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Fronius Acerios, Operating Instructions Manual

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Plasma torch gets very hot

Plasma torch is under-dimensioned
Observe duty cycle and load limits

Coolant flow too low
Check coolant level, coolant flow rate, water contamination, etc. If
coolant pump blocked: use a screwdriver to turn on the shaft of the
coolant pump at the gland

Parameter C-C is set to "OFF".
In the Setup menu, set parameter C-C to "Aut" or "ON".

Cause:
Remedy:

Cause:
Remedy:

Cause:
Remedy:

76

Summary of Contents for Acerios

Page 1: ...Operating instructions Acerios 42 0426 0326 EA 003 21032022 EN US Operating instructions...

Page 2: ......

Page 3: ...as 13 Safety Measures at the Setup Location and During Transport 14 Safety Measures in Normal Operation 14 Maintenance and repair 15 Safety Inspection 15 Disposal 15 Safety symbols 16 Data backup 16 C...

Page 4: ...ssing the Setup Menu 55 Accessing the 2nd Level Setup Menu 55 Adjusting Parameters 55 Parameters in the Setup Menu 56 Parameters in the 2nd Level Setup Menu 57 Exiting the 2nd Level Setup Menu 60 Exit...

Page 5: ...urce Troubleshooting 75 Service maintenance and disposal 77 General 77 Safety 77 At every start up 77 Every 2 Months 77 Every 6 Months 78 Disposal 78 Appendix 79 Technical data 81 Special Voltage 81 A...

Page 6: ...r material assets belonging to the operating company inefficient operation of the device All persons involved in the commissioning operation maintenance and servicing of the device must be suitably qu...

Page 7: ...ge resulting from improper use Temperature range of the ambient air During operation 10 C to 40 C 14 F to 104 F During transport and storage 20 C to 55 C 4 F to 131 F Relative humidity Up to 50 at 40...

Page 8: ...ve the following properties Flame resistant Insulating and dry Covering the entire body and in good condition with no damage Safety helmet Cuffless pants Protective clothing involves the following Pro...

Page 9: ...om the work area using appropriate equipment Use breathing apparatus with air supply if there is insufficient ventilation When no work is taking place close the valve of the gas cylinder or the main g...

Page 10: ...itudinal axis and pretension Do not wrap cables or leads around your body or parts of the body The electrode never immerse it in liquids to cool it never touch it when the power source is switched on...

Page 11: ...ugh 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 sit...

Page 12: ...the plasma torch and other parts with a high operating temperature to cool before working on them Special regulations apply in areas at risk of fire or explosion follow the appropriate national and in...

Page 13: ...g open flames sparks and arcs Mount the gas cylinders vertically and secure them in accordance with instruc tions so they cannot fall over Keep gas cylinders away from electrical circuits Ensure that...

Page 14: ...and regional guidelines and acci dent prevention regulations are observed when transporting the device espe cially guidelines concerning hazards during transport and shipment Do not lift or transport...

Page 15: ...they satisfy safety require ments Use only original spare and wearing parts also applies to standard parts Do not carry out any modifications alterations etc to the device without the manufacturer s c...

Page 16: ...eclaration of Conformity is available on the following website http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA Data...

Page 17: ...General information 17...

Page 18: ...18...

Page 19: ...t cycle times and high repeatability NOTE The plasma surface treatment process will simply be referred to as the plasma process in the rest of these instructions Operating Prin ciple The central contr...

Page 20: ...ed on an upright console 1 Acerios plasma power source Robot interface 2 FK 9000 R cooling unit 3 TU Podium upright console 4 Gas control 5 30 l digital external gas regulator 5 PCT 2000 plasma torch...

Page 21: ...Operating controls and connec tions 21...

Page 22: ...22...

Page 23: ...ice versa In addition individual figures may also differ slightly from the operating ele ments of your device However the function of these operating elements is identical Safety WARNING Danger from i...

Page 24: ...e from the starting current Istart to the spe cified main current Imain during the plasma process Main current for the plasma process DownSlope Period of time it takes to fall from the specified main...

Page 25: ...ameters starting current Istart main current Imain and final current Iend The left digital display shows the set value before the start of the plasma process For Istart and Iend the right digital disp...

