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Fronius Calibration system 2.0, Operating Instructions Manual

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Summary of Contents for Calibration system 2.0

Page 1: ...Operating instructions Calibration system 2 0 42 0426 0270 EN 012 14032022 EN Operating instructions...

Page 2: ......

Page 3: ...ormation 13 General 15 Device concept 15 Proper use intended purpose 15 Crane transport 16 Accessories and options 17 Interface and trolley 17 Accessories 17 Options 19 Required for calibration 20 Com...

Page 4: ...e calibration system 60 Connecting the computer to the calibration system and signature pad 60 Preparing the gas calibration system 60 Calibrating the welding system 61 Calibrating other Fronius weldi...

Page 5: ...pany inefficient operation of the device All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read a...

Page 6: ...rt and storage 0 C to 40 C 32 F to 104 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or substances etc Can be used a...

Page 7: ...ts of noise and to prevent in jury Keep all persons especially children out of the working area while any devices are in operation or calibration is in progress If however there are people in the vici...

Page 8: ...tial and industrial areas This is also true for residential areas in which the energy is supplied from the public low voltage mains EMC device classification as per the rating plate or technical data...

Page 9: ...panels are fitted properly Keep all covers and side panels closed The welding wire emerging from the wire speed measuring system poses a high risk of injury piercing of the hand injuries to the face a...

Page 10: ...der Close the shielding gas cylinder valve if no welding is taking place If the shielding gas cylinder is not connected leave the valve cap in place on the cylinder The manufacturer s instructions mus...

Page 11: ...exact designation and part number as shown in the Spare Parts List as well as the serial number of your device The housing screws provide the ground conductor connection for earthing the housing parts...

Page 12: ...al requirements of the low voltage and electromagnetic compatibility directives Further details can be found in the appendix or the section headed Technical data in your documentation Data protection...

Page 13: ...General information 13...

Page 14: ...14...

Page 15: ...tc Proper use in tended purpose The device is only intended to be used for calibrating and testing welding systems and power sources Any use above and beyond this purpose is deemed improper The manufa...

Page 16: ...or 4 ropes to the 4 suspension points Route chains ropes so they are at the smallest angle possible to the vertical Check and maintain load carrying equipment to ensure it adheres to national regulat...

Page 17: ...Accessories and options Interface and trolley Interface calibration system 4 050 211 Trolley calibration system 4 077 022 Accessories 1 2 3 4 5 6 7 8 9 14 15 16 13 12 11 10 17 17 EN...

Page 18: ...for use with the Euro central connector adapter 44 0001 1204 8 1 x gas hose 1 5 m 2 x 1 4 44 0001 0538 9 Adapter ZA Euro FSC 44 0350 3329 10 1 x USB connection cable to PC laptop 43 0004 5963 11 Sock...

Page 19: ...socket 43 0004 4850 2 x USB Ethernet adapter EU 4306 43 0004 5688 Options Designation Item no Signotec signature pad 41 0006 0126 1 5 m gas hose 2 x 1 4 44 0001 0538 5 m gas hose 2 x 1 4 44 0001 0695...

Page 20: ...2 0 Interface calibration system Welding wire calibration system Accessories calibration system Trolley calibration system Required for cal ibration of the WeldCube Con nector For the calibration of...

Page 21: ...injector RJ45 30 W 802 3at PoE 42 0411 0213 M12 X RJ45 network cable 5 m 42 0411 0232 TPS 500i power source WF 25i WF 30i wirefeeder with Euro central connection alternatively WF 25i WF 30i wirefeede...

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Page 23: ...Controls connections and mechan ical components 23...

Page 24: ...24...

Page 25: ...5 USB port computer laptop 6 USB port for adapter 7 USB port for adapter 8 SpeedNet connection socket 9 Welding wire calibration system connection socket 10 Status indicator Lights up green Device is...

