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FPA 2030 Orbital Servo-Control
Operating instructions
EN
Orbital system controller
42,0426,0106,EN V03 - 31012017
Inhalt
General ............................................................................................................................................................ 5
Principle......................................................................................................................................................5
Device concept ........................................................................................................................................... 5
Application areas ........................................................................................................................................ 6
Warning notices on the unit ........................................................................................................................ 6
Controls and connections ................................................................................................................................ 7
Control panel ............................................................................................................................................. 7
Toolbar........................................................................................................................................................ 9
Connections, switches and system add-ons ................................................................................................. 10
Description ............................................................................................................................................... 11
FPA 2030RC remote control ..........................................................................................................................12
Safety ....................................................................................................................................................... 12
Controls .................................................................................................................................................... 12
Description of displays ............................................................................................................................. 17
Before commissioning ................................................................................................................................... 20
Safety ....................................................................................................................................................... 20
Proper use ................................................................................................................................................ 20
Setup regulations ..................................................................................................................................... 20
Connection ............................................................................................................................................... 20
Commissioning .............................................................................................................................................. 21
Safety ....................................................................................................................................................... 21
Connecting gas cylinders for shielding gas and forming gas ................................................................... 21
Establishing a connection to the workpiece ............................................................................................. 22
Connecting the orbital spot welding gun .................................................................................................. 22
Alignment of the orbital spot welding gun ...................................................................................................... 23
General.....................................................................................................................................................23
Qualied technicians ................................................................................................................................ 23
Path alignment, rotation ........................................................................................................................... 23
Path alignment, wirefeed .......................................................................................................................... 24
Path alignment, oscillation (OSC) ............................................................................................................ 25
Menus with direct selection ........................................................................................................................... 26
Principle....................................................................................................................................................26
F1 button .................................................................................................................................................. 26
"Shielding gas and cooling" menu ............................................................................................................ 26
"Data transfer" menu ................................................................................................................................ 27
"Printer conguration" menu ..................................................................................................................... 28
Alarms and device-specic data .............................................................................................................. 31
Main menu ..................................................................................................................................................... 33
Entering the password ............................................................................................................................. 33
Forgotten password ................................................................................................................................. 33
Selection window ..................................................................................................................................... 34
"Orbital spot welding gun/manual welding torch" menu ................................................................................ 35
Calling up the menu ................................................................................................................................. 35
Selecting the type of orbital spot welding gun .......................................................................................... 35
Selecting the type of orbital spot welding gun .......................................................................................... 35
Selecting the type of manual welding torch .............................................................................................. 36
"Synergic" menu ............................................................................................................................................ 37
Calling up the "Synergic" menu ................................................................................................................ 37
Principle....................................................................................................................................................37
Entering parameters ................................................................................................................................. 37
3
"Setup and system parameters" menu .......................................................................................................... 39
Calling up the "Setup and system parameters" menu .............................................................................. 39
Principle....................................................................................................................................................39
Calling up "USER" settings ...................................................................................................................... 39
Logging on a dierent user, and changing the password ......................................................................... 39
Changing the password ........................................................................................................................... 40
User permissions......................................................................................................................................40
User-specic settings ............................................................................................................................... 41
Brightness and contrast ........................................................................................................................... 41
Ignition parameters .................................................................................................................................. 42
Welding mode & AC ................................................................................................................................. 42
Value adjustment ...................................................................................................................................... 43
More parameters ...................................................................................................................................... 43
AVC, OSC value adjustment .................................................................................................................... 44
