How it Works
Fronius
Loading...
F
Loading...
Loading...
FRC-60

Fronius FRC-60 Operating Instruction [EN]

Download
/ Perfect Welding / Solar Energy / Perfect Charging
FRC-60
Operating Instructions
EN
Remote control
42,0410,1669,EN V04 - 06072016
Table of content
Function of this document .......................................................................................................................... 4
Target group ............................................................................................................................................... 4
Abbreviations used ..................................................................................................................................... 4
Format ........................................................................................................................................................ 4
Copyright .................................................................................................................................................... 4
Meaning of the special safety instructions ................................................................................................. 5
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
1 / 1
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
2 / 35
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.
3 / 35
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.
4 / 35
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.
5 / 35
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.
6 / 35
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.
7 / 35
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.
8 / 35
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.
9 / 35
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.
10 / 35
Risks from mains current and weld­ing current
(continued)
Before working on the device, switch it o󰀨 and disconnect it from the mains
supply.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from reconnecting it to the mains and switching it on again.
After opening the device:
- discharge all live components
- ensure that all components in the device are de-energised.
If work on live parts cannot be avoided, appoint a second person to switch o󰀨 the main switch at the right moment.
EMC measures
It is the operator's responsibility to ensure that no electromagnetic interfer­ence occurs in electrical and electronic devices
If electromagnetic interference is detected, the operator is obliged to take ac­tion to rectify the situation.
Check for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international require­ments:
- Safety features
- power, signal and data transfer lines
- computer and telecommunications devices
- measuring and calibrating devices
- other persons' health, e.g. wearers of pacemakers and hearing aids
- those with pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
Electromagnetic elds may pose as yet unknown risks to health.
Supporting measures for avoidance of EMC problems:
a) Mains supply
- if electromagnetic interference arises despite correct mains connection,
additional measures are necessary (e.g. use a suitable line lter).
b) Welding leads
- keep leads as short as possible
- allow them to run closely together
- kept well apart from other leads
c) Equipotential bonding
d) Earthing the workpiece
- if necessary, establish an earth connection using suitable capacitors.
e) Shield, if necessary
- shield o󰀨 other nearby devices
- screen o󰀨 entire welding installation
11 / 35
Specic areas of risk
Keep hands, hair, clothing and tools away from moving parts, for example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wire
- Pneumatic equipment
Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.
Work environment: The operator alone is responsible for the work environment, e.g. wearing eye protection when welding, extraction of gases and vapours, and enclosing the machine and/or the workstation (if not already integrated into the machine).
The operator alone is responsible for:
- connecting the machine to the existing layout
- enclosing the machine
- wearing eye protection when welding
- ensuring gases and vapours are extracted
- ensuring that workers are wearing personal protective equipment while
welding
Fronius accepts no liability for accidents or injuries arising from failure to
observe these points.
During operation:
- Ensure that all covers are closed and all side panels are tted properly.
- Keep all covers and side panels closed.
- While machines are running, never reach into openings, holes and slots.
- When machines are moving/rotating, take care that parts of the body are
not caught, pulled in, trapped, crushed, etc.
- Observe the mechanical loading of the device, otherwise there is a risk of
dangerous fractures that will impair the stability of the device.
Special provisions apply in areas at risk of re or explosion - observe relevant
national and international regulations.
Devices that are to be used in rooms/areas with increased electric risk (e.g.
near boilers) must carry the Safety sign.
Use only suitable load-carrying equipment when transporting devices by
crane.
- Attach chains and/or ropes to the suspension points provided on the load-
carrying equipment.
- Chains/ropes must be at the smallest angle possible to the vertical.
If the device has a carrying strap or handle, this is intended solely for carry-
ing by hand. The carrying strap is not to be used if transporting with a crane, fork-lift or other mechanical hoist.
