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Fronius FOH 10-76, Инструкция по эксплуатации, обслуживание

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Contents

General information 

9

Safety rules ................................................................................................................................................... 11

General remarks....................................................................................................................................... 11

Proper use ................................................................................................................................................ 11

Environmental conditions ......................................................................................................................... 12

Obligations of the operator ....................................................................................................................... 12

Obligations of the personnel .................................................................................................................... 12

Mains connection ..................................................................................................................................... 12

Protecting yourself and others ................................................................................................................. 13

Information on noise emission values ...................................................................................................... 13

Dangers posed by mains current and welding current ............................................................................. 14

EMC device classifications

 ....................................................................................................................... 14

EMC measures......................................................................................................................................... 15

EMF measures with implants ................................................................................................................... 15

Specific hazards

 ....................................................................................................................................... 16

Impairment of the welding results ............................................................................................................ 16

Danger from shielding gas cylinders ........................................................................................................ 17

Safety measures at installation location and during transport .................................................................. 17

Safety measures in normal operation ...................................................................................................... 18

Maintenance and repair ........................................................................................................................... 18

Safety inspection ...................................................................................................................................... 19

Disposal.................................................................................................................................................... 19

Safety labelling ......................................................................................................................................... 19

Data protection ......................................................................................................................................... 19

Copyright .................................................................................................................................................. 19

About this document ......................................................................................................................................20

Function of this document ........................................................................................................................ 20

Explanation of safety symbols .................................................................................................................. 20

Qualified technicians

 ................................................................................................................................ 20

Copyright .................................................................................................................................................. 20

General remarks ............................................................................................................................................21

Principle.................................................................................................................................................... 21

Device concept and applications .............................................................................................................. 21

Safety 23

Operational reliability and tips for the user ....................................................................................................25

Proper use ................................................................................................................................................ 25

Foreseeable misuse ................................................................................................................................. 25

Conversions or modifications

 ................................................................................................................... 25

Duty to provide instruction ........................................................................................................................ 25

Operating instructions .............................................................................................................................. 26

Personal protective equipment ................................................................................................................. 26

Local regulations ...................................................................................................................................... 26

Additional overarching policies and regulations ....................................................................................... 26

Spare parts, wearing parts and auxiliary materials .................................................................................. 27

Transportation and storage ...................................................................................................................... 27

Danger points and safety precautions ...........................................................................................................28

Safety instructions .................................................................................................................................... 28

Содержание FOH 10-76

Страница 1: ...FOH 8 40 FOH 10 76 FOH 20 114 FOH 40 168 Translated document Operating Instructions Maintenance Open weld head EN Perfect Welding Solar Energy Perfect Charging 42 0426 0234 EN V06 06092018...

Страница 2: ......

Страница 3: ...tained in them This will prevent faults and incorrect operation or possible damage to installed components Please also obey the safety rules doing so will ensure greater safety when using the product...

Страница 4: ...4...

Страница 5: ...easures in normal operation 18 Maintenance and repair 18 Safety inspection 19 Disposal 19 Safety labelling 19 Data protection 19 Copyright 19 About this document 20 Function of this document 20 Explan...

Страница 6: ...e type of orbital open weld head 52 Welding process 53 Creating a program 53 Starting the welding process 53 After the welding process 55 Removing the open weld head 55 Troubleshooting maintenance and...

Страница 7: ...OH 20 114 81 FOH 20 114 82 FOH 40 168 83 Orbital welding torch TTWO 2000 F 86 Wire adjustment unit FOH 86 Wire feeding Orbital TTWO 2000 87 Extension hose pack FCH FOH 10m 87 Motor control cable 88 Tr...

Страница 8: ...8...

Страница 9: ...9 General information...

Страница 10: ...10...

Страница 11: ...moved must not be covered pasted or painted over For the location of the safety and danger notices on the device refer to the section headed General remarks in the operating instructions for the devic...