Welding direction and wirefeed ................................................................................................................ 44
Wire threading .......................................................................................................................................... 44
OSC parameters ...................................................................................................................................... 45
AVC parameters ....................................................................................................................................... 45
Date, time and calibrating the touchscreen .............................................................................................. 45
"Parameter settings" menu ............................................................................................................................ 46
Calling up the "Parameter settings" menu................................................................................................ 46
Principle....................................................................................................................................................46
Waveform parameters for TIG manual welding torch ............................................................................... 46
Waveform parameters for orbital spot welding gun .................................................................................. 47
Parameters for pulsing and welding speed .............................................................................................. 48
Parameters for wirefeed ........................................................................................................................... 48
Parameters for AC welding ..................................................................................................................... 49
Parameters for OSC torch oscillation ...................................................................................................... 49
Parameters for AVC torch distance control .............................................................................................. 49
Calling up the start point parameters ....................................................................................................... 50
Parameters for start point ......................................................................................................................... 50
Parameters for start point - OSC .............................................................................................................. 51
Parameters for start point - AVC ...............................................................................................................53
Saving parameters ................................................................................................................................... 53
Successor programs ................................................................................................................................ 54
"Orbital and TIG welding" menu .................................................................................................................... 56
Safety ....................................................................................................................................................... 56
Calling up the "Welding" menu ................................................................................................................. 56
Control, monitoring, actual values ............................................................................................................ 57
Welding process status ............................................................................................................................ 58
Correcting the welding process ................................................................................................................ 58
Limit values .............................................................................................................................................. 59
Troubleshooting ............................................................................................................................................. 60
General.....................................................................................................................................................60
Alarms and error messages ..................................................................................................................... 61
Servo error list .......................................................................................................................................... 65
Displayed service codes .......................................................................................................................... 67
Orbital system controller...........................................................................................................................68
Maintenance and care ................................................................................................................................... 70
General.....................................................................................................................................................70
At every start-up ....................................................................................................................................... 70
Technical data ............................................................................................................................................... 71
Orbital system controller...........................................................................................................................71
Spare parts .................................................................................................................................................... 72
4
General
Principle The FPA 2030 is a completely digitised, microprocessor-controlled orbital system control-
ler for orbital welding. An active power source manager is coupled with a digital signal
processor, and together they control and regulate the entire welding process. The actual
data are measured continuously and the machine responds immediately to any changes.
The rule algorithms ensure that the speci-
ed target status is maintained at all times.
This gives the weld process an unrivalled
degree of precision, with exact reproducibility of all results and excellent welding
properties. Alongside its welding properties, the high degree of eciency is another key feature of the new orbital system
controller.
An intuitive operating concept makes your
work much easier. Last but not least, as
the tasks of the main control elements are
now controlled from the generously proportioned touchscreen, essential functions
can be seen at a glance and adjusted as
required.
FPA 2030 orbital system controller
Device concept The FPA 2030 is a 6-axis orbital system controller used for interfacing to Fronius's TT/
MW 2500 and 3000 digital TIG power sources. 6-axis orbital system control means programming and controlling the following 6 parameters:
- Shielding gas
- Welding current
- Rotational movement of the welding head
- Wire parameters
- AVC parameter (torch distance control)
- OSC parameter (torch oscillation)
Placing the system controller above the power source on the pickup trolley provides for a
comfortable working height. The front panel on the system controller protects the control
panel and the printer. When the front panel is open it doubles up as an anti-glare screen
for the touchscreen display.
In addition to the many orbital spot welding guns available for a wide variety of applications, the system controller also supports manual welding torches.
The manual remote control allows the orbital welding system to be operated in close
proximity to the workpiece.
5
Application areas There are a vast number of applications for the FPA 2030 in trade and industry. In this
I
1
U
1
4 A55 V
IEC 60974-1
A-4600 Wels
www.fronius.com
Type:
Ser.No.:
Art.No.:
P
1max
220 W
U
2
42 V
FPA 2030
8,040,067
I
2
4 A
24 V4 A
IP 23
19449503
This machine includes following additional parts (options):
8,100,133 Adressing AVC/ Touch & retract
8,100,134 Adressing OSC/ Electrode- centering
connection the pharmaceutical and foodstus industries are well worth mentioning, since
they place high demands on the quality of pipelines and containers. As regards its suit-
ability for welding dierent materials, the controller is just as much "at home" welding
unalloyed and low-alloy steel as it is welding high-alloy chrome-nickel steels. These "allrounder" qualities are enhanced by the machine's optimised ignition sequence.
For TIG-AC welding, the FPA 2030 takes account not only of the diameter of the electrode, but also of its temperature, calculated with reference to the preceding welding
and weld-o times. Moreover, the system controller does sterling service when welding
aluminium, aluminium alloys, copper alloys, magnesium and titanium. The AC frequency
can be adjusted over a very wide range, permitting optimum adaptation to your particular
requirements.
Warning notices
on the unit
A number of safety symbols can be seen on the device's rating plate. The safety symbols
must not be removed or made illegible.
FPA-2030 rating plate
6
Controls and connections
Control panel
NOTE! As a result of rmware updates, you may nd that there are functions
available on your device that are not described in these operating instructions or
vice versa. Certain illustrations may also dier slightly from the actual controls
on your device, but these controls will still work in exactly the same way.
