Fronius FPA_3020 Operating Instruction [EN]

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FPA 3020 Orbital

Translated document: Operating instructions, Spare parts list

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 denitely helps to prolong its enduring quality and reliability - things which are both essential prerequisites for getting outstanding results.

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 classications ....................................................................................................................... 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 afxed 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 preow ....................................................................................................................... 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

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 congu- ration“ menu .................................................................................................................. 49

Alarms and device-specic 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-specic 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

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

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,

- efcient working with the equipment.

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

- be suitably qualied

- 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 dened by the “Intended purpose”.

The machine may ONLY be used for the welding processes stated on the rating plate. Utilisation for any other purpose, or in any other manner, shall be deemed to be “not

in accordance with the intended purpose”. The manufacturer shall not be liable for any

damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises:

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

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

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

The machine is designed to be used in industrial and workshop environments. The

manufacturer shall not be liable for any damage resulting from use of the machine in residential premises.

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

Ambient conditions

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 conrmed 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 conrm 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.

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.

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 sufcient 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 qualied 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

classications

EMC device classication as per the rating plate or technical specications

Devices with emission class A:

- are only designed for use in an industrial setting

- can cause conducted and emitted interference in other areas.

Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas. This also applies to residential areas in which power is supplied from the public low-voltage grid.

EMC 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

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 identied 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 Teon 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

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 outt, 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 specications 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.

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

- efcient 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, frostproong, 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 modications 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.

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 certied electrician, is prescribed:

- after any alterations

- after any modications 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 fulls 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 fulls 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.

The text and illustrations are all technically correct at the time of going to print. The right

to effect modications 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.

General information

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

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 the welding

properties, the high degree of efciency 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 signicant 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.

Warning notices

1l/min

500 W

4.3 bar (0.43 MPa)

1 eff

1 max

230 V 23 A 14 A16A

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

X(40°C) 60% 100%

44 V

9.5 kV

IP 23

IEC 60974-1/-10 Cl.A

FPA 3020

8,040,098

XXXXXXXX

Ser.No.

Part No.

www.fronius.com

afxed 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

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)

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 conguration key

For setting specic 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

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 identication 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)

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)

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

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

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

(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)

(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, conrmation 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.

Remote control unit

(continued)

(8) Arc on/off button

If the LED in the key (8) lights up, the arc will come on for welding. The arc can also be switched off for setting up purposes. In addition, dialog window 1 in the “Troubleshooting” section shows the relevant entry.

(9) Forming gas key

Opens the forming gas valve for testing purposes. Press the button (9) again to close the forming gas button.

IMPORTANT! If you do not press key (9) again before the delay expires, the forming gas valve closes again automatically. The delay time corresponds to the

“forming gas pre-ow time” parameter in the menu with direct selection “shielding

gas and cooling”.

(10) Wire-feed unit on/off button

For switching the wire-feed unit on or off during welding

(11) Start/Stop button

For starting and ending the welding process

For closed welding guns with no wirefeed, welding starts immediately the Start/Stop button is pressed.

On open welding guns with wirefeeding, the following process applies:

► If the “ROLL-UP” parameter in dialog window 221 “Parameters for start point”

(see “Parameter settings”) is set to “ACTIVE”, the hosepack is rolled up when

the key (11) is rst pressed. Once the start point is reached, welding starts

when the key (11) is pressed again.

► If the “ROLL-UP” parameter in dialog window 221 “Parameters for start point”

(see “Parameter settings”) is set to “AUTOSTART”, the welding process can be activated by simply pressing the key (11) once. Welding starts once the hosepack has rolled up automatically and the start point has been reached.

► If the „ROLL-UP“ parameter in dialog window 221 „Parameters for start point“

(see „Parameter settings“) is set to „INACTIVE“, the welding process can be

activated by simply pressing the key (11) once. The dened start position is

not moved to and the hosepack is not rolled up. Welding starts from the position last reached.

NOTE! On open orbital welding guns, the hosepack may be damaged if it is not rolled up before welding starts.

If welding is nished with key (11), there is a driving downslope according to the

“driving downslope” parameter in dialog window 221 “parameters for start point” (see “Parameter settings”).

When not in welding mode, pressing key (11) and the “left” key (13) moves the orbital welding gun back to the starting position

Remote control unit

(continued)

(12) Stop button

Pressing key (12) stops welding immediately.

IMPORTANT! Regardless of the settings in the “Parameter settings” menu, welding stops with no downslope when key (12) is pressed.

For all orbital welding guns: Pressing key (12) and the “left” key (13) at the same time sets the present position of the orbital welding gun to zero.

(13) “Left” key

Pressing the key START/STOP (11) and the “left” key (13) moves the orbital welding gun back to the starting position.

Pressing key STOP (12) and the “left” key (13) at the same time sets the present position of the orbital welding gun to zero.

(14) “Right” key

Pressing key STOP (12) and the “right” key (14) at the same time stops welding immedia- tely, and the previous position is deleted. Welding starts again from the original start position.

Pressing key STOP (12) and the “right” key (14) at the same time after a stop of an alarm, or because Start/Stop, Stop or emergency stop was pressed causes an immediate exit from the automatic mode.

(15) Emergency stop button

Stops welding immediately, without any downslope, for example to prevent an accident.

IMPORTANT! Pressing the „left“ (13) and „right“ (14) keys at the same time calibrates the touchscreen in the same way that the „calibrate“ button in dialog window 263 „Date, time and calibrating the touchscreen“ does, as described in the „Setup and system parameters“ section.

Display idle

FCH-6-76 READY Pos 0/ Wirespeed

Seg 1

0.0 0

04.12.15 10:20:57 CrNi_40.0x1.5

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

POSITIONING 12.0

FCH-6-76 Start--> CONT. Stop --> BREAK Pos 0 / 0.0 Seg 1

04.12.15 10:20:57

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

GAS-PREFLOW 6.0

- Date and time

- Name of the currently loaded welding program

- Orbital welding gun type

- READY/NOT READY - power source ready to weld, or error needs to be

rectied

- Seg 1 status indicator for current segment

- Pos - position of the orbital welding gun [°] / welding speed [cm/min]

- Wire feed speed [cm/min]

Display after welding starts, if positioning takes place

Display after positioning and before gas pre-

ow

- Number appearing next to „POSITIONING“ is the time elapsed since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

IMPORTANT! If the „ROLL-UP“ parameter in dialog window 221 „Parameters for start point“ (see „Parameter settings“) is set to „AUTOSTART“, the system goes straight from

positioning to gas pre-ow.

- Date and time

- Orbital welding gun type

- Start --> CONTINUE press Start/ Stop to start welding

- Stop --> BREAK press Stop to stop welding immediately

- Pos: position of the orbital welding gun [°] / welding speed [cm/min]

- Seg 1 status indicator for current segment

If ller wire is available and activated while the orbital welding gun is open, then the

„Wire Real Value“ also appears for the wire feed speed [cm/min]

Display during

gas preow

- Number appearing next to „GAS PREFL.“ is the elapsed time since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

Display during

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

START, UPSLO 3.0

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

WELDING 12.0

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

DOWNSLOPE 3.0

Pos/D Speed Curr Volt

0.0 0

0.0

Seg 1 cm/min A V

GAS-POSTFLOW 6.0

upslope

- Number appearing next to „START, UPSLO“ is the time elapsed since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

Display during welding

Display during downslope

- Number appearing next to „WELDING“ is the time elapsed since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

- Number appearing next to „DOWNSLOPE“ is the time elapsed since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

Display during

gas post-ow

- Number appearing next to „GAS POSTFL“ is the time elapsed since welding started

- Seg 1 status indicator for current segment

- Pos position of the orbital welding gun [°]

- Spd welding speed [cm/min]

- Cur welding current [A]

- Volt welding voltage [V]

Display after

Start --> CONT. R.Stop --> BREAK Pos 0 / 0.0 Seg 1

FCH-6-76

04.12.15 10:20:57

welding is cancelled

If welding was interrupted because of an alarm, or because Start/Stop, Stop or Emergency stop was pressed, the following appears:

- Date and time

- Orbital welding gun type

- Start —> CONTINUE press Start/ Stop (11) to start welding

- R+Stop —> BREAK exit the automatic mode by pressing the „right“ (14) and „Stop“ (12) keys at the same time

- Pos position of the orbital welding gun [°] / welding speed [cm/min]

- Seg 1 status indicator for current segment

Start-up

Before commissioning

Utilisation in accordance with „intended purpose“

Setup regulations

The power source is intended exclusively for TIG welding with approved orbital guns and TIG welding torches. 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

- following all the instructions in this manual

- Performing all stipulated inspection and servicing work.

