Fronius FCU-20 / FCU-20.O Operating Instruction [EN]

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FCU-20.O

FCU-20

Operating Instructions

Control unit

42,0426,0103,EN V05 - 06072016

Safety rules

DANGER!

WARNING!

CAUTION!

NOTE!

Important!

“DANGER!” indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices that may cause property damage.

“NOTE!” indicates a situation which implies a risk of impaired welding result and damage to the equipment.

“Important!” indicates practical hints and other useful special-information. It is no signal word for a harmful or dangerous situation.

General remarks

Whenever you see any of the symbols shown above, you must pay even closer attention to the contents of the manual!

This equipment has been made in accordance with the state of the art and all recognised safety rules. Nevertheless, incorrect operation or misuse may still lead to danger for

- the life and well-being of the operator or of third parties,

- the equipment and other tangible assets belonging to the owner/operator,

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and maintaining the equipment must

- be suitably qualified

- know about welding and

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In addition to the instruction manual, copies of both the generally applicable and the local accident prevention and environmental protection rules must be kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

- must be kept in a legible condition

- must not be damaged, must not be removed

- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are located on the machine, please see the section of your machine’s instruction manual headed “General remarks”.

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General remarks

(continued)

Any malfunctions which might impair machine safety must be eliminated immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

Utilisation for intended purpose only

The machine may only be used for jobs as defined by the “Intended purpose”.

The machine may ONLY be used for the welding processes stated on the rating plate. Utilisation for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose". The manufacturer shall not be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual

- complete reading and following of all the safety instructions and danger warnings

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

The machine is designed to be used in industrial and workshop environments. The manufacturer shall not be liable for any damage resulting from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work results.

Ambient conditions

Obligations of owner/operator

Operation or storage of the power source outside the stipulated range is deemed to be “not in accordance with the intended use”. The manufacturer shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

The owner/operator undertakes to ensure that the only persons allowed to work with the machine are persons who

- are familiar with the basic regulations on workplace safety and accident prevention and who have been instructed in how to operate the machine

- have read and understood the sections on “safety rules” and the “warnings“ contained in this manual, and have confirmed as much with their signatures

- be trained in such a way that meets with the requirements of the work results

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Regular checks must be performed to ensure that personnel are still working in a safety-conscious manner.

Obligations of personnel

Before starting work, all persons to be entrusted with carrying out work with (or on) the machine shall undertake

- to observe the basic regulations on workplace safety and accident prevention

- to read the sections on “safety rules” and the “warnings” contained in this manual, and to sign to confirm that they have understood these and will comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of injury or damage being caused during their absence.

Mains connection High-performance devices can affect the quality of the mains power due to

their current-input. This may affect a number of types of device in terms of:

- connection restrictions

- criteria with regard to maximum permissible mains impedance

- criteria with regard to minimum short-circuit power requirement

at the interface with the public mains network

see Technical Data

In this case, the plant operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.

Protection for yourself and other persons

When welding, you are exposed to many different hazards such as:

- flying sparks and hot metal particles

- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pacemaker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable protective clothing with the following characteristics:

- flame-retardant

- isolating and dry

- must cover whole body, be undamaged and in good condition

- protective helmet

- trousers with no turn-ups

III

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Protection for yourself and other persons

(continued)

“Protective clothing” also includes:

- protecting your eyes and face from UV rays, heat and flying sparks with an appropriate safety shield containing appropriate regulation filter glass

- wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield

- wearing stout footwear that will also insulate even in wet conditions

- protecting your hands by wearing appropriate gloves (electrically insulating, heat-proof)

- To lessen your exposure to noise and to protect your hearing against injury, wear ear-protectors!

Keep other people - especially children - well away from the equipment and the welding operation while this is in progress. If there are still any other persons nearby during welding, you must

- draw their attention to all the dangers (risk of being dazzled by the arc or injured by flying sparks, harmful welding fumes, high noise immission levels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Information on noise emission values

Hazards from noxious gases and vapours

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 60974-1.

It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

The fumes given off during welding contain gases and vapors that are harmful to health.

Welding fumes contain substances which may cause birth defects and cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off. Extract all fumes and gases away from the workplace, using suitable means.

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Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an independent air supply.

If you are not sure whether your fume-extraction system is sufficiently powerful, compare the measured pollutant emission values with the permitted threshold limit values.

Hazards from noxious gases and vapours

(continued)

The harmfulness of the welding fumes will depend on e.g. the following components:

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc radiation.

Hazards from flying sparks

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from the arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through small cracks and openings. Take suitable measures here to ensure that there is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion, or in enclosed tanks, barrels or pipes, unless these latter have been prepared for welding in accordance with the relevant national and international standards.

Welding must NEVER be performed on containers that have had gases, fuels, mineral oils etc. stored in them. Even small traces of these substances left in the containers are a major explosion hazard.

Hazards from mains and welding current

An electric shock is potentially life-threatening, and can be fatal.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or else use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a dry base or cover that provides adequate insulation against the ground/frame potential. The base or cover must completely cover the entire area between your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly insulated and adequately dimensioned. Immediately replace any loose connections, scorched, damaged or underdimensioned cables or other leads.

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Hazards from mains and welding current

(continued)

Do not loop any cables or other leads around your body or any part of your body.

Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.

Twice the open-circuit voltage of one single welding machine may occur between the welding electrodes of two welding machines. Touching the potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a qualified electrician to ensure that the PE (protective earth) conductor is functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and plugged into a power outlet socket without a protective-conductor contact, this counts as gross negligence and the manufacturer shall not be liable for any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is sufficiently grounded (earthed).

Stray welding currents

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently plugging the machine back into the mains and switching it back on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second person on hand to immediately switch off the machine at the main switch in an emergency.

If the following instructions are ignored, stray welding currents may occur. These can cause:

- fires

- overheating of components that are connected to the workpiece

- destruction of PE conductors

- damage to the machine and other electrical equipment

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Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way that it is sufficiently insulated from the floor.