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 the operating instructions for the system components, especially the
safety rules
(3)
(2)
(4)
(1)
(5)
(6)
(7)
Control panel
No. Function
(1) Adjusting dial
Selecting menu items
1. Turn the adjusting dial until the required menu item is highlighted in blue
2. Press the adjusting dial to select the menu item
Selecting and adjusting parameters
1. Turn the adjusting dial until the required parameter is highlighted in blue
2. Press the adjusting dial; the selected parameter now turns violet
3. Turn the adjusting dial to adjust the parameter to the required value
4. Press the adjusting dial to apply the value; the blue highlighting then moves
on to the next parameter
Important! If you do not wish to apply the value, touch the "Esc" button (8).
Important! These functions are also directly supported by the touchscreen (3).
Simply touch a menu item or parameter. Where applicable this will open a list
from which you can select from several values. However, the adjusting dial must
be used to enter a numerical value. It is advisable just to use the adjusting dial
when working, for example, in dusty environments if the touchscreen is covered
with protective lm.
(2) "Next" button
Opens the next menu window
(3) Touchscreen
Screen with context-sensitive buttons that can be touched directly
(10)
(9)
(8)
7
Control panel
(continued)
No. Function
(4) "F1" key
Freely programmable function key (in the "Setup and system parameters" menu)
(5) "Shielding gas and cooling" button
Opens the "Shielding gas and cooling" menu
(6) "Data exchange" button
Opens the data transfer menu
(7) "Printer conguration" button
For setting specic data for printing or saving to a memory stick.
(8) "ESC" button
- Returns to the previous menu window
- Resets alarms
- Abandons a parameter setting without applying the changed value
(9) "i" button
Displays versions, alarms and information for service engineers
(10) "Menu" button
For returning to the main menu; pressing the button again opens a window
where you can enter the page number directly (see below).
8
Toolbar
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 the operating instructions for the system components, especially the
safety rules
Display elements on the display
Time/date
Segment 1-10
indicates the welding path segment in which the orbital weld head is currently
located.
Important! More detailed information on "segments" can be found in the section
headed "Parameter settings".
Page in program sequence - every dialog box in the menu structure has a page
number for identication purposes during maintenance work (for example)
Name of the currently loaded program
User name - more detailed information can be found in the section headed "Setup and system parameters"
Touching the symbol opens the active
alarm page
3: Main current signal
2: Arc on signal
1: Process active signal
Wire-feed unit selected and active (blue)
Wire-feed unit selected but not active (black)
Wire-feed unit not selected (black, with blue cross)
Clockwise welding direction
Anti-clockwise welding direction
Welding activeWelding preselected
Test mode preselected
Shielding gas valve not active Shielding gas valve active (blue)
Forming gas valve not active
Limit switch for closed-chamber
orbital weld head not active
9
Forming gas valve active (blue)
Limit switch for closed-chamber
orbital weld head active (blue)
Connections, switches and system add-ons
General
Connections
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 the operating instructions for the system components, especially the
safety rules
(1)
(2)
(3)
(4a)
(4b)
(4)
(7)
FPA 2030 system controller, front side
(5)
(6)
(8)
(9)
(13)
FPA 2030 system controller, rear side
(10)
(12)
(11)
10
Description
No. Function
(1) USB port
To save and load individual welding programs or all orbital system controller data
to or from a USB stick
(2) Ethernet connection
The Ethernet interface for connecting the FPA 2030 control unit to a PC. The
"FPA Explorer" software can be used to record measurement data while welding.
(3) RS 232 port
The serial interface for remote maintenance and diagnostics for Fronius Technical Support. In this case, the control unit is connected to a PC that has an analog
or digital modem.
(4) Printer
Used to document process parameters
(4a) "Open cover/Ready" button
Unlocks the paper roll cover. When unlocked, the button ashes green.
When the printer is ready, the button ashes green.
(4b) "Paper feed" button
To fast-forward the printer paper
(5) Orbital welding gun connection
Controls the following functions: AVC/OSC/rotation/internal wire feed.
(6) Remote control connection
The FPA 2030-RC remote control is connected to the system here.
(7) Shielding gas output connection
For the orbital weld head and the manual TIG welding torch.
(8) Forming gas connection (input)
For the forming gas supply from the gas cylinder or ring main.
