includes
- carefully reading these Operating Instructions
- following all the instructions and safety rules in these Operating Instructions
- performing all stipulated inspection and maintenance work
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
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Crane transport
WARNING!
Risk of injury due to falling device or device parts.
► Do not walk under the device when it is being suspended in an elevated position or
dwell in hazardous locations
► Exclusively use load-carrying equipment approved by Fronius
► Attach 4 chains or 4 ropes to the 4 suspension points
► Route chains/ropes so they are at the smallest angle possible to the vertical
► Check and maintain load-carrying equipment to ensure it adheres to national regula-
tions
WARNING!
Risk of injury due to falling device or device parts.
When transporting by crane, make sure that:
► There are no objects on the shelf or in the storage compartments
► All accessory drawers are closed and locked
Required for calibration
4 suspension points for transporting by crane
- Computer, laptop
- Calibration software (available from the Fronius Download Center)
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Accessories and options
Accessories
(1) (2) (3) (4) (5) (6) (7) (8)
EN
(13)(14) (12) (11)
Item Designation Item no.
(1) 1 x mains cable, 5 m 43,0004,2862
(2) 1 x Euro/central connector adapter with Tuchel socket 44,0350,5407
(3) 1 x Fronius/central connector adapter 44,0350,4504
(4) 1 x (+) power cable with sense lead (red) 43,0004,5883
(5) 1 x LocalNet passive splitter 4,100,261
(6) 1 x (-) power cable with sense lead (blue) 43,0001,5882
(7) 1 x cooling unit bridging hose
for use with the Euro/central connector adapter
(8) 1 x gas hose 1.5 m, 2 x 1/4“ 44,0001,0538
(9) 1 x USB connection cable to PC/laptop 43,0004,5963
(10) 2 x high-current socket to bayonet adapter 42,0001,4482
(11) 1 x LocalNet/USB converter 4,101,026
(12) 2 x bayonet adapter 25 mm2 to 50 mm
2
(10)
(9)
44,0001,1204
4,001,549
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Item Designation Item no.
(13) 1 x Tuchel adapter cable 43,0004,5884
(14) 1 x welding wire calibration system
+
5 m connection cable
Further accessories (not pictured)
Designation Item no.
1 x power adapter 4,051,091
1 x connection cable for gas sensor, 5 m 43,0004,5914
1 x 1.6 m SpeedNet cable 4,051,021
2 x 5 m SpeedNet cable 4,051,022
2 x insulating sleeve adapter 42,0100,1411
1 x 2.5 m 8-pin data cable, PUR 43,0004,4361
1 x LocalNet 6-pin cable with Molex Microfit socket 43,0004,4850
2 x USB Ethernet adapter EU 4306 43,0004,5688
4,050,210
43,0004,5997
Options
Designation Item no.
Signotec signature pad 41,0006,0126
1.5 m gas hose, 2 x 1/4" 44,0001,0538
5 m gas hose, 2 x 1/4" 44,0001,0695
10 m gas hose, 2 x 1/4" 44,0001,3423
Double nipple 1/4" 42,0401,0874
Gas fitting connection, 1/4" 44,0450,0281
Gas hosepack adapter, external 1/4" - internal 5/8-18 UNF 42,0001,3540
Gas fitting 5 /8" - 8400 + 8411 42,0001,6601
Removable cable tie, 180 mm 42,0407,0558
Calibration system trolley 4,077,022
TU Car 4 Basic trolley 4,077,009
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Controls, connections and mechani-
cal components
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Controls and connections on calibration system
Front of device
(11)
(10)
(9)
(12)
EN
(8)
(7)
(6)
(5)
(4)
(3)
(2)
(1)
Item Designation
(1) + power connection (red)
(2) + sense lead connection socket (red)
(3) - sense lead connection socket (blue)
(4) - power connection (blue)
(5) USB port computer/laptop
(6)
USB port for adapter
(7)
(8) SpeedNet connection socket
(9) Wire speed measuring system connection socket
(10) Status indicator
(13)
(14)
(15)
(16)
(17)
(18)
Lights up green
device is ready for operation
Lights up red
an error has occurred
A description of the error will be displayed by the software during the calibration
process.
(11) Gas calibration system connection socket
(12)
(13)
SpeedNet connection socket
(14)
(15)
(16) Gas IN connection socket (option)
(17) Gas OUT connection socket (option)
(18) Data connection socket (option of connecting to the calibration system)
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Rear of device
(without trolley)
(5) (6) (7)
(4)
(3)
(2)
(1)
(9) F3 fuse (1 A slow-blow)
AC voltage measurement fuse protection
(10) F7 fuse (1 A slow-blow)
Automatic start/stop fuse protection
(11) F6 fuse (8 A slow-blow)
24 V fan fuse protection
(8)
(9)
(10)
(11)
Item Designation
(1) F5 fuse (2 A slow-blow)
24 V PLC fuse protection
(2) F4 fuse (2 A slow-blow)
24 V PLC fuse protection
(3) Mains cable connection
(4) Main fuse for the device F1
(4 A slow-blow)
(5) Mains switch
(6)
230 V socket
(7)
(for 230 V power supply)
(8) F2 fuse (1 A slow-blow)
AC voltage measurement fuse protection
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Mechanical components on trolley
EN
Calibration system trolley
(5)
(4)
(3)
(2)
(1)
Item Designation
(1) Calibration system trolley
(option)
(2) Accessory drawers
(3) Cable hanger
(4) Tray
(5) Storage trays
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Installation
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Installing the calibration system
EN
General
TwinCat Prerequisite:
NOTE!
Installation of the calibration system was created based on Windows7 and may differ on other operating systems.
Unzip the software package provided onto your PC:
1
WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI.zip
The USB cable is not connected.
NOTE!
If a version of TwinCat is already present on your PC (TwinCat 2 or TwinCat 3), installation is not mandatory.
However, Fronius recommends that the version of TwinCat provided is used.