Page 26: ...tection 2 F4 fuse 2 A slow blow 24 V PLC fuse protection 3 Mains cable connection 4 Main fuse for the device F1 4 A slow blow 5 Mains switch 6 230 V socket for 230 V power supply 7 230 V socket for 23...

Page 27: ...Mechanical components on trolley Calibration sys tem trolley 5 4 3 2 1 Item Designation 1 Calibration system trolley option 2 Accessory drawers 3 Cable hanger 4 Tray 5 Storage trays 27 EN...

Page 28: ...28...

Page 29: ...Installation 29...

Page 30: ...30...

Page 31: ...ationSystem2 0_vX X XX X_MULTI twincat 2 Install the file located there and follow the setup instructions 3 Restart the PC only if prompted to do so at the end of installation USB to LAN driver Window...

Page 32: ...librationSystem2 0_vX X XX X_MULTI driver OMNIKEY 2 Depending on the operating system select the subfolder install the file loc ated there and follow the instructions Win7 Win8 Successful installation...

Page 33: ...er Ports Ports COM LPT 8 Restart the PC only if prompted to do so at the end of installation 9 If a driver is already installed ensure that it is the latest version and if necessary update it If the d...

Page 34: ...TANT Prerequisites for USB calibration DHCP server which starts automatically when the program starts net Framework at least version 4 7 2 1 Specify network settings for USB calibration a Via the cali...

Page 35: ...ly from the power source and reconnect it again Only connect the USB Ethernet adapter to the calibration system not to the computer laptop Setting a Twin Cat route 1 Click on the TwinCat symbol in the...

Page 36: ...a Check network settings The calibration station must be accessible in the Windows command prompt CMD at the IP address 192 168 120 50 with the ping command b Various security programmes e g F Secure...

Page 37: ...he program is restarted NOTE Only the user interface of the calibration software is displayed in the chosen language The language for the calibration report must be set separately Retrieving sys tem i...

Page 38: ...38...

Page 39: ...Calibrating welding systems 39...

Page 40: ...40...

Page 41: ...he FLUKE measuring device used Correcting set values and load resistances If the values specified by the calibration software are not achieved the set value or load resistance may need to be modified...

Page 42: ...required TSt 2500c 2700c 3000 c Pulse 3500c TIG welding systems TT 800 2200 2500 3000 4000 5000 TT 800 2200 2500 3000 4000 5000 Job TT 2200 2500 3000 4000 5000 Comfort MW 1700 2200 2500 3000 4000 5000...

Page 43: ...Connect the LocalNet USB con verter to the calibration system and to a free LocalNet port on the welding system If there is no LocalNet port avail able use the LocalNet passive dis tributor 4 100 261...

Page 44: ...ystem 8 Remove the right side panel from the power source 9 Connect the cable harness 43 0004 4850 to the 6 pin con nector on the PC board LST MAG20 as shown in the illustration 10 Connect the cable h...

Page 45: ...ct the connection cable to the welding wire calibration system IMPORTANT A maximum of 3 connection cables max 15 m can be used to connect the welding wire calibration system and the cal ibration syste...

Page 46: ...he contact tip of the robot welding torch If in this case it is not possible to attach it properly the following longer contact tips may be used on the robot welding torch 42 0001 0056 contact tip 1 6...

Page 47: ...2 2 Connect the Signotec signature pad to the calibration system 47 EN...

Page 48: ...lding system and calibration system must be connected to each other 1 1 1 Connect the gas hose to the pres sure regulator and to the Gas IN connection on the calibration sys tem max supply pressure 5...

Page 49: ...tractor data are displayed 3 Enter the details for a new contractor Person performing calibration Name Address Postcode Calibration technician 4 Click on Add or select current contractor from the list...

Page 50: ...lues M1 M5 for each power source and wirefeeder Welding current A Welding voltage V Wire speed 13 Click Next The preliminary settings general measurement data are displayed Ambient temperature C Mains...

Page 51: ...welding wire emerges Keep the welding wire calibration system away from the head and body and wear suitable protective goggles Make sure that when the welding wire emerges it does not touch any elec t...