(9) Forming gas connection (output)
Orbital welding gun connection
(10) Shielding gas connection (input)
For the shielding gas supply from the gas cylinder or ring main
(11) Pressure reducing valve
Connection to the "Shielding gas input"
NOTE! Shielding gas is colourless and odourless and is hazardous to health.
The control valve must be shut fully when welding is nished; failure
to do so is dangerous. Colourless and odourless shielding gas may
escape undetected.
• Do not, under any circumstances, meddle with the adjusting screw
on the pressure reducing valve. If the screw is adjusted, Fronius
will not accept any liability for resultant damage.
• Never exceed the maximum supply pressure of the shielding gas
supply. The maximum supply pressure is 9 bar (130 psi).
(12) LocalNet connection
Connection to the power source for
• power supply to the control unit
• communication with the power source
(13) External connection
Connection to SGI-3 residual oxygen measuring device
11
t
s
v
AVC
ON
FPA 2030RC remote control
Safety
Controls
WARNING!
Incorrect operation may result in serious injury or damage.
Do not use the functions described here 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
(23)
(1)
(2)
(22)
(21)
(20)
(4)
(5)
(3)
(6)
(7)
(19)
(18)
(17)
(16)
(15)
(14)
(13)
FPA 2030-RC remote control unit
(12)
(8)
(9)
(10)
(11)
12
Controls
(continued)
Screen Description of the buttons
(a)
(1) "Group selection" button
Press (+) or (-) to access the menu for
selecting the program group.
The previously selected group is
displayed (a).
Press (+) or (-) again to select the
desired group.
Note! To exit the selection menu without changing the original settings, press the
"Stop" button (12).
(2) "Program selection" button
Press (+) or (-) to select the desired
welding program (b)
(b)
During loading, conrmation of the
selected welding program is indicated
by its name (b) that appears on the
(b)
display.
Once loading is complete, the display
shows the new program name (b)
(b)
while on standby.
Note! To exit the selection menu without changing the original settings, press the
"Stop" button (12).
13
Controls
(continued)
Description of the buttons
(3) "F2" key
Freely programmable function key (see the "Setup and system parameters"
menu)
(4) "Left" button
Activates various functions when used in combination with the following buttons:
• "Stop" button (12): sets the current position of the spot welding gun to zero
• "Start/Stop" button (13): moves the spot welding gun to the zero position
• "Auto torch positioning" button (6): activates automatic torch positioning
• "Right" button (5): opens the window for calibrating the touchscreen
(5) "Right" button
Activates various functions when used in combination with the following buttons:
• "Stop" button (12): stops the welding process immediately. The "Start/Stop"
button (13) is used to return to the original start position.
• "Left" button (4): opens the window for calibrating the touchscreen.
(6) "Auto torch positioning" button
Used in combination with the "Left button" (4) to activate automatic "Touch &
Retract" torch positioning. Using the AVC axis, the torch is moved towards the
workpiece (speed: AVC v-T&R; for details, see "Parameters for start point - AVC"
in the Parameter settings" section) until it makes contact with the workpiece.
If the electrode touches the workpiece, the downward movement is halted
immediately and upward movement is started. At the end of the "AVC T&R up"
time, AVC is halted.
NOTE! Risk of damage to the welding torch.
If connections (e.g. the earth contact) are missing, the point at which the
electrode touches the workpiece will not be detected and there will not
be any upward movement.
The welding torch and the mechanical parts of the orbital spot welding
gun can be damaged as a result of a torch collision.
Before starting automatic torch positioning, make sure that all
connections to the orbital spot welding gun are in place.
(7) "Torch up/down" button
For moving the torch up or down
Welding mode:
For moving the torch up or down if the AVC function has not been activated.
For increasing or decreasing the torch voltage (AVC control set value)
(8) "AVC ON" button
For activating or deactivating AVC control (torch distance control).
(9) "Wire-feed unit on/o" button
For activating and deactivating the wire-feed unit. The wire-feed unit can also be
deactivated while welding is in progress.
(10) "Oscillation unit left/right" button
Moves the oscillation unit to the left or right
Welding mode: to shift the oscillation oset, the oscillation seam is moved to the
left or right while retaining the same oscillation path (weaving width)
(11)
"Oscillation path +/-" button
For increasing or decreasing the oscillation path (weaving width). The oscillation
path can only be adjusted while the oscillation unit is running.
(12) "Stop" button
Stops the welding process immediately. The interrupted welding process may be
continued by pressing the "Start/Stop" button (13).