Страница 12: ...ed as much with their signatures are trained to produce the required results Checks must be carried out at regular intervals to ensure that operators are working in a safety conscious manner Before us...

Страница 13: ...gulation protective goggles with side protection behind the protective visor wear stout footwear that provides insulation even in wet conditions protect the hands with suitable gloves electrically ins...

Страница 14: ...or the mains cable to be checked regularly by a qualified electrician to en sure the ground conductor is functioning properly The device must only be operated on a mains supply with a ground conductor...

Страница 15: ...e arises despite correct mains connection additional measures are necessary e g use a suitable line filter 2 Welding power leads Keep the power leads as short as possible Allow the power leads to run...

Страница 16: ...urce must not be located in such areas Risk of scalding from escaping coolant Switch off cooling unit before disconnecting coolant flow or return lines Observe the information on the coolant safety da...

Страница 17: ...ing gas cylinder is not connected leave the valve cap in place on the cylinder The manufacturer s instructions must be observed as well as applicable national and international regulations for shieldi...

Страница 18: ...manufacturer s original coolant with other coolants The manufacturer accepts no liability for damage resulting from use of a different coolant In addition all warranty claims will be forfeited The co...

Страница 19: ...st be collected separately and returned to an approved recycling facility Be sure to return any device that you no longer require to your dealer or find out about the approved collection and recycling...

Страница 20: ...nt knowledge of how to use the device Explanation of safety symbols DANGER Indicates immediate and real danger If it is not avoided death or serious injury will result WARNING Indicates a potentially...

Страница 21: ...ividual open weld heads are controlled via the FPA 3020 or FPA 3030 control units The FOH series open weld heads are intended for mobile welding use in the food tech nology general mechanical engineer...

Страница 22: ...22...

Страница 23: ...23 Safety...

Страница 24: ...24...

Страница 25: ...e stipulated intervals Keeping a service book with the most important information date operator activities carried out Using the spare parts stipulated by Fronius Using this document in combination wi...

Страница 26: ...tions Personal protec tive equipment The operator alone is responsible for the immediate working environment The following safety measures must be put in place and employed Welding goggles Welding shi...

Страница 27: ...The manufacturer cannot accept any liability for damage resulting from the use of spare or wearing parts or auxiliary materials that are not approved by the manufacturer Additional overarching policie...

Страница 28: ...his can cause severe injury to the eyes Do not look directly into the light beam Use suitable protective goggles or protective shields level of protection 9 15 WARNING Risk of eye injuries due to arc...

Страница 29: ...nts The residual heat generated during welding can heat up components to extremely high temperatures Falling components can lead to burns and severe injuries to feet Wear welding footwear when inserti...

Страница 30: ...30...

Страница 31: ...31 Description of the open weld heads...

Страница 32: ...32...

Страница 33: ...sories Wearing parts box TTWO 2000 F 48 0100 0041 Extension hosepack FCH FOH 10 m 38 0100 0440 1 FOH open weld head 2 Plug in control line 6 m 3 Transport case with foam insert and removable trolley s...

Страница 34: ...34 Accessories continued FOH wire support 58 0913 7000 Balancer spring return 6 10 kg lifting length 2 m 48 0005 1033 Balancer spring return 14 18 kg lifting length 2 m 48 0005 1035...

Страница 35: ...eld head 1 Attachment eyelet 2 Head 3 Tool carrier 4 Torch arm 5 Torch holder 6 TIG welding torch 7 Handle with drive unit 8 Clamping system 9 Reducing jaw 10 Fastening screws for reducing jaw 11 Hose...

Страница 36: ...eld head 1 2 4 3 1 Control line for the open weld head open weld head end 2 Control line for the open weld head control unit end 3 Combined welding current and shielding gas connection 4 Water cooling...

Страница 37: ...weld head and control unit power source 2 Wirefeeder connection cable For controlling the wire exit speed at the open weld head 3 Wirefeed 4 Grounding cable 5 TIG welding torch 6 FRC FPA 3030 remote c...

