Fronius FCH 3-21, FCH 3-38, FCH 6-76, FCH 9-114 Operating Instruction [EN]

/ Perfect Welding / Solar Energy / Perfect Charging

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

30

Description of the orbital weld heads

31

32

Scope of supply

Weld head

conguration

Accessories

(1)

(2)

(1) FCH orbital Weld head

(2) FCH transport case

FCH offset electrode holder

- for electrode diameter 1.6 mm
Item no.: 48,0005,1880

- for electrode diameter 2.4 mm
Item no.: 48,0005,2075

33

FCH rotating electrode holder

- for electrode diameter 1.6 mm
Item no.: 48,0005,2076

- for electrode diameter 2.4 mm
Item no.: 48,0005,2077

Accessories

(continued)

Sealing washer set

Sealing washer set (without through hole)

Sealing washer bracket

Sealing washer bracket

Option: Tool and wear part box

34

Weld head components

FCH Weld head

(3) (3)

(1)

(2)

(4)

(5)

(1) Clamping shell housing with clamping shells

(2) Clamping lever

(3) Fitting rails for power transmission and xing

(4) Grip piece

(5) Hosepack

35

FCH Weld head
hosepack

(5)

(2)

(1)

(4)

(3)

FCH 3-21 & FCH 3-38 Weld head hosepack

(5)

(1)

FCH 6-76 & FCH 9-114 Weld head hosepack

(2)

(3)

(4)

(1) Connection for the warm water of the torch head water cooling system (if pre-

sent)

(2) Connection for the cold water of the torch head water cooling system (if present)

(3) Earth connection (+)

(4) Welding current connection (-)

(5) Power cable for the Weld head

36

Controls and connections

Connections

(6)

(1)

(2)

(3)

(4) (5)

Forming gas

Shielding gas

(3)

Hosepack

(5)

(2)

(1)

(4)

FCH 3-21 & FCH 3-38 Weld head hosepack

37

Connections

(continued)

(5)

Controls for FCH
Weld head

(1)

(2)

(3) (4)

FCH 6-76 & FCH 9-114 Weld head hosepack

(1) Cold water connection for the torch head cooling system (if present)

(2) Power cable for the Weld head

(3) Warm water connection for the torch head cooling system (if present)

(4) Earth connection (+)

(5) Welding current connection (-)

(6) FRC-FPA 3020 remote control with 10-metre cable

(1) Limit switch LED

Limit switch for 360 degree position

(2) Stop/Start button

For starting and stopping the weld­ing process.

(1)

(2)

(3)

(4)

(3) Rotation button

The welding torch rotates in the set
direction of rotation.

(4) Stop/Test key

- Stops the welding process im­mediately.

- Hold down for two seconds for
gas test

Controls on the Weld head

38

Welding position

Welding position

Horizontal position on rigid pipe

Possible welding positions:

- PG (xed pipe, horizontal welding axis, vertical-down welding position)

- PF (xed pipe, horizontal welding axis, vertical-up welding position)

Vertical position on rigid pipe

Possible welding positions:

- PC (xed pipe, vertical welding axis, transverse welding position)

39

40

Commissioning

41

42

Starting up the weld head

General

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

As it is possible to weld various pipe diameters with the weld head, it is necessary to
adjust the Weld head clamping shells to the respective diameter.

NOTE! Ensure that the correct clamping shell diameter is selected.
A clamping shell diameter that is too large results in:

► Loss of the welding gas environment
► Increased electrode wear
► A deterioration in weld seam quality

The following instructions relate to both sides of the Weld head.

1. Flip the clamping lever at the side of
the Weld head and open the welding
head.

2. Loosen the retaining screw on the
clamping shell using an Allen key.

3. Remove the old clamping shell.

4. Insert the new clamping shell

5. Replace the retaining screw and
tighten using the Allen key.

6. Repeat the process for the other
clamping shells.

43

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

CAUTION!

Risk of minor physical injury and material damage through sudden
release of the clamping shell.

Fingers and hands may be squashed or pricked.
The electrode may be bent during a clamping shell replacement.

- Pull the clamping shell out of the bracket using gentle, even force.

The following instructions relate to both sides of the Weld head.

(a) Small cut-out at the front for the

lock.

(b) Large cut-out at the rear for the

xing.

(a)

(b)

(c) Immoveable bolt for xing.

(d) Moveable screw for the lock.

(c) (d)

1. Flip the clamping lever at the side of
the Weld head and open the welding
head.

2. Using a screwdriver, turn the locking
screw through 180°. The lock is now
open.

...Lock closed

...Lock open

44

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

(continued)

3. Remove the old clamping shell.

4. Insert the new clamping shell

5. Using a screwdriver, turn the locking
screw through 180°. The lock is now
closed.

6. Repeat the process for the other
clamping shells.

Setting the elec­trode length

1. Flip the clamping lever at the side of
the Weld head and open the welding
head.

2. By pressing the "Rotation" button on
the Weld head, turn the rotor until
the adjusting screw for the electrode
length appears.

3. Push the electrode into and through
the opening and hold it on the inside
of the rotor.

IMPORTANT! Do not simply allow
the electrode to fall through, as this
can damage the tip of the electrode.

4. Using a gauge, set the electrode
spacing in line with the requirement.
Refer to the section entitled "Table
of electrode length".

45

5. Turn the rotor back to the starting
position.

6. Close the welding head with the
clamping shells and lock using the
two clamping levers.

Table of electrode
length

Electrode length =

External diameter of rotor - external diameter of pipe

2

– Electrode spacing

Wall thickness

(a)

Electrode spacing

(b)

0.5 mm - 1.0 mm 0.8 mm

(b)

(a)

