Fronius FRC-60 Operating Instruction [EN]

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FRC-60

Operating Instructions

EN

Remote control

42,0410,1669,EN V04 - 06072016

Table of content

Introduction ...................................................................................................................................................... 3

About this document ........................................................................................................................................ 4

Function of this document .......................................................................................................................... 4

Target group ............................................................................................................................................... 4

Abbreviations used ..................................................................................................................................... 4

Format ........................................................................................................................................................ 4

Copyright .................................................................................................................................................... 4

Meaning of the special safety instructions ................................................................................................. 5

For your safety ................................................................................................................................................ 6

General.......................................................................................................................................................6

Utilisation for intended purpose .................................................................................................................. 6

Environmental conditions ........................................................................................................................... 7

Obligations of the operator ......................................................................................................................... 7

Obligations of personnel ............................................................................................................................ 7

Protecting yourself and others ................................................................................................................... 8

Danger from toxic gases and vapours ....................................................................................................... 9

Danger from ying sparks .......................................................................................................................... 9

Risks from mains current and welding current ......................................................................................... 10

EMC measures......................................................................................................................................... 11

Specic areas of risk ................................................................................................................................ 12

Pneumatic equipment .............................................................................................................................. 13

Safety measures at the installation location and during transport ............................................................ 13

Data protection ......................................................................................................................................... 13

Safety measures in normal operation ...................................................................................................... 14

Maintenance and repair ........................................................................................................................... 14

Safety inspection ...................................................................................................................................... 14

Disposal....................................................................................................................................................15

Safety symbols ......................................................................................................................................... 15

General .......................................................................................................................................................... 16

Device concept ......................................................................................................................................... 16

Proper use ................................................................................................................................................ 16

Standard equipment ................................................................................................................................. 16

Options ..................................................................................................................................................... 16

System descriptions ...................................................................................................................................... 17

General.....................................................................................................................................................17

"Welding axis" application ........................................................................................................................17

"O󰀨set welding axis" application .............................................................................................................. 18

Control elements and connections ................................................................................................................ 19

Safety ....................................................................................................................................................... 19

FRC-60 remote control, front view ........................................................................................................... 19

FRC-60 remote control, rear view ............................................................................................................ 21

Commissioning .............................................................................................................................................. 22

Safety ....................................................................................................................................................... 22

Checking the connections ........................................................................................................................ 22

Connecting the remote control ................................................................................................................. 22

Switch on system components ................................................................................................................. 23

Checking the EMERGENCY STOP safety equipment .............................................................................23

Positioning the welding torch ................................................................................................................... 23

Lowering and setting up the welding torch ............................................................................................... 24

Loading a welding program ...................................................................................................................... 25

Dening parameters for the tripod unit ..................................................................................................... 25

Carrying out a test run .............................................................................................................................. 26

Starting the welding process .................................................................................................................... 26

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Troubleshooting ............................................................................................................................................. 27

General.....................................................................................................................................................27

Safety ....................................................................................................................................................... 27

Basic requirements for the system to work .............................................................................................. 27

Possible errors in "Welding axis" application ...........................................................................................27

Possible errors in "O󰀨set welding axis" application .................................................................................. 28

Technical data ............................................................................................................................................... 29

FRC-60 technical data ............................................................................................................................. 29

Spare parts overview ..................................................................................................................................... 30

Ordering details ........................................................................................................................................ 31

Spare parts list ......................................................................................................................................... 31

Circuit diagrams ............................................................................................................................................ 32

EU-Declaration of conformity ........................................................................................................................ 35

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Introduction

These operating instructions will help you familiarise yourself with the product FRC-60. It is in your interest to
read these instructions carefully and to observe the directions contained herein. This will prevent faults and

incorrect operation or possible damage to the product or its system components.

Please also obey the safety rules; doing so will ensure greater safety when using the product. Careful handling
of the product will repay you with years of safe and reliable operation. These are essential prerequisites for

excellent results.

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About this document

Function of this
document

Target group The FRC-60 operating instructions are designed for trained technicians or persons with

Abbreviations
used

These operating instructions will tell you how to commission and operate the product
FRC-60 in combination with its system components.
Look after the operating instructions carefully; they must always be to hand at the lo­cation where the product is being used. They can be used as a reference should any

operational or functional problems occur in the future.

practical welding experience. The manufacturer accepts no liability for damages caused by
insu󰀩cient knowledge on the part of the user.