Страница 38: ...eight adjuster and scanner For setting the torch height above the workpiece 3 Angle lock for torch holder For setting the tilt angle of the torch head 4 Knurled screws for lateral adjustment For adjus...

Страница 39: ...ntrol cable For suppling and controlling the open weld head 7 Adjusting screw for clamping system For setting the clamping jaws to the respective pipe diameter Controls for open weld head continued Co...

Страница 40: ...l position on rigid pipe Possible welding positions PG fixed pipe horizontal welding axis vertical down welding position PF fixed pipe horizontal welding axis vertical up welding position Possible wel...

Страница 41: ...41 Commissioning...

Страница 42: ...42...

Страница 43: ...en the clamping lever and close by to revolution of the adjusting screws Close the clamping lever 4 Release the torch arm Hold the torch arm and pull out the lock for the torch arm NOTE Hold the torch...

Страница 44: ...res a constant distance to the pipe is main tained 5 Use the knurled screw on the torch arm to adjust the lateral position in relation to the centre of the pipe 6 Use an Allen key to set the torch hea...

Страница 45: ...ng application Positioning the open weld head on the workpiece continued a b Wall thickness a Electrode spacing b 0 5 mm 1 0 mm 0 8 mm 1 25 mm 2 0 mm 1 3 mm 2 25 mm 3 9 mm 1 8 mm With cold wire allowa...

Страница 46: ...st the tilt an gle of the holder Once the desired value has been set the fixing screw must be retightened Free length of wire The free length of wire at the wire exit can be adjusted by undoing the fi...

Страница 47: ...Switch the main switch on the control unit FPA 3020 FPA 3030 to OFF 2 Disconnect the control unit from the mains by pulling out the mains plug 3 Fold open and release both lock mechanisms on the motor...

Страница 48: ...mains by plugging the mains plug back in again 2 Switch the main switch on the control unit FPA 3020 FPA 3030 to ON 3 Press and hold the Thread button on the control unit 4 The welding wire is guided...

Страница 49: ...49 Operation...

Страница 50: ...50...

Страница 51: ...injury from premature arc ignition The arc may be ignited accidentally This can cause serious eye injuries Before operating the open weld head ensure that welding is not switched on by mistake in the...

Страница 52: ...Voltage Control Selecting the type of orbital open weld head 1 To select an orbital open weld head call up the Orbital open weld head menu in the main menu of the control system 6 If available select...

Страница 53: ...settings menu Detailed information on this can be found in the FPA 3020 Operating Instructions or FPA 3030 Operating Instructions document in the section entitled Parameter settings menu 3 Click the...

Страница 54: ...ntinued 5 The open weld head begins to execute the set welding program The hose pack is wound up automatically by the control system s welding program NOTE Ensure that the hose pack is being guided co...

Страница 55: ...welding process 1 Pull back the torch arm until the lock engages taking care not to damage the hosepack in the process 2 Open the clamping piece at the quick release lever and remove Removing the ope...

Страница 56: ...56...

Страница 57: ...57 Troubleshooting maintenance and disposal...

Страница 58: ...58...

Страница 59: ...place motor control board Replace plastic inter mediate coupling Check welding program Speed is not being regulated Faulty pulse generator Electronic error in the control unit Check pulse generator Re...

Страница 60: ...rating instructions for the power source in the section entitled Troubleshooting Errors Cause Remedy Speed is not being regulated Faulty pulse generator Electronic error in the control unit Replace pu...

Страница 61: ...cal layperson Someone who is neither a skilled person nor an instructed person The following measures regarding maintenance must be put in place by the system operator a service book containing the re...

Страница 62: ...not be used as the basis of any claims whatsoever for defects that arise subsequently 1 Use an Allen key 4 mm to unscrew the retaining bolts of the tool carrier 2 Remove the tool carrier from the head...

