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FPA 3020 Orbital
Translated document:
Operating instructions,
Spare parts list
EN
TIG power source
42,0426,0232,EN
V11 - 07042020
Dear Reader
Introduction
Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many great
features of your new Fronius product. This really is the best way to get the most out of all
the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this denitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
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Contents
Safety rules ..................................................................................................................................................... 9
General remarks.........................................................................................................................................9
Utilisation for intended purpose only .......................................................................................................... 9
Ambient conditions ................................................................................................................................... 10
Obligations of owner/operator .................................................................................................................. 10
Obligations of personnel .......................................................................................................................... 10
Mains connection ..................................................................................................................................... 10
Protection for yourself and other persons ................................................................................................ 11
Information on noise emission values ...................................................................................................... 11
Hazards from mains and welding current ................................................................................................. 12
EMC device classications ....................................................................................................................... 12
EMC measures.........................................................................................................................................13
EMI Precautions ....................................................................................................................................... 13
Particular danger spots ............................................................................................................................ 14
Factors affecting welding results .............................................................................................................. 14
Danger from shielding-gas cylinders ........................................................................................................ 15
Safety precautions at the instalation site and when being transported .................................................... 15
Safety precautions in normal operation .................................................................................................... 16
Preventive and corrective maintenance ................................................................................................... 16
Safety inspection ...................................................................................................................................... 17
Disposal....................................................................................................................................................17
Safety markings........................................................................................................................................17
Data security ............................................................................................................................................ 17
Copyright .................................................................................................................................................. 17
General information 19
General .......................................................................................................................................................... 21
Principle....................................................................................................................................................21
Device concept ......................................................................................................................................... 21
Application areas ...................................................................................................................................... 21
Warning notices afxed to the device .......................................................................................................22
Controls and connections .............................................................................................................................. 23
Control panel ........................................................................................................................................... 23
Symbol bar ............................................................................................................................................... 25
Connections, switches and system add-ons ................................................................................................. 27
Safety ....................................................................................................................................................... 27
Power source FPA 3020 ........................................................................................................................... 27
Remote control unit .................................................................................................................................. 29
Display idle ............................................................................................................................................... 33
Display after welding starts, if positioning takes place ............................................................................. 33
Display after positioning and before gas pre- ow ................................................................................... 33
Display during gas preow ....................................................................................................................... 33
Display during upslope ............................................................................................................................. 34
Display during welding ............................................................................................................................. 34
Display during downslope ........................................................................................................................ 34
Display during gas post-ow .................................................................................................................... 34
Display after welding is cancelled ............................................................................................................ 35
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Start-up 37
Before commissioning ................................................................................................................................... 39
Utilisation in accordance with ................................................................................................................... 39
„intended purpo- se“ ................................................................................................................................. 39
Setup regulations ..................................................................................................................................... 39
Mains connection ..................................................................................................................................... 39
Generator- powered operati- on ............................................................................................................... 39
Commissioning .............................................................................................................................................. 40
Safety ....................................................................................................................................................... 40
Note regarding the cooling unit ................................................................................................................ 40
Connecting gas cylinders for shielding gas and forming gas ................................................................... 40
Establishing a connection to the workpiece ............................................................................................. 41
Connecting the orbital welding gun .......................................................................................................... 41
Technical Data ............................................................................................................................................... 42
Special voltages ....................................................................................................................................... 42
Power source ........................................................................................................................................... 42
Integral cooling unit .................................................................................................................................. 43
Rating plate .............................................................................................................................................. 43
Operation 45
Menus with direct selection ........................................................................................................................... 47
Principle....................................................................................................................................................47
Button F1 .................................................................................................................................................. 47
„Shielding gas and cooling“ menu ............................................................................................................ 47
„Data transfer“ menu ................................................................................................................................ 48
„Printer congu- ration“ menu .................................................................................................................. 49
Alarms and device-specic data .............................................................................................................. 54
................................................................................................................................................................ 54
Main menu ..................................................................................................................................................... 57
Safety ....................................................................................................................................................... 57
Entering a password ................................................................................................................................ 57
Selection window ..................................................................................................................................... 58
Orbital welding gun ........................................................................................................................................ 59
Calling up the „orbital welding gun“ menu ................................................................................................ 59
Selecting the type of orbital welding gun .................................................................................................. 59