The power source is tested to IP23, meaning:

- Protection against penetration by solid foreign bodies with diameters > 12.5 mm (.49 in.)

- protection against direct sprays of water up to 60° from the vertical

WARNING! Risk of injury from toppling or falling equipment!

If one of these devices topples over or falls it could cause serious or even fatal injury

- Place device on a solid, level surface in such a way that it remains stable.

Mains connection

NOTE! The venting duct is a very important safety feature. When choosing

the device location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Any electroconductive metallic dust from e.g. grinding work must not be allowed to get sucked into the device.

DANGER!

Risk of fatal injury from dangerous electrical voltage.

An electric shock can be fatal.

- Connection to the mains supply may only be done by Fronius technicians. The manufacturer assumes no responsibility for damage to persons or property caused by incorrect connection by the client.

CAUTION!

Risk of serious damage to property due to insufciently dimensioned

electrical installations..

The mains lead and its fuse protection must be rated accordingly. The technical data shown on the rating plate applies.

Generatorpowered operation

The power source is generator-compatible, provided that the maximum apparent power delivered by the generator is at least 10 kVA.

NOTE! The voltage delivered by the generator must NEVER fall below or exceed the mains voltage tolerance range. Details of the mains voltage tolerance are given in the section headed „Technical data“.

Commissioning

Safety

DANGER! An electric shock can be fatal.

If the device is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when

- the mains switch is in the „O“ position,

- the device is unplugged from the mains.

This section describes how to put the power source into service

- for the principal application (orbital welding)

- with reference to a standard conguration for an orbital welding installation.

The standard conguration consists of the following components:

- Power source with integral cooling unit

- Orbital 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 power source into service. For detailed information on each of these steps, please refer to the instruction manuals for the appliances in question.

Note regarding the cooling unit

Connecting gas cylinders for shielding gas and forming gas

The cooling unit is powered from the power source. The cooling unit is ready for operation when the mains switch of the power source is in the „I“ position.

WARNING!

Compressed gas bottle can become dangerous, if they are wrongly treated.

They have to be protected against heat and have to be placed upright.

- The gas bottles at the plant must be secured against dumps or falling down with a chain.

- Fix the safety strap at the same height as the top part of the cylinder.

- Never x the safety strap around the neck of the cylinder

1. Fix gas cylinder in place at the desired location

2. To connect the gas cylinder:

- Take the protective cap off the gas cylinder

- Briey turn the gas cylinder valve anti-clockwise to blow off any dust and dirt

- Inspect the seal on the pressure regulator

- Screw the pressure regulator onto the gas cylinder and tighten it

Connecting gas cylinders for shielding gas and forming gas

(continued)

If using an orbital 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 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

Establishing a connection to the workpiece

Connecting the orbital welding gun

1. Turn the mains switch to the „O“ position

2. Plug the earthing (grounding) cable into the (+) current socket and twist to fasten it

3. With the other end of the earthing (grounding) cable, establish a connection to the workpiece

1. Turn the mains switch to the „O“ position

2. Plug the welding cable of the orbital welding gun into the „minus“ current socket and twist it clockwise to latch it into place

3. Connect orbital welding gun to orbital welding gun control connection

4. If available, plug control plug of the orbital welding gun into the torch control connec- tion and lock in place

IMPORTANT! A TIG welding torch is also connected to the „minus“ current socket in the same way as the orbital welding gun. Plug the control plug of the TIG welding torch into the orbital welding gun control connection socket or torch control connection socket..

5. Tool up the welding torch (see the torch instruction manual)

If using an orbital welding gun with an integral gas connector:

6. Connect shielding gas hose to shielding gas output connection

7. If available, connect forming gas hose to forming gas output connection

Only if using a water-cooled orbital welding gun or water-cooled TIG welding torch:

8. Plug water connections on the orbital welding gun or TIG welding torch into the

water ow and water return connections

Technical Data

For devices designed for special voltages, the technical data on the rating plate applies.Special voltages

Power source

Rated supply voltage (U1) 1x 230 V

Maximum effective primary current (I1eff) 13.2 A

Maximum primary current (I1max) 22.2 A

Mains fuse protection 16 A slow-bow

Supply voltage tolerance - 10 / +15 %

Supply voltage frequency 50 / 60 Hz

Cos phi (1) 0.99

Recommended type of RCD B

Welding current range (I2) TIG

Welding current at 10 min / 40°C (104°F) U1 230 V

Output voltage acc. Standard (U2) TIG

Rated no-load voltage (U0 peak / r.m.s.) 44 V

Reduced rated no-load voltage (Ur) not applicable

Rated peak voltage (Up) 9.5 kV

Degree of protection IP 23

Type of cooling AF

Overvoltage category III

Pollution degree according IEC 60664 3

EMC emission class A

Marks of conformity S, CE

Dimensions L x W x H 650 x 290 x 480 mm

Weight 38 kg

Coolant Original Fronius

Sound power level (LWA) ---

35 % 60 % 100 % 200 A 145 A 110 A

25.6 x 11.4 x 18.9 in

5 – 200 A

10.2 – 18.0 V

84 lb

Integral cooling

unit

The cooling capacity of a cooling unit depends on:

- Pump type

- Ambient temperature

- Delivery head

- Flow rate Q (l/min)

- The ow rate Q depends on the length of the hosepack and the diameter of the hose.

Supply voltage 1 x 230 V

Mains frequency 50 / 60 Hz

Fuse protection 16 A slow-bow

Current input 1,3 A

Feed rate (Q

max

)

max. 3,0 l / min

Cooling capacity at 40°C / 104°F 1l / min 500 W

1706 BTU / h

Delivery head max. 30 m

max. 98 ft. 5 in.

Pump pressure max. 4,3 bar

max. 62.37 psi

Pump type Centrifugal pump

Coolant capacity 1,8 l

Rating plate

www.fronius.com

44 V

IP 23

9.5 kV

50-60Hz

FPA 3020

Part No.

Ser.No.

X(40°C) 60% 100%

230 V 23 A 14 A16A

IEC 60974-1/-10 Cl.A

5 A / 10.2 V - 200 A / 18.0 V

35%

200

4.3 bar (0.43 MPa)

8,040,098

XXXXXXXX

145 A

15.8 V 14.4 V18.0 V

P1l/min

10 A

I1 effI1 max

500 W

Operation

Menus with direct selection

Principle

Button F1

„Shielding gas and cooling“ menu

You can call up individual menus directly using keys on the control panel. A detailed description of this menu is carried out on the following pages.

F1 calls up a user-dened function. The following functions are available::

- Active alarm page

- Alarm history

- Move to starting position

- Save screenshot to USB

- Water pump OFF/ON

For more detailed information on how to assign a function to the F1 key, please refer to

the “Setup and system parameters” menu, section “User-specic settings”

Open the menu by pressing the „Shielding

gas and cooling“ key. Provide the following

(1)

(2)

information:

Shielding gas

- GPr: Shielding gas pre-ow time [s]

- GPo: Shielding gas post-ow time [s]

(4)

Forming gas

- No forming gas: Forming gas deactivated or not connected

- Gas synchron: Forming gas is controlled along with shielding gas according to the previously set

shielding gas pre-ow and shielding gas post-ow times

- Pre / Post Flow: For the forming gas pre-ow and post-ow, the set forming gas pre-ow and postow times apply

- Pre-ow: Forming gas pre-ow time [min]

- Post-ow: Forming gas post-ow time [min]

To test the forming gas ow, touch the „forming gas“ button (2)

Pump

- ON Coolant pump permanently ON once power source is switched on

- OFF Coolant pump switched OFF

- AUTO Coolant pump only switched on when required

(3)

- To test the shielding gas ow, touch the “Gas test” button (1)

„Shielding gas and cooling“ menu

(continued)

IMPORTANT! If the „OFF“ setting has been selected, the coolant pump will be in „AUTO“

mode after every power source restart provided that no gas-cooled welding torch is connected.