Open the path:
1
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\twincat
Install the file located there and follow the setup instructions
2
Restart the PC
3
(only if prompted to do so at the end of installation)
USB to LAN driver
Connect the PC to the calibration system via USB and switch on the calibration system
1
(green LED lights up)
Open the Device Manager
2
If no driver is yet installed, the device will appear as unknown
Install the required driver software from the unzipped software package:
3
Right click on LAN9500
Update driver software
4
Find the driver software on the computer
5
Open the path:
6
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\USBTOLAN\
29
Page 30
Depending on the operating system, select the subfolder (win / win_64) and follow the
7
instructions
After successful installation, the driver can be found under the network adapters:
If a driver is already installed,
8
ensure that it is the latest version and if necessary update it
Also use the connected USB port for future work with the calibration system.
TPS/i SmartCard
driver
Open the path:
1
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\OMNIKEY\
Depending on the operating system, select the subfolder, install the file located there
2
and follow the instructions
Win7 / Win8:
Successful installation will be displayed in the Device Manager as follows:
Win 10 x 64:
a) Open the Device Manager
If no driver is yet installed, the following will be displayed under SmartCard reader:
b) Right click on Microsoft Usbccid SmartCard reader (WUDF)
c) Update driver software
d) Find the driver software on the computer
e) Open the path:
C:\OMNIKEY (or wherever the software was installed)
f) Confirm and follow the instructions
30
The device should now be recognised as OMNIKEY in the Device Manager.
NOTE!
If several SmartCard readers appear in the Device Manager, select the correct one:
Right-click on the existing SmartCard reader and select "Properties"
1
Under General / Storage location, a port is specified
e.g..:
Port_#0002.Hub_#0002
This device must be activated!
Page 31
If under Properties / General / Storage location NO port is specified for a SmartCard
reader, it must be deactivated:
Right-click on the affected SmartCard reader and select "Disable Device"
1
EN
31
Page 32
LocalNet FTDI
driver
Connect the power source with LocalNet to the calibration system via USB and switch
1
on both components
Open the Device Manager
2
If no driver is yet installed, the device will appear as unknown (USB Serial Port, USBRS232 cable, etc.)
Install the required driver software from the unzipped software package:
3
Right click on USB Serial Port
Update driver software
4
Find the driver software on the computer
5
Open the path:
6
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\driver\FTDI\
Confirm and follow the instructions
7
Desktop software
installation
After successful installation of the driver, the COM Port can be found under Ports:
Restart the PC
8
(only if prompted to do so at the end of installation)
If a driver is already installed,
9
ensure that it is the latest version and if necessary update it
If the device still appears as unknown after installation, repeat the process.
Requirements:
- Windows 7 or higher
- Local admin rights
- Screen resolution higher than 1024 * 768
- .net Framework 4.7.2
If this .net Framework version is not yet installed on the computer, a message is displayed to this effect.
The appropriate .net Framework version can be downloaded and installed from the following link:
https://dotnet.microsoft.com/download/dotnet-framework-runtime/net472
32
Open the path:
1
\WT_SW_Fronius_CalibrationSystem2.0_vX.X.XX.X_MULTI\application
Install the file located there and follow the setup instructions
2
Page 33
Changing network settings
Setting network settings
1
a) via the calibration software:
or
b) under the network settings (TCP/IPv4) of the adapter:
EN
Changing the network settings for
USB calibration
IMPORTANT! Prerequisites for USB calibration:
- DHCP server, which starts automatically when the program starts.
- .net Framework, at least version 4.7.2
Specify network settings for USB calibration
1
a) Via the calibration software:
Settings / Configure network adapter / SpeedNet / Ethernet ...
or
b) From the network settings (TCP/IPv4) of the adapter:
Use the following IP address: 192.168.125.200
Check if the IP address 192.168.125.1 is displayed on the power source
2
Action if the IP address 192.168.125.1 is not displayed on the power source:
- Check if the DHCP server is running (icon!)
If the DHCP server is not running, restart the software.
- Disconnect the USB briefly from the power source and reconnect it again
- Only connect the USB Ethernet adapter to the calibration system, not to the computer/
laptop
33
Page 34
Setting a TwinCat
route
Click on the TwinCat symbol in the lower bar of your PC and select "Edit routes"
1
Add a new route by going to "Add" and then "Broadcast Search"
2
The calibration system is then normally displayed.
Implement the following settings:
3
34
Deactivate "Encrypt password (Twincat 3 only)"
4
If connection is successful, an X is displayed in the overview.
Page 35
Close the window by clicking "Close"
5
EN
Possible errors/points to check if the route cannot be set as described above include:
a) Check network settings:
the calibration station must be pingable at the address 192.168.120.50
b) Various security programmes (e.g. F-Secure, etc.) may block the network connection.
If necessary, allow network traffic
c) Reset the calibration station and ensure that the green LED is on
d) Remove the USB cable for a short time, then reconnect it and try again
e) Restart the PC
35
Page 36
Setting the language, system information
Setting the language
After the calibration software has been installed, the language can be set for the user
interface:
The system switches to the chosen language when the program is restarted.
NOTE!
Only the user interface of the calibration software is displayed in the chosen language. The language for the calibration report must be set separately!
Retrieving system information
Clicking on the ? displays the following system information:
- Software version of the calibration software installed
- Software version of the Beckhoff elements installed in the calibration system
36
Page 37
Calibrating welding systems
Page 38
Page 39
General information
EN
Mains voltage
measurement for
single-phase
power sources
Correcting set
values and load
resistances
With single-phase machines, the mains voltage must be measured manually using a
FLUKE measuring device.
Enter the measured mains voltage in the box
1
[ ] Enable In Use
2
Under external measuring equipment, enter the FLUKE measuring device used
3
If the values specified by the calibration software are not achieved, the set value or load
resistance may need to be modified.
Examples:
AccuPocket 150 / 400 Tig
Current calibration (M1: Set value [A] = 60 A / RLoad [mOhm] = 240 mOhm)
TransTig 2200 Job
Current calibration (M5: RLoad [mOhm] = 96 mOhm)
VarioSynergic 3400
Read the measured value for the respective level in the calibration program and enter it in
the "set value" box.