1.25 mm - 2.0 mm 1.3 mm

2.25 mm - 3.9 mm 1.8 mm

Welding head FCH 3-21 FCH 3-38 FCH 6-76 FCH 9-114

External diameter of rotor D = 58 D = 86 D = 136 D = 176

Gas quantity 6-8 l/min 10-12 l/min 12-16 l/min 14-18 l/min

Gas pre-ow time 20 s 20 s 30 s 45 s

External diameter of pipe

3.17 mm

6 mm

6.35 mm

8 mm

9.53 mm

10 mm

12 mm

12.7 mm

13 mm

16 mm

18 mm

19 mm

19.05 mm

21.3 mm

23 mm

25.4 mm

26.9 mm

28 mm

29 mm

33.7 mm

35 mm

38.1 mm

41 mm

42.4 mm

44.5 mm

48.3 mm

50.8 mm

26 mm 40 mm - -

25 mm 39 mm 64 mm -

25 mm 39 mm 63 mm -

24 mm 38 mm 63 mm 83 mm

23 mm 37 mm 62 mm 82 mm

23 mm 37 mm 62 mm 82 mm

22 mm 36 mm 61 mm 81 mm

21 mm 35 mm 60 mm 80 mm

21 mm 35 mm 60 mm 80 mm

20 mm 34 mm 59 mm 79 mm

18 mm 32 mm 57 mm 77 mm

17 mm 31 mm 56 mm 76 mm

17 mm 31 mm 56 mm 76 mm

16 mm 30 mm 55 mm 75 mm

- 29 mm 54 mm 74 mm

- 28 mm 53 mm 73 mm

- 27 mm 52 mm 72 mm

- 27 mm 52 mm 72 mm

- 26 mm 51 mm 71 mm

- 24 mm 49 mm 69 mm

- 23 mm 48 mm 68 mm

- 22 mm 47 mm 67 mm

- - 45 mm 65 mm

- - 44 mm 64 mm

- - 43 mm 63 mm

- - 41 mm 61 mm

- - 40 mm 60 mm

46

Table of electrode
length

(continued)

Welding head FCH 3-21 FCH 3-38 FCH 6-76 FCH 9-114

53 mm

54 mm

60.3 mm

63.5 mm

70 mm

76.1 mm

85 mm

88.9 mm

101.6 mm

104 mm

108 mm

114.3 mm

- - 39 mm 59 mm

- - 39 mm 59 mm

- - 35 mm 55 mm

- - 34 mm 54 mm

- - 31 mm 51 mm

- - 28 mm 48 mm

- - - 43 mm

- - - 41 mm

- - - 35 mm

- - - 34 mm

- - - 32 mm

- - - 28 mm

Screwing-in the
electrode holder

Electrode holder
with lateral offset

Welding head Maximum

diameter

A

FCH 6-76 50.8 mm

FCH 9-114 88.9 mm

Welding head Lateral

offset

B

FCH 6-76 Variable depending on

FCH 9-114

interplay of electrode

length, angle and

measurement A

Welding head Maximum

diameter

A

FCH 6-76 50.8 mm

FCH 9-114 88.9 mm

47

Welding head Lateral

offset

B

FCH 6-76 5 mm - 7 mm

FCH 9-114 5 mm - 7 mm

Positioning the
Weld head on the
workpiece

1. Flip the clamping lever at the side of
the Weld head and open the welding
head.

2. By pressing the appropriate buttons
on the remote control, turn the rotor
until the component can be inserted.

3. Position the Weld head so that the

electrode is located exactly in the

centre.

4. Close the welding head with the
clamping shells and lock using the
two clamping levers.

NOTE! Ensure that the correct
clamping shell diameter is se­lected. A clamping shell diam­eter that is too large results in:

► Loss of the welding gas

environment
► Increased electrode wear
► A deterioration in weld seam

quality

48

Operation

49

50

Before welding

Safety

Checking the
connections

Switching on
the system
components

WARNING!

Danger of injury from premature arc ignition.

The arc may be ignited accidentally. This can cause serious
eye injuries.

- Before operating the Weld head, ensure that welding is not switched on by
mistake in the system control program.

Check all connections between the individual components before starting up the Weld
head:

- System control

- Power source

- Grounding cable connection

Detailed information on the assembly and connection of the individual system compo­nents can be found in the relevant operating instructions.

IMPORTANT! Only switch on the external system components after they have been con­nected to the Weld head. This is necessary to enable the Weld head to record its current
position correctly.

- Remote control

- Cooling unit

- Shielding gas supply

After starting up the system control
(FPA 3020 or FPA 3030), the start screen
with all the setting options appears.

Detailed information can be found
in the "FPA 3020 Operating Instructions"
or "FPA 3030 Operating Instructions"
document.

51

Selecting the
type of orbital
Weld head

(a)

1. To select an orbital Weld head, call up
the "Orbital Weld head" menu in the
main menu of the control system.

2. Select the desired type of orbital Weld
head

(a) Open orbital weld head
(b) Closed orbital weld head
(c) Manual welding torch

(b)

(c)

(d)

3. Select the desired type of orbital Weld
head (d)

4. Use the "BACK" button (e) to return
to selecting orbital Weld heads, or the
"Menu" button to return to the main
menu

(e)

52

Welding process

Creating a
program

1. Open the "Parameter settings" menu.

The parameter settings allow the user
to enter or correct the most important
welding parameters for the orbital
welding process.

2. Create the welding program based on

the requirements for the weld seam
and the workpiece in the parameter
settings menu.

Detailed information on this can be
found in the "FPA 3020 Operating
Instructions" or "FPA 3030 Operating
Instructions" document, in the section
entitled

"Parameter settings menu".

Starting the
welding process

1. Call up the "Welding" menu

2. Therstwindowfortheweldingpro-

cess status appears

3. Click the "START" button to start

welding

4. Usethe"STOP"buttontonishweld-

ing, with downslope

IMPORTANT! To stop the welding process
directly, e.g. for safety reasons:

- Click the "CANCEL" button. Welding

stops immediately, with shielding gas

post-owbutnodownslope

53

Starting the
welding process

(continued)

5. The Weld head begins to execute the

set welding program.

54

After the welding process

Removing the
Weld head

1. Flip the clamping lever at the side of
the Weld head and open the welding
head.

2. Remove the Weld head from the
welded component.

55

56

Troubleshooting, maintenance and

disposal

57

58

Troubleshooting

General

Basic
requirements for
the system to
work

Troubleshooting

In the event of faults, note that the functioning of the entire system depends on many

additional components (power source, cooling unit, etc.) that are also potential sources
of problems.

When an error occurs, the corresponding error message appears either on the system

control display or on the display of the power source.

