Fronius FCH Operating Instruction [EN]

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FCH 3-21

FCH 3-38

FCH 6-76

FCH 9-114

Translated document:
Operating Instructions,
Maintenance

EN

Orbital weld head

42,0426,0233,EN

V

10 - 09042020

Dear reader,

Introduction

These operating instructions will help you familiarise yourself with the machine. It is in
your interest to read these instructions carefully and to observe the directions contained
in them. This will prevent faults and incorrect operation or possible damage to installed
components.

Please also obey the safety rules; doing so will ensure greater safety when using the
product. Careful handling of the entire system will repay you with years of safe and reli­able operation. These are essential prerequisites for excellent results.

3

4

Contents

General information 9

Safety rules ................................................................................................................................................... 11

General remarks....................................................................................................................................... 11

Proper use ................................................................................................................................................ 11

Environmental conditions ......................................................................................................................... 12

Obligations of the operator ....................................................................................................................... 12

Obligations of the personnel .................................................................................................................... 12

Mains connection ..................................................................................................................................... 12

Protecting yourself and others ................................................................................................................. 13

Information on noise emission values ...................................................................................................... 13

Dangers posed by mains current and welding current ............................................................................. 14

EMC device classications ....................................................................................................................... 14

EMC measures.........................................................................................................................................15

EMF measures with implants ................................................................................................................... 15

Specic hazards ....................................................................................................................................... 16

Impairment of the welding results ............................................................................................................ 16

Danger from shielding gas cylinders ........................................................................................................ 17

Safety measures at installation location and during transport .................................................................. 17

Safety measures in normal operation ...................................................................................................... 18

Maintenance and repair ........................................................................................................................... 18

Safety inspection ...................................................................................................................................... 18

Disposal....................................................................................................................................................19

Safety labelling ......................................................................................................................................... 19

Data protection ......................................................................................................................................... 19

Copyright .................................................................................................................................................. 19

About this document ...................................................................................................................................... 20

Function of this document ........................................................................................................................ 20

Explanation of safety symbols .................................................................................................................. 20

Qualied technicians ................................................................................................................................ 20

Copyright .................................................................................................................................................. 20

General remarks ............................................................................................................................................ 21

Principle....................................................................................................................................................21

Device concept and applications .............................................................................................................. 21

Materials to be welded ............................................................................................................................. 21

Safety 23

Operational reliability and tips for the user .................................................................................................... 25

Proper use ................................................................................................................................................ 25

Foreseeable misuse ................................................................................................................................. 25

Conversions or modications ................................................................................................................... 25

Duty to provide instruction ........................................................................................................................ 25

Operating instructions .............................................................................................................................. 26

Personal protective equipment ................................................................................................................. 26

Local regulations ...................................................................................................................................... 26

Additional overarching policies and regulations ....................................................................................... 26

Spare parts, wearing parts and auxiliary materials .................................................................................. 27

Transportation and storage ......................................................................................................................27

Danger points and safety precautions ........................................................................................................... 28

General.....................................................................................................................................................28

Safety instructions .................................................................................................................................... 28

5

Description of the orbital weld heads 31

Scope of supply ............................................................................................................................................. 33

Weld head conguration ...........................................................................................................................33

Accessories ............................................................................................................................................. 33

Weld head components .................................................................................................................................35

FCH Weld head ........................................................................................................................................ 35

FCH Weld head hosepack .......................................................................................................................36

Controls and connections .............................................................................................................................. 37

Connections ............................................................................................................................................. 37

Controls for FCH Weld head .................................................................................................................... 38

Welding position ............................................................................................................................................ 39

Welding position ....................................................................................................................................... 39

Commissioning 41

Starting up the weld head .............................................................................................................................. 43

General.....................................................................................................................................................43

Replacing clamping shells on the FCH 3-21 and FCH 3-38 .................................................................... 43

Replacing clamping shells on the FCH 6-76 and FCH 9-114 ................................................................... 44

Setting the electrode length ..................................................................................................................... 45

Table of electrode length .......................................................................................................................... 46

Screwing-in the electrode holder .............................................................................................................. 47

Electrode holder with lateral offset ........................................................................................................... 47

Positioning the Weld head on the workpiece ..........................................................................................48

Operation 49

Before welding ............................................................................................................................................... 51

Safety ....................................................................................................................................................... 51

Checking the connections ........................................................................................................................ 51

Switching on the system components ..................................................................................................... 51

