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Trolley/rack TP06
Operating Instructions,
Maintenance
EN
Trolley
42,0426,0140,EN V03 - 03022017
Dear reader,
Introduction
Thank you for the trust you have placed in our company and congratulations on buying
this premium Fronius product. These instructions will help you familiarise yourself with
the product. Reading the instructions carefully will enable you to learn about the many
dierent features it has to oer. 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.
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Inhaltsverzeichnis
General information 7
About this document ........................................................................................................................................ 9
Function of this document .......................................................................................................................... 9
Explanation of safety symbols .................................................................................................................... 9
Qualied technicians .................................................................................................................................. 9
Copyright .................................................................................................................................................... 9
General .......................................................................................................................................................... 10
Device concept ......................................................................................................................................... 10
Application area ....................................................................................................................................... 10
Notes regarding the marking of control elements and connections ......................................................... 10
Scope of supply ........................................................................................................................................ 10
Safety 11
Operational reliability and tips for the user .................................................................................................... 13
Proper use ............................................................................................................................................... 13
Improper use ............................................................................................................................................ 13
Conversions or modications ................................................................................................................... 13
Operating instructions .............................................................................................................................. 13
Instructions ............................................................................................................................................... 14
Third-party and untrained personnel ........................................................................................................ 14
Distribution of keys ................................................................................................................................... 14
Mains voltage adaptation ......................................................................................................................... 14
Securing electrical systems ...................................................................................................................... 15
Protection device for power sources ........................................................................................................ 15
Local regulations ...................................................................................................................................... 15
Replacement parts, wearing parts and auxiliary materials ....................................................................... 15
Details when ordering spare parts ........................................................................................................... 15
Safety features .............................................................................................................................................. 16
General.....................................................................................................................................................16
Lockable front wheels .............................................................................................................................. 16
Power source safety device in the trolly ................................................................................................... 17
Warning notices axed to the trolly .........................................................................................................18
Description of the warning notices ........................................................................................................... 19
Residual risks ................................................................................................................................................ 20
General.....................................................................................................................................................20
Description of residual risks ..................................................................................................................... 20
Description of the system 21
Transporting and storing ................................................................................................................................23
Handling and transporting items .............................................................................................................. 23
After delivery ............................................................................................................................................ 24
Temporary storage ...................................................................................................................................24
Transporting and setting up ......................................................................................................................24
Technical description ..................................................................................................................................... 27
Description of trolly ................................................................................................................................... 27
Trolly data ................................................................................................................................................ 28
Dimensions...............................................................................................................................................28
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Commissioning, operation 29
Commissioning .............................................................................................................................................. 31
Properties of the installation site .............................................................................................................. 31
Stability ..................................................................................................................................................... 31
Energy connections .................................................................................................................................. 32
Operation ....................................................................................................................................................... 33
Fitting the power sources ......................................................................................................................... 33
Safety ....................................................................................................................................................... 35
Connecting the grounding (earthing) cable .............................................................................................. 35
Checking the connections ........................................................................................................................ 35
Switching on the trolly ............................................................................................................................. 35
Troubleshooting, maintenance and disposal 37
Troubleshooting ............................................................................................................................................. 39
General.....................................................................................................................................................39
Safety ....................................................................................................................................................... 39
Basic requirements for the system to work .............................................................................................. 39
Maintenance .................................................................................................................................................. 40
Safety ....................................................................................................................................................... 40
Maintenance engineers ............................................................................................................................ 40
Stopping the system ................................................................................................................................. 40
Securing against unexpected movements ............................................................................................... 40
Switching o the system and ensuring it cannot be switched back on again ........................................... 40
Maintenance record ................................................................................................................................. 41
Maintenance intervals and procedures .................................................................................................... 41
Disassembly and disposal ............................................................................................................................. 42
Personnel ................................................................................................................................................. 42
Disassembling the system ....................................................................................................................... 42
Disposal of components ........................................................................................................................... 42
Appendix 43
Replacement parts ........................................................................................................................................ 45
Replacement parts, wearing parts and auxiliary materials ....................................................................... 45
Ordering details ........................................................................................................................................ 45
Trolly replacement parts ........................................................................................................................... 46
Trolly/rack circuit diagram ........................................................................................................................47
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General information
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About this document
Function of this
document
Explanation of
safety symbols
These operating instructions tell you how to commission and operate the
trolly/rack TP06 in conjunction with the installed system components. Look after the operating instructions carefully; they must always be to hand at the location where the trolly
is being used. They can be used as a reference should any operational or functional
problems occur in the future.