► Connections established between separate system components
► System components are supplied with electricity and the mains voltage is as speci-

ed (see rating plate)

Errors Cause Remedy

No ignition - Grounding cable not

connected

- No welding gas

- Faulty electrode

- Welding not switched
on

Gas shield impaired - Gas ow quantity un-

suitable

- Gas lens in poor condi­tion

- Electrode protrusion
length too great

- Gas cylinder is empty

No rotation - Electrical connections

not made

- Motor fault

- Plastic intermediate
coupling broken

- Programming error

Speed is not being regulated - Faulty pulse generator

- Electronic error in the
control unit

No pulses - Faulty pulse generator

- Electronic error in the
control unit

Rotation less than 360° - Programming error

- Drive unit damaged

- Plastic intermediate
coupling broken

Speed is not being regulated - Faulty pulse generator

- Electronic error in the
control unit

- Check grounding cable

- Check gas supply

- Check condition of
electrode

- Check welding program

- Check gas supply

- Replace gas lens

- Check electrode spac­ing

- Connect new gas cyl­inder

- Check connections

- Replace motor

- Replace motor control
board

- Replace plastic interme­diate coupling

- Check welding program

- Check pulse generator

- Replace motor control
board

- Check pulse generator

- Replace motor control
board

- Check welding program

- Check drive unit

- Replace plastic interme­diate coupling

- Replace pulse generator

- Replace motor

- Replace motor control
board

59

Error messages
in the system
control unit

Detailed information on the error messages shown can be found in the
"FPA 3020 Operating Instructions" or "FPA 3030 Operating Instructions" document, in the

section entitled "Troubleshooting".

Error messages
on the power
source

Detailed information on the error messages shown can be found in the operating instruc-

tions for the power source, in the section entitled "Troubleshooting".

60

Maintenance

Maintenance
personnel

WARNING!

Risk of injury and damage from incorrectly performed maintenance work.

It is essential to adhere to the maintenance intervals and maintenance proce­dures. The manufacturer accepts no liability for any damage caused by inad­equate or poorly performed maintenance.

- All maintenance work on the Weld head must only be carried out by trained

and qualied personnel.

Electrically skilled person (electrician):

Person who, due to specialist training, knowledge and experience of the relevant
regulations, is able to evaluate the tasks assigned to him/her and to identify and avoid
potential hazards.

Electrically instructed person:

Person adequately advised or supervised by skilled persons to enable him or her to
perceive risks and to avoid hazards which electricity can create and to understand the
necessary safety precautions and protection devices.
Note: Instruction must be recorded in writing.

Electrical layperson:

Someone who is neither a skilled person nor an instructed person.

Maintenance
record

Maintenance
intervals and
procedures

The following measures regarding maintenance must be put in place by the system
operator:

- a service book containing the required information (date, operator, maintenance work
carried out) must be kept.

The closed welding head of the FCH series must be dismantled and cleaned in line with
the degree of use, but at least once a week, and reassembled without using grease.
Foreign bodies such as welding beads must be removed, the current transfer rail and the
rotor must be cleaned of carbon black.
Check all gear teeth for damage and replace if necessary.

The maintenance interval based on the number of weld seams is as follows:

► Standard pipeline construction approx. 20 to 50 welding operations per day

– once a week

► Use in production facilities approx. 200 to 500 welding operations per day

– once a day

► Aluminium components

– once a day (due to increased formation of carbon black in the welding head)

NOTE! Use a dry cleaning cloth to clean the machine components. Only
use a cleaning agent if this is indicated in the maintenance procedure for a

specic part.

61

Opening the
welding head

NOTE! The manufacturer shall not be liable for any damage that arises due

to improper handling. The following are suggestions that cannot be used as
the basis of any claims whatsoever for defects that arise subsequently.

1. Flip the clamping lever at the side
of the Weld head and open the
welding head.

2. Loosen the Allen screws in the

nickel-plated, rectangular tting

rails. Fully unscrew the screw on
the lid side.

62

3. Remove the clamping shell housing

from the welding head.

Opening the
welding head

(continued)

4. Unscrew the polyamide screws on

the welding head.
To do this, please use a suitable
large screwdriver so as not to dam­age the slots.

5. Remove the lid of the Weld head.

NOTE! Graphite kidney-shaped pieces may only be replaced by Fronius per­sonnel, as calibration using a special tool must be carried out after replace­ment.

6. Clean the inside of the welding

head. Remove carbon black and
foreign bodies (e.g. grinding dust
and/or welding beads).

7. Clean the rotor with non-woven ma-

terial. Do not use sandpaper under
any circumstances.

8. Remove all gear wheels.

9. Clean the current transfer loop

with non-woven material. Do not
use sandpaper under any circum­stances.

10. Blow down the welding head with
compressed air and then clean
with brake cleaner and a lint-free
cloth. Assemble without using any
grease.

63

Opening the
welding head

(continued)

11. Check the gear wheels and shim
rings for damage and replace if
necessary.

Checking and
replacing the
drive shaft

NOTE! The manufacturer shall not be liable for any damage that arises due

to improper handling. The following are suggestions that cannot be used as
the basis of any claims whatsoever for defects that arise subsequently.

1. Loosen the 2 Allen screws using an
Allen key (the screws are offset by
90°).

2. Remove the aluminium coupling
using pliers.

64

3. Unscrew the slotted screws on the
retaining ring using a screwdriver.

Checking and
replacing the
drive shaft

(continued)

4. Remove the drive shaft assembly
and the brass clamping ring as­sembly.

5. Check the bevel gear wheel. If this
is damaged the drive shaft assem­bly will need to be replaced.
The two milled-off areas for the
clamping screws of the aluminium
coupling can be clearly seen in the
picture.

NOTE! When assembling,
please ensure that the screws
clamp on these areas.

Setting the limit
switch pressure
pin in the rotor

IMPORTANT! The homing or limit switch can only be set with the welding head com-

pletely disassembled. In order to simplify the individual work steps, the welding head is
shown disassembled here.

The limit switch is securely xed with screws and insulated in the body of the welding

head.
This limit switch unit cannot be adjusted.
The limit switch pressure pin (for triggering the limit switch signal in the welding head) is
located in the rotor. The limit switch pressure pin is hardened and nitrided. This means
that it is resistant to wear.

1. By pressing the appropriate buttons
on the remote control, turn the rotor

until the grub screw for xing the

limit switch pressure pin is located
in the centre of the Weld head.