Selecting the type of orbital Weld head .................................................................................................... 52

Welding process ........................................................................................................................................... 53

Creating a program ................................................................................................................................. 53

Starting the welding process .................................................................................................................... 53

After the welding process ............................................................................................................................. 55

Removing the Weld head ......................................................................................................................... 55

Troubleshooting, maintenance and disposal 57

Troubleshooting ............................................................................................................................................. 59

General.....................................................................................................................................................59

Basic requirements for the system to work .............................................................................................. 59

Troubleshooting ........................................................................................................................................ 59

Error messages in the system control unit .............................................................................................. 60

Error messages on the power source ..................................................................................................... 60

Maintenance .................................................................................................................................................. 61

Maintenance personnel ............................................................................................................................ 61

Maintenance record ................................................................................................................................. 61

Maintenance intervals and procedures .................................................................................................... 61

Opening the welding head ....................................................................................................................... 62

Checking and replacing the drive shaft ................................................................................................... 64

Setting the limit switch pressure pin in the rotor ...................................................................................... 65

Assembling the Weld head .......................................................................................................................66

6

Technical data 67

Technical data ...............................................................................................................................................69

Weld head FCH 3-21 ................................................................................................................................69

Weld head FCH 3-38 ................................................................................................................................69

Weld head FCH 6-76 ................................................................................................................................69

Weld head FCH 9-114 .............................................................................................................................. 69

Environmental conditions ......................................................................................................................... 70

FCH dimensions ....................................................................................................................................... 70

Rating plates ............................................................................................................................................ 71

Spare parts, circuit diagram 73

Spare parts .................................................................................................................................................... 75

Spare parts, wearing parts and auxiliary materials .................................................................................. 75

Ordering details ........................................................................................................................................ 75

FCH 3-21 .................................................................................................................................................. 76

FCH 3-38 .................................................................................................................................................. 81

FCH 6-76 .................................................................................................................................................. 86

FCH 9-114 ................................................................................................................................................ 92

Driving unit FCH 3-21 ............................................................................................................................... 98

Driving unit FCH 3-38 ............................................................................................................................... 98

Driving unit FCH 6-76 ............................................................................................................................. 101

Driving unit FCH 9-114 ........................................................................................................................... 101

Offset electrode holder FCH ...................................................................................................................104

Offset electrode holder, stepless adjustable FCH .................................................................................. 104

Seal disc / Holder for seal disc ............................................................................................................... 104

Transport case FCH ............................................................................................................................... 105

Extension hose pack 10m ...................................................................................................................... 105

Tool and wear part box ........................................................................................................................... 105

Collets ........................................................................................................................................................ 106

Collets-dimension ................................................................................................................................... 106

Wiring diagram ............................................................................................................................................ 110

EU-Declaration of conformity .......................................................................................................................111

7

8

General information

9

10

Safety rules

General remarks

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 operator,

- inefcient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing
the device must:

- be suitably qualied,

- have sufcient 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 remarks" in the operating instructions for the device. Before switching

on the device, remove any faults that could compromise safety.

Proper
use

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

The device is intended for the welding process described on the rating plate only. 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 also 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.

Never use the device for the following purposes:

- Thawing out pipes

- Charging batteries

- Starting engines

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.

11

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 temperature range:

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

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

- free from dust, acids, corrosive gases and substances, etc.

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

Altitudes above sea level:

- up to 2000 m (6561 ft. 8.16 in.)

Environment:

- Under no circumstances may the device be operated in rainy or snowy environments.

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 conrmed 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
the 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

conrm 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 cur-

rent
consumption. This may affect a number of types of device 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 operator or user of the device should check whether the device may be

connected, discussing the matter with the
power supply company where appropriate.

NOTE! Ensure that the mains connection is earthed properly

12

Protecting
yourself and
others

Persons involved with welding expose themselves to numerous risks, e.g.:

- arc radiation, which can damage eyes and skin

- hazardous electromagnetic elds, which can endanger the lives of those using car-

diac pacemakers

- risk of electrocution from mains current and welding current

- greater noise pollution

- harmful welding fumes and gases

Anyone working on the workpiece whilst welding is taking place must wear suitable pro­tective clothing with the following properties:

- ame-resistant

- insulating and dry

- covers the whole body, is undamaged and in good condition

- safety helmet

- trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

- protect eyes and face from UV rays, heat and sparks using a protective visor and

regulation lter.