To test the coolant pump

1. Select “AUTO” in window (3)

2. Touch button (4)

„Data transfer“ menu

Open the menu using the „Load export/import“ key

To save all data from the power source to the USB stick:

1. Select arrow symbol (a) pointing

towards USB stick (b)

2. Start the save by pressing “OK”

(d)

(c)

To load all data from the USB stick to the power source:

1. Select arrow symbol (c) pointing

towards the power source (d)

(e)

(a)

(b)

2. Start the save by pressing “OK”

With / without system parameters (e): Saves either the entire system parameters including the welding program or only the welding program..

To load the selected welding program from the power source internal memory or to

save it to the USB stick

1. Select power source symbol (d)

2. Select the welding program to be

transferred using the dialog window shown. >

3. Using the „LOAD“ button, transfer

the welding program to the power source memory

4. Transfer the welding program to the

USB stick using the „FPA ->USB“ button

To load the selected welding program from the power source internal memory or to

save it to the USB stick

1. Select USB stick symbol (b)

2. Select the welding program to be

transferred using the dialog window shown. >

3. Using the „LOAD“ button, transfer

the welding program to the power source memory

4. Transfer the welding program to the power source internal memory using

the „USB ->FPA“ button

„Printer congu-

ration“ menu

Open the menu by pressing the „Printer conguration“ key Provide the following information:

1. Realvalue Printout“ for relevant process data

Options include:

► No Print Out ► Printer

Prints to paper using the integral printer

► USB Stick

No printing occurs. Instead, the relevant data is saved to the USB stick.

► Printer & USB

Data is printed and also saved to

USB stick.

Every xx degrees - data is printed at the following angle intervals:

- „OFF“ ... do not document

- „5 Deg“ ... document every 5°

- „10 Deg“ ... document every 10°

- „15 Deg“ ... document every 15°

- „20 Deg“ ... document every 20°

- „45 Deg“ ... document every 45°

and only for every xx-th seam, as per the „every xx seams“ entry

2. “Alarm Printout” Settings are made in the same way as those for “Realvalue Printout”, but for print-

ing out alarm messages in this case

3. “Parameter Printout” Settings made in the same way as those for “Realvalue Printout”, but for printing

out relevant process parameters for the loaded program in this case

4. “Start-Stop Printout”

Settings made in the same way as those for “Realvalue Printout”, but for printing

out relevant data for welding start and stop in this case

IMPORTANT! To change the printer paper:

- Remove cover from printer

- Remove remaining paper

- Insert suitable paper roll for thermo sublimation printer

- Replace cover

„Printer congu-

ration“ menu

(continued)

Example of „Realvalue Printout“ on paper:

Example of „Realvalue Printout“ as a .txt le for USB stick:

„Printer congu-

ration“ menu

(continued)

Example of „Parameter Printout“ on paper:

„Printer congu-

ration“ menu

(continued)

Example of „Parameter Printout“ as a .txt le for USB stick:

Example of „Alarm Printout“ and „Start-Stop Printout“ on paper:

„Printer congu-

ration“ menu

(continued)

Example of „Alarm Printout“ and „Start-Stop Printout“ as .txt le for USB stick:

If „Start-Stop Printout“ has been selected, the following is printed every hour:

device-specic

data

Open the menu by pressing the „i“ keyAlarms and

Version numbers of the main modules

- To display the present alarms, touch the „ALARMS“ button

Current alarms

These could be faults or application errors that have not yet been rectied.

- To display the saved alarms, touch the „HISTORY“ button

Saved alarms with time and error number

These could be rectied or non-rectied

faults or application errors.

- To obtain a list of present alarms,

touch the „CONFIG“ button

1. Use „NEXT“ to scroll through the alarm list

2. Use „ACTIVE“ to return to the present alarms

3. Use „HISTORY“ to return to the

saved alarms

Alarms and

device-specic

data

(continued)

In the rst window, touch the „i“ key on the „HEAD.INFO“ button to call up the orbital

welding gun data.

IMPORTANT! The elds contained in this

window are not controls and are for display purposes only.

- Diameter min. - minimum diameter of the pipe joins to be welded [mm]

- Diameter max. - maximum diameter of the pipe joins to be welded [mm]

- Pulses

- Sync. switch - position in tenths of a degree of the synchronisation switch A value

of 0 means that no synchronisation switch is connected. A value of 3600 means, for example, that the limit switch is tted at the 360 ° position

- Max. speed - highest rotation speed [cm/min]

- Speed adj. - correction factor for the rotation speed OFF - no correction factor

- Wire - maximum wire feed speed [cm/min]

The illustration on the left shows the pin

assignment for the welding torch connec-

tion as seen from the front

The table illustrated below shows which numbers the „torch plug“ eld contains depending on the pin just activated. The table also explains the meaning of the number shown in the „torch plug“ eld for a welding torch and an orbital welding gun.

Pin Indicator Welding torch Up/Down Orbital welding gun

2 4 Down -

2 5 - Remaining air alarm

3 8 Lower -

3 9 - External stop

4 2 Up -

5 16 Start -

5 17 - External start

8 1/0* Up/Down -

9 - GND GND

* The value becomes 0 when the Pin 8 - Pin 9 (=GND) contact is closed

- Welding torch Up/Down: contact closed

- Orbital welding gun: contact open

Alarms and

device-specic

data

(continued)

WARNING!

Operating the device 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 the operating instructions for the system components, especially the “Safety Rules”

WARNING!

Risk of injury and damage from machines that start up automatically!

Automatically starting machines can cause serious injury and property damage caused by snagging, pulling or crushing of body parts.

- 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

The following illustration shows one possible arrangement of keys on the orbital welding gun, and to the right of it, information on which pins are activated by them and which number appears in the display.

(1) (2) (3) (4)

Controls on the orbital welding gun

Nr. Function

(1) Button “Stop / Test”

- To immediately stop the welding process.

- Hold for 2 sec. for gas test

(2) Button “Rotation”

The torch rotates in the set direction of rotation.

(3) Button “Start / Stop”

To start and stop the welding process.

(4) LED limit switch

Signal for the 360 degree position

of the limit swich.

Main menu

Safety

Entering a password

WARNING!

Risk of injury and damage from electric shock!

As soon as the mains switch is in the „I“ position, the tungsten electrode of the orbital welding gun is LIVE.

- Make sure that the tungsten electrode does not touch

- any persons or electrically conducting or earthed parts (e.g. housing etc.)

If the password entry is pre-set in the „Setup and system parameters“ menu, you will be requested to enter a valid password each time you switch on the power source.

1. Turn the mains switch to the „ON“ position

2. A window appears requesting you to enter the password

3. Touch the area marked (1)

(1)

IMPORTANT! If you touch the area marked „CANCEL“ (2), the power source will go into „Locked“ status and only the

(2)

actual welding mode will be supported. You cannot change any settings.

4. A keypad appears

5. Enter the password using this

keypad and conrm by pressing the

„tick“ key (3)

IMPORTANT! The default password is a full stop „.“(Point). If this default pass-

(3)

With the „CANCEL“ button, only the following functions are available:

- „Setup and system parameters“ menu, but for logging on only

- Welding menu

- Loading programs from the power source memory or USB stick

- Printing out process data

word has been changed and the new password is not recognised, you cannot log on using the full stop „.“(Point).

Selection window

(6)

(5)

(4)

(3)

The selection window offers the following menus:

(1) Parameter settings

(2) Setup and system parameters

(3) Synergic (characteristic)

(4) Weld

(5) Orbital welding gun/manual welding torch

IMPORTANT! If a TIG welding torch has been selected instead of the orbital welding gun, the following symbol appears (4) as follows:

(1)

(2)

(6) Entry shows the currently selected orbital welding gun or manual torch.

A detailed description of the menus is provided in the following sections.

Orbital welding gun

Calling up the „orbital welding gun“ menu

Selecting the type of orbital welding gun

(c)

To select an orbital welding gun or welding torch, call up the orbital welding gun menu.

Select the desired type of orbital welding gun:

(a)

(a) Open orbital welding gun

(b)

(b) Closed orbital welding gun (c) Manual welding torch

If choosing an orbital welding gun, please turn to the section headed “Selecting the type of orbital welding gun and wire-feed unit”.