Stray welding currents

(continued)

When using current supply distributors, twin head wire feeder fixtures etc., please note the following: The electrode on the unused welding torch/welding tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

EMC device classifications

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 low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures In certain cases, even though a device complies with the standard limit values

for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

Examine and evaluate any possible electromagnetic problems that may occur on equipment in the vicinity, and the degree of immunity of this equipment, in accordance with national and international regulations:

- safety features

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply

- If electromagnetic interference still occurs, despite the fact that the mains connection is in accordance with the regulations, take additional measures (e.g. use a suitable mains filter).

b) Welding cables

- Keep these as short as possible

- Arrange them so that they run close together (to prevent EMI problems as well)

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

VII

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EMI Precautions

Electromagnetic fields may cause as yet unknown damage to health.

- Effects on the health of persons in the vicinity, e.g. users of heart pacemakers and hearing aids

- Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces

- Keep as much space as possible between welding cables and head/body of welder for safety reasons

- Do not carrywelding cables and hose pack over shoulder and do not loop around body or or any part of body

Particular danger spots

Keep your hands, hair, clothing and tools well away from all moving parts, e.g.:

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the wirefeed drive.0

Covers and sideguards may only be opened or removed for as long as is absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are properly mounted ...

- ... and that all covers and sideguards are kept closed.

When the welding wire emerges from the torch, there is a high risk of injury (the wire may pierce the welder’s hand, injure his face and eyes ...). For this reason, when feeder-inching etc., always hold the torch so that it is pointing away from your body (machines with wirefeeder).

Do not touch the workpiece during and after welding - risk of injury from burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason, continue to wear the regulation protective gear, and to ensure that other persons are suitably protected, when doing post-weld finishing on workpieces.

Allow welding torches - and other items of equipment that are used at high operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observe all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g. boilers) must be identified by the (for “safety”) mark. However, the power source should not be in such rooms.

Risk of scalding from accidental discharge of hot coolant. Before unplugging the connectors for coolant forward flow and return flow, switch off the cooling unit.

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VIII

Particular danger spots

(continued)

When hoisting the machines by crane, only use suitable manufacturersupplied lifting devices.

- Attach the chains and/or ropes to all the hoisting points provided on the suitable lifting device.

- The chains and/or ropes must be at an angle which is as close to the vertical as possible.

- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG units).

When hoisting the wirefeed unit by crane during welding, always use a suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that this strap is ONLY to be used for lifting and carrying the machine by hand. The carrying strap is NOT suitable for transporting the machine by crane, fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, when using an adapter for the inert gas protection. Seal the adapter thread for the inert gas connection using Teflon tape before assembly.

Danger from shielding-gas cylinders

Shielding-gas cylinders contain pressurized gas and may explode if they are damaged. As shielding-gas cylinders are an integral part of the overall welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed, from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas cylinder.

Use only shielding-gas cylinders that are suitable for the application in question, together with matching, suitable accessories (pressure regulators, hoses and fittings, ...). Only use shielding-gas cylinders and accessories that are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and international rules applying to shielding-gas cylinders and accessories.

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Safety precautions at the installation site and when being transported

A machine that topples over can easily kill someone! For this reason, always place the machine on an even, firm floor in such a way that it stands firmly.

- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observe all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m (1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and regional guidelines and accident protection regulations are followed. This applies in particular to guidelines in respect of dangers during transportation and carriage.

Before transportation, completely drain any coolant and dismantle the following components:

- Wire feed

- Wire wound coil

- Gas bottle

Safety precautions in normal operation

Before commissioning and after transportation, a visual check for damage must be carried out. Any damage must be repaired by trained service personnel before commissioning.

Only operate the machine if all of its protective features are fully functional. If any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by your doing so.

- At least once a week, check the machine for any damage that may be visible from the outside, and check that the safety features all function correctly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogether before hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frostproofing, materials-compatibility, combustibility etc.), only original coolant of the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.

- Do not mix original coolant of the manufacturer with other coolants.

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Safety precautions in normal operation

(continued)

- If any damage occurs in cases where other coolants have been used, the manufacturer shall not be liable for any such damage, and all warranty claims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport the coolant in closed original containers, and keep it away from sources of ignition.

- Used coolant must be disposed of properly in accordance with the relevant national and international regulations. A safety data sheet is available from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check the coolant level.

Preventive and corrective maintenance

Safety inspection

With parts sourced from other suppliers, there is no certainty that these parts will have been designed and manufactured to cope with the stressing and safety requirements that will be made of them. Use only original spares and wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the relevant part number, as given in the spare parts list. Please also quote the serial number of your machine.

The owner/operator is obliged to have a safety inspection performed on the machine at least once every 12 months.

The manufacturer also recommend the same (12-month) interval for regular calibration of power sources.

A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations

- after any modifications or installations of additional components

- following repairs, care and maintenance

- at least every twelve months.

Disposal

Observe the relevant national and international standards and directives in connection with the safety inspection.

More detailed information on safety inspections and calibration is available from your regional or national service centre, who will be pleased to provide you with copies of the necessary documents upon request.

Do not dispose of this device with normal domestic waste! To comply with the European Directive 2002/96/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 Any device that you no longer require must be returned to our agent, or find out about the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!

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Safety markings

Equipment with CE-markings fulfils the basic requirements of the LowVoltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). .

Equipment marked with the CSA-Test Mark fulfils the requirements made in the relevant standards for Canada and the USA.

Data security

The user is responsible for the data security of changes made to factory settings. The manufacturer is not liable, if personal settings are deleted.

The text and illustrations are all technically correct at the time of going to print. The right to effect modifications is reserved. The contents of the instruction manual shall not provide the basis for any claims whatever on the part of the purchaser. If you have any suggestions for improvement, or can point out to us any mistakes which you may have found in the manual, we should be most grateful for your comments.