- wear regulation protective goggles with side protection behind the protective visor.

- wear stout footwear that provides insulation even in wet conditions.

- protect the hands with suitable gloves (electrically insulated and providing protection
against heat).

- wear ear protection to reduce the harmful effects of noise and to prevent injury.

Information on
noise
emission
values

Keep all persons, especially children, out of the working area while any devices are in

operation or welding is in progress. If, however, there are people in the vicinity,

- make them aware of all the dangers (risk of dazzling by the arc, injury from ying

sparks, harmful welding fumes, noise, possible risks from mains current and welding

current, etc.),

- provide suitable protective equipment or

- erect suitable safety screens/curtains.

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling

and in the cooling phase following operation at the maximum permissible operating point
under maximum rated load conditions according to EN 11201.

13

Dangers posed
by 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.

- During TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of
metal that are in contact with the welding wire are live.

- Always set the wirefeeder up on a sufciently insulated surface or use a suitable,
insulated wirefeeder holder.

- Make sure that you and others are protected with an adequately insulated, dry tem-

porary backing or cover for the earth or ground potential. This temporary backing 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. Loose connectors, scorched, damaged or inadequately dimensioned cables
and leads must be replaced immediately.

- Do not loop cables or leads around the body or parts of the body.

- Never submerge the electrode (rod electrode, tungsten electrode, welding wire, etc.)

in uids to cool it.

- Never touch the electrode when the power source is switched on.

- Double the open circuit voltage of a power source can occur between the welding
electrodes of two power sources. Touching the potentials of both electrodes at the
same time may be fatal under certain circumstances.

- Arrange for the mains cable to be checked regularly by a qualied 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 mains 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.

- Wear a safety harness if working at height.

- 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 components that store electrical charges

- Ensure that all components of the device are currentless.

- If work on live parts is required, appoint a second person to switch off the main switch
at the right moment.

EMC device

classications

EMC device classication according to the rating plate or the technical data.

Devices with emission class A:

- are only designed for use in an industrial setting.

- can cause conducted and emitted interference in other areas.

Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas.
This also applies to residential areas in which power is supplied from the public low­voltage grid.

14

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.

Check and assess the immunity of equipment in the vicinity of the device in accordance

with 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 power supply

- If electromagnetic interference arises despite correct mains connection, additional

measures are necessary (e.g. use a suitable line lter).

2. Welding power-leads

- Keep the power-leads as short as possible

- Allow the power-leads to run close together (also to avoid EMF problems)

- Lay the power-leads far away from other lines

3. Equipotential bonding

4. Earthing the workpiece

- If necessary, establish an earth connection using suitable capacitors.

5. Shielding, if required

- Where necessary, shield other equipment in the vicinity.

- Shield off the entire welding installation

EMF measures
with implants

Electromagnetic elds may pose as yet unknown risks to health:

- Effects on the health of persons in the vicinity, e.g. those with pacemakers and hear-
ing aids

- Individuals with pacemakers must seek advice from their doctor before approaching
the device or any welding that is in progress

- For safety reasons, maintain as large a distance as possible between the welding
cables and the head/torso of the welder.

- Do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body

15

Specic hazards Keep hands, hair, clothing and tools away from moving parts.

For example:

- Fans

- Cogs

- 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 or removed for as long as maintenance

or repair work is being carried out.

During operation:

► Ensure that all covers are closed and all side panels are tted properly.
► Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).

► Do not look into the contact tip
► Wear suitable protective goggles.

- Never touch the workpiece during or after welding - risk of burns.

- Welding torches and other parts with a high operating temperature must be allowed to
cool down before handling.

- Special provisions apply in areas at risk of re 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.

- Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting

coolant ow or return lines.

- Observe the information on the coolant safety data sheet when handling coolant. The
coolant safety data sheet may be obtained from your service centre or downloaded
from the manufacturer's website.

- The device is equipped with a carrying handle. This is only to be used for transport by
hand. The carrying handle is not suitable for use if transporting with a crane, counter-

balanced lift truck or other mechanical hoist.

- As a minimum, the test interval and scope of the test must comply with the relevant
valid national standards and guidelines.

- Odourless and colourless shielding gas may escape unnoticed if an adapter is used
for the shielding gas connection. Prior to assembly, seal the device-side thread of the

adapter for the shielding gas connection using suitable Teon tape.