12 / 35
Pneumatic equipment
On welding machines with integral pneumatic equipment, observe the follow­ing:
- The maximum operating pressure of the pneumatic system of 8 bar may not be exceeded, unless other operating pressure values are speci-
ed in the operating instructions.
- Fluctuations in compressed air result in erratic operation of the device.
- Contaminated compressed air shortens the service life of pneumatic com­ponents. A maintenance list for pneumatic components has therefore been included in the operating instructions.
- Keep the ambient air free from: dust, acids, corrosive gases or substanc­es.
- Only dismantle the cylinder and other pneumatic components with the as­sistance of Fronius-trained service personnel.
- When commissioning machines note that valves may have undened switching positions. This may lead to uncontrolled movements. Maintain a
safe distance.
- Switch o󰀨 compressed air when working on the pneumatic system.
Vent the entire system and prevent it from being switched on again.
Safety measures at the installa­tion location and during transport
A device that topples over can easily kill someone. Place the device on a solid, level surface in such a way that it remains stable
Special regulations apply in rooms at risk of re or explosion
Observe the applicable national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec­tion shown on the rating plate.
When setting up the device, ensure there is a clearance of 0.5 m (1.6 ft.) all round so that cooling air can enter and exit unhindered.
When transporting the device, observe the relevant national and local guide­lines and accident prevention regulations. This applies especially to guide-
lines regarding the risks arising during transportation.
Before transporting the device, unplug all cables and remove all components
that are not built in (e.g. printers, keyboards, etc.).
After transporting the device, and before commissioning, you MUST carry out
a visual inspection to check whether it has been damaged in any way. Any
damage must be repaired by Fronius-trained service personnel before com-
missioning takes place.
Data protection
The user is responsible for the safekeeping of any changes made to the fac­tory settings. The manufacturer accepts no liability for any deleted personal settings.
13 / 35
Safety measures in normal opera­tion
Only operate the device when all protection devices are fully functional. If the protection devices are not fully functional, there is a risk of
- 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.
Any safety devices that are not functioning properly must be repaired before
switching on the device. Never bypass or disable protection devices. Before switching on the device, ensure that no one is likely to be endan-
gered.
- Check the device at least once a week for obvious damage and proper
functioning of safety devices.
Maintenance and repair
Safety inspec­tion
It is impossible to guarantee that bought-in parts are designed and manufac­tured to meet the demands made on them, or that they satisfy safety require-
ments. Use only original replacement and wearing parts (also applies to
standard parts).
- Only trained experts may change parts and may only do so after having read the supplied installation and dismantling
instructions.
- Components that are not in perfect condition must be changed immedi­ately.
- When ordering, provide the exact description and item number according
to the spare parts
list, as well as the serial number of your device.
Do not carry out and changes, installations or
conversions to the device without the manufacturer's permission.
Emergency Stop protective equipment:
The EMERGENCY STOP protective feature must be checked once a week to ensure it is functioning correctly. The only exception to this is if a di󰀨erent
inspection frequency is called for in the operating instructions of the device or
relevant system conguration.
The operator is obliged to carry out a safety inspection of the device at least once every 12 months.
A safety inspection must be carried out by a qualied electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international
standards and directives.
For further details on safety inspections, contact your local Fronius service centre. They will provide you on request with any documents you may re­quire.
14 / 35
Disposal
Do not dispose of this device with normal domestic waste! To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equip-
ment 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 your dealer, or nd out about the approved collection and
recycling facilities in your area.
Ignoring this European Directive may have potentially adverse a󰀨ects on the environment and your health!
Safety sym­bols
Devices with the CE marking satisfy the essential requirements of the low-
voltage and electromagnetic compatibility directives.
Devices with the CSA test mark satisfy the requirements of the relevant
standards in Canada and the USA.