39
Page 40
Calibrating welding systems with LocalNet (TPS,
TSt, MW, TT)
Overview - LocalNet
Welding systems with external wirefeeder
- TS 4000 / 5000
- TPS 3200 / 4000 / 5000
- TIME 5000 Digital
- CMT 4000 Advanced
- TSt 3500/5000
- TSt 3500 / 5000 Rob
- TSt 3500 / 5000 Syn
Welding systems with integrated wire drive
- TPS 2700
- TSt 2200c (cable harness 43,0004,4850 also required)
- TSt 2500c / 2700c / 3500c
TIG welding systems
- TT 800 / 2200 / 2500 / 3000 / 4000 / 5000
- TT 800 / 2200 / 2500 / 3000 / 4000 / 5000 Job
- TT 2200 / 2500 / 3000 / 4000 / 5000 Comfort
- MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000
- MW 1700 / 2200 / 2500 / 3000 / 4000 / 5000 Job
- MW 2200 / 2500 / 3000 / 4000 / 5000 Comfort
Manual metal arc welding systems
- TP 4000 / 5000 CEL
Connecting the
power source and
calibration system
The power sources listed above have a LocalNet port and are calibrated using the following calibration process.
Plug in the mains cable
1
Switch on the mains switch
2
2
1
40
Page 41
Connect the + power cable to the cali-
3
bration system and the power source
Connect the sense lead (red) to the ca-
4
EN
libration system
4
3
3
Connect the - power cable to the cali-
5
bration system and the power source
Connect the sense lead (blue) to the
6
calibration system
5
6
5
Connect the LocalNet/USB converter
7
to the calibration system and to a free
7
LocalNet port on the welding system
If there is no LocalNet port available,
use the LocalNet passive distributor
7
(4,100,261)
e.g. for TSt 5000
Switch on the power source
8
Start calibration
9
41
Page 42
For TransSteel TSt 2200c only:
A cable harness (item number 43,0004,4850) is also required when calibrating a TSt 2200c
power source.
The calibration process is performed with an open power source housing.
WARNING!
An electric shock can be fatal.
All work on the power source may only be carried out in a de-energised state.
Before opening the device
► Move the mains switch to the "O" position
► Unplug the device from the mains
► Ensure the device cannot be switched back on
► Using a suitable measuring instrument, check to make sure that electrically charged
components (e.g. capacitors) have been discharged
Connect the LocalNet/USB converter
7
to the calibration system
Remove the right side panel from the
9
8
power source
Connect the cable harness
9
43,0004,4850 to the 6-pin connector
on the PC board LSTMAG20 as shown
in the illustration
Connect the cable harness and Local-
10
Net/USB converter
WARNING!
An electric shock can be fatal!
The calibration process is performed with an open housing.
After switching on the power source
► Do not touch any parts in the housing interior!
► Use only suitable measuring or test probes to touch parts inside the device!
► Keep people away from the open power source when carrying out the calibration!
Connect the power source to the mains and switch it on
11
Start calibration
12
42
Page 43
Connecting the
welding wire calibration system
Connect the connection cable to the
1
welding wire calibration system
1
IMPORTANT! A maximum of 3
EN
connection cables (max. 15 m) can be
used to connect the welding wire calibration system and the calibration system!
Connect the connection cable to the
2
calibration system
2
Connect the welding torch to the wel-
3
ding system
Thread the wire
4
Remove the gas nozzle from the wel-
5
ding torch
Thread the wire
6
The welding wire should protrude
approx. 200 mm from the contact tip.
Thread the welding wire into the intake
7
part of the sensor
7
Secure the welding torch in the welding
8
wire calibration system at the contact
tip
8
43
Page 44
NOTE!
When calibrating robot welding systems, the welding wire calibration system is usually attached to the contact tip of the robot welding torch.
If, in this case, it is not possible to attach it properly, the following longer contact tips may
be used on the robot welding torch:
- 42,0001,0056
contact tip 1.6/M6/ø8x33 mm
- 42,0001,3485
contact tip 1.6/M8/ø8x35 mm/CB4.8
- 42,0001,5413
contact tip 3.2/M10/ø10x40 mm
Connecting the
computer to the
calibration system and signature
pad
Connect the USB connection cable to
1
the calibration system and the computer / laptop
1
16
Connect the Signotec signature pad to
2
the calibration system
44
2
Page 45
Preparing the gas
calibration system
IMPORTANT! If a shielding gas supply is to be calibrated, it must be connected to the cali-
bration system before starting the calibration process.
The welding system and calibration system must be connected to each other.
Connect the gas hose to the pressure
1
regulator and to the Gas IN connection
on the calibration system
EN
1
1
Connect the gas hose to the wirefee-
2
der or the power source and to the Gas
OUT connection on the calibration system
2
2
max. supply pressure: 5 bar
Connect the gas and data connections
3
to each other
3
3
45
Page 46
Calibrating the
welding system
IMPORTANT! Before starting the calibration process:
- All devices to be calibrated must be connected to the calibration system:
power source, wirefeeder, shielding gas supply; etc.
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
The calibration process is started from the calibration software on the computer / laptop.
Start the calibration program
1
Click [New calibration]
2
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
3
- Name
- Address
- Post code
- Calibration technician
Click on [Add]
4
or
select current contractor from the list shown
Enter the serial numbers of the measuring equipment:
5
- Calibration system
- Welding wire calibration system
- Gas measuring system
Click [Next >]
6
The preliminary settings / customer data are displayed.
Enter the details for a new client:
7
- Name
- Address
- Post code
- Customer number
Click on [Add]
8
or
select current client from the list shown
46
Under Others, inventory numbers, order numbers and observations can be entered.
Click [Next >]
9
The preliminary settings / device selection are displayed.
Under Settings, select the connection to the power source:
10
o LocalNet
Page 47
Click on [Establish connection]
11
If the connection is established successfully, a message to this effect is displayed and
the data from the power source and wirefeeder is automatically read in.
Welding current, welding voltage and wire speed are pre-selected. To deselect them,
click on the respective check box.
If a gas flow calibration is to be performed, click on the check box.
Click [Next >]
12
The preliminary settings / calibration parameters are displayed:
five measured values M1 - M5 for each power source and wirefeeder
- Welding current [A]
- Welding voltage [V]
- Wire speed
Click [Next >]
13
The preliminary settings / general measurement data are displayed:
- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage US [V]
If no data is displayed, it can be determined by clicking on [Start measuring process].