2. Loosen the grub screw with an
Allen key (clamping for limit switch
pressure pin)

3. Adjust the limit switch pressure
pin by screwing in the Allen screw
using the Allen key. The limit switch
pressure pin is pushed out on the
opposite side of the rotor.

65

Setting the limit
switch pressure
pin in the rotor

(continued)

4. Tighten the grub screw in order to
clamp the limit switch pressure pin
in place once again.

NOTE! Do not push the pressure pin too far towards the outside all at once.
The limit switch can be destroyed mechanically by being moved too far.
In the event that the limit switch does not respond, repeat this process again
in multiple small steps until the limit switch responds.

Assembling the
Weld head

1. Assembly takes place in the re­verse order.

2. When mounting the clamping shell
housing, care should be taken
to ensure that the body and the

clamping shell housing make rm

contact with one another.

No gap must be visible, as oth­erwise the welding gas will be
contaminated by ambient air
penetrating the device.

This can result in:

► Misres
► Dark temper colour on the out-

side of the weld seam

► Increased electrode wear

1. Assembly takes place in the reverse order.

2. Before starting up the welding head, the rotor must be turned once by hand. The

rotor must not tilt or block at any spot.

3. Check the limit switch setting.

4. After completing the maintenance work, carry out a trial welding operation with the
welding head.

66

Technical data

67

68

Technical data

Weld head
FCH 3-21

Weld head
FCH 3-38

Weight (with hosepack) 5.9 kg (13 lb)

Power supply 24 V DC

Hosepack length 8 m

Welding position PC, PF, PG

Rotation speed:

Electrode position: 17,5 mm (0.69 in)

Electrode Ø: 1,6 / 2,4 mm (0.06 / 0.09 in)

Weight (with hosepack) 6.5 kg (14.33 lb)

Power supply 24 V DC

Hosepack length 8 m

Welding position PC, PF, PG

Rotation speed:

Electrode position: 17,5 mm (0.69 in)

Electrode Ø: 1,6 / 2,4 mm (0.06 / 0.09 in)

Min: 0,363 RPM
Max: 10,913 RPM

Min: 0,201 RPM
Max: 9,214 RPM

Weld head
FCH 6-76

Weld head
FCH 9-114

Weight (with hosepack) 11.9 kg (26.23 lb)

Power supply 24 V DC

Hosepack length 8 m

Welding position PC, PF, PG

Rotation speed:

Electrode position: 20 mm (0.79 in)

Electrode Ø: 1,6 / 2,4 mm (0.06 / 0.09 in)

Weight (with hosepack) 13.7 kg (30.20 lb)

Power supply 24 V DC

Hosepack length 8 m

Welding position PC, PF, PG

Rotation speed:

Electrode position: 20 mm (0.79 in)

Electrode Ø: 1,6 / 2,4 mm (0.06 / 0.09 in)

Min: 0,100 RPM
Max: 4,188 RPM

Min: 0,067 RPM
Max: 4,188 RPM

69

Environmental
conditions

Operation or storage of the system 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: +5 °C to +40 °C (41 °F to 104 °F)

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

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

Keep ambient air free from dust, acids, corrosive gases and substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

FCH dimensions

E

F

B

C

D

A

W

Weld head type A B C D E F W

FCH 3-21

FCH 3-38

FCH 6-76

FCH 9-114

70 mm

(2.76 in)

102 mm
(4.02 in)

160 mm
(6.30 in)

200 mm
(7.87 in)

36,5 mm

(1.44 in)

51 mm

(2.08 in)

77 mm

(3.03 in)

97 mm

(3.82 in)

143 mm
(5.63 in)

174 mm
(6.85 in)

224 mm
(8.82 in)

273 mm

(10.39 in)

358 mm

(14.09 in)

389 mm

(15.31 in)

453 mm

(17.83 in)

493 mm

(19.40 in)

35 mm

(1.38 in)

35 mm

(1.38 in)

40 mm

(1.57 in)

40 mm

(1.57 in)

17,5 mm

(0.69 in)

17,5 mm

(0.69 in)

20 mm

(0.79 in)

20 mm

(0.79 in)

6,35 mm

(0.25 in)

6,35 mm

(0.25 in)

10 mm

(0.39 in)

10 mm

(0.39 in)

70

Rating plates

NOTE! The rating plates may not be removed or modied without the consent

of Fronius International GmbH. Ensure that the rating plates remain legible.

A-4600 Wels

www.fronius.com

Art.No.:

Ser.No.:

24 V 5,9 kg

Rating plate for FCH 3-21 Weld head

A-4600 Wels

www.fronius.com

Art.No.:

Ser.No.:

24 V11,9 kg

FCH 3-21

8,044,197

XXXXXXXX

FCH 6-76

8,044,199

XXXXXXXX

A-4600 Wels

www.fronius.com

Art.No.:

Ser.No.:

24 V 6,5 kg

Rating plate for FCH 3-38 Weld head

A-4600 Wels

www.fronius.com

Art.No.:

Ser.No.:

24 V 13,7 kg

FCH 3-38

8,044,198

XXXXXXXX

FCH 9-114

8,044,200

XXXXXXXX

Rating plate for FCH 6-76 Weld head

Rating plate for FCH 9-114 Weld head

All illustrations of rating plates are representative images.

71

72

Spare parts, circuit diagram

73

74

Spare parts

Spare parts,
wearing parts
and auxiliary
materials

Ordering details

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.

NOTE! Only trained technicians may change parts and may only do so after
having read the installation and dismantling instructions supplied.