If selecting a manual welding torch, please turn to the section headed „Selecting the type of manual welding torch“.

Selecting the type of orbital welding gun and wire-feed unit

1. Select the desired orbital welding gun type

2. If available, select the wire-feed unit

- No wire

- Wire internal

- KD 4000 (cold wire feeder for external wire)

3. Use the „BACK“ button to select the orbital welding guns

Use „Menu“ to go back to the main menu

Selecting the type of manual welding torch

1. For gas-cooled welding torches, call up the „GAS M. TORCH“ entry

2. For water-cooled welding torches, select the „WATER M. TORCH“ entry

3. IMPORTANT! For gas-cooled or water- cooled welding torches,

- Gas-cooled: standard setting for coolant pump is “OFF”.

- Water-cooled: standard setting for coolant pump is “AUTO”.

4. Use the „BACK“ button to select the orbital welding guns

Use „Menu“ to go back to the main menu

Synergic

Calling up the „Synergic“ menu

Principle In synergic mode, it is sufcient merely to enter a few well-known settings for the arc

process. Using this information, the power source calculates all other settings for an optimum welding result.

Entering parameters

Call up the „Synergic“ menu

Provide the following information:

1. Type of base material

- Inox

- Steel

- Alu

- Titan

2. Gas - (shielding gas)

- Argon

3. Wall thickness

Wall thickness of the pipe [mm]

4. Diameter

Outer diameter of pipe join [mm]

5. Conrm settings by pressing OK The parameters are calculated

IMPORTANT! To make settings for the tack program, touch the „TACK.PR“ button

Parameter TACK.PR

Make the following settings in the „Tack Program“ window:

- „Tackpoints“ OFF - tacking deactivated

1 .... 20 - number of tack points

- “Tack.Welding time” duration of welding current for a tack point [s]

- “Position 1st tack point” position of the rst tack point [degrees]

- “Tack gas preow“ shielding gas pre-ow before tacking

- „Tack welding current“ welding current for tacking

- “Tack gas postow” shielding gas post-ow for tacking

IMPORTANT! On closed orbital welding guns, gas pre-ow and gas post-ow only take place at the rst and last tack points.

Setup and system parameters

Calling up the „Setup and system parameters“ menu

Principle

Calling up „OPERATOR“ settings

Call up the „Setup and system para- meters“ menu

A detailed description of the menus is provided in the following

sections.

The „Setup and system parameters“ menu allows users to adjust the power source and

orbital welding gun specically to their requirements.

1. Touch the „USER“ button in the

„Ignition parameters“ window

2. A window appears for user-specic

settings

User permissions

If the user name is to be changed

- Touch button (1) to open the keypad for changing the user name

(1)

(3)

(4)

(5)

To assign the user’s permissions:

1. Touch the area “RIGTHS” (2) and select one of the following entries:

- LOCKED ...the power source goes immediately into “Locked” status and

only the actual welding mode is supported. You cannot change any settings.

- BASIC ... The user has no permissions, and may only change welding parameters within the limits specied for him.

- SAVE ... The user may also save the welding parameters changed by him.

- PAR. FINDER ... The user may also change the parameters beyond the

predened limits.

- ADMIN ... The user may also reset parameters and adjust setup and system para- meters.

(2)

If the password needs to be changed:

- Touch button (3) to open the keypad for changing the password

User permissions

(continued)

2. If required, press the „RESET USER“ (4) button to reset the settings to their original status

3. Use the „Op.-“ and „Op. +“ (5) buttons to call up the settings for others users

4. Use the „BACK“ button to go back to the „Change Operator“ window

5. In the „Change Operator“ window, use the „>>“ button to call up the user-specic

settings window

Changing password

1. Touch the button (1) to change the password.

(1)

2. You are requested to enter the new password. Touch the into the eld (2) to open a keypad for entering for entering the new password.

(2)

Logging on a different user, and changing the password

To call up a different pre-saved user

in order to log him on under his name, touch the „USER ++“ button.

If the password of the user that has just been logged on is to be changed:

(1)

(3)

(2)

1. Touch button (1)

2. Further details can be found in the

section headed “Changing password”

To assign user permissions:

3. Touch „EDIT USER“ button (2)

4. Further details can be found in the section headed “User permissions”

IMPORTANT! Only an administrator is authorised to assign user permissions. If a user’s details have been changed, the user can no longer log on using his original user details.

To protect the power source from parameter changes:

5. Lock the power source by touching the padlock symbol (3)

IMPORTANT! The power source goes immediately into “Locked” status and only the actual welding mode is supported. You cannot change any settings.

To unlock the power source:

6. Touch the padlock symbol (3) again.

7. Click on the request to enter the password. Once the keypad appears, type in the password.

User-specic

settings

8. Press „>>“ to call up the settings for User-specic settings

Provide the following information:

1. Language currently selected

select the desired language

2. F1 select a function that has been dened for the F1 key by the user

3. F2

select a function that has been de-

ned by the user for the F2 key on

the remote control unit

4. APPLY: if “With Conrmation” is selected,

a warning prompt is displayed

before data is overwritten.

5. The following user-dened functions are available for the keys:

- No function

- Active alarm page

- Alarm history

- Move to starting position

- Save screenshot to USB

- Water pump OFF/ON

- Load next program

6. Press „>>“ to call up the settings for brightness and contrast

Brightness and contrast

1. Using buttons (1) and (2), adjust

(1)

the brightness and contrast of the touchscreen

2. Make the following settings in the

(2)

input area (3):

(3)

The numeric values to be entered correspond to the sequence of coloured boxes shown on the left. Example:

- „0“ = black

- “16” = white

Background general background colour

Entry font colour and background colour of selected texts when pressing the

adjusting dial

Selected font colour and background colour of texts during selection

Text font colour and background colour for text - general

Field font colour and background colour for text in text elds

IMPORTANT! „FG“ is the colour of the font in the foreground, and „BG“ is the colour of the text background. Use the “Default” button to reset the factory settings if necessary.

Ignition parameters

Provide the following information:

1. „Reverse P. Ignition“ reverse polarity ignition

- ON: activate

- OFF: deactivate

2. “tAC” - pulsed ignition

Pulsed ignition is activated

automatically when selecting a tack program.

IMPORTANT! For more detailed information on the tack program, please refer to the „Synergic“ section.

► 0.1 - 9.9: Duration of a pulsed welding current when welding starts [s]

- ON: activate

- OFF: deactivate

IMPORTANT! The tacking function is only available for the TIG-DC welding process.

Ignition parameters

(continued)

3. “Ignition time out” time until switch-off if no ignition occurs [s] To attempt ignition again, welding must

be started again

4. “Arc strike” time until switch-off after the arc has broken [s]. If the arc-break function is activated, clean the surface of the workpiece and start

welding again

5. “HF-pulse time” [s]

- High-voltage pulse duration for the high-voltage ignition

- Ext-HF: high-voltage ignition with external power source

- NO HF: high-voltage ignition deactivated

6. Use “>>” button to call up the “Welding mode & AC” window

Welding mode & AC

Provide the following information:

1. Operation mode

- AC

- DC-

2. Electrode-Diameter

diameter of the tungsten electrode

[mm]

3. AC welding: Pos. Wave

- Triangle

4. AC welding: Neg. Wave

- Triangle ... triangular waveform

- Sinus ... sinusoidal waveform (the standard setting for a low noise, stable arc)

- Soft square ... rectangular waveform with decreased edge steepness, for reducing noise levels compared to those that occur with the 100% rectangular waveform

- Square wave ... 100% rectangular waveform (stable but loud arc)

5. CAP Use the CAP key to activate tungsten balling (cap shaping)

The automatic cap-shaping function ensures that the optimum shape of electrode

tip is formed automatically during the welding start-up. A separate cap-shaping operation on a test workpiece is no longer necessary.

IMPORTANT! No further cap-shaping is needed at the next welding start-up. After the cap- shaping function has been performed once, it is deactivated for every subsequent welding start-up.