If there is still no data displayed, check the F2 and F3 fuses on the back of the calibration system.
EN
Carry out a visual inspection of the welding system and the calibration system, accord-
14
ing to the calibration instructions
If the visual inspection does not reveal any defects, select [Click here]
15
Click [Next >]
16
The summary of the calibration process is displayed.
Define the calibration class:
17
o Precision
o Standard
Click [Start automatic calibration]
18
The calibration process starts.
When a calibration process is active:
- A corresponding notification is displayed
- The [Interrupt calibration] button is available
- All measuring points are checked one after the other
- Current measured values are displayed
- A progress bar with the remaining time is displayed
If the calibration process is interrupted before the welding wire has been calibrated, a
corresponding notification is displayed.
47
Page 48
CAUTION!
Risk of injury from emerging welding wire.
As soon as the calibration process resumes, the welding wirefeed starts and the welding
wire emerges.
► Keep the welding wire calibration system away from the head and body and wear suit-
able protective goggles.
► Make sure that when the welding wire emerges, it does not touch any electrically con-
ducting, earthed or live parts.
► Make sure that there is sufficient space for the emerging welding wire (approx. 10 m).
► Make sure that no one is endangered by the emerging welding wire.
Click on [OK] to start calibration of the wirefeeder system
19
When the calibration process is complete, a corresponding notification is displayed
and the [Print calibration report] button is available.
Click [Print calibration report]
20
Calibration system / create report is displayed.
Enter the details to create the calibration report:
21
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
22
Press [OK] on the Signotec signature pad
23
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
Click [Create PDF]
24
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
48
Page 49
Calibrating welding systems with SpeedNet (TPSi)
EN
Overview SpeedNet
Connecting the
power source and
calibration system
Welding systems with external wirefeeder
- TPS 320i / 400i / 500i / 600i
- TPS 400i LSC ADV
Welding systems with integrated wire drive
- TPS 270i C
- TPS 320i C
The power sources listed above have a SpeedNet port and are calibrated using the following calibration process.
Plug the mains cable into the calibration system
1
Plug the mains cable into the grid
2
Switch on the mains switch
3
NOTE!
If there is a power connector for the high current socket on the power source, use
the adapter for the high current sockets to bayonet (42,0001,4482).
Connect the + power cable to the calibration system and the power source
4
Connect the sense lead (red) to the calibration system
5
Connect the - power cable to the calibration system and the power source
6
Connect the sense lead (blue) to the calibration system
7
Switch on the power source
8
Connect the SpeedNet cable to the calibration system and to a free SpeedNet con-
9
nection socket on the welding system
Connecting the
welding wire calibration system
Connect the connection cable to the welding wire calibration system
1
IMPORTANT! A maximum of 3 connection cables (max. 15 m) can be used to connect
the welding wire calibration system and the calibration system!
Connect the connection cable to the calibration system
2
Connect the welding torch to the welding system
3
Remove the gas nozzle from the welding torch
4
Thread the wire
5
The welding wire should protrude approx. 200 mm from the contact tip.
Thread the welding wire into the intake part of the sensor
6
Use clamps to secure the welding torch in the welding wire calibration system at the
7
contact tip
Make sure that the torch hosepack is arranged as straight as possible
8
49
Page 50
Connecting the
computer to the
calibration system and signature
pad
Connect the USB connection cable to the calibration system and the computer / laptop
1
Connect the Signotec signature pad to the calibration system
2
Switch on the power source
3
Preparing the gas
calibration system
IMPORTANT! If a shielding gas supply is to be calibrated, it must be connected to the cali-
bration system before starting the calibration process.
The welding system and calibration system must be connected to each other.
Connect the gas hose to the pressure
1
regulator and to the Gas IN connection
on the calibration system
max. supply pressure: 5 bar
1
1
Connect the gas hose to the wirefee-
2
der or the power source and to the Gas
OUT connection on the calibration system
2
2
50
Page 51
Connect the gas and data connections
3
to each other
EN
3
3
Calibrating the
welding system
IMPORTANT! Before starting the calibration process:
- All devices to be calibrated must be connected to the calibration system:
power source, wirefeeder, shielding gas supply; etc.
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
The calibration process is started from the calibration software on the computer / laptop.
Start the calibration program
1
Click [New calibration]
2
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
3
- Name
- Address
- Post code
- Calibration technician
Click on [Add]
4
or
select current contractor from the list shown
Enter the serial numbers of the measuring equipment:
5
- Calibration system
- Welding wire calibration system
- Gas measuring system
Click [Next >]
6
The preliminary settings / customer data are displayed.
51
Page 52
Enter the details for a new client:
7
- Name
- Address
- Post code
- Customer number
Click on [Add]
8
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be entered.
Click [Next >]
9
The preliminary settings / device selection are displayed.
Under Settings, select the connection to the power source:
10
o SpeedNet
Click on [Establish connection]
11
If the connection is established successfully, a message to this effect is displayed and
the data from the power source and wirefeeder is automatically read in.
Welding current, welding voltage and wire speed are pre-selected. To deselect them,
click on the respective check box.
If a gas flow calibration is to be performed, click on the check box.
Click [Next >]
12
The preliminary settings / calibration parameters are displayed:
five measured values M1 - M5 for each power source
- Welding current [A]
- Welding voltage [V]
For the wirefeeder, enter five wire speed measured values M1 - M5 [m/min]:
The measured value M5 is the maximum value for the wirefeeder.
Press the Tab key to enter the other measured values.
Click [Next >]
13
The preliminary settings / general measurement data are displayed:
- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage US [V]
52
If no data is displayed, it can be determined by clicking on [Start measuring process].
If there is still no data displayed, check the F2 and F3 fuses on the back of the calibration system.
Carry out a visual inspection of the welding system and the calibration system, accord-
14
ing to the calibration instructions
If the visual inspection does not reveal any defects, select [Click here]
15
Page 53
Click [Next >]
16
The summary of the calibration process is displayed.
Define the calibration class:
17
o Precision
o Standard
Click [Start automatic calibration process]
18
The calibration process starts.