Impairment
of the welding
results

The following requirements with regard to shielding gas quality must be met if the weld­ing system is to operate in a correct and safe manner:

- Solid particle size < 40 μm

- Pressure dew point < -20 °C

- Max. oil content < 25 mg/m³

Filters must be used if necessary.

NOTE! There is an increased risk of soiling if ring mains are being used.

16

Danger from
shielding gas
cylinders

Shielding gas cylinders contain gas under pressure and can explode
if damaged. As shielding gas cylinders form part of the welding equipment,
they must be handled with great care.

- Protect shielding gas cylinders containing compressed gas from excessive heat, me-

chanical impact, slag, naked ames, 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.

- Only use shielding gas cylinders suitable for the application in hand, along with the

correct and appropriate accessories (regulator, hoses and ttings). 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.

Safety measures
at installation
location and
during transport

- Place the device on a solid, level surface.
The maximum permissible tilt angle is 10°.

- Special provisions apply in areas at risk of re 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 ow 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.

- Before transporting the device, allow coolant to drain completely.

- 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.

17

Safety measures
in normal
operation

Only operate the device if 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,

- inefcient 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.
Always secure the shielding gas cylinder to prevent it from falling over.
Only the manufacturer's original coolant is suitable for use with our devices due to its

properties (electrical conductibility, anti-freeze agent, material compatibility, ammability,

etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
The manufacturer accepts no liability for damage resulting from use of a different coolant.
In addition, all warranty claims will be forfeited.
The coolant can ignite under certain conditions. Transport the coolant

only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your ser­vice centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

Maintenance and
repair

Safety
inspection

With parts sourced from third-parties, there is no guarantee that they are constructed and

manufactured so
as to meet the demands and safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
Do not carry out any modications, alterations, etc. to the device without the manufac­turer's consent.
Parts 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 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 carried out by a qualied electrician is recommended

- after modication

- after installing or converting components

- after repairs, updates and maintenance

- at least every twelve months.

- 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.

18

Disposal

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

2012/19/EC 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. Be sure to return any device
that you no longer require to your dealer, or nd out about the

approved collection and recycling facilities in your area. Ignoring this European Directive
may be harmful to the environment and your own health!

Safety
labelling

Data protection

Copyright

Devices with the CE mark satisfy the essential requirements of the low-voltage and elec­tromagnetic compatibility directive (e.g. relevant product standards from the EN 60 974
series).

Devices with the CSA test mark satisfy the requirements of the relevant standards in

Canada and the USA.

The user is responsible for backing up any changes made to the

factory settings. The manufacturer shall not be liable in the event
that personal settings are deleted.

Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing.

Fronius reserves the right to make changes. The contents of the operating instructions

shall

not provide the basis for any claims whatsoever on the part of the purchaser. We are

grateful for any suggestions for improvement and for drawing our attention
to any errors in these operating instructions.

19

About this document

Function of this
document

Explanation of
safety
symbols

These operating instructions explain how to commission and operate the device in
conjunction with the installed system components.
Look after the operating instructions carefully; they must always be to hand at the loca­tion where the device 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
equipment.

IMPORTANT! Indicates tips for correct operation and other particularly useful informa­tion. It does not indicate a potentially damaging or dangerous situation.

Qualied

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

practical welding experience. Personnel must be trained through veriable regular

instruction.

- Maintenance and repair of the machine may likewise only be carried out by trained

technicians and in compliance with the specied maintenance activities and mainte­nance intervals.

- The manufacturer accepts no liability for damage caused by insufcient knowledge of

how to use the device.

Copyright of these operating instructions remains with Fronius International GmbH. Text
and illustrations were accurate at the time of printing. Fronius reserves the right to make
changes. The contents of the operating instructions shall
not provide the basis for any claims whatsoever on the part of the purchaser.

20

General remarks

Principle

Device concept
and applications

Materials to be
welded

The Weld heads in the FCH series are devices with a closed design and are powered by
24 V direct current motors. Regulation is achieved by means of an encoder, which deter­mines the speed at all times and transmits it to the control unit.

The Weld heads in the FCH series are intended for welding butt welds (PG, PF & PC)
using the TIG welding process without wirefeed.
The individual Weld heads are controlled via the FPA 3020 or FPA 3030 control units.

The FCH series Weld heads are intended for mobile welding use in the food technology,
general mechanical engineering, chemical, cleaning technology and pharmaceutical sec­tors.

In principle it is possible to weld all conventional materials with one another.
If you have any welding-related questions, our engineers will of course be happy to
help.