6. Use “>>” button to call up the “Value adjustment” window

Value adjustment

The following values allow you to provide the step width and the maximum value:

1. Welding current [A]

2. v-Rotation

rotation speed of orbital welding

gun [cm/min]

3. WFS wire feed speed [cm/min]

4. Use the “>>” button to open the

“More Parameters” window

IMPORTANT! The values are not active if the „PAR. FINDER“ and „ADMIN“ user permissions are selected. More detailed information on the user settings can be found in

the „User settings“ section

More parameters

Provide the following information:

1. Screensaver Time time until the touchscreen goes off,

counted down from the previous

operation [min:s] If set to OFF, the display goes off after two hours.2.

2. Seam number

(a)

alloca- tion of a number for the currently active weld seam

Password On / Start

► OPEN - the user last logged on is automatically logged on once the power

source is switched on, without the need to provide a password

► PWD INPUT - a password is requested when the power source is switched on.

► LOCKED - when the power source is switched on, no password is requested

the power source goes immediately into „Locked“ status and only the actual welding mode is supported. You cannot change any settings. To unlock, please

see the section headed „Logging on a different user and changing the password“

4. Auto Reset Energy

- If “Autoreset energy” active, the energy is automatically deleted at the start of a new weld.

- If “Autoreset energy” inactive, the energy is to be deleted manually (by pressing the Stop button) at the start of a new weld.> Multilayer welds with different

programs can be realized.

5. Touch button “Fronius-Automation”(a) to bring up a keypad for entering text

6. Use the „ROTATION“ button to call up the window for the rotation and welding speed parameters.

Welding direction and wirefeeding

Provide the following information:

1. Welding direction Clockwise Anti-clockwise

IMPORTANT! Only closed welding guns with no wirefeeding support the anti-

clockwise welding direction.

2. Manual speed

welding speed in manual mode

[cm/min]

3. Rapid motion speed high-speed welding [as % of the maximum welding speed of the orbital gun]

4. Path adjustment path adjustment as a percentage. Parameter enables balancing path nominal and actual value.

5. Welding circuit inductance

Display of the determined value after a measuring operation

6. Welding circuit resistance

Display of the determined value after a measuring operation

Start of L/R measurement

Wire inching

Use the „L-R MEASURING“ button to open the window.

Provide the following information:

1. Start

There is performed an automatic measurement of the welding circuit

resistance and inductance. The

result is automatically entered in the

display.

2. Cancel

Cancel measurement and close the

window.

Use the „WIRE“ button to call up the set-

tings for wire inching.

Provide the following information:

1. Wire inching speed starting speed for wire inching [cm/ min]

2. Wire start time

time before start speed changes

over to high speed [sec]

3. Wire rapid speed high-speed wire inching [cm/min]

4. Wire upslope time the transition from starting speed to high speed is continuous, and is shown as an upslope. The duration of the transition can be set here.

5. Use the „TIME“ button to call up the settings for date, time and calibrating the

touchscreen

Date, time and calibrating the touchscreen

In the „Set time“ window, you can provide

the following information:

- Year

- Month

- Day

- Hour

- Minute

- Second

Touch the “Set clock” button to apply the

time set

To calibrate the touchscreen

1. Touch the „Calibration“ button

2. Touch the crosshair

3. Repeat this process until the “Set time” window reappears

4. To return to the setup menu, press the “SETUP” button

Parameter settings

Calling up the „Parameter settings“ menu

Principle

Waveform parameters for TIG manual torch

Call up the „Parameter settings“ menu

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

Provide the following information:

Step mode

2-Step-mode 4-Step-mode

Puls Mode

pulsed arc welding ON / OFF

I-P - pulsing current [A] t-P - pulsing current time [ms] I-G - background current [A] t-G - background current time [ms]

Touch „Page - 2“ button to call up the window for further settings

Display for 2-step operating mode

IMPORTANT! If the „2-step mode“ has been set in the previous dialog box, the left-hand dialog box applies. For the „4-step mode“, the right-hand dialog box applies.

I-S Starting current [A] t-S time for starting current [s] UPS time for upslope [s] dSL time for downslope [s] I-E Final current [A]

t-E    Timefornalcurrent[s]

Reduced current Reduced current [A] Value Value of gas per minute. [l/m]

Display for 4-step operating mode

Waveform parameters for orbital weld head

Provide the following information:

1. Welding path [degrees]

(a)

2. Diameter External diameter of pipe join [mm]

3. Offset for offsetting the start point of segment drawing in degrees

[deg].Offsethasnoinuenceon

(b)

weld.

IMPORTANT! Enteringagurehigherthan360°willmeananoverlapoftheweld

seam at the end of welding.

4. I-S ... Starting current [A]

5. t-S ... time for starting current [sec]

6. UPS ... time for upslope [sec]

7. Set main current by selecting button (a) or (b)

IMPORTANT! For more detailed information on the settings for the main current, please see the following section „Parameters for pulsing and welding speed“.

8. dSL ... time for downslope [sec] Depending on the selected “Driving downslope” value. You can take up to

speciedbythesystemminimumtimecanbeset.

9. I-E ... Final current [A]

10. t-E ... Time for nal current [sec]

Parameters for pulsing and welding speed

This window allows the user to divide the welding path into several segments. For each of these segments, the parameters

(b)

listed below for pulses and welding speed

(a)

can be set individually.

To create several segments, proceed as follows:

1. Inthe“Seg.Path”inputeld,enterasegmentpaththatisshorterthanthe

present travel path.

2. An extra segment is automatically created, and completes the remainder of the

welding path

3. Use the arrow buttons „<<„ and „>>“ to switch to the new segment

IMPORTANT! The digit (a) shows the number of currently created segments.

Digit(b)showsthepresentsegment.Themaximumnumberofsegmentsis10.

4. If the value for this segment is reduced, another new segment is created, and this

new segment extends to the end of the welding path

5. Continue this process until the desired number of segments is reached

Parameters for pulsing and welding speed

(continued)

6. If required, adjust the segment path for each segment once more

The following parameters for the main current can be set individually for the segments:

- I-P ... Pulsing current [A]

- t-P ... Pulsing current time [ms]

- I-G ... Base current [A]

- t-G ...Base-current time [ms]

- v-Weld ... Welding speed [mm/min]

- Slope ... slope time between segments [sec]

7. Use the “BACK” button to return to the parameters for the waveform

8. Once all the “STARTPOINT” parameters have been set for the waveform, press

the “STARTPOINT” button to open the window for setting the start point.

Parameters for start point

Provide the following information:

1. ROLL-UP for rolling up the hosepack on the open orbital welding gun with wire feeding

► INACTIVE

The orbital welding gun does not move to the start point

► ACTIVE

The orbital welding gun moves

tothestartpointthatisdened

by the “Roll up Path”

► AUTOSTART

The orbital welding gun moves to the start point and begins welding immediately

2. Roll up Path [°] anti-clockwise roll-up path for the hosepack, in degrees from the vertex

3. Start delay [s] time between start of welding current and the point when the orbital welding gun starts rotating

4. Driving Downslope [°] continuous reduction in the welding speed in addition to the downslope already set for the welding current

- The set value directly affects the DSL (time for downslope).

5. v-SYNCHRON

denesthebehaviouroftheorbitalweldheadduringthepulsingcurrentphase.

- P.SLOW Orbital weld head moves at a reduced speed. IMPORTANT! This speed is preset by the system and cannot be altered.

- P.FAST Orbital weld head moves at the set welding speed „v-Weld“.

- INACTIVE Synchronous mode deactivated. The orbital weld head always (in

both pulsing current and base current phases) moves at the set welding speed „v-Weld“.

Parameters for start point

(continued)

6. RETURN TRAVEL

► NO ► WITH BACK TRAVEL

Afterweldingnishes,theorbitalweldinggunmovesbacktothestartposition

► ES-360

forclosedweldinggunswithnoexternalwirefeeding.Afterweldingnishes,

the orbital welding gun moves back to the limit switch.

► X-360

Afterweldingnishes,theorbitalweldingguntakestheshortestpathtothe

start and sets the angle for the travel path to zero

► SET ZERO

The point where welding stops is where the angle for the travel path is set to zero, producing the start point for the next weld sequence.

7. Use button „ENERGY“ to call up the parameters for welding energy.

IMPORTANT! For more detailed information, please see the following section „Parameters for welding energy“.