15 / 35
General
Device concept
Proper use
The FRC-60 remote control is a system component and is used to operate the pow­ered FTU 900-500, 900-1000, 1200-1000 and 1600-1500 tripod units. The system performs mechanised length­wise seam and overlay welding. The re­mote control is connected to the tripod unit
using a anged plug connector. The device
2
H
FRC-60
t
4
6
0
10
V
t
4
6
2
8
0
10
cm/ min
8
STARTSTOP
can also be used in harsh environments
owing to its robust design, stable aluminium frame and powder coating of all housing
components. The FRC-60 remote control
is equipped with a digital display and thus allows continuous monitoring of the travers-
ing speed in real time.
FRC-60 remote control
The FRC-60 remote control should only be used for remotely operating and presetting
the powered FTU 900-500, 900-1000, 1200-1000 and 1600-1500 tripod units. Any use
above and beyond this purpose is deemed improper. The manufacturer shall not be li­able for any damage resulting from such improper use.
The device can be used for:
- Remote control of welding axis ... for performing mechanised lengthwise seam welds
- Remote control of o󰀨set welding axis ... for performing overlay welding
Can be used in the following welding processes:
- MIG/MAG process
- CMT process
- TIG process
Proper use includes:
- following all the information in the operating instructions
- using the spare parts stipulated by Fronius
- using this document in combination with the operating instructions for the integrated system components (tripod unit, power source, wire-feed unit, etc.)
Standard equip­ment
The FRC-60 remote control is equipped with the following as standard:
- connected to the remote control: 1 remote control cable, 17-pin, 3 m, incl. anged plug with union nut
- attached to the remote control: remote control holder
Options Designation Item no.
Remote control holder (designed for wall mounting or for mounting on the vertical column of the tripod unit) BP8,0604,000
3 m adapter cable (cable for connecting the FTU control box to the
power source) 38,0100,0018
Installation kit for the FTU o󰀨set axis (only in combination with 8,100,151) 8,100,152
16 / 35
System descriptions
General
"Welding axis" application
The illustrations below show the FRC-60 remote control connected up to commonly-used components. Two separate applications are represented.
In this application the remote control is used to activate a mechanised lengthwise seam weld. This is done with the workpiece in either a horizontal or vertical position. The weld­ing path is set by means of adjustable limit positions on the tripod unit. The remote control positions the welding torch in relation to the workpiece by means of a motor, and the welding process then begins. Welding nishes when the limit position on
the tripod unit is reached.
FTU tripod unit ...
Wire-feed unit
Welding torch
Power source
Use as a welding axis
FRC-60 remote control
FRC-60
cm/ min
t
t
4
4
6
6
2
2
8
8
10
10
0
0
H
STARTSTOP
V
Workpiece
17 / 35
"O󰀨set welding axis" application
This application involves mechanised overlay welding on pipes. The FRC-60 remote control works alongside a higher-level rotary unit controller. Its function is to preset the parameters on the tripod unit. Welding is performed with the workpiece in either a hori­zontal or vertical position. The welding path is set by means of adjustable limit positions
on the tripod unit.
The FRC-60 remote control positions the welding torch relative to the workpiece by means of a motor. Overlay welding is started by the rotary unit controller. For each complete revolution the welding torch is shifted by 1 step. The direction and duration of the o󰀨set is dened on the remote control. Welding nishes when the limit position is
reached.
FTU tripod unit ...
Wire-feed unit
Power source
control
FRC-60
FRC-60
t
4
6
2
2
8
10
0
H
V
"Oset welding axis" application
Remote
Welding torch
cm/ min
t
4
6
8
10
0
STARTSTOP
Workpiece
Control
Rotary unit
Rotary unit
18 / 35
Control elements and connections
Safety
FRC-60 remote control, front view
(12)
(11)
WARNING! Operating the equipment incorrectly can cause serious injury and dam­age.