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XII

Table of contents

General ........................................................................................................................................................... 5

Device concept ...........................................................................................................................................5

Field of application FCU 20 ........................................................................................................................ 5

Field of application FCU 20.O .................................................................................................................... 5

Control elements ........................................................................................................................................... 6

Control elements ........................................................................................................................................ 6

Control panel .............................................................................................................................................. 6

Rear view ...................................................................................................................................................7

Touchscreen display ..................................................................................................................................... 9

Touchscreen display ................................................................................................................................... 9

Tips for use ................................................................................................................................................. 9

Parameter entry options ............................................................................................................................. 10

General.....................................................................................................................................................10

Multifunction wheel ...................................................................................................................................10

Numerical pad .......................................................................................................................................... 10

Menu navigation .......................................................................................................................................... 11

Navigating through process parameter pages ......................................................................................... 11

Touch buttons ........................................................................................................................................... 11

Multifunction wheel ................................................................................................................................... 11

List of parameters ....................................................................................................................................... 12

Process parameters ................................................................................................................................. 12

Description of process parameters ........................................................................................................... 13

General.....................................................................................................................................................13

Parameter page 1 ....................................................................................................................................13

Parameter page 2 ....................................................................................................................................14

Parameter page 3 ....................................................................................................................................15

Parameter page 4 ....................................................................................................................................16

Parameter page 5 ....................................................................................................................................17

Parameter page 6 ....................................................................................................................................18

Parameter page 7 ....................................................................................................................................19

Parameter page - pneumatic test ............................................................................................................. 19

Parameter calibration .................................................................................................................................. 20

General.....................................................................................................................................................20

Procedure .................................................................................................................................................20

Program management ................................................................................................................................ 21

General.....................................................................................................................................................21

Saving welding programs ......................................................................................................................... 21

Loading welding programs ....................................................................................................................... 22

Segment mode ............................................................................................................................................. 23

General.....................................................................................................................................................23

Segment ON mode ..................................................................................................................................23

Segment OFF mode .................................................................................................................................24

Description of pedal remote control .......................................................................................................... 24

FRC-1 .......................................................................................................................................................24

Service parameters ..................................................................................................................................... 25

General.....................................................................................................................................................25

Navigation ................................................................................................................................................25

Calling up service parameters ..................................................................................................................25

Parameter page 1 - PLC inputs and outputs ............................................................................................ 25

PLC list of inputs and outputs ..................................................................................................................26

Parameter page 2 - Language selection .................................................................................................. 26

Parameter page 3 - Power source ...........................................................................................................27

Parameter page 4 - Calibration ................................................................................................................ 28

Parameter page 5 - Hardware ..................................................................................................................28

Decommissioning ..................................................................................................................................... 29

Data table FCU-20 ...................................................................................................................................29

Data table FCU-20.O ...............................................................................................................................29

Calculating the MFaktor ...........................................................................................................................29

Troubleshooting ..........................................................................................................................................30

Safety ....................................................................................................................................................... 30

General.....................................................................................................................................................30

Troubleshooting ........................................................................................................................................ 30

Error messages ........................................................................................................................................ 30

Technical data .............................................................................................................................................. 32

FCU-20 technical data .............................................................................................................................32

Rating plate FCU-20 / 20.O ......................................................................................................................32

Spare parts list FCU-20 ............................................................................................................................... 33

FCU-20 spare parts list ............................................................................................................................33

Accessories and options FCU-20 .............................................................................................................. 35

System overview ...................................................................................................................................... 35

Installation kit ...........................................................................................................................................35

Pedal remote control ................................................................................................................................ 35

Connecting lead .......................................................................................................................................35

Spare parts list FCU-20.O ........................................................................................................................... 36

FCU-20.O spare parts list.........................................................................................................................36

Accessories and options FCU20.O ............................................................................................................ 38

System overview ...................................................................................................................................... 38

Installation kit ...........................................................................................................................................38

Pedal remote control ................................................................................................................................ 38

Connecting lead .......................................................................................................................................38

EU Declaration of conformity FCU20 ........................................................................................................ 39

EU Declaration of conformity FCU20.O ..................................................................................................... 40

Circuit diagrams .......................................................................................................................................... 41

General

Device concept

Field of application FCU 20

The compact and rugged design of the FCU-20 control unit allows it to be used in a wide variety of control applications. Powder coating of all aluminium housing components. Can be used with the Fronius FTT and FRT rotation tables. The FCU-20 control unit has a touchscreen display to facilitate menu navigation and parameter entry.

FCU-20 control unit

The FCU-20 control unit is intended exclusively for use with the Fronius FTT-10/ 40/ 150/ 300 and FRT-50/ 150 rotation tables. It can be used in the following welding processes:

- MIG/MAG process

- TIG process

- Plasma process

Field of application FCU 20.O

The FCU-20.O control unit is intended exclusively for use with the Fronius FTT-380 70000 and FRT 1000 - 10000 rotation tables. It can be used in the following welding processes:

- MIG/MAG process

- TIG process

- Plasma process

Control elements

Control panel

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have thoroughly read and understood the following documents:

- these operating instructions

- all operating instructions for the system components

(1)

(2)

(3)

(5)(6)(7)

FCU-20 control panel

(1) Touchscreen display

For menu navigation, input and editing of parameter values by touching the display.

The multifunction wheel (3) can also be used to input and edit data.

(2) Emergency Stop button

Stops all movements and prevents restarting. The power source arc is broken imme-

diately. The "EMERGENCY STOP" message appears on the FCU-20 control panel display. All controls are disabled during an emergency stop.

NOTE! Before starting work, check that the Emergency Stop

protection device is working correctly.

(3) Multifunction wheel

For selecting and editing welding parameters, even during an automatic program

sequence. Press the multifunction wheel once to select the highlighted parameter and then edit it.

(4) Stop button

- Used to stop an automatic program sequence. The start button (7) cannot be used to restart the program sequence.

- Pressing this button and the start button (7) simultaneously changes the direction of rotation of the face plate.

- Pressing this button and the manual mode button (6) simultaneously activates the pneumatic unit

- Press for > 5 seconds to access the service parameter pages.

(4)

FRC-1

FTU FPT

FRT 150

230V~

50 / 60 Hz

Control panel

(continued)

(5) Welding ON/OFF selector switch

For choosing whether to run the automatic program sequence with or without weld-

ing.

Important! Welding can also be activated/deactivated using the "Welding ON/OFF"

parameter.

(6) Manual mode button

To move the face plate manually. Press and hold the button for more than seven

seconds to change to the maximum traversing speed.