Abbrev. Meaning in English Meaning in German

FRC Fronius Remote Control Fronius Fernbedienung

FTU Fronius Tripod Unit Fronius Stativeinheit

FCU Fronius Control Unit Fronius Steuergerät

FTT Fronius Tilting Turntable Fronius Drehkipptisch

FRT Fronius Rotation Table Fronius Drehtisch

FRU Fronius Rotator Unit Fronius Rollenbock

FPT Fronius Pneumatic Torch Fronius Brenner-Absenkeinheit

FGU Fronius Guide Unit Fronius Führungseinheit

FSU Fronius Swivel Unit Fronius Brenner-Verstelleinheit

FTH Fronius Torch Holder Fronius Brennerhalter

Format

Copyright

Text Meaning

- List in no strict order

1 Reference number for description

Key 1 .. Actions in order: You need to do something here

1., 2. Prompt to take actions in order: You need to do something here

1., 1.1 Identication of spare parts

A, B Measurements

Copyright of these operating instructions remains with Fronius International GmbH. The

text and illustrations are all technically correct at the time of printing. We reserve the right

to make changes. The contents of the operating instructions shall not provide the basis
for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we
will be most grateful for your comments.

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Meaning of the
special safety
instructions

"DANGER!" indicates immediate and real danger. If it is not avoided, death or

serious injury will result.

"WARNING!" indicates a possibly dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.

"CAUTION!" indicates a situation where damage or injury could occur. If it is
not avoided, minor injury and/or damage to property may result.

"NOTE!" indicates a risk of awed results and possible damage to the equip-
ment.

"Important!" highlights tips for correct operation and other particularly useful informa­tion. It does not indicate a potentially damaging or dangerous situation.

If you see any of the symbols depicted in the "For your safety" section, special care is
required.

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For your safety

General

The device is manufactured using state-of-the-art technology and according

to recognised safety standards. If used incorrectly or misused, however, it

can cause

- injury or death to the operator or a third party,

- damage to the device and other material assets belonging to the operator,

- ine󰀩cient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing
the device must:

- be suitably qualied,

- have su󰀩cient knowledge of welding

- read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is

being used. In addition to the operating instructions, generally applicable and
local regulations regarding accident prevention and environmental protection
must be made available and observed.

All safety and danger notices on the device

- must be kept in a legible state

- must not be damaged/marked

- must not be removed

- must not be covered, pasted or painted over.

Utilisation for
intended pur­pose

Before switching on the device, remove any faults that could compromise

safety.

Your personal safety is at stake!

The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process described in the

operating instructions.
Any use above and beyond this purpose is deemed improper. The manufac­turer shall not be liable for any damage resulting from such improper use.

Utilisation in accordance with the "intended purpose" also includes

- reading carefully and following all operating instructions to the letter

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and servicing work.

The device is designed for use in industry and the workshop. The manu-

facturer accepts no responsibility for any damage caused through use in a
domestic setting.

Fronius accepts no liability for inadequate or incorrect results.

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Environmental
conditions

Operation and/or storage of the device outside the stipulated area will be
deemed as "not in accordance with the intended purpose." The manufacturer

shall not be liable for any damage resulting from such improper use.

Ambient temperature:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)
Ambient air: free from dust, acids, corrosive gases and substances, etc.

For use at altitudes above sea level: up to 2000 m (6500 ft)

Obligations of the
operator

Obligations of
personnel

The operator undertakes to allow only such people to work with the device
who:

- are familiar with the fundamental instructions regarding safety and acci­dent prevention, and have been instructed how to use the device

- have read and understood the "Safety rules" section and warning notices
in these operating instructions, and then signed them to conrm this

- are trained to produce the required results.

The safe working of personnel must be checked at regular intervals.

Before using the device, all persons instructed to do so undertake:

- to wear personal safety equipment and to use it correctly

- follow the basic instructions regarding safety at work and accident preven-

tion

- to read the "Safety rules" section and warning notices in these operating
instructions, and sign them to conrm that they have understood them
and will follow them.