Do not use the functions described until you have thoroughly read and under-
stood the following documents:
- these operating instructions
- all operating instructions for the system components
(2)
(3)
(4)
t
4
2
0
H
FRC-60
6
2
8
10
V
(1)
t
4
6
8
0
10
cm/ min
STARTSTOP
(7)(8)(9)(10)
FRC-60 control panel
(6)
(1) Traverse speed digital indicator
... indicates the current traverse speed of the tripod unit in cm/min. The digital
display has green background lighting which is permanently on.
Display unit: cm/ min Display range: 0.0 - 99.9
(2) Traverse speed potentiometer
... for setting the traverse speed on the tripod unit. This can also be
changed while the unit is in motion.
(3) Emergency Stop button
... deactivates the control voltage, stops all tripod unit movements and prevents
restarting. The power source arc is broken immediately. All controls are disabled
during an emergency stop.
NOTE! The EMERGENCY STOP safety equipment must be checked each
time before starting work to ensure it is functioning correctly.
(4) Welding ON/OFF selector switch
... For choosing whether to run the welding sequence with or without welding. This can be done without welding for test purposes.
(5)
19 / 35
FRC-60 remote control, front view
(continued)
(5) Pneumatic system on/o󰀨 button
... in order for a pneumatic unit to raise or lower the torch (pneumatic torch lowering). The button will be lit when this function is activated. Important! Press "Stop" button when welding torch is lowered to preselect the welding process. The welding torch is raised and selected for the start of the welding
process.
(6) Stop button
... for stopping a welding process. The welding process can be continued by
pressing the "Start" button.
(7) Start button
... for starting or continuing a welding process.
(8) Manual Move button
... for precision manual positioning. If this button is held down in one direction for longer than three seconds, it automatically switches to high speed mode.
(9) Traverse direction selector switch
... for specifying the traverse direction for the selected axis.
(10) H/V axis selector switch
... for switching the horizontal/vertical axes. Switching to the other axis can even be done while the torch is moving.
(11) Start-up delay potentiometer
... for setting the time between arc
Welding current
ignition and the start of welding
movement (FTU tripod unit ...). Unit: 0.5 s
FTU tripod unit movement ...
t
V
Setting range: 0 - 10
tV ...Start-up delay
(12) O󰀨set potentiometer
... for setting o󰀨set time on the tripod unit. When overlay welding, for each complete revolution of the rotary unit, the welding torch is switched to the specied direction for the specied length of time. This can also be changed while the unit is in motion.
Unit: 0.5 s Setting range: 0 - 10
20 / 35
FRC-60 remote control, rear view
(1)
(2)
(3)
FRC-60 rear view
(1) remote control holder
... for attaching the remote control to the remote control holder on the tripod.
(2) Cable gland
... Cable gland with strain relief device and anti-kink protection.
(3) Connecting plug with cable
... for connecting to the tripod unit control box.
21 / 35
Commissioning
Safety
Checking the connections
WARNING! Risk of injury or damage if the equipment is operated incorrectly. Do not
use the functions described until you have thoroughly read and understood the
following documents:
- these operating instructions
- all operating instructions for the system components
The following activities and work steps apply to the installed system. All connections
must be established.
Check the connections to the following system components before commissioning:
- Tripod unit
- Power source
- Cooling circuit
- Gas cylinder
- Wire-feed unit
- Welding torch with hosepack
- Rotary unit (when using o󰀨set welding axis)
- Rotary unit controller (when using o󰀨set welding axis)
Precise information on the assembly and connection of the system components can be found in the relevant system component operating instructions.
Connecting the remote control
Important! The connection socket for the
FRC-60 remote control is located on the underside of the tripod unit control box.
1. Connect the remote control plug to the
connecting socket on the tripod unit
control box.
2. Tighten the union nut by hand to x the
torch in place
Connect the FRC-60
22 / 35
Switch on system compo­nents
WARNING! Danger of injury when welding torch moves downwards.
When a pneumatic torch lowering unit is used, the torch is lowered when the "Pneumatic ON/OFF" button is actuated. Hands can be crushed or otherwise injured.