8. Press the “BACK” button to return to the parameters for the waveform

Parameters for welding energy

Provide the following information:

1. Specied energy for entering the set value, from which the limits are calculated.

Entering„0“deactivatestheenergy

analysis.

2. Lower limit % for specifying the lower limit as a percentage of the

setvalue(Speciedenergy). Settingrange:0-30%

3. Lower limit kJ for specifying the lower limit in [kJ].

4. Upper limit %

forspecifyingtheupperlimitasapercentageofthesetvalue(Speciedenergy). Settingrange:0-30%

5. Upper limit kJ

forspecifyingtheupperlimitaskilojoule[kJ]ofthesetvalue(Speciedenergy).

6. Energy Correction correctionfactorforweldingengergyinputin[%].

Application example:

EnteredEnergycorrection:-10% Internalmeasuredenergy:100kJ Measurementresult:90kJ

7. Print energy:

- inactive parameter and actual value printout without welding energy parameters

- active parameter and actual value printout with welding energy parameters

8. Use the „BACK“ button to return to the start point parameters.

Calling up parameters for wirefeeding or AC welding

IMPORTANT! If a TIG manual welding torch has been connected instead of the orbital

welding gun, the corresponding windows differ slightly from the following illustrations. The parameters however are similar.

1. Selecting the surface (a) calls up the settings for the main current again

(a)

IMPORTANT! Depending on the functions available, one of the buttons below may appear instead of the „POWER“ button:

- WIRE parameters for wirefeeding

- AC parameters for AC welding”

Parameters for wirefeeding

Provide the following information:

1. Different segment

Use the “<<” or “>>” button to select a different segment

2. Wire start

delay time between start of welding current and start of wire- feeding [s]

3. Wire Puls Set v

wire feed speed during the pulse phase [cm/min]

4. Wire Back Set v

wire feed speed during the background current phase [cm/min]

5. Wire stop delay time between the main current and end of wirefeeding [s]. Depending on the selected „DSL“ (Downslope time), and the „traveling downslope“.

6. Wire retract path

Path of wire retract after the main current.

7. Use the “AC” button to call up the window for setting the AC parameters

Parameters for AC welding

Provide the following information:

1. AC Frequency [Hz] SYNC for mains synchronisation of two power sources for simultaneous AC welding

2. AC Balance

-5: highest fusing power, lowest cleaning action +5: highest cleaning action, lowest fusing power

3. Use the „POWER“ button to call up the settings for the main current again Use the „BACK“ button to return to the parameters for the waveform

4. In one of the two named windows, use the „SAVE“ button to call up the „Saving parameters“ window

Saving parameters

Success programs

Enter a name to save the previously selected parameters as a welding program.

► After touching the “NAME=””” button,

the buttons arranged above enable a name to be entered from individual items of process data.

(a)

IMPORTANT! Selecting the bar (9) displays a keyboard that you can use to enter a name for the program, as well as for deleting or editing the text.

A successor program is a welding program that is linked to the original welding program. All welding programs must originate from the same group. Programs from different groups cannot be nested. By the same token, program links are lost when programs are saved in a new group.

(a)

(b)

Procedure:

Starting from the currently displayed welding program (a), further programs can be selected and linked using the „SELECT“ (b) button.

Success programs

(continued)

After the „SELECT“ button has been touched, a screen opens for the group that contains the original welding program. Successor programs are selected here (c).

(c)

(f)

(e)

(d)

(g) (h)

The selected successor programs are listed under the original program (d). Use the << and >> buttons (e) to switch between programs.

Once all the programs have been selected, programs can be linked using one of two methods. Touch the „START POINT“ (f) button. In the „Positions“ window, the settings for the „RETURN TRAVEL“ (g) function allow you to control how the successor programs behave.

Programm 1

Method 1

Programm 2

Method 2

Programm 2

Programm 3

Method 1: Return travel: „NONE“ (h)

In this mode, all the selected programs are nested into a single program.

Method 1:

Return travel: „........“ any mode, apart from

„NONE“ (h)

In these modes, all the selected programs are called separately. Welding stops between programs, welding restarts and all necessary movements such as hosepack unwinding are performed automatically.

Orbital and TIG welding

Safety

Calling up the „Welding“ menu

DANGER!

An electric shock can be fatal.

If the device is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when

- the mains switch is in the „O“ position,

- the device is unplugged from the mains.

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”

WARNING! Risk of injury and damage from electric shock!

As soon as the mains switch is in the „I“ position, the tungsten electrode of the orbital welding gun is LIVE.

- Make sure that the tungsten electrode does not touch

- any persons or electrically conducting or earthed parts (e.g. housing etc.)

Controlling and monitoring the welding process

Call up the „Welding“ menu. The rst window for the welding process status appears

WARNING!

Risk of injury and damage from machines that start up automatically!

Automatically starting machines can cause serious injury and property damage caused by snagging, pulling or crushing of body parts.

- 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

Controlling and monitoring the welding process

(continued)

1. START

to start the welding process.

(e)

2. STOP

to nish the welding, with downslope

IMPORTANT! If welding has to be

(c)

(a)

(b)

(d)

stopped immediately, for safety reasons for example:

- Click the ABORT button. Welding stops immediately, with gas post-ow but no downslope

IMPORTANT! If the „not ready“ message appears in the window, touch the text; the next window shows the problematic status.

The following parameters appear:

Totaltime: Running time since the start of the current welding program [min].

Sector: Actual runtime for the present welding section [min]

IMPORTANT! A new welding section begins after every event

- e.g. gas pre-ow or moving to start point.

Position: Position of the electrode [degrees]

v- Weld: Welding speed [cm/min]

The following elds appear:

(a) Actual welding current [A]

(b) Actual welding voltage [V]

IMPORTANT! The seam number is also part of the le name when the actual value is recorded. If the seam number is highlighted in orange, the value displayed indicates the number of the currently welded tacking point.

(d) Welding energy [kJ]

With button (e), call up the “welding process status” window.

Welding energy status

Green font: “Welding energy OK”:

measured welding energy is in permitted range

Red font: “Welding energy fail”: measured welding energy has exceeded the higher limit or underrun the lower limit

By pressing the STOP button 2x on the remote control, the value will be reset.

Welding process status

Status display of the following parameters:

► PROCESS-ACTIVE-STATUS ► POWER SOURCE STATUS ► LIMIT SWITCH ACTIVE ► ALARM - STATUS FPA

Correcting the welding process

This window appears when a change is made on the remote control. For every segment (up to a maximum of 10) the latest change to the original value is shown.

For example, if the current for segment „S1“ has been changed by 4 A, „4“ appears in the relevant eld.

If the changed parameters are to be applied:

1. Touch the “ >> “ button (a), to move to the next page.

(a)

2. Touch the “ Segment 9/10 “ button (b), to move to the next page.

3. Touch the „CORRECT“ button (c) or press the „Start/Stop“ button on the remote control unit.

4. Touch the “BACK” button or press the “Stop” button on the remote control unit to close the window without applying any

changed values.

IMPORTANT! The parameters are only applied if the following user permissions are selected: “SAVE”, “FIND PAR”, and“ADMIN”. More detailed information on the user settings can be found in the “User settings” section.

Troubleshooting

General remarks

Safety

In the event of faults, note that the function of the orbital system controller depends on many additional components (power source, orbital weld head, wire feed unit, ...) which are also potential sources of problems. All the service codes that are shown on the current source’s display device also appear on the orbital system controller’s touchscreen display.

WARNING!

Risk of injury and damage to property during, or by incorrect maintenance activities.

Compliance with maintenance procedures and intervals is absolutely neces-

sary. For damages incurred due to insufcient or improper maintenance, the

manufacturer is not responsible. Before you starting a maintenance:

- Turn all main switches on system controllers to the 0 position (OFF)!

- Unplug the system controllers from the mains!

- Switch off all system components and unplug them from the mains!

- Ensure that all moving parts are stationary!

- All maintenance work on the system may only be carried out by trained technicians.

WARNING! A failure to connect a correctly-dimensioned earth lead may result in

serious injury or damage.

Inadequate PE conductor connections can cause serious injury and damage. The housing screws provide an adequate PE conductor connection for earthing the housing.

- After completing the maintenance work to reuse the original screws!