When ordering spare parts, you should provide the following data:

- Exact designation of the spare part

- Corresponding item number as per spare parts list

- Model name of the device

- Serial number of the device (shown on the rating plate)

75

FCH 3-21 Art.Nr: 8,044,197

11

10

17

7

3

14 1516

3

4

22

19

8

12

20

1

9

19

13

2

18

6

5

21

6

76

FCH 3-21 Art.Nr: 8,044,197

Pos. Quantity Article number Description

1 48,0005,2330 Component assembly clamp housing right

1 1 48,0005,2331 Upper clamp housing right

2 1 48,0005,2332 Lower clamp housing right

3 1 48,0005,2333 Join pin

4 1 48,0005,2334 Clamp housing cover A

5 1 48,0005,2335 Clamp housing cover B

6 2 48,0005,2336 Cylinder screw hexagon socket ISO 4762

1 48,0005,2337 Component assembly clamp housing left

7 1 48,0005,2338 Upper clamp housing left

8 1 48,0005,2339 Lower clamp housing left

3 1 48,0005,2333 Join pin

9 2 48,0005,2340 Component assembly latch

1 Upper clamping system

1 Lower clamping system

1 Lever

2 Clamping rail

2 Bolt d3x8

1 Bolt d3x5

1 Cylinder screw hexagon socket ISO 4762 (bottom)

1 Cylinder screw hexagon socket ISO 4762 (top)

1 Spring 1.4x7x9

Indiviual parts

10 1 48,0005,2341 Cover (clamp housing)

11 2 48,0005,2342 Cylinder screw hexagon socket ISO 4762

12 1 48,0005,2343 Bar (back)

13 1 48,0005,2344 Bar (front)

14 1 48,0005,2345 Water bridge

15 2 48,0005,2346 Bolt

16 2 48,0005,2336 Cylinder screw hexagon socket ISO 4762

17 4 48,0005,2347 O-ring 3.5x1.5

18 2 48,0005,2348 Countersunk screw hexagon socket ISO 10642

19 4 48,0005,2349 Cylinder screw hexagon socket ISO 4762

20 4 48,0005,2350 Cylinder screw hexagon socket ISO 4762

21 1 48,0005,2329 Cylinder screw hexagon socket ISO 4762

22 2 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

77

FCH 3-21 Art.Nr: 8,044,197

34

1

2

5

46

43

23

39

1516

25

32

6

42

31

24

47

8

12

9

10

11

3

4

21

36

27

30

26

19

7

24

29

28

20

35

41

78

FCH 3-21 Art.Nr: 8,044,197

Pos. Quantity Article number Description

1 48,0005,2294 Component assembly FCH 3-21

1 1 Body FCH 3-21

2 1 Conductor loop

3 1 Pin conduction

4 2 Bearing pin spur gear

5 13 Cross recesses countersunk screw ISO 7046-1

6 1 Segment conduction

7 1 48,0005,2295 Component assembly drive shaft

1 Drive shaft

2 Grooved ball-bearing

1 Bevel gear

1 Grooved pin ISO 8740

8 1 48,0005,2296 Component assembly gearbox

1 Bevel gear

1 Spur gear

1 Bearing pin with a top ring

1 Thread pin hexagon socket ISO 4029

1 48,0005,2297 Component assembly thrust pin for homing switch

9 1 48,0005,2298 Thrust pin ceramic

10 1 48,0005,2299 Commpression spring

11 1 48,0005,2300 Retaining washer

12 2 48,0005,2301 Component assembly spur gear Z30 PPS40%

1 Spur gear

1 Grooved ball-bearing

15 4 48,0005,2302 Component assembly graphite kidneys

1 48,0005,2303 Graphite kidney

2 48,0005,2304 Ball

2 48,0005,2305 Spring

2 48,0005,2306 Cross recesses countersunk screw ISO 7046-1

79

FCH 3-21 Art.Nr: 8,044,197

Pos. Quantity Article number Description

Individual parts

16 1 48,0005,2307 Cover for body FCH 3-21

19 2 48,0005,2308 Conduction pin

20 2 48,0005,2309 Spring connection

21 1 48,0005,2310 Homing switch (with lever)

23 1 48,0005,2311 Rotor FCH 3-21

24 3 48,0005,2312 Grooved ball-bearing

25 1 48,0005,2313 Lifter

26 3 48,0005,2314 Contact pin for hominig switch with cable strand

27 1 48,0005,2315 Bold ground transmission

28 1 48,0005,2316 Connector

29 1 48,0005,2317 Fixing ring drive shaft

30 1 48,0005,2318 O-ring

31 1 48,0005,2319 O-ring

32 2 48,0005,2320 Washer

34 10 48,0005,2321 Slotted cylinder screw ISO 1207

35 2 48,0005,2322 Slotted countersunk screw ISO 7046-1

36 2 48,0005,2323 Slotted countersunk screw ISO 7046-1

39 3 48,0005,2324 Thread pin hexagon socket ISO 4028

41 2 48,0005,2325 Thread pin hexagon socket ISO 4029

42 1 48,0005,2326 Thread pin hexagon socket with stud ISO 4028

43 1 48,0005,2327 Thread pin hexagon socket with stud ISO 4028

46 2 48,0005,2328 Sealing

47 2 48,0005,2329 Cylinder screw hexagon socket ISO 4762

80

FCH 3-38 Art.Nr: 8,044,198

10

11

4

8

6

14 1516

5

17

12

7

22

0291

5

4

3

1

9

13

18

19

21

2

81

FCH 3-38 Art.Nr: 8,044,198

Pos. Quantity Article number Description

1 48,0005,2362 Component assembly clamp housing right

1 1 48,0005,2363 Upper clamp housing right

2 1 48,0005,2364 Lower clamp housing right

3 1 48,0005,2365 Heat shield (right)

4 4 48,0005,2366 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2333 Join pin

1 48,0005,2367 Component assembly clamp housing left

6 1 48,0005,2368 Upper clamp housing left

7 1 48,0005,2369 Lower clamp housing left

8 1 48,0005,2370 Heat shield (left)

4 4 48,0005,2366 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2333 Join pin

9 2 48,0005,2340 Component assembly latch

1 Upper clamping system

1 Lower clamping system

1 Lever

2 Clamping rail

2 Bolt d3x8

1 Bolt d3x5

1 Cylinder screw hexagon socket ISO 4762 (bottom)

1 Cylinder screw hexagon socket ISO 4762 (top)

1 Spring 1.4x7x9

Indiviual parts

10 1 48,0005,2371 Cover (clamp housing)

11 2 48,0005,2342 Cylinder screw hexagon socket ISO 4762

12 1 48,0005,2343 Bar (back)

13 1 48,0005,2344 Bar (front)