- Avoid contact with the torch lowering unit
- Before switching on, make sure that the "Pneumatic ON/OFF" button on the FRC-60 remote control is unlocked.
Important! There are no xed rules for the sequence in which the system components are switched on. They can be switched on in any order.
Turn the main switch to the "1" position (ON) on the following system components:
- Tripod unit control box
- Power source
- Wire-feed unit (if power is not supplied from the power source)
- Rotary unit controller (when using o󰀨set welding axis)
Checking the EMERGENCY
NOTE! The EMERGENCY safety equipment must be checked each time before
starting work to ensure it is functioning correctly.
STOP safety equipment 1. Press the EMERGENCY STOP button
on the FRC-60 remote control.
2. Check the following points:
- Control voltage on the tripod unit control is deactivated
- All other control elements on the remote control are deactivated
- All movements have stopped
- Any active arc is immediately
broken
- Compressed air supply is switched
o󰀨
Emergency Stop button
Positioning the welding torch
NOTE! The workpiece must be aligned and located in its welding position.
You should check this before positioning the torch.
Use the FRC-60 remote control for the positioning operation:
1. Congure the following tripod unit settings:
- Traverse axis
- Traverse direction
- Traverse speed
2. Press the MANUAL MOVE button and move the welding torch to the workpiece. Important! If the button is held down for longer than three seconds then the torch
will switch over to high speed. This high speed is preset by the system and cannot be
altered.
23 / 35
Positioning the welding torch
(continued)
3. Switch over the "H/V axis" selector switch. The opposite axis will now be activated.
4. Press the MANUAL MOVE button and continue the positioning process. Continue positioning the welding torch using the respective axes until it is correctly
positioned.
Lowering and setting up the welding torch
WARNING! Danger of injury when welding torch moves downwards.
Hands can be crushed or otherwise injured. Avoid contact with the torch lowering unit
CAUTION! Danger of the welding torch colliding with the workpiece.
If the torch is not moved back far enough it may collide with the workpiece.
- Before lowering the welding torch, rst make sure that it is positioned far enough back.
- Bear in mind the extension stroke of the torch lowering unit being used.
1. Press the "Pneumatic" button. Welding torch is lowered.
2. Turn the adjusting dial on the relevant mechanical adjustment unit (FGU, FSU) until the correct welding torch
2.
position is reached.
2.
Setting up the welding torch
3. Press Stop button. The welding torch is raised slightly and the torch lowering unit is selected for the welding process.
24 / 35
Loading a weld­ing program
Load the relevant welding program on the control panel for the power source. More de­tailed information on managing welding programs can be found in the operating instruc­tions for the power source.
Important! When an analogue power source is used, the requisite welding parameters must be set manually on the power source.
Information about the welding programs: A relevant welding program should be cre­ated for each workpiece. This contains a list of welding parameters that is saved under a specic program number (JOB number). These programs can be reloaded at any time, and corrected as required. The programs are managed from the power source control
panel.
Dening parame­ters for the tripod unit
The following parameters should be dened on the FRC-60 remote control for the weld­ing process:
- Traverse axis
- Traverse direction
- Traverse speed
- Start-up delay
- O󰀨set (when using o󰀨set welding axis)
- Pneumatic ON/OFF
- Welding ON/OFF
Set up the welding path on the tripod unit according to the length or height of the work­piece. Reposition the vertical or horizontal contact cams depending on the welding direc-
tion.
Important! Each contact cam is secured
with two size 5 cheese-head screws tted
on the inside.
vertical
1. Undo the cheese-head screws using a hollow hexagon wrench
2. Move the contact cam to the desired position
horizontalhorizontal
3. Tighten the cheese-head screws
Contact cams on the tripod unit
vertical
25 / 35
Carrying out a test run
Perform a test run to check that all system components work together correctly. This is carried out without an arc and thus allows every movement to be checked:
WARNING! Risk of injury from moving machine parts.