When a calibration process is active
- A corresponding notification is displayed
- The [Interrupt calibration] button is available
- All measuring points are checked one after the other
- Current measured values are displayed
- A progress bar with the remaining time is displayed
If the calibration process is interrupted before the welding wire has been calibrated, a
corresponding notification is displayed.
CAUTION!
Risk of injury from emerging welding wire.
As soon as the calibration process resumes, the welding wirefeed starts and the welding
wire emerges.
► Keep the welding wire calibration system away from the head and body and wear suit-
able protective goggles.
► Make sure that when the welding wire emerges, it does not touch any electrically con-
ducting, earthed or live parts.
► Make sure that there is sufficient space for the emerging welding wire (approx. 10 m).
► Make sure that no one is endangered by the emerging welding wire.
EN
Click on [OK] to start calibration of the wirefeeder system
19
When the calibration process is complete, a corresponding notification is displayed
and the [Print calibration report] button is available.
Click [Print calibration report]
20
Calibration system / create report is displayed.
Enter the details to create the calibration report:
21
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
22
53
Page 54
Press [OK] on the Signotec signature pad
23
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
Click [Create PDF]
24
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
54
Page 55
Calibrating welding systems with USB / SpeedNet
Overview - USB Software version 1.0.28 and higher:
TIG welding systems
- TransTig 230i
- MagicWave 190
- MagicWave 230i
Welding systems with external wirefeeder
- TPS 320i / 400i / 500i / 600i
- TPS 400i LSC ADV
Welding systems with integrated wire drive
- TPS 270i C
- TPS 320i C
The TPSi power sources can be calibrated via both the SpeedNet port and the USB port.
The power sources listed above have a USB port and are calibrated using the following
calibration process.
EN
Connecting the
power source and
calibration system
Also required:
- 2 USB Ethernet adapters (supplied with the calibration system)
- 1 Ethernet cable with RJ45 plug connectors
Plug the mains cable into the calibration system
1
Plug the mains cable into the grid
2
Switch on the mains switch
3
NOTE!
If there is a power connector for the high current socket on the power source, use
the adapter for the high current sockets to bayonet (42,0001,4482).
Connect the + power cable to the calibration system and the power source
4
Connect the sense lead (red) to the calibration system
5
Connect the - power cable to the calibration system and the power source
6
Connect the sense lead (blue) to the calibration system
7
Switch on the power source
8
Connect the USB Ethernet adapter to the calibration system
9
Connect the USB Ethernet adapter to the USB port of the welding system
10
Connect the USB Ethernet adapter using the Ethernet cable
11
55
Page 56
Connecting the
welding wire calibration system
Connect the connection cable to the welding wire calibration system
1
IMPORTANT! A maximum of 3 connection cables (max. 15 m) can be used to connect
the welding wire calibration system and the calibration system!
Connect the connection cable to the calibration system
2
Connect the welding torch to the welding system
3
Remove the gas nozzle from the welding torch
4
Thread the wire
5
The welding wire should protrude approx. 200 mm from the contact tip.
Thread the welding wire into the intake part of the sensor
6
Use clamps to secure the welding torch in the welding wire calibration system at the
7
contact tip
Make sure that the torch hosepack is arranged as straight as possible
8
Connecting the
computer to the
calibration system and signature
pad
Preparing the gas
calibration system
Connect the USB connection cable to the calibration system and the computer / laptop
1
Connect the Signotec signature pad to the calibration system
2
Switch on the power source
3
IMPORTANT! If a shielding gas supply is to be calibrated, it must be connected to the calibration system before starting the calibration process.
The welding system and calibration system must be connected to each other.
Connect the gas hose to the pressure
1
regulator and to the Gas IN connection
on the calibration system
max. supply pressure: 5 bar
1
1
56
Page 57
Connect the gas hose to the wirefee-
2
der or the power source and to the Gas
OUT connection on the calibration sys-
EN
tem
2
2
Connect the gas and data connections
3
to each other
3
Calibrating the
welding system
3
IMPORTANT! Before starting the calibration process:
- All devices to be calibrated must be connected to the calibration system:
power source, wirefeeder, shielding gas supply; etc.
- Check/specify the network settings for USB calibration (see page 33).
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
The calibration process is started from the calibration software on the computer / laptop.
Start the calibration program
1
Click [New calibration]
2
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
3
- Name
- Address
- Post code
- Calibration technician
57
Page 58
Click on [Add]
4
or
select current contractor from the list shown
Enter the serial numbers of the measuring equipment:
5
- Calibration system
- Welding wire calibration system
- Gas measuring system
Click [Next >]
6
The preliminary settings / customer data are displayed.
Enter the details for a new client:
7
- Name
- Address
- Post code
- Customer number
Click on [Add]
8
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be entered.
Click [Next >]
9
The preliminary settings / device selection are displayed.
Under Settings, select the connection to the power source:
10
o SpeedNet
[ ] Activate USB
11
Click on [Establish connection]
12
If the connection is established successfully, a message to this effect is displayed and
the data from the power source and wirefeeder is automatically read in.
If the connection is not established successfully, proceed as follows:
- Check if the DHCP server is running (icon in the task bar!)
If the DHCP server is not running, restart the software and check the network settings.
- Disconnect the USB briefly from the power source and reconnect it again
58
Welding current, welding voltage and wire speed are pre-selected. To deselect them,
click on the respective check box.
If a gas flow calibration is to be performed, click on the check box.
Page 59
Click [Next >]
13
The preliminary settings / calibration parameters are displayed:
five measured values M1 - M5 for each power source
- Welding current [A]
- Welding voltage [V]
For the wirefeeder, enter five wire speed measured values M1 - M5 [m/min]:
The measured value M5 is the maximum value for the wirefeeder.
Press the Tab key to enter the other measured values.
Click [Next >]
14
The preliminary settings / general measurement data are displayed:
- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage U
S
[V]
If no data is displayed, it can be determined by clicking on [Start measuring process].
If there is still no data displayed, check the F2 and F3 fuses on the back of the calibration system.
Carry out a visual inspection of the welding system and the calibration system, accord-
15
ing to the calibration instructions
EN
If the visual inspection does not reveal any defects, select [Click here]
16
Click [Next >]
17
The summary of the calibration process is displayed.
Define the calibration class:
18
o Precision
o Standard
Click [Start automatic calibration process]
19
The calibration process starts.
