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Calibration system 2.0

Fronius Calibration system 2.0 Operating Instruction [EN]

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Operating instructions
Calibration system 2.0
Operating instructions
EN
42,0426,0270,EN 012-14032022
Contents
Safety rules 5
EN
General information 13
General 15
Device concept 15 Proper use / intended purpose 15 Crane transport 16
Accessories and options 17
Interface and trolley 17 Accessories 17 Options 19
Required for calibration 20
Computer & software 20 Hardware & accessories 20 Required for calibration of the WeldCube Connector 20
Controls, connections and mechanical components 23
Controls and connections on calibration system 25
Mechanical components on trolley 27
Calibration system trolley 27
Installation 29
Installing the calibration system 31
Setting the language, system information 37
3
Calibrating welding systems 39
General information 41
Mains voltage measurement for single-phase power sources 41 Correcting set values and load resistances 41
Calibrating welding systems with LocalNet (TPS, TSt, MW, TT) 42
Calibrating welding systems with SpeedNet (TPS /i, iWave 300i - 500i) 53
Overview - SpeedNet 53 Connecting the power source and calibration system 53 Connecting the welding wire calibration system 53 Connecting the computer to the calibration system and signature pad 54 Preparing the gas calibration system 54 Calibrating the welding system 55
Calibrating welding systems with USB / SpeedNet 59
Calibrating other Fronius welding systems 65
Overview - other Fronius devices 65 Connecting the power source and calibration system 65 Connecting the welding wire calibration system 66 Connecting the computer to the calibration system and signature pad 66 Preparing the gas calibration system 66 Calibrating the TransPocket welding system 67 Calibrating TransTig 1750 Puls 70 Calibrating VarioSynergic 3400 74 Calibrating TransTig 170 / 210 78
Calibrating WeldCube Connector 82
Overview 82 Connecting the TPS /i power source, WeldCube Connector and calibration system 82 Connecting the welding wire calibration system 84 Connecting the computer to the calibration system and signature pad 84 Preparing the gas calibration system 84 Calibrating WeldCube Connector 85
Troubleshooting 91
Troubleshooting 93
The status indicator is not lit up 93 The status indicator lights up red 93 No connection 93 No USB/SpeedNet connection 94
Technical data 95
Technical data 97
Calibration system 2.0 97 Wire speed measuring system 97 Interface box 98 Gas measurement option 98
4
Safety rules
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.
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.
-
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!
5
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 in-
-
structions 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
Obligations of the operator
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)
-
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.)
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 sec-
-
tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.
-
Obligations of personnel
6
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention 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.
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
EN
Protecting your­self and others
Risks from mains current and welding current
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 in-
-
jury.
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
-
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.
7
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.
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.
EMC Device Classifications
EMC measures In certain cases, even though a device complies with the standard limit values for
Devices in emission class A:
Are only designed for use in industrial settings
-
Can cause line-bound and radiated interference in other areas
-
Devices in emission class B:
Satisfy the emissions criteria for residential and industrial areas. This is also
-
true for residential areas in which the energy is supplied from the public low­voltage mains.
EMC device classification as per the rating plate or technical data.
emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to recti­fy the situation.
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
-
Network, signal and data transfer lines
-
IT and telecommunications devices
-
Measuring and calibrating devices
-
Supporting measures for avoidance of EMC problems:
Mains supply
1. If electromagnetic interference arises despite the correct mains connec-
-
tion, additional measures are necessary (e.g. use of a suitable line filter)
Welding power-leads
2. must be kept as short as possible
-
must be laid close together (to avoid EMF problems)
-
must be kept well apart from other leads
-
Equipotential bonding
3.
8
Earthing of the workpiece
4. If necessary, establish an earth connection using suitable capacitors.
-
Shield, if necessary
5. Shield other devices nearby
-
Shield the entire welding installation
-
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, e.g. those with pacemakers
-
and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-
-
proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the
-
welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind
-
them around any part of the body
EN
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.
-
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.
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.
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-carry-
-
ing 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,
9
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.
Danger from shielding gas cyl­inders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
Safety measures at the installa­tion location and during transport
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.
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.
10
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
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.
EN
Commissioning, maintenance and repair
Safety inspec­tion
It is impossible to guarantee that bought-in parts are designed and manufac­tured to meet the demands made of them, or that they satisfy safety require­ments.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent. Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the Spare Parts List, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and torque to 3 Nm.
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 12-month 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.
-
Calibration of the calibration system
For safety inspections, follow the appropriate national and international stand­ards and directives.
Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may re­quire.
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.
11
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 electromagnetic 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.
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.
12
General information
13
14
General
Device concept The 2.0 calibration system is designed
for calibrating power sources. All types of Fronius power sources 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.).
EN
Proper use / in­tended purpose
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.