21

22

Safety

23

24

Operational reliability and tips for the user

Proper use

Foreseeable
misuse

The Weld heads in the FCH series are intended exclusively for executing circumferen­tial welds using the TIG process, without any additives. Any other use shall be deemed
improper and the manufacturer will assume no responsibility for any damages arising.

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 information (date, operator, activities

carried out)

- Using the spare parts stipulated by Fronius

- Using this document in combination with the operating instructions for the integrated

system components (power source, cooling units, etc.)

IMPORTANT! The Weld head 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 it remains operationally reliable.

Any use other than for the intended purpose shall be deemed improper use. This in­cludes:

- Use outside the permitted technical operating limits

- Use in hazardous areas

- Use in rain or snow

Conversions or

modications

Duty to provide

instruction

Any unauthorised conversions or modications made to the Weld head by the user shall
invalidate all liability or warranty obligations on the part of the manufacturer.
The electromagnetic characteristics of the Weld head can be adversely affected by addi­tions or modications of any kind.
No modications or upgrades to the Weld head should therefore be undertaken without
rst consulting FRONIUS International GmbH and obtaining written approval.

Before they start work, the device operator must instruct or train all persons working with
the Weld head in:

- the theoretical and practical aspects of operation

- the safety regulations.

IMPORTANT! The duty to provide instruction applies in particular to those who only work
with the Weld head occasionally.

25

Operating in-

structions

The operating instructions help you to use the Weld head safely and efciently and must
be accessible at all times.

- The various sections of the operating instructions must always be kept near the de-

vice.

- Clearly mark the place where the instructions are kept

- Ensure that all persons using the Weld head 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.

Personal protec­tive equipment

The operator alone is responsible for the immediate working environment.
The following safety measures must be put in place and employed:

- Welding goggles

- Welding shield

- Welding gloves

- Welding apparel

- Welding footwear

Local regulations 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

Additional ov-

erarching poli­cies and regula-

tions

EU- Directives:

2009/104/EC Use of work equipment

89/391/EEC OSH Framework directive

89/654/EEC Workplace requirements

26

Additional

overarching
policies and

regulations

(continued)

National regulations in their valid / current version:

ESV Electro-technics protection regulation

ETV Electro-technic regulation

MSV Machinery safety regulation

EMVV Electromagnetic compatibility regulation

AMVO Work equipment regulation

ASchG Employees law

BetrSichV Operational safety regulation

Spare parts,
wearing parts
and auxiliary
materials

Transportation
and storage

Using spare parts and wearing parts from third-party manufacturers may pose risks. Use
Fronius original replacement parts only.
The manufacturer cannot accept any liability for damage resulting from the use of spare
or wearing parts or auxiliary materials that are not approved by the manufacturer.

The Weld head is supplied with all of the
connection cables required for operation in
a custom-t plastic case.

Transport case with Weld head

27

Danger points and safety precautions

General

Safety instruc­tions

During arc welding you can incur injury and cause harm to other people. For this reason,
always adhere to the applicable safety and accident prevention regulations, including
when orbital welding.

WARNING!

Risk of burns from hot surfaces.

The parts, housing or drives carrying this symbol get hot when in use
for a long time. If touched they can cause burns to hands or other
parts of the body.

- Avoid contact with these parts.

WARNING!

Risk of injury from arc radiation.

The equipment bearing this symbol contains equipment that emits
intense light levels. This can cause severe injury to the eyes.

- Do not look directly into the light beam!

- Use suitable protective goggles or protective shields (level of
protection 9-15).

WARNING!

Risk of cuts or burns due to weldments.

Weldments are heated up to high temperatures by the welding pro­cess.
If touched they can cause burns to hands or other parts of the body.

- Wear appropriate welding apparel.

WARNING!

Risk of eye injuries due to arc radiation.

Use suitable welding goggles or welder's shields (level of protection
9-15).

- Observe the DIN levels of protection for welding lters

WARNING!

Risk of cuts or burns due to weldments!

Weldments are heated up to high temperatures by the welding pro­cess.
Touching the plate may cause burns.

- Wear welding gloves when inserting and removing the weld­ments.

28

Safety
instructions

(continued)

WARNING!

Risk of skin injuries or burns due to hot weldments.

The residual heat generated during welding can heat up components
to extremely high temperatures. Falling components can lead to
burns and severe injuries to feet.

- Wear welding footwear when inserting and removing compo­nents.

29

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