The moving tripod unit or rotating rotary unit can cause serious injuries if body
parts are snagged by machine parts.
- Ensure there is no-one in the danger area of the machine before starting the procedure
- Avoid contact with these machine parts
1. Turn the Welding ON/OFF selector switch to OFF
2. Press START button on FRC-60 remote control. To stop the process early press the STOP button.
Important! If an o󰀨set welding axis is used, start the test run by pressing the START
button on the rotary unit controller.
3. Carry out a visual check during the test run
4. If required, make any corrections (welding torch position, workpiece, contact cam,
etc.)
Starting the weld­ing process
WARNING! Risk of injury from moving machine parts.
The moving tripod unit or rotating rotary unit can cause serious injuries if body
parts are snagged by machine parts.
- Ensure there is no-one in the danger area of the machine before starting the procedure
- Avoid contact with these machine parts
Start the welding process:
1. Turn the Welding ON/OFF selector switch to ON
2. Press START button on FRC-60 remote control. To stop the process early press the STOP button.
Important! If an o󰀨set welding axis is used, start the welding process by pressing the
START button on the rotary unit controller.
The welding process stops automatically once the relevant contact cam is reached.
26 / 35
Troubleshooting
General
Safety
In the event of faults, note that the function of the entire system depends on many ad­ditional components that are also potential sources of problems.
NOTE! Repairs may only be carried out by qualied experts or by Fronius serv- ice personnel.
WARNING! An electric shock can be fatal.
Before opening the unit
1. Switch the device mains switch to the "O" position
2. Unplug the device from the mains
3. Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
WARNING! Failure to connect a correctly-dimensioned earth lead may result in seri­ous injury or damage.
The housing screws provide an adequate PE conductor connection for earth­ing the housing.
They must NOT be replaced by any other screws that do not provide a reliable
PE conductor connection.
Basic require­ments for the system to work
Possible errors in "Welding axis" application
- Connections established between separate system components
- System components are supplied with electricity and the mains voltage for each com­ponent complies with the rating plate
- Pneumatic system is supplied with compressed air at the correct pressure (see tripod
unit rating plate)
No movements possible
All control elements on the remote control are inoperative, digital traverse speed indica­tor is dark
Cause: no connection to the tripod unit
Remedy: check connecting lead and control box connection - union nut must
be securely tightened
Cause: no power supply or tripod unit control box switched o󰀨 Remedy: check mains connection, check circuit breaker (13 A), switch on
tripod unit control box
Cause: the Emergency Stop protection feature of the FRC-60 remote control
was activated because of an emergency
Remedy: rectify emergency stop situation and reset emergency stop button
27 / 35
Possible errors in "Welding axis" application
(continued)
Tripod unit moves but arc does not ignite
After the START button is pressed, the tripod unit carries out the welding movement but
the arc does not ignite
Cause: welding is deactivated (test mode) Remedy: Turn the Welding ON/OFF selector switch to ON
Cause: no start signal on the power source Remedy: check control line to power source
Cause: fault on the power source - error message on display Remedy: address the error message that is displayed - see power source
operating instructions
Cause: special function activated on the power source
Remedy: select normal mode