Page 52: ...software x Cancel signature Refresh new signature A corresponding notification is displayed after the signature has been re ceived successfully 25 Click Create PDF IMPORTANT Only after the confirmati...

Page 53: ...on system and the power source 5 Connect the sense lead red to the calibration system 6 Connect the power cable to the calibration system and the power source 7 Connect the sense lead blue to the cali...

Page 54: ...onnect the USB connection cable to the calibration system and the com puter laptop 2 Connect the Signotec signature pad to the calibration system 3 Switch on the power source Preparing the gas calibra...

Page 55: ...calibration process is started from the calibration software on the com puter laptop 1 Start the calibration program 2 Click New calibration The preliminary settings contractor data are displayed 3 En...

Page 56: ...ge to this effect is dis played and the data from the power source and wirefeeder is automatically read in Welding current welding voltage and wire speed are pre selected To deselect them click on the...

Page 57: ...c calibration process The calibration process starts When a calibration process is active A corresponding notification is displayed The Interrupt calibration button is available All measuring points a...

Page 58: ...eport Calibration system create report is displayed 22 Enter the details to create the calibration report Under Template select the language for the calibration report from the list Enter the output p...

Page 59: ...nto the calibration system 2 Plug the mains cable into the grid 3 Switch on the mains switch NOTE If there is a power connector for the high current socket on the power source use the adapter for the...

Page 60: ...ing wire should protrude approx 200 mm from the contact tip 6 Thread the welding wire into the intake part of the sensor 7 Use clamps to secure the welding torch in the welding wire calibration system...

Page 61: ...urce wirefeeder shielding gas supply etc Check specify the network settings for USB calibration see page 34 The power source to be calibrated must be switched on at least 5 minutes before the calibrat...

Page 62: ...der Settings select the connection to the power source o SpeedNet 11 Activate USB 12 Click on Establish connection If the connection is established successfully a message to this effect is dis played...

Page 63: ...he back of the calibration system 15 Carry out a visual inspection of the welding system and the calibration sys tem according to the calibration instructions 16 If the visual inspection does not reve...

Page 64: ...t calibration of the wirefeeder system When the calibration process is complete a corresponding notification is dis played and the Print calibration report button is available 22 Click Print calibrati...

Page 65: ...Net or LocalNet port and are calibrated using the following calibration process Connecting the power source and calibration system 1 Plug the mains cable into the calibration system 2 Plug the mains c...

Page 66: ...f the sensor 7 Use clamps to secure the welding torch in the welding wire calibration system at the contact tip 8 Make sure that the torch hosepack is arranged as straight as possible Connecting the c...

Page 67: ...ck New calibration The preliminary settings contractor data are displayed 4 Enter the details for a new contractor Person performing calibration Name Address Postcode Calibration technician 5 Click on...

Page 68: ...age V Open circuit voltage US V IMPORTANT The mains voltage displayed is incorrect With single phase machines the mains voltage must be measured manually using a FLUKE measuring device and entered 17...

Page 69: ...path Enter or search for Browse the file name If the Signotec signature pad is connected and has been detected by the cal ibration system a notification to this effect is displayed under Signature pa...

Page 70: ...libration process to be started from the calibration software on the computer laptop 2 Set manual metal arc welding mode on the power source and in the Rod elec trode setup menu specify the welding pa...

Page 71: ...External start with calibration system 15 Enter the serial number of the TT 1750 Puls in the box 16 Click Next The preliminary settings general measurement data are displayed 17 Click Start measuring...

Page 72: ...tion report button is available 30 Click Print calibration report Calibration system create report is displayed 31 Enter the details to create the calibration report Under Template select the language...

Page 73: ...34 Click Create PDF IMPORTANT Only after the confirmation PDF created successfully is dis played will the calibration report be saved 73 EN...

Page 74: ...d from the calibration software on the computer laptop 4 Start the calibration program 5 Click New calibration The preliminary settings contractor data are displayed 6 Enter the details for a new cont...