- the housing must NOT be replaced by any other screws that do not provide a reliable PE conductor connection.

Retrieving alarm list

A display showing alarms that have occurred is useful for fault diagnosis purposes.

- Assign the „active alarm page“ function to the F1 button

- Touch F1 to call up the active alarm page

IMPORTANT! For more detailed information on how to assign a function to the F1 button, please refer to the „Setup and system parameters“ section.

Alternatively, touch button (a) in the symbol bar to call up the tray page

(1)

Retrieving alarm list

(continued)

The following actions can be performed from the tray screen:

- Open the active alarm page by touching the „Alarmlist“ button

IMPORTANT! For more detailed information on the alarms, please refer to the section headed “Alarms and error messages”.

- Press the „Acknowledge“ button to reset all alarms

- Press „Clockwise“ or „Counterclockwise“ to enter the welding direction

- Press the „Welding on“ button to start a test (without arc or shielding/forming gas)

- Press the “Wire on” button to enable or disable wire feeding

- Press the „Left“ or „Right“ button to advance or retract the wire

- Press the „Left“ or „Right“ button to move the orbital welding gun in the desired direction

Alarms and error messages

Group 001

001 Alarms are bypassed

002 Internal connection problem

Internal communication problem in the processors

003 Gateway Timeout

Faulty connection to the gateway

004 USB

Problem retrieving data from USB stick

005 Low Gas Pressure

Alarm for shielding gas monitor

006 Power supply

Power supply alarm

007 Weldhead error

Motor controller error

008 Wire error

Motor controller error

009 Emergency Stop activated

The emergency stop button has activated a safety cut-out

--- SA Internal alarm

Alarm as per plain text display

Alarms and error messages

(continued)

Group 002

001 Power source not ready

LocalNet is sending data

002 Limit exceeded

LocalNet: Limit exceeded

003 Torch collision

LocalNet: Torch collision

004 Gateway not ready

LocalNet: Gateway not ready

005 Wire sticking

Wire stuck fast

006 PS (service codes)

For a detailed explanation of the service codes, please see the section headed “Service codes displayed”.

--- SA Power module

Alarm as per plain text display

Group 003

Group 004

IMPORTANT! Alarms and error messages

in Group 3 are internal errors that need to

be rectied by a service engineer.

IMPORTANT! Alarms and error messages in Group 4 appear when welding is stopped..

001 IR: RECE error from UST

LocalNet: Error number

002 IR: RECE PS Ready missing

LocalNet: The „Power Source Ready“signal is missing - Power source ready

003 IR: SEND Rob Ready missing

FPA-2030 not ready

Alarms and error messages

(continued)

Group 004 (continued)

004 IR: Emergency pressed

The emergency stop button has activated a safety cut-out

005 IR Stop key -> interrupt

Welding was interrupted by the Stop button

006 IR Alarm (see alarm page)

Miscellaneous alarm

007 IR Arc w/o main current signal

Main current signal missing

008 IR No arc signal

Arc OK signal missing

009 IR Start key -> H(21)

Start button -> Halt is active

--- SA Weld manager

Alarm as per plain text display

Group 005

001 Weldhead no movement

No rotation taking place, despite a command being sent

002 Wire feed unit

Wire not being transported, despite a command being sent

003 Motor.Curr.Weldhead

The analog entry value for the motor current is too high. Check rotation.

004 Motor.curr.wire

The analog entry value for the motor current is too high. Check wire-feed unit.

005 Oxygen Alarm

Residual oxygen measuring device measures residual oxygen at the welding location.The input is active and an alarm occurs.

006 Print on USB problem

A problem has occurred while printing as a le to the USB stick. Check USB stick

or change the printout parameters.

007 OSC Stepper drive problem 0

see Servo controller error list

008 AVC Stepper drive problem 0

see Servo controller error list

009 AVC T&R Timeout

T&R function has timed out. Cause: earth not connected on workpiece; workpiece is very dirty.

--- SA Internal alarm

Alarm as per plain text display

Alarms and error messages

(continued)

Group 006

001 Current Puls Limit

002 Current Backg Limit

003 Torch Voltage Limit

004 Head speed Limit

005 Wire speed Limit

--- SA Limit high/low

Alarm as per plain text display

Applies to all alarms: Check how long and by how much the limit value has been exceeded. The limit value may be too restrictive. A general check of limit values is required.

Group 007

001 Current Puls icker

002 Current Backg icker

003 Torch Voltage icker

004 Head speed icker

005 Wire speed icker

--- SA Limits icker

Alarm as per plain text display

Applies to all alarms: Check the earth is securely in place. Check part and electrode for dirt.

Alarms and error messages

(continued)

(a) (b) (c)

To deactivate further error-related alarms:

1. Touch the touchscreen. A symbol bar appears (a)

2. Use the arrow keys (b) to select the alarm concerned

3. Select the padlock symbol in the symbol bar (c)

4. The alarm concerned is greyed out

To reactivate the alarm,

5. select it again using the arrow keys (b)

6. touch the „padlock symbol“ (c). The alarm is reactivated, and again presented in black font.

Error list servo

If errors can not be acknowledged, switch the system off and on again. Explanation of error see Error List Servo.

Alarms information for service technicians

To access the alarms for service technician, button press “i”.

1. In the rst „i“ key window, touch the „SYSTEM“ button to call up more service-related information.

2. Press the „INTERN“ button to call up the window shown below to display additional data

Displayed service codes

IMPORTANT! If an error message that is not described here appears on the displays,

then the fault is one that can only be put right by a service engineer. Make a note of the error message shown in the display, and of the serial number and conguration of the power source, and get in touch with our After-Sales Service, giving them a detailed description of the error.

Cause: Overtemperature in the primary circuit of the power source

Remedy: Allow the power source to cool down

tS1 | xxx, tS2 | xxx, tS3 | xxx

Cause: Overtemperature in the secondary circuit of the power source

Remedy: Allow the power source to cool down

tSt | xxx

Cause: Overtemperature in the control circuit

Remedy: Allow the power source to cool down

Err | 051

Cause: Mains undervoltage: The mains voltage has dropped below the

tolerance range (see „Technical data“)

Remedy: Check the mains voltage

Err | 052

Cause: Mains overvoltage: The mains voltage has exceeded the upper limit of

the tolerance range (see „Technical data“)

Remedy: Check the mains voltage

no | IGn

Cause: „Ignition time-out“ function is active: No current started owing before

the end of the time specied in the Set-up menu. The safety cut-out of

the power source has been triggered.

Remedy: Restart welding; clean workpiece surface.

Err | PE

Cause: The earth fault current watchdog has triggered the safety cut-out of the

power source.

Remedy: Switch off the power source, wait for 10 seconds and then switch it on

again. If you have tried this several times and the error keeps occurring, contact After-Sales Service.

Err | IP

Cause: Primary overcurrent Remedy:

Remedy: Contact After-Sales Service

Err | bPS

Cause: Fault in power module

Remedy: Contact After-Sales Service

Cause: Fault in central control and regulation unit

Remedy: Contact After-Sales Service

Displayed service codes Power source

no | Arc

Cause: Arc-break

Remedy: Restart welding; clean workpiece surface.

no | H2O

Cause: Cooling unit ow watchdog has been triggered

Remedy: Check the cooling unit; if necessary, top up the coolant or bleed the

water ow as described in “Putting the cooling unit into service”

hot | H2O

Cause: Thermostat on cooling unit has tripped

Remedy: Wait until the end of the cooling phase, i.e. until “Hot | H2O” is no longer

displayed.

-St | oP

(where the power source is being operated with a robot interface or a eld bus)

Cause: Robot not ready

Remedy: Initialise “Robot ready” signal, initialise “Source error reset” signal

(“Source error reset” only available in conjunction with ROB 5000 and

eld bus coupler for robot control)

Power source does not function

Mains switch is ON, but indicators are not lit up

Cause: There is a break in the mains lead; the mains plug is not plugged in.

Remedy: Check the mains lead, ensure that the mains plug is plugged in

Cause Mains outlet socket or plug is faulty.

Remedy: Replace faulty components

Power source does not function

Mains switch is ON, but indicators are not lit up

Cause: Mains fuse is faulty

Remedy: Change the mains fuse

No welding current

Mains switch is ON, overtemperature indicator is lit up

Cause: Overloading; the duty cycle has been exceeded.