When used in combination with the "Left" button (4), sets the current position of
the orbital spot welding gun to zero
Important! Regardless of the settings in the "Parameter settings" menu, welding
stops with no downslope when the "Stop" button (12) is pressed.
14
Controls
(continued)
Description of the buttons
NOTE! Risk of damage to the welding torch.
If connections (e.g. the earth contact) are missing, the point at which the
electrode touches the workpiece will not be detected and there will not
be any upward movement.
The welding torch and the mechanical parts of the orbital spot welding
gun can be damaged as a result of a torch collision.
Before starting automatic torch positioning, make sure that all
connections to the orbital spot welding gun are in place.
(13) "Stop/Start" button
Starts and ends the welding process:
For closed-chamber spot welding guns with no wirefeed, welding starts
immediately after the "Start/Stop" button is pressed. For open-chamber spot
welding guns with a wirefeed, the following process applies:
• If the "ROLL-UP" parameter in dialog window 221 is set to "ACTIVE", the
hosepack is rolled up when this button is rst pressed. Once the start point is
reached, welding starts when the button is pressed again.
• If the "ROLL-UP" parameter in dialog window 221 is set to "AUTOSTART",
this button only needs to be pressed once to activate the welding process.
Welding starts once the hosepack has rolled up automatically and the start
point has been reached.
Other functions:
When used in combination with the "Left" button (4), sets the orbital spot welding
gun to position 0
(14) "Dwell times" button
Increases or decreases the torch dwell time in the oscillation unit reversal
position. Adjustment applies to the left and right reversal position. The dwell time
can only be adjusted while the oscillation unit is running.
(15) "Oscillation speed" button
Increases or decreases the oscillation motion speed. The speed can only be
adjusted while the oscillation unit is running.
(16) "Arc on/o" button
Pressing this button activates or deactivates welding. The LED is illuminated
while welding is in progress. Has the same function as the "Welding on" button in
the "Troubleshooting" section.
(17) "Auto torch centring" button
When used in combination with the "Left" button (4) activates automatic "Touch &
Retract" torch centring. The torch is automatically positioned in the centre of the
weld seam.
Important! If there is only one workpiece boundary, the midpoint between
the workpiece on the one side and the limit switch position on the other side
is calculated. If there is no workpiece boundary on either side, the midpoint
between the two limit switch positions is calculated.
Important! Always ensure you enter a value greater than zero for the T&R Oset,
otherwise the torch will collide with the workpiece. For detailed information, see
"Parameters for start point - OSC" in the section headed "Parameter settings
menu".
15
Controls
1
2
3
(continued)
Description of the buttons
Oscillation unit
Torch end position
Workpiece
Seam centre
Torch start position
Contacting on the rightContacting on the left
Torch is centred
Torch start position
(18) "Welding speed" button
Increases or decreases the speed of the torch head rotational movement during
the welding process. See the "v-Rotation" parameter in the "Value adjustment"
window (screen 233) in the "Setup and system parameters" section.
(19) "Welding current" button
Increases or decreases the welding current during the welding process. See the
"v-Rotation" parameter in the "Value adjustment" window (screen 233) in the
"Setup and system parameters" section.
(20) "Wire feed speed" button
Increases or decreases the wire feed speed during the welding process. See the
"WFS" parameter in the "Value adjustment" window (screen 233) in the "Setup
and system parameters" section.
This button is used to position the welding wire during set-up and maintenance
work.
(21) "Forming gas" button
Opens the forming gas valve for test purposes. Press the button again to close
the valve.
Important! If the valve is not closed by pressing the button, it closes
automatically after the delay time has elapsed. See the "Forming gas" parameter
in the menu with direct "Shielding gas and cooling" selection.
(22) "Gas test" button
For an acoustic check of the set shielding gas ow rate. After you press the
button, shielding gas will ow out for 30 seconds. Press the button again to stop
the gas test ow before the end of this period. See the "Shielding gas" parameter
in the menu with direct "Shielding gas and cooling" selection.
(23) "Emergency stop" button
Only use in an emergency! The welding process stops immediately along with all
other movements on the machine (rotation, oscillation, etc.)
16
Description of
displays
The section below provides a line-by-line description of the screens in the dierent
operating statuses.