Page 75: ...ary settings calibration parameters are displayed five measured values M1 M5 for each power source Welding current A Welding voltage V For the wirefeeder enter five wire speed measured values M1 M5 m...

Page 76: ...d NOTE In the case of step switched machines the set values can be adapted manually in the calibration program 24 Set the stage switch on the power source as specified in the calibration pro gram for...

Page 77: ...38 Thread the wire until it protrudes approx 200 mm from the contact tip 39 Thread the welding wire into the intake part of the sensor 40 Use clamps to secure the welding torch in the welding wire cal...

Page 78: ...d to the calibration system and then click on Reconnect 49 Sign the Signotec signature pad with the corresponding digital pen 50 Press OK on the Signotec signature pad The signature is sent to the cal...

Page 79: ...mOhm Current on the device A 10 480 20 15 480 29 20 480 39 25 480 49 30 480 59 Calibration procedure 1 Start the calibration program 2 Click New calibration The preliminary settings contractor data ar...

Page 80: ...ess The following data is displayed Ambient temperature C Mains voltage V Open circuit voltage US V IMPORTANT The mains voltage displayed is incorrect With single phase machines the mains voltage must...

Page 81: ...r Template select the language for the calibration report from the list Enter the output path Enter or search for Browse the file name If the Signotec signature pad is connected and has been detected...

Page 82: ...or is calibrated using a TPS 500i power source WF 25i 30i with Euro connection or TPS 500i power source WF 25i 30i adapter ZA FSC S G Euro STD WeldCube Connector with current voltage measurement and w...

Page 83: ...ith Tuchel socket to the WCC Euro wire sensor 7 Connect the power cable to the calibration system and the Euro central connector adapter with Tuchel socket 8 Connect the sense lead red to the calibrat...

Page 84: ...stem 3 Disconnect the power cable from the Euro central connector adapter with Tuchel socket 4 Disconnect the Euro central connector adapter with Tuchel socket from the WCC Euro wire sensor 5 Connect...

Page 85: ...Connect the gas and data connec tions to each other Calibrating WeldCube Con nector IMPORTANT Before starting the calibration process All devices to be calibrated must be connected to the calibration...

Page 86: ...ry settings customer data are displayed 7 Enter the details for a new client Name Address Postcode Customer number 8 Click on Add or select current client from the list shown Under Others inventory nu...

Page 87: ...hernet cable between the WeldCube Connector and the laptop If connection is successful a message to this effect will be displayed 19 Click Next The preliminary settings calibration parameters are disp...

Page 88: ...over welding system for wire calibration see page 84 CAUTION Risk of injury from emerging welding wire As soon as the calibration process resumes the welding wirefeed starts and the welding wire emer...

Page 89: ...the language for the calibration report from the list Enter the output path Enter or search for Browse the file name If the Signotec signature pad is connected and has been detected by the cal ibratio...

Page 90: ...90...

Page 91: ...Troubleshooting 91...

Page 92: ...92...

Page 93: ...has occurred during the calibration process A description of the error is displayed by the calibration software Various Follow the instructions in the calibration software Contact our After Sales Serv...

Page 94: ...system Check the Ethernet connection cable for any possible damage and for functionality Check that the Ethernet connection cable is connected correctly to the USB Ethernet adapters Check that the DH...

Page 95: ...Technical data 95...

Page 96: ...96...

Page 97: ...600 A Max permissible loading of the load 24 kW for 20 s Max permissible voltage of the load 113 V peak EMC device class EN 61010 1 2010 Safety symbols CE Dimensions l x w x h 686 x 304 x 497 mm Tota...

Page 98: ...mensions l x w x h 466 x 355 x 85 mm Weight incl gas measurement I kit 3 85 kg Ambient temperature 0 40 C Gas measure ment option Operating voltage 18 30 V DC Max current consumption 100 mA Max operat...

Page 99: ...99 EN...

Page 100: ...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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