Arc ignites but tripod unit does not move
After the START button is pressed, the arc ignites but the tripod unit does not move
Cause: "Start-up delay" setting too high
Remedy: use potentiometer to adjust the start-up delay setting
Cause: frequency inverter malfunction Remedy: 1. Switch o󰀨 control box
2. Wait 15 seconds
3. Switch control box back on
Possible errors in "O󰀨set welding axis" ap­plication
No o󰀨set movement
Welding torch not o󰀨set at the end of the entire revolution
Cause: o󰀨set time or traverse speed of torch too low Remedy: use appropriate potentiometer to adjust the setting
Cause: Emergency Stop protection device activated Remedy: rectify emergency stop situation and reset emergency stop button
Cause: limit position reached on tripod unit
Remedy: move away from or correct limit position
Cause: no o󰀨set signal from rotary unit - limit switch for 360° damaged or
cam moved
Remedy: replace limit switch or adjust cam position
28 / 35
Technical data
FRC-60 technical data
Supply voltage 24 V DC voltage
Current input 200 mA
Power consumption 5 VA
Housing components Aluminium
Colour powder coating, black
Dimensions A 280 mm B 185 mm C 145 mm D 65 mm E 55 mm
Weight 2 kg
Connecting cable length 3 m
No. of pins on connecting plug 17
Suitable types of tripod unit FTU 900-500 FTU 900-1000 FTU 1200-1000 FTU 1600-1500
A
4
2
0
H
FRC-60
t
6
8
10
V
t
4
6
2
8
0
10
cm/ min
B
STARTSTOP
C
D
FRC-60 remote control, dimensions
E
29 / 35
Spare parts overview
13
13.1
13.2
13.3
12
12.1
11
11.1
t
4
2
0
H
FRC-60
6
2
8
10
V
14
14.1
14.2
14.3
t
4
0
15
15.1
15.2
15.3
1
2
2.1
3
cm/ min
6
8
10
STARTSTOP
4
4.1
5
5.1
6
6.1
10
10.1
7
7.1
8
8.1
9
16
Spare parts for FRC-60 remote control
30 / 35
Ordering details NOTE! Only trained technicians may change parts and may only do so after
having read the installation and dismantling instructions supplied.
When ordering spare parts for the FRC-60 remote control you should provide the follow­ing data:
- Exact designation of the spare part
- Associated item number as per spare parts list
- Model name of the device
- Serial number (shown on the rating plate)
Spare parts list
Item Designation Number Item no.
FRC-60 with 3 m cable 1 8,045,128
1 Traverse speed digital indicator 1 38,0102,0019
2 Emergency Stop button 1 38,0002,0056
2.1 N.C. contact element 2 38,0002,0091
3 Emergency Stop adhesive labels 1 38,0002,0060
4 Welding ON/OFF selector switch 1 38,0002,0095
4.1 N.O. contact element 1 38,0002,0090
5 Pneumatic system ON/OFF button 1 38,0002,0094
5.1 N.O. contact element 1 38,0002,0090
6 Stop button 1 38,0002,0093
6.1 N.O. contact element 1 38,0002,0090
7 Start button 1 38,0002,0092
7.1 N.O. contact element 1 38,0002,0090
8 Cable gland 1 42,0407,0481
8.1 Lock nut 1 38,0004,0047
9 Connecting plug with cable 1 38,0100,0201
10 Manual Move button 1 38,0002,0097
10.1 N.O. contact element 2 38,0002,0090
11 Traverse direction selector switch 1 38,0002,0095
11.1 N.O. contact element 1 38,0002,0090
12 H/V axis selector switch 1 38,0002,0095
12.1 N.O. contact element 1 38,0002,0090
13 Start-up delay potentiometer 1 41,0001,0481
13.1 Adjusting knob 1 42,0406,0099
13.2 Pointer dial 1 42,0406,0109
13.3 Cover 1 42,0406,0213
14 O󰀨set potentiometer 1 41,0001,0481
14.1 Adjusting knob 1 42,0406,0099
14.2 Pointer dial 1 42,0406,0109
14.3 Cover 1 42,0406,0213
15 Traverse speed potentiometer 1 41,0001,0586
15.1 Adjusting knob 1 42,0406,0099
15.2 Pointer dial 1 42,0406,0139
15.3 Cover 1 42,0406,0107
16 Remote control holder 1 BE58,0355,0308
31 / 35
Circuit diagrams
32 / 35
33 / 35
34 / 35
EU-Declaration of conformity
35 / 35
FRONIUS INTERNATIONAL GMBH
TechSupport Automation
E-Mail: support.automation@fronius.com
www.fronius.com
www.fronius.com/addresses
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use