DANGER! Indicates immediate and real danger. If it is not avoided, death or
serious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of awed results and possible damage to the equip-
ment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information. It does not indicate a potentially damaging or dangerous situation.
Qualied
technicians
Copyright
Special care is required if you see any of the symbols shown.
These operating instructions are designed for trained technicians or persons with practi-
cal welding experience. Personnel must be trained through veriable regular instruction.
Maintenance and repair of the trolly/rack may only be carried out by trained technicians
and in compliance with the specied maintenance activities and maintenance
intervals. The manufacturer accepts no responsibility for damages caused by insucient
knowledge of how to use the product.
Copyright of these operating instructions remains with Fronius International GmbH.
Text and illustrations were accurate 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.
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General
Device concept
Application area
The trolly/rack TP06 has been specially
developed for the TP 2500 power source.
The carriage is designed to hold six
TP 2500 power sources.
There are two shelves on the trolly/rack
TP06, which can accommodate up to three
power sources each. The copper busbars
installed on the trolly each allow up to
three power sources to be connected
to a common earthing point.
Trolly/rack TP06
NOTE! Connecting both copper busbars is not permitted as this could cause
an overload on the connected grounding (earthing) cable.
The trolly/rack TP06 is suitable for use in any situation where a high degree of exibility
and mobility is required of the welding system.
The trolly/rack TP06 can be used for the following Fronius products:
- TP 2500 power sources
Notes regarding
the marking of
control elements
and connections
Scope of supply
Care has been taken when writing the operating instructions to ensure that identical
control elements and connections are identied in the same way.
Examples:
- If the grounding (earthing) connection is marked with (A) on the power source, the
grounding (earthing) connection is also marked with (A) on the carriage.
The scope of supply for the trolly/rack TP06 comprises:
- the trolly/rack TP06
- six short 35mm² grounding (earthing) cables, length 45cm (for connecting the power
sources to the ground bars)
Not included in the scope of supply:
- two 95mm² earth leads, three metres with M12 cable lugs tted at both ends (for
connecting the trolly to the ground potential)
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Safety
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Operational reliability and tips for the user
Proper use
Improper use
The trolly/rack TP06 is intended for transporting power sources and supplying these
same power sources with power. Any other use shall be deemed improper and the manufacturer will assume no responsibility for any resulting damages.
Proper use also includes:
- complying with all the instructions in the operating instructions
- carrying out all maintenance work at the stipulated intervals
- keeping a service book with the most important data (date, operator, activities carried
out)
- using the spare parts stipulated by Fronius
- using this document in conjunction with the operating instructions for the integrated
system components (power sources, wire-feed units, etc.)
- Operating electrical devices that have been approved
(e.g drills, angle grinder,etc.)
IMPORTANT! The trolly/rack TP06 must only be used for its intended purpose, and must
always be kept in perfect condition in terms of its safety features. This is the only way to
ensure that the trolly remains operationally reliable.
Any use of the trolly other than for its intended purpose shall be deemed improper use.
This includes:
- Transporting people
- Hoisting processes (hoisting, manoeuvring of loads) --> crane activities
- Using as ascent aids
- Use outside of the permitted technical operating limits (e.g. max. permitted load
exceeded)
- Use in hazardous areas
Conversions or
modications
Operating
instructions
If the user carries out any unauthorised conversion or modication of the trolly, any liability or warranty from the manufacturer is invalidated. The electromagnetic characteristics
of the trolly can be adversely aected by any kind of addition or modication. No modications or additions to the trolly should the refore be undertaken without rst consulting
the manufacturer and receiving written approval.