Selecting the type of orbital welding gun and wire-feed unit .................................................................... 59
Selecting the type of manual welding torch .............................................................................................. 60
Synergic ........................................................................................................................................................ 61
Calling up the „Synergic“ menu ................................................................................................................ 61
Principle....................................................................................................................................................61
Entering parameters ................................................................................................................................. 61
Parameter TACK.PR ................................................................................................................................ 62
Setup and system parameters ...................................................................................................................... 63
Calling up the „Setup and system parame- ters“ menu ............................................................................ 63
Principle....................................................................................................................................................63
Calling up „OPERATOR“ settings ............................................................................................................. 63
User permissions...................................................................................................................................... 63
Changing password ................................................................................................................................. 64
Logging on a different user, and changing the password ......................................................................... 65
User-specic settings ............................................................................................................................... 65
Brightness and contrast ........................................................................................................................... 66
Ignition parameters .................................................................................................................................. 66
Welding mode & AC ................................................................................................................................. 67
Value adjustment ...................................................................................................................................... 68
More parameters ...................................................................................................................................... 68
Welding direction and wirefeeding ...........................................................................................................69
Start of L/R measurement ........................................................................................................................ 69
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Wire inching..............................................................................................................................................69
Date, time and calibrating the touchscreen .............................................................................................. 70
Parameter settings ........................................................................................................................................ 71
Calling up the „Parameter settings“ menu ................................................................................................ 71
Waveform parameters for TIG manual torch ............................................................................................ 71
Waveform parameters for orbital weld head ............................................................................................72
Parameters for pulsing and welding speed .............................................................................................. 72
Parameters for pulsing and ...................................................................................................................... 73
Parameters for start point ......................................................................................................................... 73
Parameters for welding energy ................................................................................................................ 74
Calling up parameters for wirefeeding or AC welding ..............................................................................75
Parameters for wirefeeding ...................................................................................................................... 75
Parameters for AC welding ..................................................................................................................... 76
Saving parameters ................................................................................................................................... 76
Success programs....................................................................................................................................76
Orbital and TIG welding .................................................................................................................................78
Safety ....................................................................................................................................................... 78
Calling up the „Welding“ menu ................................................................................................................. 78
Controlling and monitoring the welding process ...................................................................................... 78
Welding energy status .............................................................................................................................. 79
Welding process status ............................................................................................................................ 80
Correcting the welding process ................................................................................................................ 80
Troubleshooting 81
Troubleshooting ............................................................................................................................................. 83
General remarks.......................................................................................................................................83
Safety ....................................................................................................................................................... 83
Retrieving alarm list .................................................................................................................................. 83
Alarms and error messages ..................................................................................................................... 84
Error list servo .......................................................................................................................................... 88
Alarms information for service technicians ............................................................................................... 89
Displayed service codes .......................................................................................................................... 90
Displayed service codes Power source ................................................................................................... 91
Maintenance and disposal 95
Care, maintenance and disposal ................................................................................................................... 97
General.....................................................................................................................................................97
Every start-up ........................................................................................................................................... 97
Symbols for care and maintenance of the cooling unit ............................................................................ 98
Preparing for maintenance ....................................................................................................................... 98
Every week ............................................................................................................................................... 98
Every 2 months ........................................................................................................................................ 99
Every 6 months ........................................................................................................................................ 99
Every 12 months ...................................................................................................................................... 99
Disassembly and disposal ........................................................................................................................... 100
Disassembling the system ..................................................................................................................... 100
Disposal of components ......................................................................................................................... 100
Spare parts list 101
EU-Declaration of conformity ...................................................................................................................... 113
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Safety rules
General remarks
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,
- efcient working with the equipment.
All persons involved in any way with starting up, operating, servicing and maintaining the
equipment must:
- be suitably qualied
- 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 “Gen-
eral remarks”.
Utilisation for
intended purpose
only
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!
The machine may only be used for jobs as dened 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.
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Ambient
conditions
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)
- Free of dust, acids, corrosive gases or substances etc.
Relative atmospheric humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Elevation above sea level:
- Up to 2000 m (6561 ft. 8.16 in.)
Application areas:
- the welding system must under no circumstances in rain or snow environments
operate.
Obligations of
owner/operator
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 “war- nings“
contained in this manual, and have conrmed as much with their signatures
- be trained in such a way that meets with the requirements of the work results
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 conrm 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.
NOTE! Ensure that the mains connection is earthed properly.
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Protection for
yourself and
other persons
When welding, you are exposed to many different hazards such as:
- arc radiation which could damage your eyes and skin
- harmful electromagnetic elds which may put the lives of cardiac pace- maker
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 pro- tective clothing with the following characteristics:
- ame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups
“Protective clothing” also includes:
- protecting your eyes and face from UV rays, heat and ying sparks with an
appropriate safety shield containing appropriate regulation lter 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 insula- ting, heat-proof)
- To lessen your exposure to noise and to protect your hearing against injury,
wear ear-protectors!