When a calibration process is active
- A corresponding notification is displayed
- The [Interrupt calibration] button is available
- All measuring points are checked one after the other
- Current measured values are displayed
- A progress bar with the remaining time is displayed
If the calibration process is interrupted before the welding wire has been calibrated, a
corresponding notification is displayed.
59
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CAUTION!
Risk of injury from emerging welding wire.
As soon as the calibration process resumes, the welding wirefeed starts and the welding
wire emerges.
► Keep the welding wire calibration system away from the head and body and wear suit-
able protective goggles.
► Make sure that when the welding wire emerges, it does not touch any electrically con-
ducting, earthed or live parts.
► Make sure that there is sufficient space for the emerging welding wire (approx. 10 m).
► Make sure that no one is endangered by the emerging welding wire.
Click on [OK] to start calibration of the wirefeeder system
20
When the calibration process is complete, a corresponding notification is displayed
and the [Print calibration report] button is available.
Click [Print calibration report]
21
Calibration system / create report is displayed.
Enter the details to create the calibration report:
22
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
23
Press [OK] on the Signotec signature pad
24
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
Click [Create PDF]
25
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
60
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Calibrating other Fronius welding systems
EN
Overview - other
Fronius devices
Connecting the
power source and
calibration system
Welding systems with external wirefeeder
- VarioSynergic 3400 / 4000 / 5000
Welding systems with integrated wire drive
- VarioStar 1500 / 2500 / 3100
- VarioSynergic 3400 / 4000 / 5000
TIG welding systems
- MagicWave 2600 / 2600 CEL / 3000
- TransTig 2600 / 2600 CEL / 3000
- TransTig 1750 Puls
Manual metal arc welding systems
- TransPocket 125 VRD / 150 / 180
- TransPocket 1100 / 1200 / 1400 / 1500 / 2000
- TransPocket 2500 / 3500 - RC, TIG, Comfort
- AccuPocket 150
The Fronius power sources listed above do not have a SpeedNet or LocalNet port and are
calibrated using the following calibration process.
Plug the mains cable into the calibration system
1
Plug the mains cable into the grid
2
Switch on the mains switch
3
NOTE!
Use the corresponding adapters depending on the size of the current sockets on the
power source.
Connect the + power cable to the calibration system and the power source
4
Connect the sense lead (red) to the calibration system
5
Connect the - power cable to the calibration system and the power source
6
Connect the sense lead (blue) to the calibration system
7
If there is a Tuchel connection on the power source:
Connect the Tuchel adapter cable to the power source and to the calibration system
8
Switch on the power source
9
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Connecting the
welding wire calibration system
Connect the connection cable to the welding wire calibration system
1
IMPORTANT! A maximum of 3 connection cables (max. 15 m) can be used to connect
the welding wire calibration system and the calibration system!
Connect the connection cable to the calibration system
2
Connect the welding torch to the welding system
3
Remove the gas nozzle from the welding torch
4
Thread the wire
5
The welding wire should protrude approx. 200 mm from the contact tip.
Thread the welding wire into the intake part of the sensor
6
Use clamps to secure the welding torch in the welding wire calibration system at the
7
contact tip
Make sure that the torch hosepack is arranged as straight as possible
8
Connecting the
computer to the
calibration system and signature
pad
Preparing the gas
calibration system
Calibrating the
TransPocket
welding system
Connect the USB connection cable to the calibration system and the computer / laptop
1
Connect the Signotec signature pad to the calibration system
2
Switch on the power source
3
IMPORTANT! If a shielding gas supply is to be calibrated, it must be connected to the calibration system before starting the calibration process.
The welding system and calibration system must be connected to each other.
Connect the gas hose to the pressure regulator and to the Gas IN connection on the
1
calibration system
max. supply pressure: 5 bar
Connect the gas hose to the wirefeeder or the power source and to the Gas OUT con-
2
nection on the calibration system
Connect the gas and data connections to each other
3
IMPORTANT! Before starting the calibration process:
- The power source to be calibrated must be connected to the calibration system.
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
62
The calibration process is started from the calibration software on the computer / laptop.
Set manual metal arc welding mode on the power source
1
Start the calibration program
2
Page 63
Click [New calibration]
3
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
4
- Name
- Address
- Post code
- Calibration technician
Click on [Add]
5
or
select current contractor from the list shown
Enter the serial numbers of the measuring equipment:
6
- Calibration system
- Welding wire calibration system
- Gas measuring system
Click [Next >]
7
The preliminary settings / customer data are displayed.
EN
Enter the details for a new client:
8
- Name
- Address
- Post code
- Customer number
Click on [Add]
9
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be entered.
Click [Next >]
10
The preliminary settings / device selection are displayed.
Under Settings, select:
11
o Fronius devices
Select the respective TransPocket variant
12
Enter the serial number and name of the power source
13
Click [Next >]
14
The preliminary settings / calibration parameters are displayed:
five measured values M1 - M5 for each power source
- Welding current [A]
63
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Click [Next >]
15
The preliminary settings / general measurement data are displayed.
Click [Start measuring process]
16
The following data is displayed:
- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage US [V]
IMPORTANT! The mains voltage displayed is incorrect!
With single-phase machines, the mains voltage must be measured manually using a
FLUKE measuring device, and entered!
Measure the mains voltage
17
Enter the mains voltage measured
18
[ ] Enable In Use and enter the measuring device used under External measuring
19
equipment
Carry out a visual inspection of the welding system and the calibration system, accord-
20
ing to the calibration instructions
If the visual inspection does not reveal any defects, select [Click here]
21
Click [Next >]
22
The summary of the calibration process is displayed.
Define the calibration class:
23
o Precision
o Standard
Set the specified measured value M1 on the power source
24
Click [ Start measuring process ]
25
Enter the value displayed on the power source in the Display [A] box
26
Click [Next >]
27
Repeat steps 24 - 27 for the measured values M2 - M5 - M1
28
(10 measurements)
64
When the calibration process is complete, a corresponding notification is displayed
and the [Print calibration report] button is available.
Click [Print calibration report]
29
Calibration system / create report is displayed.