14 1 48,0005,2345 Water bridge

15 2 48,0005,2346 Bolt

16 2 48,0005,2336 Cylinder screw hexagon socket ISO 4762

17 4 48,0005,2347 O-ring 3.5x1.5

18 2 48,0005,2348 Countersunk screw hexagon socket ISO 10642

19 4 48,0005,2349 Cylinder screw hexagon socket ISO 4762

20 4 48,0005,2350 Cylinder screw hexagon socket ISO 4762

21 1 48,0005,2329 Cylinder screw hexagon socket ISO 4762

22 2 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

82

FCH 3-38 Art.Nr: 8,044,198

34 16

152539 23 43

13

32

1

2

5

46

6

36

3142

47

24

12

8

29

9

10

11

3

4

21

27

30

26

19

7

20

24

35

28

41

83

FCH 3-38 Art.Nr: 8,044,198

Pos. Quantity Article number Description

1 48,0005,2351 Component assembly FCH 3-38

1 1 Body FCH 3-38

2 1 Conductor loop

3 1 Pin conduction

4 4 Bearing pin spur gear

5 14 Cross recesses countersunk screw ISO 7046-1

6 1 Segment conduction

7 1 48,0005,2295 Component assembly drive shaft

1 Drive shaft

2 Grooved ball-bearing

1 Bevel gear

1 Grooved pin ISO 8740

8 1 48,0005,2296 Component assembly gearbox

1 Bevel gear

1 Spur gear

1 Bearing pin with a top ring

1 Thread pin hexagon socket ISO 4029

1 48,0005,2352 Component assembly thrust pin for homing switch

9 1 48,0005,2298 Thrust pin ceramic

10 1 48,0005,2299 Commpression spring

11 1 48,0005,2353 Retaining washer

12 2 48,0005,2354 Component assembly spur gear Z30 PPS40%

1 Spur gear

1 Grooved ball-bearing

13 2 48,0005,2355 Component assembly spur gear Z30 V2a

1 Spur gear

1 Grooved ball-bearing

15 4 48,0005,2356 Component assembly graphite kidneys

1 48,0005,2357 Graphite kidney

2 48,0005,2304 Ball

2 48,0005,2305 Spring

2 48,0005,2306 Cross recesses countersunk screw ISO 7046-1

84

FCH 3-38 Art.Nr: 8,044,198

Pos. Quantity Article number Description

Individual parts

16 1 48,0005,2358 Cover for body FCH 3-38

19 2 48,0005,2308 Conduction pin

20 2 48,0005,2309 Spring connection

21 1 48,0005,2310 Homing switch (with lever)

23 1 48,0005,2359 Rotor FCH 3-38

24 3 48,0005,2312 Grooved ball-bearing

25 1 48,0005,2313 Lifter

26 3 48,0005,2314 Contact pin for hominig switch with cable strand

27 1 48,0005,2315 Bold ground transmission

28 1 48,0005,2316 Connector

29 1 48,0005,2317 Fixing ring drive shaft

30 1 48,0005,2318 O-ring

31 1 48,0005,2360 O-ring

32 2 48,0005,2320 Washer

34 10 48,0005,2321 Slotted cylinder screw ISO 1207

35 2 48,0005,2322 Slotted countersunk screw ISO 7046-1

36 2 48,0005,2323 Slotted countersunk screw ISO 7046-1

39 3 48,0005,2324 Thread pin hexagon socket ISO 4028

41 2 48,0005,2325 Thread pin hexagon socket ISO 4029

42 1 48,0005,2326 Thread pin hexagon socket with stud ISO 4028

43 1 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

46 2 48,0005,2361 Sealing

47 2 48,0005,2329 Cylinder screw hexagon socket ISO 4762

85

FCH 6-76 Art.Nr: 8,044,199

1617

22

23

20

21

25

12

14

4

6

18

5

27

7

13

89

5

11

3

1

7

15

10

6

19

24

25

26

2

86

FCH 6-76 Art.Nr: 8,044,199

Pos. Quantity Article number Description

1 48,0005,2386 Component assembly clamp housing right

1 1 48,0005,2387 Upper clamp housing right

2 1 48,0005,2388 Lower clamp housing right

3 1 48,0005,2389 Heat shield (right)

4 4 48,0005,2348 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2390 Join pin

6 1 48,0005,2391 Lock bolt A

7 1 48,0005,2392 Lock bolt A

8 2 48,0005,2393 Washer

9 2 48,0005,2394 Lock ring DIN 471

10 2 48,0005,2395 Slotted thrust pin with spring ball

11 2 48,0005,2396 Retaining pin for collets

1 48,0005,2397 Component assembly clamp housing left

12 1 48,0005,2398 Upper clamp housing left

13 1 48,0005,2399 Lower clamp housing left

14 1 48,0005,2400 Heat shield (left)

4 4 48,0005,2348 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2390 Join pin

6 1 48,0005,2391 Lock bolt A

7 1 48,0005,2392 Lock bolt A

8 2 48,0005,2393 Washer

9 2 48,0005,2394 Lock ring DIN 471

10 2 48,0005,2395 Slotted thrust pin with spring ball

11 2 48,0005,2396 Retaining pin for collets

15 2 48,0005,2401 Component assembly latch

1 Upper clamping system

1 Lower clamping system

1 Lever

2 Clamping rail

2 Bolt d3x10

1 Bolt d3x6

1 Cylinder screw hexagon socket ISO 4762 (bottom)

1 Cylinder screw hexagon socket ISO 4762 (top)

1 Spring

87

FCH 6-76 Art.Nr: 8,044,199

Pos. Quantity Article number Description

Indiviual parts

16 1 48,0005,2402 Cover (clamp housing)

17 1 48,0005,2349 Cylinder screw hexagon socket ISO 4762

18 1 48,0005,2403 Bar (back)

19 1 48,0005,2404 Bar (front)