Information on
noise emission
values
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
ying 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.
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation at the maximum permissible operating point
under maximum rated load conditions according to EN 11201.
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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 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 oor or base, or else use a
suitable insulating wirefeeder holder.
- Ensure sufcient 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 rmly attached, undamaged, properly insulated
and adequately dimensioned. Immediately replace any loose connections, scorched,
damaged or underdimensioned cables or other leads.
- 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.
- 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 qualied 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 negli-
gence and the manufacturer shall not be liable for any resulting damage.
- Wherever necessary, use suitable measures to ensure that the workpiece is suf-
ciently grounded (earthed).
- 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 inad-
vertently 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.
EMC device
classications
EMC device classication as per the rating plate or technical specications
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.
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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:
1. Mains supply
- If electromagnetic interference still occurs, despite the fact that the mains con
nection is in accordance with the regulations, take additional measures
(e.g. use a suitable mains lter).
2. 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
3. Equipotential bonding
4. Workpiece grounding (earthing)
- where necessary, run the connection to ground (earth) via suitable capacitors.
5. Shielding, where necessary
- Shield other equipment in the vicinity
- Shield the entire welding installation.
EMI Precautions Electromagnetic elds may cause as yet unknown damage to health.:
- Effects on the health of persons in the vicinity, e.g. users of heart pace- makers 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
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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 ngers anywhere near the rotating toothed wheels of the wirefeed
drive.
► 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 feederinching etc.,
► always hold the torch so that it is pointing away from your body (machines with wire-
feeder).
► wearing a pair of appropriate regulation goggles (with sideguards)
- Do not touch the workpiece during and after welding - risk of injury from burning!
- 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 re 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 identied 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 con-
nectors for coolant forward ow and return ow, switch off the cooling unit.
- If a machine is tted 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
- Inspection interval and extent of testing have at least to comply with the relevant
national standards and guidelines.
- 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 connec-
tion using Teon tape before assembly.
Factors affecting
welding results
The following requirements with regard to shielding gas quality must be met
if the welding system is to operate in a correct and safe manner:
- Size of solid matter particles <40μm
- Pressure dew point <-20°C
- Max. oil content <25mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
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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 outt, they also have
to be treated with great care.
- Protect shielding-gas cylinders containing compressed gas from excessive heat, me-
chanical impact, slag, naked ames, sparks and arcs.
- Mount the shielding-gas cylinders 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 ttings, ...). 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.
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, rm oor in such a way that it stands rmly.
- An angle of inclination of up to 10° is permissible.
- Special regulations apply to rooms at risk from re 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 specications 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.
- 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.
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Safety precautions in normal
operation
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
- efcient working with the equipment.
Any safety devices 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 rmly, and remove it altogether before
hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frostproong,
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.
- If any damage occurs in cases where other coolants have been used, the manu-
facturer shall not be liable for any such damage, and all warranty claims shall be null
and void.
- Under certain conditions, the coolant is ammable. 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
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 modications to the machine without getting
permission from the manufacturer rst.
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.
16
Safety inspection
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 certied electrician, is prescribed:
- after any alterations
- after any modications or installations of additional components
- following repairs, care and maintenance
- at least every twelve months.
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.
Disposal
Safety markings
Data security
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2012/19/EC on Waste Electrical and Electronic
Equipment and its implementation as national law, electrical equipment that has reached
the end of its life must be collected separately and returned to an approved recycling
facility Any device that you no longer require must be returned to our agent, or nd out
about the approved collec- tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Equipment with CE-markings fulls the basic requirements of the Low- Voltage and
Electromagnetic Compatibility Guideline (e.g. relevant product standards according
to EN 60 974).
Equipment marked with the CSA-Test Mark fulls the requirements made in the relevant
standards for Canada and the USA.
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
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 modications is reserved. The contents of the in- struction 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.
17
18
General information
19
20
General
Principle The FPA 3020 is a completely digitised, microprocessor-controlled inverter power source
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 device responds immediately to any changes.
The control algorithms ensure that the
specied 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 the welding
properties, the high degree of efciency
is another key feature of the new orbital
power source.
An intuitive operating concept makes your
work much easier. Last but not least, as
the tasks of the related control elements
are now controlled from the generously
proportioned touchscreen, essential functions can be seen at a glance and adjusted
as required.