Idle display
Display after
welding has
started, if
positioning
takes place
- Date and time
- Name of the currently loaded welding
program
- Orbital spot welding gun type
- READY / NOT READY - power source
ready to weld, or error needs to be
rectied
- Seg 1 - status indicator for current
segment
- Pos - position of the orbital spot
welding gun [°] / welding speed [cm/
min]
- Wire feed speed [cm/min]
- Number displayed next to
"POSITIONING" is the time that has
elapsed since welding started
- Seg 1 - status indicator for current
segment
- Pos - position of the orbital spot
welding gun [°]
- Ges - welding speed [cm/min]
- Str - welding current [A]
- Spg - welding voltage [V]
Display after
positioning
and before gas
pre-ow
Important! If the "ROLL-UP" parameter in dialog window 221 is set to "AUTOSTART",
the system goes straight from positioning to gas pre-ow.
- Date and time
- Orbital spot welding gun type
- Start --> CONT. - press "Start/Stop"
button to start welding
- Stop --> BREAK - press "Stop" button
for immediate welding stop
- Pos - position of the orbital spot
welding gun [°] / welding speed [cm/
min]
- Seg 1 - status indicator for current
segment
Important! If a welding wire is available and activated while the orbital spot welding gun
is open, "Wirespeed" is also displayed for the wire feed speed [cm/min]
17
Display during
gas pre-ow
- Number displayed next to "GASPREFLOW" is the time that has
elapsed since welding started
- Seg 1 - status indicator for current
segment
- Pos - position of the orbital spot
welding gun [°]
- Speed - welding speed [cm/min]
- Curr- welding current [A]
- Volt - welding voltage [V]
Display during
upslope
Display during
welding
- Number displayed next to "START,
UPSLO" is the time that has elapsed
since welding started
- Pos - position of the orbital spot
welding gun [°]
- Seg 1 - status indicator for current
segment
- Speed - welding speed [cm/min]
- Curr - welding current [A]
- Volt - welding voltage [V]
- Number displayed next to "WELDING"
is the time that has elapsed since
welding started
- Pos - position of the orbital spot
welding gun [°]
- Seg 1 - status indicator for current
segment
- Speed - welding speed [cm/min]
- Curr - welding current [A]
- Volt - welding voltage [V]
Display during
downslope
- Number displayed next to
"DOWNSLOPE" is the time elapsed
since welding started
- Pos - position of the orbital spot
welding gun [°]
- Seg 1 - status indicator for current
segment
- Speed - welding speed [cm/min]
- Curr - welding current [A]
- Volt - welding voltage [V]
18
Display during
gas post-ow
- Number displayed next to "GASPOSTFLOW" is the time that has
elapsed since welding started
- Pos - position of the orbital spot
welding gun [°]
- Seg 1 - status indicator for current
segment
- Speed - welding speed [cm/min]
- Curr - welding current [A]
- Volt - welding voltage [V]
Display after
welding is
cancelled
If welding was interrupted because of an alarm, or because the "Start/Stop", "Stop" or
"Emergency stop" button was pressed, the following appears:
- Date and time
- Orbital spot welding gun type
- Start --> CONT. - press the "Start/
Stop" button to start welding (13)
- R.Stop --> BREAK - exit the alarm
status by pressing the "Right" (5) and
"Stop" (12) buttons at the same time
- Pos - position of the orbital spot
welding gun [°] / welding speed [cm/
min]
- Seg 1 - status indicator for current
segment
19
Before commissioning
Safety
Proper use
WARNING!
Incorrect operation may result in serious injury or damage.
Do not use the functions described here 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
The FPA 2030 orbital system controller is used exclusively for interfacing to the Fronius
TT/ MW 2500 and 3000 digital TIG power sources. To connect the device it should be
installed on the pickup trolley using the "reinforce pickup" option.
Power is supplied to the orbital system controller via the LocalNet connection of the active TIG power source.
The device is for controlling and monitoring the TIG welding process with approved
orbital guns and TIG welding torches (list is available on the controller: see the section
headed "Orbital spot welding gun/manual welding torch menu").
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be liable for any damage resulting from such improper use.
Proper use also includes:
- Following all the information in the operating instructions
- Carrying out all the specied inspection and servicing work
- Using the spare parts stipulated by Fronius
- Using this document in conjunction with the operating
instructions of the integrated system components (power source, cooling circuit, spot
welding gun, wire-feed unit, etc.)
Setup regulations
Connection
The orbital system controller is tested to "Degree of protection IP23", meaning:
- Protection against penetration by solid foreign bodies with diameters greater than
Ø 12.5 mm (0.49 in.)