The traversing direction in manual mode is changed by modifying the "Direction"

service parameter.

(7) Start button

- Used to start an automatic program sequence.

- Pressing this button and the stop button (4) simultaneously changes the direction

of rotation of the face plate.

Important! Please note that once the start button has been pressed, rotation will not

start until the start-up delay has expired.

Rear view

(8)

FCU-20 rear view

(8) Mains switch

 UsedtoswitchtheFCU-20controlunitonando󰀨.Thesupplyvoltageforthecon-

nectedrotationtableisalsoswitchedon/o󰀨usingthisswitch.Themainsfuse(1.5A)

is in the mains switch. When the device is switched on, this switch is illuminated.

(9) "FTU connecting plug" option

EMERGENCY STOP connection to tripod unit

(10) Cable output for pneumatic unit

24 VDC output

(11) Cable output to start external unit

Start release for external device (12) Cable output FRT 150 (FCU-20) Control line to the rotation table (3,5 m)

(13) Limit switch cable output

Control line to the rotation table limit switches (3.5 m).

(9) (10) (11)

(15)(16)(17) (14)(18)

(12)

(13)

Rear view

(continued)

(14) Motor cable output

Control line to the rotation table (3.5 m).

(15) "FRC-1 connecting plug" option

Start/Stop function via remote control

(16) Power source B connecting plug

Connection to the relevant power source

(17) Power source A connecting plug

Connection to the relevant power source

(18) Mains cable output

Mains cable (5 m)

Touchscreen display

Touchscreen display with protective lm

Tips for use Please note the following when using the touchscreen display.

- The touchscreen display consists of an analogue resistive layer covered by a protec-

tivelm.Removetheprotectivelmifitbecomesheavilysoiledandattachanew

one.

 TheitemnumberofthelmcanbefoundintheFCU-20sparepartslist.

Important! Fronius accepts no liability for damage arising from working without a

protectivelm.Thisalsoappliesifthedamageoccursduringthedevice'sguarantee

period.

- To use the touchscreen display, gently press the relevant button on the display with

yournger.

- Do not touch more than one part of the display at a time.

- Do not touch the display with sharp objects.

- Avoid excessively humid environments - the touchscreen display should not come into contact with water.

- Avoid using in situations where the touchscreen display may be exposed to direct sunlight or condensation.

- Avoidusinginplaceswhereammableorcorrosivegases,orairbornepollutants suchasdust,ironlingsoroilsmokearepresent.

- Avoid using in places where the device may be exposed to biological solvents (thinner, benzene) or strong alkaline substances (alkalis, caustic soda).

Parameter entry options

General

Multifunction wheel

Numerical pad

Some parameters can be amended during an automatic program sequence. The amended values are applied immediately, but are not saved in the currently loaded program.

To use the multifunction wheel, proceed as follows:

1. Move the cursor (black rectangle) to the parameter that you wish to change by turning the multifunction wheel.

2. Press the multifunction wheel once to enable the parameter for editing - the black

rectanglenowashes.

3. Turn the multifunction wheel clockwise to increase the value. Turn anti-clockwise to decrease the value.

4. Press the multifunction wheel again to block parameter entry.

To use the numerical pad, proceed as follows:

1. Press the parameter value that is to be changed. The numerical pad then opens.

2. Enter the value by touching the relevant number keys.

3. ConrminputvaluebypressingEnter.Thenumericalpadclosesautomatically.

0 ESC

(1)

7 8 9 0 AC

4 5 6 +/- DEL

1 2 3 . ENT

(5)

(6)(7)

(1) ESC button

To quit the numerical pad.

(2) AC button

To delete the whole value.

(3) DEL button

To delete one decimal place, i.e. move the cursor back one space.

(4) Enter button

To apply the entered value. Once applied, the numerical pad closes automatically.

(5) Decimal button

To enter a decimal point.

(6) + / - button

To change the sign.

(7) Numeric buttons

To enter the required value.

(2)

(3)

(4)

Menu navigation

Navigating through process parameter pages

Touch buttons

Multifunction wheel

On the process parameter pages, the user can scroll back and forth using the following controls:

- Scroll to the next page

- Scroll to the previous page

- Escape to main menu (parameter page 1)

Line change:

- Next parameter line = turn 3 steps clockwise

- Previous parameter line = turn 3 steps anti-clockwise

Scroll forwardsScroll back

List of parameters

Process parameters

Parameter designation Setting range

Direction << >> Clockwise rotation, anti-clockwise rotation Rotation speed rpm (depends on rotation table) Welding ON / OFF Operation 2-step Job 0-3 Downslope 0.0 - 60.0 s Crater-lling 0.0 - 60.0 s Start-up delay 0.0 - 60.0 s Flying Start 0.0 - 60.0 s Overlapping 0.0 - 60.0 s Cooling time 0.1 - 60.0 s External start 0.0 - 99.00 s Successor program 0 - 99 Return travel ON / OFF Pneumatic ON / OFF Segment ON / OFF Power source A (2 power sources option) ON / OFF Power source B (2 power sources option) ON / OFF Pneumatic - UP No status indicators Pneumatic - DOWN No status indicators

Description of process parameters

General

Parameter page 1

A whole range of parameters must be coordinated to ensure that the various components in the power source and control unit work together properly. These parameters are

referredtoasprocessparameters,andcontainmainlyinformationforthene-tuningof

the components (devices) used.

(2)

(1) Direction << >>

 Denesthedirectionofrotationoftherotationtablefaceplateinautomaticand

manual mode. Pressing the start and stop buttons simultaneously also changes the direction.

Important! Changing the direction in the service parameters also changes the direc-

tion.

Unit: Setting range: Anti-clockwise rotation, clockwise rotation Factory setting: Clockwise rotation

(2) Speed of rotation in rpm Denesthespeedofrotationoftherotationtablefaceplate.

Unit: rpm Setting range: depends on rotation table (please see rating plate) Factory setting: 3

(1)

Parameter page 2

(1) (2)

(3)

(1) Welding ON/OFF

For preselecting whether to run the automatic program sequence with or without

welding. The welding ON/OFF selector switch (5) must also be switched to "ON" during a sequence where welding takes place.

Unit: Setting range: OFF / ON Factory settings OFF

(2) 2-step mode Operating mode for the automatic

START

2-step

program sequence.

The amperage (I

) must be set on

START

the power source.

...Starting current

START

Starting current and duration as well

asnalcurrentanddurationmustalso

be set on the power source (special 2-step mode).

(3) Job

When using a robot interface, ready made jobs may be called up from the power

source via the FCU-20 control unit. Jobs that can be called up: 0, 1, 2, 3.

Important! For "Job" mode, the "Rob" service parameter must be set to ON. Unit: Setting range: 0 - 3 Factory settings: 0

Parameter page 3

(1) (2)

Welding current (2-step)

Movement rotation table

...Travel time in downslope

S ...Start point of the weld E ...End point of the weld

Welding current

Movement rotation table

tC ...Cooling time tE ...Timeforend-craterlling

(1) Downslope

...Duration of welding movement in

the welding current downslope phase. The rotation table continues to move after the end point of the weld (determined by cam). The downslope for the welding current must be set at the power source.

Unit: s

Setting range: 0.0 - 60.0 Factory setting: 1.0

(2) Crater-lling

... Length of time that the arc remains

on at the end of the weld seam in or-

dertollthecrater.Thearcisignited

again for the duration of the crater

llingprocessafterthecoolingtimetC

has elapsed. Unit: s Setting range: 0.0 - 60.0 Factory setting: 0.0

Parameter page 4

Welding current

tV ...Start-up delay

...Timeforying-start

(1) (2)

(3)

Movement rotation table

Welding current

(1) Start-up delay

tV...Time between arc ignition and the

start of welding movement. Unit: s Setting range: 0.0 - 60.0 Factory setting: 0.0

(2) Flying-start

tFS... Time delay between the start of

the rotational movement and the igni-

tion of the arc. The rotary movement

is not stopped while the arc is igniting.

Advisable when welding thin pipes

to minimise heat input in the start-up

phase. Unit: s Setting range: 0.0 - 60.0 Factory setting: 0.0

Welding path

S E t

S ...Start point of the weld E ...End point of the weld tÜL...Overlapping R ...Return path

(3) Overlapping

... Length of time that welding con-

ÜL

tinues beyond the end point (marked

by cam). This allows the start of the

weld seam to be overlapped in the

ÜL

case of circumferential welds. After

weldinghasnished,andthecooling

time has elapsed, the rotation table

returns automatically to the end point

of the weld (at high speed, and with

no welding). Unit: s Setting range: 0.0 - 60.0 Factory setting: 0.0

Parameter page 5

Welding current

tC ...Cooling time

(1) (2)

(3)

Movement rotation table

Gasow

(1) Cooling time

... Length of time that the torch

should dwell over the end of the weld

seam to allow the seam to cool under

the shielding gas. Once this cooling

time has elapsed, the time for crater

llingstarts.

Important! The cooling time is ob-

served again after the end crater has

beenlled.

Unit: s Setting range: 0.0 - 60.0 Factory setting: 3.0

(2) External start

... Start signal delay when start-

Automatic procedure

ing an external device (e.g. cold wire

feeder, oscillation unit, AVC, etc.). Unit: s

External device

...Delay time for external start

S .....Start of automatic procedure (Start button

pressed)

Setting range: 0.0 - 99.0 Factory setting: 0.0

(3) Successor prg.

 Enteroneof99successorprograms.Oncethecurrentlyloadedprogramhasn-

ished, the successor program is loaded and started. Unit: Setting range: 00 - 99 Factory setting: 00

Parameter page 6

(1)

(2) (3)

Return travel

S ...Start point of the weld E ...End point of the weld

tP ...Delay time for automatic procedure

S .....Start of automatic procedure (Start button

pressed)

Welding path

Output pneumatic

Automatic procedure

(1) Return travel ON/OFF

Activates/deactivates the automatic

return travel of the rotation table from the end point of the weld to the start

point. Return travel takes place at

high speed, and with no welding. Unit: Setting range: ON / OFF Factory setting: OFF

(2) Pneumatic ON/OFF

Activates/deactivates optional pneu-

matic equipment (pneumatic torch

positioning) for automatic welding.

There is a set delay between press-

ing the start button and the start of the

automatic procedure to allow the torch

su󰀩cienttimetomoveintoposition.

Activating the "Pneumatic UP/DOWN"

parameter tests the unit. Advisable

before starting an automatic welding

process to check the position of the

torch in relation to the component. Unit: Setting range: ON / OFF Factory setting: OFF

(3) Segment ON/OFF

To activate/deactivate segment mode. This parameter enables certain programs

to be linked together. For further information on program linking, see the "Segment

mode" section. Unit: Setting range: ON / OFF Factory setting: ON

Parameter page 7

(1) (2)

(1) 2 power sources option - power source A

Activates/deactivates power source A.

"2 power sources option".... optional parameter for controlling two power sources.

Important! Service parameter "DOWN" must be set to ON to activate or deactivate

power source A (see Service parameters).

Unit: Setting range: OFF/ON Factory setting: OFF

(2) 2 power sources option - power source B

Activates/deactivates power source B.

"2 power sources option".... optional parameter for controlling two power sources.

Important! Service parameter "DOWN" must be set to ON to activate or deactivate

power source B (see Service parameters).

Unit: Setting range: OFF/ON Factory setting: OFF

Parameter page pneumatic test

Note! The following parameter page is called

up from "Parameter page 1" using the left arrow key.

(1)

(2)

(1) Pneumatic - UP

For testing the pneumatic unit (raising pneumatic torch position). Advisable test func-

tion before starting an automatic welding process, for checking the position of the

torch in relation to the component.

Unit: Setting range: No status indicator Factory setting: -

(2) Pneumatic - DOWN

For testing the pneumatic unit (lowering pneumatic torch position). Advisable test

function before starting an automatic welding process, for checking the position of

the torch in relation to the component.

Unit: Setting range: No status indicator Factory setting: -

Parameter calibration

General

Procedure

To accelerate the whole process, it is advisable to calculate the parameter values automatically. The following parameters can be coordinated:

- Speed of rotation in rpm

- Workpiece diameter in mm

- Welding speed in cm/min

Note! Two values are always required to calculate a parameter.

1. Press the value for speed of rotation; the parameter calculation screen opens.

2. Press value for workpiece diameter. The numerical pad opens.

3. Type in the desired value for the workpiece diameter and press Enter. Alternatively, press the previously selected value again. Repeat the procedure using the v-welding parameter.

4. The recalculated value for speed of rotation is shown in rpm.

Important! The speed of rotation can only be adjusted in the mains screen (parameter page 1) using the multifunction wheel. A value for the workpiece diameter must exist before the welding speed (v-Welding) can be calculated.

Program management

General

Saving welding programs

The FCU-20 control unit allows the user to save and load up to 99 complete parameter lists. The working parameters created for one single component can be saved using a program number selected by the user. These parameter lists can be reloaded at any time, and corrected as required. Programs can be saved and loaded from any parameter page.

After successfully entering the required working parameters, the whole list can be saved.

NOTE! If a parameter list is saved under a pre-existing program number, the parameters in this list are overwritten.

Once the values for the working parameters have been entered, carry out the following procedure:

1. Brieypressthetouchbuttonfor

saving programs (diskette symbol) the "Prg. save" page appears.

2. Presstheprogramnumbereld,

the numerical pad opens.

3. Enter the desired program number

usingthenumericalpadandconrm

by pressing Enter. Alternatively, press the previously selected value again.

4. Press the "Save OK" touch button to apply the selected program.

Press the "Cancel" touch button to

cancel this procedure.

Saving programs

Loading welding programs

1. Brieypressthetouchbuttonfor

loading programs (folder symbol) - the "Load program" page appears.

2. Presstheprogramnumbereld,the

numerical pad opens.

3. Enter the desired program number

usingthenumericalpadandconrm

by pressing Enter. Alternatively, press the previously selected value again.

Loading programs

NOTE!Successorprogramsmaybedened(seepage15,point3).Oncethe currentlyloadedprogramhasnished,thesuccessorprogramisloadedand

started.

4. Press the "Load OK" touch button to load the selected program.

Press the "Cancel" touch button to

cancel this procedure.

Segment mode

General

Segment ON mode

Welding programs may also be linked in order to cover more complex requirements (see

page15,point3).Thisisalwaysnecessaryifdi󰀨erentweldingparametersarerequired

for a particular section of a welding path, or various other settings are required. The FCU-20 control unit provides two segment modes (Segment ON, Segment OFF) as described below.

NOTE! The functions described here are only available in conjunction with the "Rob 3000" interface.

START

Program. 1 SEG. ON

Segment Segment

Program. 5 SEG. ON

Program. 26 SEG. ON

S.........Start automatic procedure (Start button)

E.........End automatic procedure

..........Cam

...Starting current

START

Program chain in SEGMENT ON mode with Rob 3000 interface

Segment ON

If segment mode is set to "ON", the complete parameter list of the saved program is processed when programs are linked. As shown in the above application, this program chain consists of three programs, Prg. 1, Prg. 5 and Prg. 26. Prg. 5 does not involve any welding, so represents a pause. However, all the parameters in this program are processed. Once the cam is reached, the currently running program is ended (end parameter) and the successor program is loaded. The transition from one program to the next is automatic.

Inthenalprograminthechain,itisadvisabletosetthe"returntravel"parametertoON.

The unit then returns automatically to the start of the whole program chain (S).

NOTE! To ensure the automatic transition from one program to the next in this mode, all programs in the chain must be set to Segment "ON".

Segment OFF mode

NOTE! The functions described here are only available in conjunction with the

"Rob 3000" interface.

Program. 7 SEG. OFF

S.....Start automatic procedure (Start button)

E.....End of automatic procedure

IHS...Main current

....Cam

Program chain in SEGMENT OFF mode with Rob 3000 interface

Program. 8 SEG. OFF

Program. 25 SEG. OFF

Segment OFF

If, in a program chain, segment mode is set to "OFF", the settings of each program are skipped when moving from one program to the next. As shown in the application above, this program chain also consists of three programs, Prg. 7, Prg. 8 and Prg. 25. Once the cam is reached and the transition to the next program has taken place, (e.g. Prg. 7 --> Prg.8),theparametersareskipped,andthedi󰀨erentspeedorjobsettingisappliedimmediately ( ... only main current is changed).

Inthenalprograminthechain,itisadvisabletosetthe"returntravel"parametertoON.

The unit then returns automatically to the start of the whole program chain (S).

NOTE! To ensure the program transition in this mode takes place as expected, all programs in the chain must be set to segment "OFF".

Description of pedal remote control

FRC-1

FRC-1 pedal remote control

FRC-1

Two functions are available (see "Service parameters" for the presettings required for each function):

Inching mode: The process continues automatically for as long as the pedal is depressed.

Permanent operation:Pressthepedalbriey

to start the automatic process. Press it again to stop the process.

Service parameters

General

Navigation

Calling up service parameters

The FCU-20 control unit service parameters provide the user with the following options:

- Display the PLC inputs and outputs

- Select the preferred language for the display (German, English, Spanish or Italian)

- Calibrate the command and actual values for traversing path and speed

- Direction preselection

- Robot interface activation option

- Activate 2 power sources option

- Activatecurrentowsignal

- Select FRC 1 inching mode/permanent operation

While in the service parameter pages, the user can only switch to other pages by pressing the following touch buttons:

- Scroll to the next page

- Scroll to the previous page

- Escape to main menu (parameter page 1)

To call up the service parameter pages, press the stop button for > 5 seconds.

Parameter page 1

- PLC inputs and outputs

> 5 sec.

(1)

(3) (2)

PLC inputs and outputs display

(1) PLC inputs and outputs status display (2) Button Scroll to the next page by pressing this arrow button. (3) ESC button

Switch to the main menu by pressing this button (parameter page 1).

PLC list of inputs and outputs

Status of PLC inputs and outputs

0 0V 1 24V DC

PLC inputs

X0 Multifunction wheel A X1 Multifunction wheel B X2 Manual mode button X3 ES segment (Prg. step) X4 Reserve X5 Manual mode button + X6 Limit switch 360 ° X7 Emergency stop X10 Start button X11 Stop button X12 WeldingOn/O󰀨 X13 FRC start X14 Press on multifunction wheel X15 Currentowsignal

PLC outputs

Y0 Actual value Y1 Power source B Y2 Motor left Y3 Motor right Y4 High speed Y5 External start Y6 Pneumatic Y7 Power source A Y10 Job Y11 Job

Parameter page 2 - Language selection

(1)

(2)

Language selection

(1) Language selection

For selecting a new display language. Simply press the appropriate touch button to

select the desired language. The language is applied immediately and the display text now appears in the selected language.

Parameter page 2

- Language selection (continued)

(2) Contrast

Press this button to open the "Display" selection window. Press the desired display

parameter to select it. The respective adjustment window then opens.

Increase or decrease the display contrast or brightness value by pressing + or -.

Changedvaluesarereectedimmediatelyonthedisplay.Oncethecorrectsetting

has been made, press the Escape button to apply the settings. Unit: Setting range: 0 - 14 Factory setting: 7

Parameter page 3

- Power source

(3)

(2)

(1)

Power source service parameter

(1) DOWN ON/OFF

For activating/deactivating the "2 power sources option" parameter.

(2) Rob ON/OFF

For activating/deactivating the robot interface option. When activated, jobs can be

called up from the digital power source.

(3) Current.ON/OFF

 Activates/deactivatesthepowersourcecurrentowsignalquery.Whenactivated

(Current.ON),anextendedquerytimeforthecurrentowsignalcanbeset.

Unit: s (seconds)

Setting range: 0-10

Factory setting: 0.0

Parameter page 4 - Calibration

(2)

(1)

(3)

Calibration parameters

(1) Direction

Manual mode + automatic mode direction. The direction can be changed, for exam-

plewhentherotationtableisinaspecicposition.

(2) MFaktor

 Multiplicationfactor-Denesthemaximumspeedofrotationoftherotationtable.

(3) FRC 1

Preselect "Inching mode" or "Permanent operation".

Parameter page 5 - Hardware

(2)

(1)

Hardware parameters

(1) Output voltage

Output voltage - for matching the control unit to whichever hardware is connected (e.g. rotation table).

NOTE! This value is a factory setting and cannot be changed.

(2) F-Setpoint

Hardware-dependent command value for the installed frequency converter.

NOTE! This value is a factory setting and cannot be changed.

Decommissioning Note! Some control settings may be lost if the device is not used for an ex-

tended period of time. Before starting up the device again, we advise that the "MFaktor" and "Output voltage" values are checked against the following table and corrected if necessary.

Data table FCU20

Data table FCU-

20.O

Calculating the MFaktor

Device MFaktor

F-Setpoint Output voltage FTT-10 10500 5000 5V FTT-40 12000 5000 5V FTT-150 6450 5000 5V FRT-150 5600 5000 5V FRT-50 7400 5000 5V FRP -150 5620 5000 5V

Device MFaktor

F-Setpoint Output voltage. FTT 380 - 1500 1400 5000 10V FTT 3000 - 7500 1000 5000 10V FTT 12000 1000 5000 10V FRT 1000 2000 5000 10V FRT 2000 - 5000 1500 5000 10V FRT 10000 1000 5000 10V

Thevalue„MFaktor“maydi󰀨er.Itisrecommendedtomatchthisvaluewiththerating

plate of the rotation table in use.

A-4600 Wels

www.fronius.com

50/60 Hz

Rating plate rotation table

Art.No.:

Ser.No.:

230 V

max

11 rpm

L x W x H

490 x 490 x 595 mm

EN 12100

0,8 A

max. load

40 kg

FTT 40/MA

0,18 kVA

weight

85 kg

Calculating the MFaktor:

On the rating plate of the rotation table, the value V

isspecied.Thevalueof

max

MFaktor results according to the following formula:

x 1000

max

Example: 11 x 1000 = MFaktor 11000

Troubleshooting

Safety

General

WARNING! An electric shock can be fatal. Before opening the device:

- Move the mains switch to the - O - position

- Unplug the device from the mains

- Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again

- Using a suitable measuring device, check that electrically charged parts (e.g. capacitors) have been discharged

CAUTION! Inadequate PE conductor connections can cause serious injury and damage. The housing screws provide a suitable PE conductor connection for earthing the housing and must NOT be replaced by any other screws that do not provide a reliable PE conductor connection.

Basic requirements to ensure a fully-functioning system:

– Connections established between separate system components – Systemcomponentsaresuppliedwithelectricityandthemainsvoltageisasspecied

(see rating plate)

Troubleshooting

Error messages

Errors Cause Remedy The rotation table does not

move

EMERGENCY STOP

EMERGENCY

STOP

Cause: Remedy:

The Emergency Stop protection device on the FCU-20 control unit was activated because of an emergency.

Fault in the installed frequency converter. Contact Fronius service personnel.

Screen No. Er-

ror

Activated by the emergency stop protection device. All control elements are disabled during an emergency stop.

Screen Number Error

See page 24 - Language selection: this error can be caused by pressing "..." if this language is not available in the software.

Data loss Correct the data according to the

table, see page 27

Rectify emergency stop situation and reset emergency stop button Contact Fronius service personnel.

Cause: Remedy:

No valid language selected. Choose a language.

Error messages

(continued)

No current ow signal

Cause: Remedy:

No arc ignition Clean surface of the workpiece, re-ignite

Fault on the power source Check power source settings and correct

No robot interface in use Integration of ROB3000 robot interface Faulty connection to power source Check connection to the power source Welding material not connected Connect welding material

Nocurrentowsignal

Nocurrentowsignaldetectedfromthepowersource(novoltage connection)

the arc

if necessary

ERFF

No screen data + ERFF

No screen

data

Cause: Remedy:

Display GT01 is not programmed. Program display. This can only be per-

formed by the manufacturer.

ERFF

Cause: Remedy:

No connection between PLC and display. • Check wiring and cables

ERFF

Communication fault

• PLC switch is set to STOP - switch to RUN.

Display in Standby mode

No communication over the display is possible, no error display

Cause: Remedy:

PLC is not programmed or is faulty. Reprogram or replace PLC (this can only

be performed by the manufacturer)

Technical data

FCU-20 technical data

Rating plate FCU20 / 20.O

Mains voltage 230 V Mains frequency 50/60 Hz Mains fuse 1.5 A Control voltage 24 V Power consumption 230 VA Nominal current 1 A Dimensions (l x w x h) 350 x 235 x 160 Weight 5 kg

Spare parts list FCU-20

FCU-20 spare parts list

38,0102,0048

38,0008,0065

38,0002,0056 38,0002,0061

38,0002,0092 38,0002,0090 38,0002,0098

38,0102,0047

38,0002,0097 38,0002,0090 38,0002,0098

38,0102,0017

38,0002,0095 38,0002,0090 38,0002,0098

4,085,185 42,0406,0102 42,0406,0093

38,0002,0093 38,0002,0091 38,0002,0098

43,0001,1115

38,0006,0087

43,0004,3206

4,085,184

38,0006,0087

38,0102,0049

Rob 3000 38,0101,0014

38,0100,0219 38,0100,0187

FCU-20 spare parts list

(continued)

Item number Name

8,040,073 FCU-20 4,085,184 TP FCU/FRC PC board 4,085,185 DGP PC board 38,0102,0049 MP FCU-20 38,0002,0061 N.C. contact element emergency stop 38,0002,0090 N.O. contact element 38,0002,0091 N.C. contact element 38,0002,0092 Start button 38,0002,0093 Stop button 38,0002,0095 Toggle switch 38,0002,0097 Manual mode button

38,0002,0098 Mountingange

38,0006,0087 Mains switch 38,0102,0017 Frequency converter

38,0008,0065 Touchscreendisplayprotectivelm

38,0002,0056 Emergency Stop button 38,0102,0047 PLC control 38,0102,0048 Touchscreen display 38,0100,0187 Hosepack 38,0100,0219 Tuchel connecting lead 42,0406,0093 Red cover 42,0406,0102 Black adjusting knob

43,0001,1115 Linelter

43,0004,3206 5 m mains cable

Accessories and options FCU-20

I-kits FCU-20

System overview

I-kit Activation FRC-1: 8,100,112

I-kit Welding step-axis: 8,100,151

I-kit Job switch: 8,100,113

I-kit Activation FRT 150: 8,100,125 (Cable for turntable included)

Start for external device

FCU-11 FCU-12 FRC-12 KD 4010

FCU-11 / FCU-12 / FRC-12:

FRC 1

KD 4010:

38,0100,0128

38,0100,0188

FTT 10 FTT 40 FTT 150 FRT 50 FRT 150

(I-kit for bracket necessary)

LEGEND:

FTU

Emergency stop

8,100,152

- - - - - - Option ______ Standard (included in delivery)

38,0100,0081

24V + DC

Pneumatic cylinder FPT 100 8,045,228

FPT 150 8,045,227

Rob

3000

38,0101,0014

Rob

TUCHEL

38,0100,0219

3000

38,0101,0014

Power source

TUCHEL

38,0100,0219

Power source

Installation kit

Pedal remote control

Connecting lead

- I-kit, start/stop A/B or A and B (for 2 welding power sources), (factory installation). Item number: 8,100,113

- I-kit, controller for FRC-1 pedal remote control (factory installation). Item number: 8,100,112

-I-kit,FCUo󰀨setaxis(onlyinconjunctionwithFTUtripodunitandFTUo󰀨setaxisI-kit

8,100,152). Item number: 8,100,151

- I-kit, FRT 150 (only in conjunction with FRT 150 rotation table)

Item number: 8,100,125

FRC-1 with 3 m cable and protection. Item number: 8,045,011

- Connecting lead 5 m, FCU-20 to FPT (pneumatic torch positioning). Item number: 38,0100,0081

- Connecting lead 5 m, FCU-20 to FCU-11, FCU-12. Item number: 38,0100,0188

- Connecting lead 3 m, FCU-20 to KD-4010. Item number: 38,0100,0128

Spare parts list FCU-20.O

FCU-20.O spare parts list

38,0102,0048

38,0008,0065

38,0002,0056 38,0002,0061

38,0002,0092 38,0002,0090 38,0002,0098

38,0102,0047

38,0002,0097 38,0002,0090 38,0002,0098

38,0002,0095 38,0002,0090 38,0002,0098

38,0006,0210

4,085,185 42,0406,0102 42,0406,0093

38,0002,0093 38,0002,0091 38,0002,0098

43,0001,1115

38,0006,0087

Rob 3000 38,0101,0014

38,0006,0087

43,0004,3206

38,0100,0219

4,085,184

38,0100,0237

38,0102,0049

38,0003,0015

38,0003,0017

38,0003,0185

38,0003,0029

FCU-20.O spare parts list

(continued)

Item number Name

8,040,073,630 FCU-20.O 4,085,184 TP FCU/FRC PC board 4,085,185 DGP PC board 38,0102,0049 MP FCU-20 38,0002,0061 N.C. contact element emergency stop 38,0002,0090 N.O. contact element 38,0002,0091 N.C. contact element 38,0002,0092 Start button 38,0002,0093 Stop button 38,0002,0095 Toggle switch 38,0002,0097 Manual mode button

38,0002,0098 Mountingange

38,0003,0015 Attachment housing 38,0003,0017 Bush insert 38,0003,0029 Bush insert 38,0003,0185 Attachment housing 38,0006,0087 Mains switch

38,0008,0065 Touchscreendisplayprotectivelm

38,0002,0056 Emergency Stop button 38,0102,0047 PLC control 38,0006,0210 Galvanic insulator 38,0102,0048 Touchscreen display 38,0100,0237 Hosepack 38,0100,0219 Tuchel connecting lead 42,0406,0093 Red cover 42,0406,0102 Black adjusting knob

43,0001,1115 Linelter

43,0004,3206 5 m mains cable