20 1 48,0005,2405 Water bridge

21 2 48,0005,2406 Bolt

22 2 48,0005,2407 Cylinder screw hexagon socket ISO 4762

23 4 48,0005,2408 O-ring 4x1.5

24 2 48,0005,2348 Countersunk screw hexagon socket ISO 10642

25 4 48,0005,2409 Cylinder screw hexagon socket ISO 4762

26 1 48,0005,2409 Cylinder screw hexagon socket ISO 4762

27 2 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

88

FCH 6-76 Art.Nr: 8,044,199

1

5

2

432339

151634

25

46

32

21 4

36

13

24

37

33 30

128

38

29

35

3

9

10

11

27

26

19

7

20

24

41

28

89

FCH 6-76 Art.Nr: 8,044,199

Pos. Quantity Article number Description

1 48,0005,2372 Component assembly FCH 6-76

1 1 Body FCH 6-76

2 1 Conductor loop

3 1 Pin conduction

4 4 Bearing pin spur gear

5 19 Cross recesses countersunk screw ISO 7046-1

7 1 48,0005,2295 Component assembly drive shaft

1 Drive shaft

2 Grooved ball-bearing

1 Bevel gear

1 Grooved pin ISO 8740

8 1 48,0005,2296 Component assembly gearbox

1 Bevel gear

1 Spur gear

1 Bearing pin with a top ring

1 Thread pin hexagon socket ISO 4029

1 48,0005,2352 Component assembly thrust pin for homing switch

9 1 48,0005,2298 Thrust pin ceramic

10 1 48,0005,2299 Commpression spring

11 1 48,0005,2353 Retaining washer DIN 6799

12 2 48,0005,2373 Component assembly spur gear Z40 PPS40%

1 Spur gear

1 Grooved ball-bearing

13 2 48,0005,2355 Component assembly spur gear Z30 V2a

1 Spur gear

1 Grooved ball-bearing

15 6 48,0005,2374 Component assembly graphite kidneys

1 48,0005,2375 Graphite kidney

2 48,0005,2304 Ball

2 48,0005,2305 Spring

2 48,0005,2306 Cross recesses countersunk screw ISO 7046-1

90

FCH 6-76 Art.Nr: 8,044,199

Pos. Quantity Article number Description

Individual parts

16 1 48,0005,2376 Cover for body FCH 6-76

19 1 48,0005,2377 Conduction pin

20 2 48,0005,2309 Spring connection

21 1 48,0005,2310 Homing switch (with lever)

23 1 48,0005,2378 Rotor FCH 6-76

24 3 48,0005,2312 Grooved ball-bearing

25 1 48,0005,2379 Lifter

26 3 48,0005,2380 Contact pin for hominig switch with cable strand

27 1 48,0005,2381 Bold ground transmission

28 1 48,0005,2316 Connector

29 1 48,0005,2317 Fixing ring drive shaft

30 1 48,0005,2382 O-ring

32 4 48,0005,2320 Washer

33 1 48,0005,2336 Cylinder screw hexagon socket ISO 4762

34 16 48,0005,2321 Slotted cylinder screw ISO 1207

35 2 48,0005,2322 Slotted countersunk screw ISO 7046-1

36 2 48,0005,2323 Slotted countersunk screw ISO 7046-1

37 1 48,0005,2383 Slotted countersunk screw ISO 7046-1

38 1 48,0005,2384 Thread pin hexagon socket with tip

39 3 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

41 2 48,0005,2325 Thread pin hexagon socket ISO 4029

43 1 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

46 1 48,0005,2385 Sealing

91

FCH 9-114 Art.Nr: 8,044,200

12

17 16

3

14

4

22 20 21 25 18 68 9

23 527

7

13

11

1

7

15

5

10

6

19

24

25

26

2

92

FCH 9-114 Art.Nr: 8,044,200

Pos. Quantity Article number Description

1 48,0005,2416 Component assembly clamp housing right

1 1 48,0005,2417 Upper clamp housing right

2 1 48,0005,2418 Lower clamp housing right

3 1 48,0005,2419 Heat shield (right)

4 4 48,0005,2348 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2390 Join pin

6 1 48,0005,2391 Lock bolt A

7 1 48,0005,2392 Lock bolt A

8 2 48,0005,2393 Washer

9 2 48,0005,2394 Lock ring DIN 471

10 2 48,0005,2395 Slotted thrust pin with spring ball

11 2 48,0005,2396 Retaining pin for collets

1 48,0005,2420 Component assembly clamp housing left

12 1 48,0005,2421 Upper clamp housing left

13 1 48,0005,2422 Lower clamp housing left

14 1 48,0005,2423 Heat shield (left)

4 4 48,0005,2348 Cylinder screw hexagon socket ISO 10642

5 1 48,0005,2390 Join pin

6 1 48,0005,2391 Lock bolt A

7 1 48,0005,2392 Lock bolt A

8 2 48,0005,2393 Washer

9 2 48,0005,2394 Lock ring DIN 471

10 2 48,0005,2395 Slotted thrust pin with spring ball

11 2 48,0005,2396 Retaining pin for collets

15 2 48,0005,2401 Component assembly latch

1 Upper clamping system

1 Lower clamping system

1 Lever

2 Clamping rail

2 Bolt d3x10

1 Bolt d3x6

1 Cylinder screw hexagon socket ISO 4762 (bottom)

1 Cylinder screw hexagon socket ISO 4762 (top)

1 Spring

93

FCH 9-114 Art.Nr: 8,044,200

Pos. Quantity Article number Description

Indiviual parts

16 1 48,0005,2424 Cover (clamp housing)

17 1 48,0005,2349 Cylinder screw hexagon socket ISO 4762

18 1 48,0005,2403 Bar (back)

19 1 48,0005,2404 Bar (front)