- Protection against direct sprays of water up to 60° from the vertical
WARNING!
If one of these machines topples over or falls it could cause serious or
even fatal injury.
The welding system (orbital system controller + power source) should be
placed on a solid, level surface in such a way that it remains stable.
Power is supplied to the FPA 2030 orbital system controller via the LocalNet connection
of the active TIG power source. The LocalNet connection doubles up as a communication connection. The orbital system controller must not be supplied by other equipment or
devices.
20
Commissioning
Safety
WARNING!
An electric shock can cause serious injury.
If the device is connected to the power source during installation, there is a
risk of serious injury and damage.
Never work on the device unless the power source mains switch is in the "O"
position
This section describes how to put the welding system into service:
- for the principal application (orbital welding),
- with reference to a standard conguration for an orbital welding installation.
The standard conguration consists of the following components:
- Orbital system controller
- Power source with cooling unit and KD supply
- Pickup trolley
- Orbital spot welding gun
- Pressure regulator for shielding gas and forming gas
- Gas cylinders for shielding gas and forming gas
The steps set out below provide an overview of how to put the welding system into
service.
For detailed information on each of these steps, please refer to the instructions for the
appliances in question.
Connecting gas
cylinders for
shielding gas
and forming gas
CAUTION!
Risk of injury from gas cylinder toppling over.
- Always use a safety strap
- Fix the safety strap in the region of the top third of the cylinder
- Never x the safety strap around the neck of the cylinder
1. Secure the gas cylinder on the pickup trolley
2. Connect the gas cylinder:
- Take the protective cap o the gas cylinder
- Briey turn the gas cylinder valve anti-clockwise to blow o any dust and dirt
- Inspect the seal on the pressure regulator
- Screw the pressure regulator onto the gas cylinder and tighten it
If using an orbital spot welding gun with an integral gas connector:
3. Using the gas hose, connect pressure regulator for shielding gas to the shielding
gas input connection
4. Tighten the union nut
5. If available/required, connect pressure regulator for forming gas to the forming gas
input connection using the gas hose.
If using an orbital spot welding gun without an integral gas connector:
3. Connect shielding gas hose to pressure regulator for shielding gas
4. If available/required, connect forming gas hose to pressure regulator for forming gas
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Establishing a
connection to the
workpiece
1. Turn the power source mains switch to the O position
2. Plug the grounding (earthing) cable into the current socket marked (+) and twist to
fasten it
3. With the other end of the grounding (earthing) cable, establish a connection to the
workpiece
Connecting the
orbital spot welding gun
1. Turn the power source mains switch to the O position
2. Plug the welding cable of the orbital spot welding gun into the current socket marked
(-) and twist it clockwise to latch it into place
3. Connect orbital spot welding gun to "orbital spot welding gun control" connection
4. If present:
- Plug the control connector for the external wire-feed unit KD 4000 D-11 into the
"Wirefeed" connection (a).
(a)
Important! A TIG manual welding torch is also connected to the current socket marked
(-), as explained for the orbital spot welding gun.
Plug the control plug of the TIG manual welding torch into the "orbital spot welding gun
control" connection socket or the "torch control" connection socket.
5. Tool up the welding torch (see the operating instructions for the torch)
If using an orbital spot welding gun with an integral gas connector:
6. Connect shielding gas hose to the "shielding gas output" connection
7. If available, connect the forming gas hose to "forming gas output" connection
Only if using a water-cooled orbital spot welding gun or water-cooled TIG welding torch:
8. Plug water connections on the orbital spot welding gun or TIG welding torch into the
"water ow" and "water return" connections.
22
Alignment of the orbital spot welding gun
t
s
v
AVC
ON
General The signals that are sent to the control unit dier depending on the model and type of
the spot welding gun. For this reason, a path alignment must be carried out for rotation,
wirefeed and oscillation (OSC) before the spot welding gun is started up for the rst time.
Qualied technicians
Path alignment,
rotation
This description is designed for trained technicians or persons with practical welding
experience. The manufacturer accepts no liability for damages caused by insucient
knowledge on the part of the user.
Alignment of the rotational movement of the welding head is described below.
1. Mark the welding head start position
(e.g. using adhesive tape), as shown
in the photograph on the left.
Adhesive tape
Start position
Marking the start position
2. Set to the zero position: keep the
"L-button" held down and press
the 'STOP' button. Check on the
display that the entry has changed as
required.
Pressing "L-button" and "Stop" button
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