Page 65
Enter the details to create the calibration report:
30
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
31
Press [OK] on the Signotec signature pad
32
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
Click [Create PDF]
33
EN
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
65
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Calibrating TransTig 1750 Puls
IMPORTANT! Before starting the calibration process:
- All devices to be calibrated must be connected to the calibration system:
power source, shielding gas supply, etc.
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
Connect the Tuchel adapter cable to the power source and to the calibration system
1
This enables the calibration process to be started from the calibration software on the computer/laptop.
Set manual metal arc welding mode on the power source and in the Rod electrode set-
2
up menu, specify the welding parameter Hti = 0
2
1
Start the calibration program
3
Click [New calibration]
4
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
5
- Name
- Address
- Post code
- Calibration technician
Click on [Add]
6
or
select current contractor from the list shown
66
Enter the serial numbers of the measuring equipment:
7
- Calibration system
- Gas measuring system
Click [Next >]
8
The preliminary settings / customer data are displayed.
Page 67
Enter the details for a new client:
9
- Name
- Address
- Post code
- Customer number
Click on [Add]
10
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be entered.
Click [Next >]
11
The preliminary settings / device selection are displayed.
Under Settings, select:
12
o Fronius devices
Select TransTig 1750 Puls
13
EN
Click [External start with calibration system]
14
Enter the serial number of the TT 1750 Puls in the box
15
Click [Next >]
16
The preliminary settings / general measurement data are displayed.
Click [Start measuring process]
17
The following data is displayed:
- Ambient temperature [° C]
- Mains voltage [V]
- Open circuit voltage U
S
[V]
IMPORTANT! The mains voltage displayed is incorrect!
With single-phase machines, the mains voltage must be measured manually using a
FLUKE measuring device, and entered!
Measure the mains voltage
18
Enter the mains voltage measured
19
[ ] Enable In Use and enter the measuring device used under External measuring
20
equipment
Carry out a visual inspection of the welding system and the calibration system, accord-
21
ing to the calibration instructions
If the visual inspection does not reveal any defects, select [Click here]
22
67
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Click [Next >]
23
The summary of the calibration process is displayed.
Define the calibration class:
24
o Precision
o Standard
Set the specified measured value M1 on the power source
25
Click [ Start measuring process ]
26
Enter the value displayed on the power source in the Display [A] box
27
Click [Next >]
28
Repeat steps 25 - 28 for the measured values M2 - M5 - M1
29
(10 measurements)
When the calibration process is complete, a corresponding notification is displayed
and the [Print calibration report] button is available.
Click [Print calibration report]
30
Calibration system / create report is displayed.
Enter the details to create the calibration report:
31
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
32
Press [OK] on the Signotec signature pad
33
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
68
Click [Create PDF]
34
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
Page 69
Calibrating VarioSynergic 3400
IMPORTANT! Before starting the calibration process:
- The power source to be calibrated must be connected to the calibration system (if pos-
sible, connect the relevant adapters).
- In accordance with standard EN50504, the power source to be calibrated must be
switched on at least 5 minutes before the calibration process starts.
Open the clamping lever on the wirefeeder
1
Thread the welding wire back again and attach to the wirespool
2
Connect the Tuchel adapter cable to the power source and to the calibration system
3
This enables the calibration process to be started from the calibration software on the computer/laptop.
Start the calibration program
4
Click [New calibration]
5
The preliminary settings / contractor data are displayed.
Enter the details for a new contractor (= Person performing calibration):
6
- Name
- Address
- Post code
- Calibration technician
EN
Click on [Add]
7
or
select current contractor from the list shown
Enter the serial numbers of the measuring equipment:
8
- Calibration system
- Welding wire calibration system
- Gas measuring system
Click [Next >]
9
The preliminary settings / customer data are displayed.
Enter the details for a new client:
10
- Name
- Address
- Post code
- Customer number
Click on [Add]
11
or
select current client from the list shown
Under Others, inventory numbers, order numbers and observations can be entered.
69
Page 70
Click [Next >]
12
The preliminary settings / device selection are displayed.
Under Settings, select:
13
o Fronius devices
Select VarioSynergic 3400
14
[Display available] and [External start with calibration system] have been pre-selected
Enter the serial number of the VarioSynergic in the box
15
Welding current, welding voltage and wire speed have been pre-selected. To deselect
them, click on the respective check box.
Click [Next >]
16
The preliminary settings / calibration parameters are displayed:
five measured values M1 - M5 for each power source
- Welding current [A]
- Welding voltage [V]
For the wirefeeder, enter five wire speed measured values M1 - M5 [m/min]:
The measured value M5 is the maximum value for the wirefeeder (= 18 m/min for VS
3400).
Enter the other measured values by pressing the Tab key.
Click [Next >]
17
The preliminary settings / general measurement data are displayed.
Specify the following settings on the power source:
18
70
Move the welding program selector switch to the MANUAL position
For the US measurement, set the coarse stage switch
to B and the fine stage switch to 7
Page 71
Set the toggle switch to A (current) Set the selector switch on the interior of the device to
2-step mode.
Click [Start measuring process]
19
Carry out a visual inspection of the welding system and the calibration system, accord-
20
ing to the calibration instructions
If the visual inspection does not reveal any defects, select [Click here]
21
Click [Next >]
22
EN
The summary of the calibration process is displayed.
Define the calibration class:
23
o Precision
o Standard
NOTE!
In the case of step-switched machines, the set values can be adapted manually in
the calibration program.
Set the stage switch on the power source as specified in the calibration program for
24
measuring point M1 (e.g. stage A1)
Click [Start calibration process]
25
Read the measured value for the respective level in the calibration program and enter
26
it in the Set value [A] box
Click [Start calibration process]
27
Enter the value displayed on the power source in the Display [A] box
28
Click [Next >]
29
Repeat steps 24 - 29 for the measuring points M2 - M5
30
For the subsequent measurement of M5 to M1, the set values entered are saved by
the calibration program.
Repeat steps 24 - 29 for the welding voltage
31
71
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At the end of the current and voltage calibration, the message [Start calibration feed
system 1!] is displayed
To calibrate the welding wire on the power source, specify the following settings:
32
Set the toggle switch to wirefeeder.