20 1 48,0005,2405 Water bridge

21 2 48,0005,2406 Bolt

22 2 48,0005,2407 Cylinder screw hexagon socket ISO 4762

23 4 48,0005,2408 O-ring 4x1.5

24 2 48,0005,2348 Countersunk screw hexagon socket ISO 10642

25 4 48,0005,2409 Cylinder screw hexagon socket ISO 7984

26 1 48,0005,2409 Cylinder screw hexagon socket ISO 7984

27 2 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

94

FCH 9-114 Art.Nr: 8,044,200

1

34 16 15

39 23

43

25

5

2

46

32

36

14

81213

21

24

33

30

29

35

37

38

9

10

3

11

4

27

26

19

7

20

24

41

28

95

FCH 9-114 Art.Nr: 8,044,200

Pos. Quantity Article number Description

1 48,0005,2410 Component assembly FCH 6-76

1 1 Body FCH 9-114

2 1 Conductor loop

3 1 Pin conduction

4 6 Bearing pin spur gear

5 19 Cross recesses countersunk screw ISO 7046-1

7 1 48,0005,2295 Component assembly drive shaft

1 Drive shaft

2 Grooved ball-bearing

1 Bevel gear

1 Grooved pin ISO 8740

8 1 48,0005,2296 Component assembly gearbox

1 Bevel gear

1 Spur gear

1 Bearing pin with a top ring

1 Thread pin hexagon socket ISO 4029

1 48,0005,2352 Component assembly thrust pin for homing switch

9 1 48,0005,2298 Thrust pin ceramic

10 1 48,0005,2299 Commpression spring

11 1 48,0005,2353 Retaining washer DIN 6799

12 2 48,0005,2373 Component assembly spur gear Z40 PPS40%

1 Spur gear

1 Grooved ball-bearing

13 2 48,0005,2355 Component assembly spur gear Z30 V2a

1 Spur gear

1 Grooved ball-bearing

14 2 48,0005,2355 Component assembly spur gear Z30 V2a

1 Spur gear

1 Grooved ball-bearing

15

8

48,0005,2411 Component assembly graphite kidneys

1 48,0005,2412 Graphite kidney

2 48,0005,2304 Ball

2 48,0005,2305 Spring

2 48,0005,2306 Cross recesses countersunk screw ISO 7046-1

96

FCH 9-114 Art.Nr: 8,044,200

Pos. Quantity Article number Description

Individual parts

16 1 48,0005,2413 Cover for body FCH 9-114

19 1 48,0005,2414 Conduction pin

20 2 48,0005,2309 Spring connection

21 1 48,0005,2310 Homing switch (with lever)

23 1 48,0005,2415 Rotor

24 3 48,0005,2312 Grooved ball-bearing

25 1 48,0005,2379 Lifter

26 3 48,0005,2380 Contact pin for hominig switch with cable strand

27 1 48,0005,2381 Bold ground transmission

28 1 48,0005,2316 Connector

29 1 48,0005,2317 Fixing ring drive shaft

30 1 48,0005,2382 O-ring

32 6 48,0005,2320 Washer

33 1 48,0005,2336 Cylinder screw hexagon socket ISO 4762

34 20 48,0005,2321 Slotted cylinder screw ISO 1207

35 2 48,0005,2322 Slotted countersunk screw ISO 7046-1

36 2 48,0005,2323 Slotted countersunk screw ISO 7046-1

37 1 48,0005,2383 Slotted countersunk screw ISO 7046-1

38 1 48,0005,2384 Thread pin hexagon socket with tip ISO 4027

39 3 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

41 2 48,0005,2325 Thread pin hexagon socket ISO 4029

43 1 48,0005,2324 Thread pin hexagon socket with stud ISO 4028

46 1 48,0005,2385 Sealing

97

Driving unit FCH 3-21 Art.Nr: 8,044,197

Driving unit FCH 3-38 Art.Nr: 8,044,198

1

3

2

38

5

17

4

34

33

23

42

21

22

20

24

25

9

18

26

27

28

41

98

Driving unit FCH 3-21 Art.Nr: 8,044,197

Driving unit FCH 3-38 Art.Nr: 8,044,198

7

11 10

13 12

6 16

19

15

14

35

36

32

40

31

43

8

3739

30

29

99

Driving unit FCH 3-21 Art.Nr: 8,044,197

Driving unit FCH 3-38 Art.Nr: 8,044,198

Pos. Quantity Article number Description

1 1 48,0005,2436 Shrinking hose 38/19 L-20cm

2 2 48,0005,2478 Power cable (+/-) 8m, 5mm²

3 1 48,0005,2438 Gas hose, 8.5 m

4 1 48,0005,2439 Motor control cable 9m 14x0.25mm, supertronic

5 1 48,0005,2440 Robot exible hose NW-29, 7.5m

6 1 48,0005,2441 Motor jacket 28x1mm, L55mm

7 1 48,0005,2479 Drive ange FCH-CW complete

8 2 48,0005,2480 O-ring Ø3x1,5mm

9 1 48,0005,2444 Strain relief L39mm x B 8mm, s-2.0

10 1 48,0005,2235 Insolation adapter

11 1 48,0005,2316 Hugo-coupling

12 1 48,0005,2445 Thrust bearing 5mm

13 3 48,0005,2446 O-ring 3mm end switch

14 1 48,0005,2447 End switch cable 14cm

15 1 48,0005,2238 Line driver round

16 1 48,0005,2448 Motor-gearbox-encoder unit

17 1 48,0005,2481 Cooling line 70cm, 6x8.2mm blue

18 1 48,0005,2450 Keypad FCH

19 1 48,0005,2451 Grub screw on motor jacket M4x5mm

20 6 48,0005,2482 Cylinder screw zinc coated M3x14mm, hexagon socket

21 2 48,0005,2483 Cylinder screw zinc coated M3x20mm, hexagon socket

22 4 48,0005,2454 Lens head screw M3x8mm, hexagon socket

23 1 48,0005,2484 Handle FCH-CW

24 2 48,0005,2456 Cylinder screw zinc coated M4x8mm

25 2 48,0005,2457 Shim 4.3mm zinc coated

26 1 48,0005,2458 Ground conductor green/Yellow, 1.5qmm length 150mm

27 1 48,0005,2459 Lock washer form A DIN 6797 A

28 1 48,0005,2460 M4 screw nut zinc coated

29 1 48,0005,2461 14-pole DDK cable plug

30 1 48,0005,2462 DDK strain relief

31 1 48,0005,2463 70 TIG TTW IG (minus pole) current plug complete

32 1 48,0005,2464 NW17 0.5mm exible robot hose

33 2 48,0005,2465 Plug nipple with bend protection open

34 1 48,0005,2466 Screw cap for plug nipple

35 6 48,0005,2467 Crimp contact

36 1 48,0005,2468 Plug housing

37 3 48,0005,2469 End switch pin complete 4x43mm, brass

38 1 48,0005,2485 Cooling line 70m, 6x8.2mm red

39 2 48,0005,2446 O-ring 3x1.5mm gas nipple

40 1 48,0005,2471 Gas nipple 20x6.5

41 4 48,0005,2472 Cylinder screw hexagon socket M4x10 ISO 4762

42 4 48,0005,2486 Lens head screw M3x6mm, hexagon socket

43 1 48,0005,2487 70 TIG TTW SW (plus pole) current plug complete

100