Page 26: ...n Input for the collision protection signal if connecting a robot interface or fieldbus coupler 12 Operating mode button For selecting the operating mode 2 step mode 4 step mode Job Mode When a mode i...

Page 27: ...ndicator illuminates on the control panel Now if a button is pressed the lock message CLo SEd will appear on the con trol panel The selection dial can only be used to change the parameter selected whe...

Page 28: ...2 1 65 432 1 hours 65 432 hours 6 mins NOTE The runtime indicator is not suitable as a basis for calculating hiring fees war ranty services etc Show coolant flow Only in conjunction with a cooling uni...

Page 29: ...control connection Input for the collision protection signal if connecting a robot interface or fieldbus coupler 4 Current socket with bayonet latch and gas outlet Connect the plasma torch here 5 Pow...

Page 30: ...30...

Page 31: ...Installation and Startup 31...

Page 32: ...32...

Page 33: ...m proper use Intended use also means Following all instructions in these Operating Instructions Reading the Operating Instructions of all the other system components es pecially the safety rules in th...

Page 34: ...attached to your version of the appli ance these must be installed according to national standards Fuse protection for the grid lead can be found in the technical data CAUTION Danger due inadequately...

Page 35: ...f the plasma system The standard configuration consists of the following system components Acerios plasma power source including robot interface FK 9000 R cooling unit PCT 2000 plasma torch Gas pressu...

Page 36: ...the plasma torch to the plasma power source and the cooling unit 6 Connect the plasma torch to the external gas regulator 7 Use a LocalNet cable to join the external gas regulator to the plasma power...

Page 37: ...s pressure regulator 5 Screw the gas pressure regulator to the gas cylinder and tighten the connec tion 6 Use a gas hose to join the gas pressure regulator and the GAS IN connection at the external ga...

Page 38: ...38...

Page 39: ...Plasma Surface Treatment 39...

Page 40: ...40...

Page 41: ...ode overloaded indicator illuminates on the control panel Possible causes of an overloaded electrode Diameter of the tungsten electrode is too small Main current Imain value is set too high Remedy Use...

Page 42: ...e robot control system 1 0 Reset trigger signal Start with starting current Istart trigger signal active UpSlope and working with main current Imain trigger signal not active Lowering to final current...

Page 43: ...al injury and damage to property Before starting work switch off all devices and components involved and disconnect them from the grid Secure all devices and components involved so they cannot be swit...

Page 44: ...corresponding process parameters 5 Set the selected parameters to the desired value with the selection dial All parameter set values that are set using the selection dial are saved until their next a...

Page 45: ...displays the service code no IGn The 2nd Level Setup Menu section describes how to set the ignition time out function ito parameter Plasma Pulsing The current set at the start of a plasma surface trea...

Page 46: ...current and process voltage values are saved each time a process ends The hold function relates to the last main current Imain to be reached If other parameters are selected the set values will be di...

Page 47: ...plasma power source is ready for use immediately The jobs can be grouped or lined up in ac cordance with the production process The result is minimal downtime at fully reproducible quality as well as...

Page 48: ...to select the desired program location or leave the suggested program location 4 Press and hold the store button NOTE If the selected program location already has a job assigned to it the existing jo...

Page 49: ...ter selection buttons to view the settings pro grammed in the job It is not possible to change these settings It is not possible to select unassigned program locations indicated by either when retriev...

Page 50: ...t free program location is suggested for the job being copied 4 Use the selection dial to select the desired program location or leave the suggested program location 5 Press and hold the store button...

Page 51: ...7 Briefly press the store button to exit the Job menu The power source switches to the setting requested before the job was copied 51 EN US...

Page 52: ...ete The DEL symbol illuminates on the gas test button 3 Press and hold the gas test button dEL shows on the left digital display the job is deleted When nPG appears on the left digital display deletin...

Page 53: ...Setup Settings 53...

Page 54: ...54...

Page 55: ...ough their own shortcut keys Accessing the Setup Menu 1 Press the operating mode button to select 2 step mode 2 Press and hold the store button 3 Press the operating mode button The power source is no...

Page 56: ...for 2 step mode OFF 0 01 9 9 s Factory setting OFF The starting current time t S indicates the duration of the starting cur rent phase Istart t E Final current time for 2 step mode OFF 0 01 9 9 s Fac...