Set the wirefeeder controller on the interior of the device under MANUAL to 100 %.
Set the wire diameter for the welding wire used.
Disconnect the +/- current cables from the calibration station on the power source
33
Connect the welding torch and Tuchel plug to the power source
34
Remove the gas nozzle
35
Thread the wire
36
Close the clamping lever on the wirefeeder
37
Thread the wire until it protrudes approx. 200 mm from the contact tip
38
Thread the welding wire into the intake part of the sensor
39
Use clamps to secure the welding torch in the welding wire calibration system at the
40
Depending on the measurement, set the wire speed
controller to the relevant measured value according to
the table.
contact tip
Click on [Start calibration wirefeeder 1!]
41
Set the respective measured value on the power source wire speed controller. (e.g.:
42
M1 = 1 m)
CAUTION!
Risk of injury from emerging welding wire.
As soon as the calibration process resumes, the welding wirefeed starts and the welding
wire emerges.
► Keep the welding wire calibration system away from the head and body and wear suit-
able protective goggles.
► Make sure that when the welding wire emerges, it does not touch any electrically con-
ducting, earthed or live parts.
► Make sure that there is sufficient space for the emerging welding wire (approx. 10 m).
► Make sure that no one is endangered by the emerging welding wire.
72
Press and hold the torch trigger to start the wirefeeder
43
After about 3 seconds of wirefeeder running time, click on "Start measuring process"
44
in the calibration program and release the torch trigger
Page 73
Enter the value displayed on the power source under "Display" and click on [Next >]
45
Repeat steps 43 - 45 for the measurements of M2 to M5 and M1
46
When the calibration process is complete, a notification is displayed to this effect and
the [Print calibration report] button is available.
Click [Print calibration report]
47
Calibration system / create report is displayed.
Enter the details to create the calibration report:
48
Under Template, select the language for the calibration report from the list
Enter the output path
Enter or search for ( [Browse] ) the file name
If the Signotec signature pad is connected and has been detected by the calibration
system, a notification to this effect is displayed under Signature pad.
If not, check the connection of the Signotec signature pad to the calibration system
and then click on [Reconnect].
Sign the Signotec signature pad with the corresponding digital pen
49
Press [OK] on the Signotec signature pad
50
EN
The signature is sent to the calibration software.
x ... Cancel signature
Refresh ... new signature
A corresponding notification is displayed after the signature has been received successfully.
Click [Create PDF]
51
IMPORTANT! Only after the confirmation "PDF created successfully!" is displayed,
will the calibration report be saved.
73
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74
Page 75
Troubleshooting
Page 76
Page 77
Troubleshooting
EN
The status indicator is not lit up
The status indicator lights up red
No power supply
Cause: Mains cable not connected
Remedy: Connect the mains cable
Cause: Faulty mains cable
Remedy: Check the mains cable and replace if necessary
Cause: Fuses F1 / F4 / F5 have tripped
Remedy: Switch off the device, disconnect it from the mains, and check fuses, e.g.:
using a multimeter
or
visual inspection (burnt-through metal strips)
An error has occurred during the calibration process
A description of the error is displayed by the calibration software.
Cause: Various
Remedy: Follow the instructions in the calibration software
Contact our After-Sales Service team if the error is constantly present.
No connection No connection between power source and calibration software
Cause: Error during installation
Remedy: Check that all cables are connected.
Check whether the TwinCat Route has been set properly.
Check whether the network adapter has been configured correctly.
Check the Firewall settings.
Check that all drivers are installed.
Check all installation steps in general
No USB/SpeedNet connection
No USB/SpeedNet connection between power source and calibration software
Cause: USB connection error
Remedy: Check that the USB Ethernet adapters are properly plugged into the power
source and calibration system.
Check the Ethernet connection cable for any possible damage and for functionality.
Check that the Ethernet connection cable is connected correctly to the USB
Ethernet adapters.
Check that the DHCP server is running (icon in the task bar!). If the DHCP
server is not running, restart the software and check the network settings.
Disconnect the USB briefly from the power source and reconnect it again.
77
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78
Page 79
Technical data
Page 80
Page 81
Technical data
EN
Calibration system 2.0
Mains voltage 100 - 240 V AC
Mains voltage tolerance +15 / -10 %
Mains frequency 50/60 Hz
Mains fuse protection (slow-blow) 4 A
Primary current 3 A @ 100 V AC
1.5 A @ 240 V AC
cos phi power factor 0.99
Internal power supply 24 V DC +/- 1%
Output current 10 A (-25 °C - +55 °C)
Max. permissible loading of the sockets 8 A
Degree of protection IP 20
Type of cooling AF
Max. permissible current of the load 600 A
Max. permissible loading of the load 24 kW for 20 s
Max. permissible voltage of the load 113 V peak
EMC device class EN 61010 -1:2010
Safety symbols CE
Dimensions l x w x h 686 x 304 x 497 mm
Total dimensions (with trolley) 1103 x 738 x 1017 mm
Weight 31.5 kg
Total weight (with trolley) 120 kg
Ambient temperature 0 – 40 °C
Load resistance 8 x 480 mOhm parallel
Wire speed measuring system
Operating voltage 5 - 30 V DC
Open-circuit current 55 mA
Wire speed 0 - max. 30 m/min
Degree of protection IP 20
EMC device class EN 61010 -1:2010
Safety symbols CE
Weight 1.5 kg
Ambient temperature 0 – 40 °C
Fuse protection T2A
81
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Interface box
Operating voltage 24 V DC
Degree of protection IP 20
EMC device class EN 61010 -1:2010
Safety symbols CE
Dimensions l x w x h 466 x 355 x 85 mm
Weight (incl. gas measurement I-kit) 3.85 kg
Ambient temperature 0 – 40 °C
Gas measurement option
Operating voltage 18 - 30 V DC
Max. current consumption 100 mA
Max. operating pressure 11 bar
Measuring range 0 - 60 l/min
Ambient temperature 0 – 40 °C
Gas temperature 0 – 50 °C
Fuse protection T2A
82
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EN
83
Page 84
FRONIUS INTERNATIONAL GMBH
Vorchdorfer Straße 40, A-4643 Pettenbach, Austria
E-Mail: sales@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations
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