15
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 posi-
▶
tion 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
▶
regulations
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
▶
4 suspension points for transporting by crane
16
Accessories and options
(1) (2) (3) (4) (5) (6) (7) (8)
(9)
(14)(15)(16) (13) (12) (11) (10)
(17)
Interface and trolley
EN
Interface calibration system 4,050,211
Accessories
Trolley calibration system 4,077,022
17
Item Description
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)
43,0004,5882
(7) 1 x cooling unit bridging hose
for use with the Euro/central connector adapter 44,0001,1204
(8) 1 x gas hose 1.5 m, 2 x 1/4“
44,0001,0538
(9) Adapter ZA Euro/FSC
44,0350,3329
(10) 1 x USB connection cable to PC/laptop
43,0004,5963
(11) Socket splitter 70/95 DIX KAB
43,0003,0704
(12) 2 x high-current socket to bayonet adapter
42,0001,4482
(13) 1 x LocalNet/USB converter
4,101,026
(14)
2 x bayonet adapter 25 mm2 to 50 mm
2
4,001,549
(15) 1 x Tuchel adapter cable
43,0004,5884
(16) Adapter ZA FSC-S-G/Euro STD
44,0350,3565
(17) 1 x welding wire calibration system
4,050,210 +
Connecting cable 5 m
43,0004,5997
18
Further accessories (not pictured)
Options
Description Item no.
1 x power adapter 4051091
1 x connection cable for gas sensor, 5 m
1 x 1.6 m SpeedNet cable 4051021
2 x 5 m SpeedNet cable 4051022
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
2 x USB Ethernet adapter EU 4306 43,0004,5688
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
43,0004,5914
43,0004,4850
EN
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
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
42,0001,3540
19
Required for calibration
https://downloadcenter.myfronius.com Software/Firmware Firmware
„Calibration“
https://collaboration.fronius.com Collaboration Perfect Welding / Products & Services PW General Topics / Services Securing Services Categories / Calibration 04_cal_software_releases
Computer & software
Computer, laptop
-
Calibration software
-
The calibration software can be downloaded from:
Fronius internal:
Hardware & ac­cessories
Required for cal­ibration of the WeldCube Con­nector
Calibration system 2.0
-
Interface calibration system
-
Welding wire calibration system
-
Accessories calibration system
-
Trolley calibration system
-
For the calibration of WeldCube Connector U/I and WeldCube Connector Ad­vanced:
PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
-
M12-X / RJ45 network cable, 5 m (42.0411.0232)
-
TPS 500i power source
-
For the calibration of WeldCube Connector U/I/WFS WSM and WeldCube Con­nector Advanced + WSM:
PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
-
M12-X / RJ45 network cable, 5 m (42.0411.0232)
-
Existing TransSteel system components
-
70/95 DIX KAB socket splitter (43,0003,0704)
-
20
For the calibration of WeldCube Connector U/I/WFS Euro and WeldCube Con­nector Advanced + Euro:
PoE injector, RJ45 30 W / 802.3at / PoE+ (42,0411,0213)
-
M12-X / RJ45 network cable, 5 m (42.0411.0232)
-
TPS 500i power source
-
WF 25i / WF 30i wirefeeder with Euro central connection
-
alternatively WF 25i / WF 30i wirefeeder with adapter ZA FSC-S-G/Euro STD (44,0350,3565) 70/95 DIX KAB socket splitter (43,0003,0704)
-
EN
21
22
Controls, connections and mechan-
ical components
23
24
Controls and connections on calibration system
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(18)
(17)
(16)
(15)
(14)
(13)
(12)
(11)
(10)
(8)
(9)
Front of device
Calibration system 2.0 with interface calibration system
Item Description
EN
(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) USB port for adapter
(8) SpeedNet connection socket
(9) Welding wire calibration system connection socket
(10) Status indicator
Lights up green
Device is ready
Lights up red
An error has occurred A description of the error is displayed by the software during the calibra­tion process.
(11) Gas calibration system connection socket
(12) SpeedNet connection socket
(13) SpeedNet connection socket
(14) SpeedNet connection socket
(15) SpeedNet connection socket
25
(16) Gas IN connection socket (option)
(1)
(2)
(3)
(4)
(5) (6) (7)
(8)
(11)
(10)
(9)
(17) Gas OUT connection socket (option)
(18) Data connection socket (option of connecting to the calibration system)
Rear of device (without trolley)
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
(for 230 V power supply)
(7) 230 V socket
(for 230 V power supply)
(8) F2 fuse (1 A slow-blow)
AC voltage measurement fuse protection
(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
26
Mechanical components on trolley
(5)
(4)
(3)
(2)
(1)
EN
Calibration sys­tem trolley
Item Designation
(1) Calibration system trolley
(option)
(2) Accessory drawers
(3) Cable hanger
(4) Tray
(5) Storage trays
27
28
Installation
29
30
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