Page 57: ...me Time from when the flow sensor is triggered until the no H2O service code is output For example if there are air bubbles in the cooling system the cooling unit will not cut out until the end of thi...

Page 58: ...The arc break monitoring function is described on page 45 SEt Country specific setting Std US Standard USA Factory setting Std metric units E P External parameter A freely selectable parameter for the...

Page 59: ...ted immediately The main cur rent Imain is not automatically selected COr Gas correction For entering a gas correction factor for the process gas only in conjunction with the digital gas control or ex...

Page 60: ...g the 2nd Level Setup Menu 1 Press the store button The power source is now located in the Setup menu 2 Press the store button again to exit the Setup menu Exiting the Setup Menu 1 Press the store but...

Page 61: ...ma System Resistance r 1 In Gas Setup set the GAS parameter to OFF 2 Establish contact between the electrode and the plasma nozzle 3 Access the 2nd level Setup menu 4 Use the left or right parameter s...

Page 62: ...can be produced especially during pulsing The increase in current is limited Correct hosepack arrangement Plasma stability can be optimized by modifying the hosepack arrangement The hosepack must alw...

Page 63: ...ut Factory setting Aut The setting for G H only applies if the maximum process current is actu ally set The actual value results from the process current at that mo ment With a medium process current...

Page 64: ...Instructions GPU Gas pre purging OFF 0 1 10 0 min Factory setting OFF Gas pre purging starts as soon as a value is set for GPU For safety reasons it is necessary to re enter a value for GPU in order t...

Page 65: ...e the selection dial to change the parameter value IMPORTANT The adjusted parameters are immediately saved and applied to the plasma process Correctable Parameters in the Job Correc tion Menu NOTE Som...

Page 66: ...oth transition of the process current from the job in ques tion to the job next in line OFF 0 1 9 9 s Factory setting OFF IMPORTANT JSL job slope can be adjusted separately for each saved job It is on...

Page 67: ...e 56 t E Final current time OFF 0 01 9 9 s Factory setting OFF More information on the t E parameter can be found on page 56 I c Imain correction range for job retrieval OFF 1 100 Factory setting OFF...

Page 68: ...68...

Page 69: ...Troubleshooting and Maintenance 69...

Page 70: ...70...

Page 71: ...and components involved and disconnect them from the grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to...

Page 72: ...to cool Cause Remedy tP5 xxx Note xxx stands for a temperature value Overtemperature in the primary circuit of the power source Leave power source to cool Cause Remedy tP6 xxx Note xxx stands for a t...

Page 73: ...he Setup menu The power source safety cut out has tripped Check the plasma torch wearing parts if necessary increase the period of time in the 2nd Level Setup Menu to the safety cut out Cause Remedy E...

Page 74: ...adjustment Poor contact between the electrode and the plasma nozzle Check the plasma torch wearing parts Cause Remedy no Arc Plasma arc break Check plasma torch wearing parts check process parameters...

Page 75: ...rmal circuit breaker has tripped Wait until the power source automatically comes back on after the end of the cooling phase Fan in the power source is faulty Contact After Sales Service Cause Remedy C...

Page 76: ...oolant flow too low Check coolant level coolant flow rate water contamination etc If coolant pump blocked use a screwdriver to turn on the shaft of the coolant pump at the gland Parameter C C is set t...

Page 77: ...switch off all devices and components involved and disconnect them from the grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable...

Page 78: ...ced compressed air 2 Also clean the cooling air ducts if there is a large accumulation of dust WARNING An electric shock can be fatal Danger of electric shock due to grounding cable and device groundi...

Page 79: ...Appendix 79...

Page 80: ...80...

Page 81: ...10 min 40 C 104 F 100 D C 3 200 A Open circuit voltage 97 V Working voltage 11 4 33 0 V Striking voltage Up 9 5 kV Protection class IP 23 Type of cooling AF Insulation class F EMC device class accord...

Page 82: ...82...

Page 83: ...83 EN US...

Page 84: ...Froniusstra e 1 4643 Pettenbach Austria contact fronius com www fronius com Under www fronius com contact you will find the adresses of all Fronius Sales Service Partners and locations spareparts fro...

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