Страница 63: ...ls and shim rings for damage and replace if necessary 8 Apply new roller bearing grease to the inside of the head 9 Re install all gear wheels in the head 10 Place the cover back on the head and screw...

Страница 64: ...the retaining bolts of the drive motor 2 Pull the drive motor out of the housing 3 Remove the faulty coupling 4 Fit the new coupling to the drive motor 5 Push the drive motor back into the housing 6 R...

Страница 65: ...65 Technical data...

Страница 66: ...66...

Страница 67: ...DC Torch type TTWO 2000 F Hosepack length 5 m Welding position PC PF PG Weight without hosepack 3 97 kg 8 75 lbs Power supply 24 V DC Torch type TTWO 2000 F Hosepack length 5 m Welding position PC PF...

Страница 68: ...type A B C D E F G max FOH 8 40 90 mm 40 mm 95 mm 7 mm 77 mm 66 mm 120 mm FOH 10 76 142 mm 64 mm 108 mm 5 mm 91 mm 90 mm 230 mm FOH 20 114 200 mm 90 mm 111 mm 7 mm 91 mm 130 mm 260 mm FOH 40 168 300...

Страница 69: ...not be held liable for any damage arising from such usage Ambient temperature range during operation 5 C to 40 C 41 F to 104 F during transport and storage 20 C to 55 C 4 F to 131 F Relative humidity...

Страница 70: ...70...

Страница 71: ...71 Spare parts circuit diagram...

Страница 72: ...72...

Страница 73: ...from the use of spare or wearing parts or auxiliary materials that are not approved by the manufacturer NOTE Only trained technicians may change parts and may only do so after having read the install...

Страница 74: ...FOH 8 40 Art Nr 8 044 201 33 53 61 62 63 54 28 26 27 56 59 60 58 24 57 23 29 55 37 32 6 5 2 1 3 36 34 35 31 4 7 38 40 39 11 18 16 9 51 41 36 44 52 43 49 42 45 46 47 48 50 12 10 19 22 17 14 15 8 20 21...

Страница 75: ...2211 Countersunk screw torx M3x20 14 1 48 0005 2093 Threaded spindle 15 2 48 0005 2212 Join pin 16 3 48 0005 2213 Cylinder pin_5m3x20_DIN6325 17 1 48 0005 2094 Link 18 1 48 0005 2095 Clamping lever 19...

Страница 76: ...insolator 42 4 48 0005 2236 Thread insert M3x6 43 1 48 0005 2237 Motor Gearbox Encoder Assembly 1 48 0005 2238 Line driver round 44 1 48 0005 2239 Clutch 45 1 48 0005 2107 Motor socket 46 1 48 0005 2...

Страница 77: ...76 Art Nr 8 044 202 46 47 48 64 20 65 66 21 8 15 14 17 22 19 10 12 50 45 42 49 43 52 44 36 41 51 9 16 18 13 11 39 40 38 31 35 34 36 3 1 2 5 6 32 37 4 7 33 53 61 62 63 54 55 28 26 27 56 59 60 58 25 24...

Страница 78: ...rsunk screw torx M4x12 14 1 48 0005 2112 Threaded spindle 15 2 48 0005 2262 Join pin 16 3 48 0005 2263 Cylinder pin 3m6x20_DIN6325 17 1 48 0005 2113 Link 18 1 48 0005 2114 Clamping lever 19 2 48 0005...

Страница 79: ...Connector plug 48 4 48 0005 2241 Cylinder screw M3x6 DIN 912 49 8 48 0005 2242 Lens head screw M3x6 DIN 7380 50 4 48 0005 2243 Countersunk screw M5x12 DIN 7991 51 4 48 0005 2244 Cylinder screw M3x16...

Страница 80: ...3 54 28 26 27 56 53 55 59 60 58 25 24 29 57 23 37 32 33 34 36 1 2 3 5 6 7 4 31 35 39 38 40 66 65 64 13 20 21 15 18 8 14 19 16 9 10 12 50 52 44 36 43 41 17 42 49 51 45 46 47 48 11 22 FOH 20 114 Art Nr...