Before leaving the work area, ensure that no-one or nothing can come to any

harm in your absence.

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Protecting your­self and others

Persons involved with welding exposes themselves to numerous risks, e.g.:

- ying sparks and hot pieces of metal

- light from the arc, which can damage eyes and skin

- hazardous electromagnetic elds, which risk the lives of those using car­diac pacemakers

- risk of electrocution from mains current and welding current

- greater noise pollution

- harmful welding smoke and gases

Anyone working on the workpiece whilst welding is taking place must wear
suitable protective clothing with the following properties:

- ame-resistant

- insulating and dry

- covers the whole body, is undamaged and in good condition

- Safety helmet

- trousers with no turn-ups

Protective clothing refers to a variety of di󰀨erent items. Operators should:

- protect eyes and face from UV rays, heat and sparks using a protective
visor and regulation lter.

- wear regulation protective goggles with side protection behind the safety

visor.

- wear solid footwear that provides insulation even in wet conditions

- protect the hands with suitable gloves (electrically insulated and providing

protection against heat).

Insulated ear protection should be worn to reduce the harmful e󰀨ects of noise
and to prevent injury.

Keep all persons, especially children, out of the working area while any de­vices are in operation or welding is in progress. If, however, there are people

in the vicinity,

- make them aware of all the dangers (risk of dazzling by the arc, injury
from ying sparks, inhaling welding fumes, noise, possible danger from
mains or welding current, etc),

- provide suitable protective equipment or

- erect suitable safety screens/curtains.

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Danger from
toxic gases and
vapours

The fumes produced during welding contain harmful gases and vapours.

This smoke contains substances which may, under certain circumstances,

cause birth defects or cancer.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases,

- must not be breathed in

- must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air.

Otherwise, a protective mask with an air supply must be worn.

If there is any doubt about whether the extraction system is powerful enough,
then the measured toxic emission values should be compared with the per-

missible limit values.

The following components are responsible, amongst other things, for the
degree of toxicity of welding fumes:

- Metals used for the workpiece

- Electrodes

- coatings

- Cleaners, degreasers etc.

Danger from y­ing sparks

The relevant material safety data sheets and manufacturer's specications

for the listed components should therefore be studied carefully.

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's

radiation area.

Flying sparks may cause res or explosions.

Never weld close to ammable materials.

Flammable materials must be at least 11 metres (35 ft) away from the arc, or
alternatively covered with an approved cover.

A suitable, tested re extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through
small gaps or openings. Take appropriate precautions to prevent any danger
of injury or re.

Welding must not be performed in areas that are subject to re or explosion
or near sealed tanks, vessels or pipes unless these have been prepared in
accordance with the relevant national and international standards.

Do not carry out welding on containers which are being or have been used to

store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.

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Risks from mains
current and weld­ing current

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

Do not touch live parts either inside or outside the device.

During MIG/MAG or TIG welding, the welding wire, the wirespool, the drive
rollers and all metal parts that are in contact with the welding wire are live.

Always set the wire-feed unit up on a su󰀩ciently insulated surface or use a
suitable, insulated wire-feed unit mount.

Make sure that you and others are protected with an adequately insulated,
dry temporary backing or cover for the earth or ground potential. This tempo­rary backing or cover must extend over the entire area between the body and

the earth or ground potential.

All cables and leads must be complete, undamaged, insulated and adequate­ly dimensioned. Loose connections, scorched, damaged or inadequately
dimensioned cables and leads must be repaired/replaced immediately .

Do not sling cables or leads either around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc) must

- never be immersed in liquid for cooling

- never be touched when current is owing.

Double the open circuit voltage of a welding machine can occur between the
welding electrodes of two welding machines. Touching the potentials of both

electrodes at the same time may be fatal under certain circumstances.

Arrange for the mains and device supply to be checked regularly by a quali­ed electrician to ensure the PE conductor is functioning properly.

The device must only be operated on a mains supply with a PE conductor
and a socket with an earth contact.

If the device is operated on a mains without a PE conductor and in a socket
without an earth contact, this will be deemed to be gross negligence. The

manufacturer shall not be liable for any damage resulting from such improper
use.

If necessary, provide an adequate earth connection for the workpiece.

Switch o󰀨 unused devices.

Wear a safety harness if working at height.

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