Power source FPA 3020
Device concept
Application areas There are a vast number of applications for the FPA 3020 in trade and industry. At this
Typical of the new power source is its adaptability to the many demands of orbital
welding. The cooling unit, tted as standard, makes a signicant contribution. In addition to the many orbital welding guns available for the most varied applications, the
power source also supports manual welding torches. Further convenience is added by a
remo- te control unit that has all the necessary functions for operating the orbital welding
system on site.
point the pharmaceutical and foodstuffs industries are well worth mentioning, since they
place high demands on the quality of pipelines and containers. As regards suitability for
welding different materials, the power source is just as suitable for welding unalloyed and
low-alloy steel as it is for welding high-alloy, chrome-nickel steels. These „all-roun- der“
qualities are enhanced by the optimised ignition sequence of the device.
For TIG-AC welding, the FPA 3020 takes account not only of the diameter of the
electro- de, but also of its temperature, calculated with reference to the preceding welding and weld-off times. Moreover, the power source does sterling service when welding
alumini- um, aluminium alloys, copper alloys, magnesium and titanium. The AC frequency can be adjusted over a very wide range, permitting optimum adaptation to your
particular re- quirements.
21
Warning notices
P
1l/min
500 W
4.3 bar (0.43 MPa)
I
1 eff
I
1 max
230 V 23 A 14 A16A
U
1
1~
50-60Hz
35%
145 A
5 A / 10.2 V - 200 A / 18.0 V
200 A110 A
15.8 V 14.4 V18.0 V
I
2
U
2
U
0
X(40°C) 60% 100%
44 V
9.5 kV
U
p
IP 23
IEC 60974-1/-10 Cl.A
f1
f2
f1
f2
1~
FPA 3020
8,040,098
XXXXXXXX
Ser.No.
Part No.
www.fronius.com
afxed to the
device
A number of safety symbols can be seen on the device’s rating plate.
The safety symbols must NOT be removed or painted over.
Rating plate
22
Controls and connections
Control panel
WARNING!
Operating the equipment incorrectly can cause serious injury and
damage
Do not use the functions described here until you have read and completely
understood all of the following documents:
- These operating instructions
- all operating instructions for the system components, especially the
“Safety rules”
NOTE! As a result of rmware updates, you may nd that there are functions
available on your unit that are not described in these operating instructions or
vice versa. Certain illustrations may also differ slightly from the actual controls
on your unit. However, the functionality of these controls is identical.
(3)
(2)
(4)
(1)
(5)
(6)
(7)
Control panel
Nr. Function
(1) Adjusting dial
For selecting a menu item:
1. Turn the adjusting dial until the desired menu item is highlighted
2. Press the adjusting dial to select the menu item
For selecting and adjusting a parameter
1. Turn the adjusting dial until the desired 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 desired 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, press the „Esc“ key (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
wor- king, for example, in dusty environments if the touchscreen is covered with
protective foil.
(10)
(9)
(8)
23
Control panel
(continued)
Nr. Function
(2) „Next“ key
for scrolling to the next menu window
(3) Touchscreen
Displays various context-sensitive keypads
(4) F1 key
freely programmable function key (in the „setup and system parameter“ menu)
(5) Shielding gas and cooling key
Opens the „shielding gas and cooling“ menu
(6) Data exchange key
Opens the data transfer menu
(7) Printer conguration key
For setting specic data for printing or saving to the memory stick.
(8) ESC key
- Returns to the previous menu window
- Resets alarms
- Abandons a parameter setting without applying the changed value
(9) „i“ key
Displays versions, alarms and information for service engineers
(10) Menu key
Returns to the main menu
24
Symbol bar
WARNING!
Operating the equipment incorrectly can cause serious injury and
damage
Do not use the functions described here until you have read and completely
understood all of the following documents:
- These operating instructions
- all operating instructions for the system components, especially the
“Safety rules”
Display element
Time/date
Segment 1-10
indicates the welding path segment in which the orbital welding gun is
currently located.
IMPORTANT! More detailed information on „segments“ can be found in the
section headed „Parameter settings“.
Page in program sequence
every dialog window in the menu structure has a page number for identication purposes during maintenance work (for example)
Program name
Name of the currently loaded program
User name
more detailed information can be found in the section
headed „setup and system parameters“
Active alarm page
Touching the symbol opens the active alarm page
3: Main current signal
2: Arc on signal
1: Process activ 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)
25
Symbol bar
(continued)
Clockwise welding direction Anti-clockwise welding direction
Welding off/no arc (black - test
Welding on/with arc (blue)
mode)
Shielding gas valve not active Shielding gas valve active (blue)
Forming gas valve not active Forming gas valve active (blue)
Limit switch for closed orbital
welding gun not active
Limit switch for closed orbital
welding gun active (red)
26
Connections, switches and system add-ons
Safety
Power source
FPA 3020
(4)
(5)
(6)
(7)
WARNING!