Страница 81: ...x M4x20 13 2 48 0005 2210 Countersunk screw torx M4x10 14 1 48 0005 2130 Threaded spindle 15 2 48 0005 2277 Join pin 16 3 48 0005 2278 Cylinder pin 5m6x20_DIN6325 17 1 48 0005 2131 Link 18 1 48 0005 2...

Страница 82: ...nector plug 48 4 48 0005 2241 Cylinder screw M3x6 DIN 912 49 8 48 0005 2242 Lens head screw M3x6 DIN 7380 50 4 48 0005 2243 Countersunk screw M5x12 DIN 7991 51 4 48 0005 2244 Cylinder screw M3x16 DIN...

Страница 83: ...0 168 Art Nr 8 044 204 54 63 62 61 53 33 28 26 27 5 5 6 5 59 60 58 25 24 23 57 37 32 5 6 2 1 3 36 34 35 31 38 40 39 18 13 16 11 9 51 41 36 44 52 43 49 42 46 47 48 45 50 12 10 19 22 17 14 15 64 20 65 2...

Страница 84: ...torx M4x10 14 1 48 0005 2144 Threaded spindle 15 2 48 0005 2290 Join pin d14x15 16 3 48 0005 2278 Cylinder pin 5m6x20_DIN6325 17 1 48 0005 2145 Link 18 1 48 0005 2146 Clamping lever 19 2 48 0005 2214...

Страница 85: ...cover 47 1 48 0005 2240 Connector plug 48 4 48 0005 2241 Cylinder screw M3x6 DIN 912 49 8 48 0005 2242 Lens head screw M3x6 DIN 7380 50 4 48 0005 2243 Countersunk screw M5x12 DIN 7991 51 4 48 0005 224...

Страница 86: ...86 Wire adjustment unit FOH Orbital welding torch TTWO 2000 F 58 0913 7000...

Страница 87: ...87 Wire feeding Orbital TTWO 2000 38 0100 0440 Extension hose pack FCH FOH 10m...

Страница 88: ...nsport case FOH 48 0005 2426 Motor control cable Quantity Article number Description 1 1 3 1610FOH Motor control cable FOH 6m 10 pole cable gland on weld head side 14 pin cable connector on controller...

Страница 89: ...xiliary materials that are not approved by the manufac turer Wearing parts box TTWO 2000 F Original spare parts Content of wearing parts box 42 0001 1150 48 0100 0041 48 0005 2187 42 0300 7287 42 0300...

Страница 90: ...12 5 19x25 5 thread type 42 0300 2857 1 Gas nozzle ceramic 11 16x13 thread type 42 0300 7287 1 Gas nozzle ceramic 19 32x24 thread type 42 0411 4002 2 Tungsten electrode WC20 2 4x175 42 0411 4003 2 Tun...

Страница 91: ...XJ 9 B 1 B B1 B3 B1 B3 02725 7RS YLHZ RQ VROGHU FXSV 0 PRWRU UHG PRWRU EODFN HQFRGHU 1 JUD HQFRGHU 9 EURZQ HQFRGHU ZKLWH HQFRGHU EOXH HQFRGHU HOORZ HQFRGHU JUHHQ UHG SXUSOH EUDXQ HOORZ RUDQJH EODFN JU...

Страница 92: ...B B1 B3 B1 B3 02725 7RS YLHZ RQ VROGHU FXSV 0 PRWRU UHG PRWRU EODFN HQFRGHU 1 JUD HQFRGHU 9 EURZQ HQFRGHU ZKLWH HQFRGHU EOXH HQFRGHU HOORZ HQFRGHU JUHHQ UHG SXUSOH EURZQ HOORZ RUDQJH EODFN JUH EODFN U...

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Страница 94: ...94 FRONIUS INTERNATIONAL GMBH TechSupport Automation www fronius com addresses www fronius com...

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