The operating instructions help you to use the trolly safely and eciently, and must therefore be to hand at all times.
- The operating instructions must always be kept near the trolly.
- Clearly mark the place where the instructions are kept
- Ensure that all persons using the trolly know where the operating instructions are
located.
- The operating instructions will only be able to help you in the event of a problem if
they are at hand!
IMPORTANT! The manufacturer shall not be liable for any damage that arises from
failure to observe the operating instructions.
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Instructions The operator must inform all people working with the trolly about the following before
starting work:
- the theoretical and practical aspects of operating the trolly
- the safety regulations applicable to the trolly.
IMPORTANT! The duty to instruct applies in particular to those who only occasionally
work with the trolly. (e.g. during set-up, maintenance, etc.)
Third-party
and untrained
personnel
Distribution
of keys
Do not allow third-party or untrained personnel unsupervised access to the trolly.
- Visitors or untrained personnel may only approach the trolly when accompanied by
trained personnel.
- Display a "No unauthorised access" sign at appropriate locations in the access areas
to the trolly.
- Ensure that the trolly is only operated under supervision and is locked when the op-
erator leaves.
Access by unauthorised persons must be prevented to avoid the risk of serious accidents.
The following components can be locked:
- Main switch on the trolly
IMPORTANT! The operator must provide a padlock to lock the main switch.
NOTE! The keys may only be given to persons who are responsible for, and
trained in, the relevant areas. If unauthorised persons gain access to the
trolly then lethal hazards can arise that will aect everyone in the vicinity.
The following measures regarding the whereabouts of keys must be put in place by the
operator:
- Keep a record of who was given which key and when
- Keep unused keys locked away in a suitable place. (key cabinet)
- Instruct personnel that a trolly must be locked even if it is unsupervised for only a
short time, and the keys stored away securely by those with responsibility.
- Check regularly to ensure that these measures are being implemented.
Mains voltage
adaptation
If adaptations to mains voltages are necessary, an electrically isolated 3-phase transformer must be used. An autotransformer is NOT SUITABLE in this situation. The elec-
trical connection specications on the trolly and/or in the operating instructions must be
observed.
- Check the supply voltage before starting up the trolly
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Securing
electrical
systems
- Only trained technicians may access the electrical working areas and any access by
unauthorised persons must be prevented.
- Display a warning sign in a suitable location if not already present.
- Cordon o electrical working areas during assembly, repair, maintenance, etc. to
ensure that no unauthorised persons can enter.
Protection device
for power sources
Local
regulations
Replacement
parts, wearing
parts and
auxiliary
materials
The power sources in the trolly are secured using a protection device that prevents them
from inadvertently falling out. This protection device must be xed to the power sources
whenever the trolly is in use. If a protection device is removed for main-tenance or set-up
work, it must be retted before the trolly is used again.
In some countries, local statutory regulations may apply that are not included in these
operating instructions. It is the duty of the operator to be aware of and comply with any
local statutory regulations. This relates primarily to regulations concerning:
- Accident prevention
- Machine safety
- Protection of personnel (protective equipment)
- Environmental protection
- Electrical system
Using replacement parts and wearing parts from third parties may pose resulting risks.
Use Fronius original replacement parts only.
The manufacturer cannot accept any liability for damage resulting from the use of
replacement or wearing parts or auxiliary materials that are not approved by the manufacturer.
Details when
ordering spare
parts
NOTE! Only trained technicians may change parts and may only do so after
having read the installation and dismantling instructions supplied.
When ordering replacement parts, you should provide the following data:
- Exact designation of the replacement part
- Corresponding item number as per spare parts list
- Model name of the machine (see rating plate)
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