Operating the equipment incorrectly can cause serious injury and
damage
Do not use the functions described here until you have read and completely
understood all of the following documents:
- These operating instructions
- all operating instructions for the system components, especially the
“Safety rules”
Front view
(3)
(2)
(1)
(18)
(19)
(20)
(21)
(22)
Rear view
(17)
(16)
(15)
(14)
(13)
(12)
(8)
(9) (10) (11)
Connections and switches on the FPA 3020 power source
Nr. Function
(1) Orbital welding gun connection socket
(-) current socket with bayonet latch, also for a standard TIG welding torch
(2) Earthing (grounding) cable connection
(+) current socket with bayonet latch
(3) USB port
for saving and loading individual welding programs or all power source data to or
from a USB stick
(4) Paper feed key
for the integral printer
(5) “Printer ready” indicator
indicates when the printer is ready.
(6) Printer
for documenting relevant process parameters and processes
(7) Remote control connection
27
Power source
FPA 3020
(continued)
Nr. Function
(8) Orbital welding gun control connection
for data capture, control and motor supply of the orbital welding gun
(9) Water ow connection
for the orbital welding gun or the TIG welding torch
(10) Water return connection
for the orbital welding gun or the TIG welding torch
(11) Torch control connection
for a standard TIG welding torch or orbital welding gun with additional controls
(12) External connection
connects the residual oxygen measuring device.
(13) Water ow connection
for the water lter (15)
(14) Water return connection
for the water lter (15)
(15) Water lter
(16) Forming gas output connection
for the orbital welding gun
(17) Forming gas input connection
for the pressure regulator
(18) Mains switch
for switching the power source on and off
(19) Coolant pump fuse
(20) Mains cable with strain relief
(21) Shielding gas input connection
for the pressure regulator
(22) Wire-feed unit connection
for a cold wire feeder
28
Remote control
________________
CrNi_21,0x1,5
DAUERTEST
FOH-10-76
________________
FRONIUS
unit
WARNING!
Risk of injury and damage from machines that start up automatically.
For your personal safety, ensure that all protective measures have been implemented and will remain in place while you are within the working area of the
welding system.
(15)
(13) (14)
(1) (2)
(3) (4)
(5) (7)
(6)
(8) (10)
(9)
(11) (12)
Nr. Function
(1) Gas-test key
for setting the required quantity
of shielding gas at the pressure
regula- tor. After you press this
key, gas will ow out for 30 s.
Press the button again to stop the
gas test-ow before the end of this
period.
(2) F2 function key
freely programmable function key
(in the “setup and system parameter” menu)
Remote controller FPA 3020
29
(a)
(3) Group selection key
Press (+) or (-) to access the
selection menu to select the
program group
The previously selected group (a)
appears.
Press (+) or (-) again to select the
desired group (a) of welding
programs.
Remote control
________________
CrNi_21,0x1,5
DAUERTEST
FOH-10-76
________________
FRONIUS
CrNi_21,0x1,5
2015/12/02 10:19:02
FPA.1
FCH-6-76
READY
Pos 23/
Wirespeed
Seg 1
0.0
0
04.12.15 10:20:57
CrNi_21.0x1.5
unit
(continued)
(b)
(b)
(a)
(4) Program selection key
Press (+) or (-) to select the
desired welding program (a) from
the group previously selected (b)
using key (3).
Load the selected welding program with the “Start/stop” key (11).
During loading, conrmation of the
selected welding program is
indicated by its name (b) appearing on the display.
Once loading is complete, the
display shows the new program
name (b).
(b)
Important! To exit the selection menu without changing the original settings, press the
„Stop“ key (12).
(5) Welding current key
For changing the current during welding according to the “welding current”
parame- ter in dialog window 233 “value adjustment” as shown in the section
headed “setup and system parameters”
(6) Welding speed key
For changing the welding head rotation speed during welding according to the
“v- Rotation” parameter in dialog window 233 “value adjustment” as shown in the
section headed “setup and system parameters”.
(7) Wire feed speed key
When not in welding mode, the key (6) is used for positioning the welding head
while setting up.
For changing the wire feed speed during welding according to the “v-Wire”
parame- ter in window 233 “value adjustment” as shown in the section headed
“setup and system parameters”.
When not in welding mode, the key (7) is used for positioning the ller wire while
setting up.
30
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