Remedy: Do not exceed the duty cycle

Cause: Thermostatic cut-out system has been tripped

Remedy: Wait until the power source automatically comes back on after the end of

the cooling phase

Cause: The fan in the power source is defective

Remedy: Change the fan

Displayed service codes Power source

(continued)

No welding current

Mains switch is ON and indicators are lit up

Cause: Incorrect earth connection

Remedy: Check the earthing (grounding) connection and clamp for correct polarity

Cause: Break in power cable in the orbital welding gun or welding torch.

Remedy: Replace orbital welding gun or welding torch

Nothing happens when welding starts

Mains switch is ON and indicators are lit up

Cause: The control plug is not plugged in

Remedy: Plug in the control plug

Cause: Orbital welding gun, torch or control line defective.

Remedy: Replace orbital welding gun or welding torch

No shielding gas or forming gas

All other functions are OK

Cause: The gas cylinder is empty

Remedy: Change gas cylinder

Cause: Gas pressure regulator is faulty

Remedy: Change the gas pressure regulator

Cause: The gas hose is not mounted, or is damaged

Remedy: Mount/change the gas hose

Cause: Orbital welding gun or welding torch faulty

Remedy: Replace orbital welding gun or welding torch

Cause: Gas solenoid valve is defective

Remedy: Replace gas solenoid valve

Poor welding properties

Cause: Incorrect welding parameters

Remedy: Check the settings

Cause: Incorrect earth connection

Remedy: Check the earthing (grounding) connection and clamp for correct polarity

Displayed service codes Power source

(continued)

Orbital welding gun or torch gets very hot

Cause: The design dimensions of the orbital welding gun or torch are not

sufcient for this task

Remedy: Observe the duty cycle and loading limits

Cause: Only on water-cooled machines: Water ow rate is insufcient

Remedy: See “Water ow too low or non-existent” below

Cause: Only on water-cooled machines: Parameter C-C is set to “OFF”.

Remedy: In the Set-up menu, set parameter C-C to “Aut” or “ON”.

Water ow too low or non-existent

Cause: Coolant level too low

Remedy: Top up with coolant

Cause: Constriction or foreign body in cooling circuit

Remedy: Remove constriction or foreign body

Cause: Coolant pump fuse defective

Remedy: Replace coolant pump fuse

Cause: Coolant pump defective

Remedy: Replace coolant pump

Cause: Coolant pump sticking

Remedy:

- Remove coolant pump fuse

- Insert a suitable slotted screwdriver from outside through the motor shaft bushing

- Tighten motor shaft

- Replace coolant pump fuse

Cause: Coolant lter (option) displaced when connecting water return

Remedy: Clean coolant lter using clean tap water or change lter element

Cause: Flow sensor has tripped (FK 4000 Rob), requesting parameter F3 from

the welding system however shows that there is still a small amount owing through: hoses kinked or coolant lter displaced when connecting water return.

Remedy: Fix hoses, clean coolant lter using clean tap water or repair lter

element

Cause: Flow sensor has tripped, requesting parameter F3 from the welding

system shows that there is nothing owing through: coolant pump

defective.

Remedy: Replace coolant pump

Cause: Permitted duty cycle exceeded

Remedy: Wait until the end of the coolant cooling phase

Displayed service codes Power source

(continued)

Insufcient cooling

Cause: Faulty ventilator

Remedy: Replace ventilator

Cause: coolant pump defective.

Remedy: Replace coolant pump

Cause: Cooler contaminated

Remedy: Blow out cooler with dry compressed air

High operating noise level

Cause: Coolant level too low

Remedy: Top up with coolant

Cause: Coolant pump defective

Remedy: Replace coolant pump

no | H2O

The cooling unit ow watchdog (option) has been triggered. The error message

appears on the power source control panel.

Cause: Coolant ow problem

Remedy: Check the cooling unit; if necessary, top up the coolant or bleed the wa-

ter ow as described in “Putting the cooling unit into service”

Cause: Coolant lter blocked

Remedy: Clean or replace lter pipe

hot | H2O

Thermostat on cooling unit has tripped. The error message appears on the power source control panel.

Cause: The coolant temperature is too high

Remedy: Wait until the end of the cooling phase, i.e. until “hot | H2O” is no longer

displayed

Maintenance and disposal

Care, maintenance and disposal

General

Every start-up

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

DANGER!

Risk of death by dangerous voltage.

An electric shock can be fatal. Before opening the device

- Turn the mains switch to the „O“ position

- Disconnect the device from the mains

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

- Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have been discharged

- Check mains plug, mains cable, orbital welding gun or welding torch, interconnecting hosepack and earthing (grounding) connection for damage

- Check that there is a gap of 0.5 m (1ft. 8in.) all around the device to ensure that

cooling air can ow and escape unhindered

NOTE! Air inlets and outlets must never be covered, not even partially.

WARNING!

Risk of scalding from hot coolant.

The coolant heats up during extended operation. In case of contact burns to the hands or other body parts may arise.

- Only check the water connec- tions once the coolant has cooled down.

When using water-cooled torches

- Check the water connections for leaks

- Monitor the coolant return amount in the coolant container

- If no coolant is returning, check the cooling unit and bleed if necessary

NOTE! If water-cooled torches are operated without coolant, this will normally result in a fault in the torch body or hosepack. Fronius shall not be liable for any damage resulting from such action. In addition, no warranty claims will be entertained.

Symbols for care and maintenance of the cooling unit

Check water level

Explanation of symbols

Change coolant Blow off

cooler

Read operating instructions

The symbols and relevant maintenance intervals are described in detail on the following pages.

Preparing for maintenance

1. Turn the mains switch to the „O“ position

2. Disconnect the device from the mains

3. Remove the left side panel

(1) (2) (3)

Coolant lter and ll nozzle Coolant container

The illustrations show the following elements of an installed cooling unit:

(1) Coolant lter

(2) Fill nozzle for the coolant

(3) Coolant container

Every week

The coolant level and cleanliness of the coolant must always be checked before starting the cooling unit.

If the coolant level is below the „min“ mark, top up with coolant

NOTE! Use only original Fronius coolant when lling cooling units. Other

coolants are not recommended for electrical conductivity or compatibility reasons.

Every 2 months

- Check the return for dirt and clean if necessary

- If present: check water lter and ow monitor are functioning correctly, check for dirt,

and clean them or replace lter pipe

- If present: clean air lter

Every 6 months

If the welding torch becomes very hot during operation, the cooling power is insufcient.

This might be caused by dust contaminating the cooler. The coolant is not being cooled sufciently.

- Dismantle device side panels and clean inside of device with dry reduced compressed air

- If a lot of dust has accumulated, clean the cooling-air ducts.

NOTE! Risk of damage to electronic components. Clean electronic components from a certain distance only.

Every 12 months After 12 months, drain the coolant and dispose of it properly

IMPORTANT! Coolant must not be disposed of in the public sewage system.

Use only original Fronius coolant (item no. 40,0009,0046) when relling the cooling unit.

Disassembly and disposal

Disassembling the system

Disposal of components

Electrical equipment:

DANGER! Risk of fatal injury from dangerous electrical voltage.

The areas bearing this symbol contain parts that are under dangerous electrical voltages. Electrically-charged parts (capacitors) can remained charged for a considerable length of time after they are switched off. An electric shock can be fatal! Before opening the power source:

- Move the mains switch to the O position

- Switch off all supply leads and unplug them from the mains

- Wait for at least 10 minutes (to allow capacitors to discharge)

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

- Check that the installation is no longer live

- Carry out earthing and short-circuiting

WARNING!

Danger of environmental damage

Incorrect disassembly and disposal of the separate system componnets can result in serious environmental damage.

- The separate system components must only be disposed of by

appropriately-qualied technicians.

Ensure that:

- all machine components and electrical parts are separated according to type and disposed of properly

- the consumables used are sorted and separated according to their properties

- all parts and consumables (such as lubricants, coolants, conductive paste, ...) are disposed of in an environmentally responsible way in accordance with regional legislation and provisions

NOTE! If you have any further questions about disposal / recycling please address them to the manufacturer.

100

Fronius FPA_3020 Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual