Fronius FOU 30 / ML6 Operating Instruction [EN]

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FOU 30 / ML6

Operating Instructions

EN

Oscillation unit

42,0410,1661 V02-23112017

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”.

I

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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.

II

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.

ud_fr_st_sv_00467 022009

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.

IV

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

Hazards from
mains and weld­ing current

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.

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.

V

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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

ud_fr_st_sv_00467 022009

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.

VI

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.

IX

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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.

ud_fr_st_sv_00467 022009

X

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!

XI

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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

Copyright

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

Copyright to this instruction manual remains the property of the
manufacturer.

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 ............................................................................................................................................................ 3

Machine concept ........................................................................................................................................ 3

Field of application ..................................................................................................................................... 3

Proper use .................................................................................................................................................. 3

Warning notices a󰀩xed to the oscillation unit.............................................................................................4

Scope of supply .......................................................................................................................................... 4

Control elements and connections .................................................................................................................. 5

Oscillation unit control panel ...................................................................................................................... 5

Start-up ............................................................................................................................................................ 6

Mounting the oscillation unit ....................................................................................................................... 6

Preparing system components ................................................................................................................... 6

Set the oscillation ....................................................................................................................................... 7

Start the welding process ........................................................................................................................... 7

Troubleshooting ............................................................................................................................................... 8

General.......................................................................................................................................................8

Basic requirements for the system to work ................................................................................................ 8

Oscillation ................................................................................................................................................... 8

Maintenance and care ..................................................................................................................................... 9

Personnel ................................................................................................................................................... 9

Maintenance activities ................................................................................................................................ 9

Technical data ............................................................................................................................................... 10

Oscillation unit FOU-30 / ML6 .................................................................................................................. 10

Dimensions of oscillation unit with driving vehicle .................................................................................... 10

Spare parts list FOU-30 / ML6 ....................................................................................................................... 11

Circuit diagram FOU-30 / ML6 ...................................................................................................................... 15

EU-Declaration of incorporation .................................................................................................................... 16

1

2

General

Machine concept

Field of
application

The oscillation unit FOU-30/ ML6 is an

optional expansion for the driving vehicle
FDV-22 MF. The system is used to ex­ecute mechanised butt and llet welds in

horizontal or vertical welding positions.
Oscillating makes it possible to produce
broad weld seams. The oscillating param­eters determine the appearance and qual­ity of the weld seam.
The universal torch holder is mounted on
the side support arm.
It is connected to the driving vehicle via a

anged plug connector.

Oscillation unit FOU-30/ML6

The oscillation unit is only to be used in conjunction with the driving vehicle FDV 22 MF.

The system can be used in all situations where a high degree of exibility is required
when executing longitudinal weld seams:

- Welding of longitudinal members

- Shipyards

- Bridge construction

- Workshops

- Production halls

- Building sites

Proper use

The oscillation unit FOU-30/ML6 is an optional expansion for the driving vehicle FDV-22
MF and is used for performing mechanised butt and llet welds in horizontal or vertical

welding positions. The oscillation unit is only to be used in conjunction with the driving
vehicle FDV -22 MF. Any use above and beyond this purpose is deemed improper. The
manufacturer shall not be liable for any damage resulting from such improper use.

The following welding processes are possible:

- MIG/MAG process

Proper use also includes:

- use of MIG / MAG welding torches with a holder diameter of 16 - 22 mm

- using the spare parts stipulated by Fronius

- following all the information in the operating instructions

- using this document in conjunction with the operating
instructions of the integrated system components (driving vehicle, power source,

wire-feed unit, etc.)

3

Warning notices

Type:

Ser.No.:

Art.No.:

A-4600 Wels

www.fronius.com

weight max. load

2,5 kg 6 kg

2009

FOU 30/ML6

8,045,370

20 26 9509

U

14,4 VDC

a󰀩xed to the

oscillation unit

The oscillation unit has safety symbols on the rating plate. These
safety symbols must NOT be removed or painted over.

Scope of supply

Do not use the functions until you have fully read all the operating instructions.

Do not dispose of used chargers with domestic waste. Dispose of them according to
safety rules.

Rating plate FOU-30/ ML6

(3)

(2)

(1)

(1) Oscillation unit FOU-30/ML6
(2) Clamp block
(3) Linkage with universal torch holder

FOU-30/ ML6 scope of supply

4

Control elements and connections

Oscillation unit
control panel

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described until you have thoroughly read

and understood the following documents:

- these operating instructions

- all the operating instructions for the system components,
especially the safety rules

(7)

(6)

Oscillation unit FOU-30/ML6 control panel

(1)

(2)

(3)

(4)

(5)

No. Function
(1) Oscillation mode toggle switch
MANUAL / OFF / AUTOMATIC

For selecting the oscillating mode of

the FOU -30.
MANUAL: Oscillating active immedi­ately

OFF: Oscillating is deactivated
AUTOMATIC: Oscillating starts simul-

taneously with program sequence.

(2) Right dwell time potentiometer

For setting the dwell time of the torch

in the right reversal
position.

Setting range: 0 - 3 seconds

(3) Oscillation speed potentiometer

For setting the traversing speed of

the oscillation unit in mm / min. The
oscillating speed can only be adjusted
while the oscillation unit is running.

(4) Connection cable with
male socket

For connection to the "Connector for

oscillation unit FOU30" of the driving
vehicle control panel.

(5) Support arm

For fastening the torch holder.

(6) Oscillation path potentiometer

To increase or reduce the oscillating

path (oscillating width).
The oscillating path can only be adjust­ed while the oscillation unit is running.

Setting range: 1 - 30 mm

(7) Left dwell time potentiometer

For setting the dwell time of the torch in the left reversal position.

Setting range: 0 - 3 seconds

5

Start-up

Mounting the
oscillation unit

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described until you have thoroughly read

and understood the following documents:

- these operating instructions

- all the operating instructions for the system components, especially the
safety rules

(a)

(c)

(b)

Preparing
system compo­nents

Mounting the oscillation unit FOU-30/ML6

1. A󰀩x the oscillation unit FOU-30/ML6 on the adjustable mount (a) using 2 Allen
screws M5 x 16 and washers 5.3 . Adjust the oscillation unit to the required height

(with the slots) and tighten the Allen screws (b).

2. Lay the connecting cable on the driving vehicle as shown.

3. Connect the anged plug connector to the socket on the driving vehicle con­trol panel.

4. Push the torch holder linkage on the support arm (c). Turn the linkage to the desired
position and tighten the lever.

The following activities and work steps apply to the installed system. All connections
must be established. Before start-up, check the connections of the following system com-

ponents:

- Driving vehicle

- Power source

- Cooling circuit

- Gas cylinder

- Wire-feed unit

- Welding torch with hosepack

Detailed information on the preparation of the system components can be found in the
corresponding operating instructions for the system components (driving vehicle, power
source, wire-feed unit, etc.)

6

Set the
oscillation

The oscillating parameters determine the appearance and quality of the weld seam.

Observe the following procedure:

1. Set the "Start LEFT / STOP / Start RIGHT" toggle switch on the
driving vehicle control panel to the "STOP" (0) position.

2. Turn the "Control unit ON/OFF" toggle switch to the "ON" position

3. Start trial run. Turn the "Oscillation mode MANUAL / OFF / AUTO­MATIC" toggle switch to the "MANUAL" position.

4. Observe the oscillating motion and set the following oscillating

parameters:

Start the welding
process

dwell time left [ s ]

dwell time right [ s ]

oscillating path [mm]

oscillating speed [mm]

5. Turn the "Oscillation mode MANUAL / OFF / AUTOMATIC" toggle
switch to the "AUTOMATIC" position. Oscillating starts at the same
time as the program sequence.

Important: If the driving vehicle has been congured for interval

welding, the oscillating motion is only active in the welding seg-

ment. In the pause segment, during crater lling and back-lling,

the oscillation unit stops and waits in the middle position.

1. Turn the "Start LEFT / STOP / Start RIGHT" toggle switch on the driving vehicle
control panel to the desired setting. To stop the process early, turn the switch to the
"STOP" (0) position.

2. Make any necessary corrections (welding torch position, direction of travel,
traversing speed, oscillating motion, etc.).

7

Troubleshooting

General

Basic require­ments for the
system to work

Oscillation

In the event of faults, note that the functioning of the entire system depends on many
additional components (driving vehicle, power source, wire-feed unit, etc.) that are also
potential sources of problems.

- Connections established between separate system components

- System components are supplied with electricity and the mains voltage for each
component complies with the rating plate

Oscillation does not work

Cause: "Oscillation mode MANUAL / OFF / AUTOMATIC" toggle switch is in the

"OFF" position.

Remedy: Turn toggle switch to the "MANUAL" or "AUTOMATIC" position.

Cause: Connecting cable to the driving vehicle control unit damaged.
Remedy: Check the connecting cable. Replace if necessary.

Cause: oscillating arm blocked.
Remedy: Check that the oscillating arm, linkage and torch holder move freely.

Oscillation unit is not oscillating, motor audible

Cause: Transmission damaged.
Remedy: Replace transmission.

8

Maintenance and care

Personnel

Maintenance
activities

WARNING! Risk of injury and damage from incorrectly performed main­tenance.

All maintenance on the FDV 22 MF driving vehicle must only be carried out by
trained technicians. 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.

Under normal operating conditions the unit requires only a minimum of care and main­tenance. However, it is vital to observe some important points to ensure it remains in a
usable condition for many years.

- Check the connecting cable to the driving vehicle for damage.

- Check the torch holder for damage

9

Technical data

Oscillation unit
FOU -30 / ML6

Dimensions of
oscillation unit
with driving
vehicle

Max. load 6 kg
Max. torque 6 Nm
Oscillating process angled, max. 11°

Oscillating path 1 - 30 mm
Oscillating frequency (R = 150, oscillation path = 10 mm) 12 - 110 strokes / min
Dwell time 0 - 3 sec.

A

L

B

M

N

C

D

K

I

J

H

A 305 - 415 mm
B 112 - 162 mm
C 29 mm
D 40 mm
E 30 mm
F 271 - 421 mm
G 288 - 398 mm
H 157 mm

G

F

E

I 52 mm
J 10 mm
K 40 mm
L 60 - 200 mm
M 398 mm
N 312 mm
O 5 mm
P 369 mm

O

P

10

Spare parts list FOU-30 / ML6

11

12

Oscillation unit FOU-30/ML6 8,045,370

(without clamping lever)

13

Oscillation unit FOU-30/ML6 8,045,370

14

Circuit diagram FOU-30 / ML6

1

1

+

=

419.04.10.00.0

-WZK-0365-04-01-15-0

blue

green

123

grey

SPEED POT

1

3

2

white

123

DWELL1 POT

1

3

2

white

green

blue

6

-WZK-0365-04-01-17-0

-S2

-S5

yellow

brown

-S8

3

4

1

2

blue

green

black

red

-W1

DWELL2 POT

1

3

2

blue

green

white

12345

-S3

-S6

3

4

1

2

white

red

black

blue

AMPLITUDE POT

1

3

2

blue

green

white

-WZK-0365-04-01-16-0

3

2

1

-S1

5

FOU30

Control PCB

4

-U1

-S4

1

2

3

white

blue

black

brown

125mm

750 mm

-WZK-0419-04-01-05-0

Ground Chassis

321

-WZK-0419-04-01-04-0

AUTO/OFF/MANUAL SELECTOR

-WZK-0419-04-01-07-0

Panel Assembly

2

FOU30 / ML6

1

10 76 8 93

234

2017-02-03

Cable connector

Gearbox assembly

STEPPER MOTOR

GAP SENSOR

15

EU-Declaration of incorporation

16

FRONIUS INTERNATIONAL GMBH

TechSupport Automation

E-Mail: [e-mail]

www.fronius.com

www.fronius.com/addresses

FCP 600 - II

Spare parts recommendation,

D

Mechanical spare parts