Arcing_Track-1200_EN_V04-2017

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<p>Arcing Track 1200 Operating instructions</p><p>Spare parts list</p><p>Welding carriage</p><p>E</p><p>N</p><p>/ Perfect Welding / Solar Energy / Perfect Charging</p><p>V04_2017</p><p>3</p><p>These operating instructions will help you familiarise yourself with the device. It is in</p><p>your interest to read these instructions carefully and to observe the directions contained</p><p>in them. This will prevent faults and incorrect operation or possible damage to installed</p><p>components.</p><p>Please also obey the safety rules; doing so will ensure greater safety when using the</p><p>product. Careful handling of the entire system will repay you with years of safe and reli-</p><p>able operation. These are essential prerequisites for excellent results.</p><p>Dear reader,</p><p>Introduction</p><p>4</p><p>5</p><p>Contents</p><p>General information 7</p><p>About this document ........................................................................................................................................9</p><p>Function of this document .......................................................................................................................... 9</p><p>Explanation of safety symbols .................................................................................................................... 9</p><p>Qualified technicians .................................................................................................................................. 9</p><p>Copyright .................................................................................................................................................... 9</p><p>Safety 11</p><p>Operational reliability and tips for the user .................................................................................................... 13</p><p>Proper use ................................................................................................................................................ 13</p><p>Foreseeable misuse ................................................................................................................................. 13</p><p>Conversions or modifications ................................................................................................................... 13</p><p>Duty to instruct ......................................................................................................................................... 13</p><p>Operating instructions .............................................................................................................................. 14</p><p>Personal protective equipment ................................................................................................................. 14</p><p>Local regulations ...................................................................................................................................... 14</p><p>Spare parts, wearing parts and auxiliary materials .................................................................................. 14</p><p>Description of the welding carriage 15</p><p>Welding carriage principe and components .................................................................................................. 17</p><p>Principe .................................................................................................................................................... 17</p><p>Carriage.................................................................................................................................................... 17</p><p>configuration ............................................................................................................................................. 17</p><p>Operating elements and connections ............................................................................................................ 19</p><p>Connections ............................................................................................................................................. 19</p><p>Control box operating elements ............................................................................................................... 19</p><p>Carriage operating elements .................................................................................................................... 20</p><p>Remote control elements ......................................................................................................................... 21</p><p>POWER CORRECTION buttons: further functions .................................................................................. 23</p><p>Software versions ..................................................................................................................................... 24</p><p>Commissioning and operation 25</p><p>Commissioning the carriage .......................................................................................................................... 27</p><p>Safety ....................................................................................................................................................... 27</p><p>Mounting the rail ....................................................................................................................................... 27</p><p>Setting the angle ...................................................................................................................................... 28</p><p>Positioning the carriage on rail ................................................................................................................. 29</p><p>Mounting hosepack and torch body ......................................................................................................... 31</p><p>Positioning the torch holder ...................................................................................................................... 32</p><p>Adjusting the angle between the torches ................................................................................................. 33</p><p>Positioning the contact cams ................................................................................................................... 34</p><p>Hosepack guidance .................................................................................................................................. 35</p><p>Changing the units of measurement ........................................................................................................ 36</p><p>Configuring the robot interface ...................................................................................................................... 37</p><p>Safety ....................................................................................................................................................... 37</p><p>Indicators .................................................................................................................................................. 37</p><p>DIP-switch ................................................................................................................................................ 38</p><p>Setting the node adresses for power sorces ............................................................................................ 38</p><p>Operation .......................................................................................................................................................39</p><p>Switching on system components ............................................................................................................ 39</p><p>Operation modes ...................................................................................................................................... 39</p><p>Recommended materials ......................................................................................................................... 40</p><p>6</p><p>Welding workflow ..................................................................................................................................... 41</p><p>Moving carriage to reference position ...................................................................................................... 42</p><p>Teaching mode settings ...........................................................................................................................</p><p>42</p><p>Saving a welding program ........................................................................................................................ 44</p><p>Loading a welding program ...................................................................................................................... 45</p><p>Starting a welding process ....................................................................................................................... 46</p><p>Start offset ................................................................................................................................................ 46</p><p>Maintenance and disposal 49</p><p>Troubleshooting .............................................................................................................................................51</p><p>General..................................................................................................................................................... 51</p><p>Basic requirements for the system to work .............................................................................................. 51</p><p>Machine state codes ................................................................................................................................ 51</p><p>Event codes ............................................................................................................................................. 51</p><p>Error codes ............................................................................................................................................... 52</p><p>Maintenance ..................................................................................................................................................53</p><p>Maintenance personnel ............................................................................................................................ 53</p><p>Maintenance record ................................................................................................................................. 53</p><p>Recommended lubricants ........................................................................................................................ 53</p><p>Maintenance intervals and procedures .................................................................................................... 54</p><p>Daily maintenance .................................................................................................................................... 54</p><p>Maintaining the torch holder arm .............................................................................................................. 54</p><p>Technical data 55</p><p>Technical data ...............................................................................................................................................57</p><p>Arcing carriage ......................................................................................................................................... 57</p><p>Remote control ......................................................................................................................................... 57</p><p>Control box ............................................................................................................................................... 57</p><p>Dimensions............................................................................................................................................... 57</p><p>Rating plates ............................................................................................................................................ 58</p><p>Environmental conditions ......................................................................................................................... 58</p><p>Spare parts, circuit diagram 59</p><p>Spare parts ....................................................................................................................................................61</p><p>Spare parts, wearing parts and auxiliary materials .................................................................................. 61</p><p>Ordering details ........................................................................................................................................ 61</p><p>Torch wear parts ............................................................................................................................................66</p><p>Circuit diagram ..............................................................................................................................................67</p><p>EC-Declaration of conformity ........................................................................................................................ 71</p><p>7</p><p>General information</p><p>8</p><p>9</p><p>About this document</p><p>Function of this</p><p>document</p><p>These operating instructions explain how to commission and operate the device in</p><p>conjunction with the installed system components. Look after the operating instructions</p><p>carefully; they must always be to hand at the location where the device is being used.</p><p>They can be used as a reference should any operational or functional problems occur in</p><p>the future.</p><p>Qualified</p><p>technicians</p><p>- These operating instructions are designed for trained technicians or persons with</p><p>practical welding experience. Personnel must be trained through verifiable regular</p><p>instruction.</p><p>- Maintenance and repair of the device may likewise only be carried out by trained</p><p>technicians and in compliance with the specified maintenance activities and mainte-</p><p>nance intervals.</p><p>- The manufacturer accepts no liability for damage caused by insufficient knowledge of</p><p>how to use the device.</p><p>Explanation of</p><p>safety</p><p>symbols</p><p>DANGER! Indicates immediate and real danger. If it is not avoided, death or</p><p>serious injury will result.</p><p>WARNING! Indicates a potentially dangerous situation. Death or serious injury</p><p>may result if appropriate precautions are not taken.</p><p>CAUTION! Indicates a situation where damage or injury could occur. Minor</p><p>injury and/or damage to property may result if appropriate precautions are not</p><p>taken.</p><p>NOTE! Indicates a risk of flawed results and possible damage to the equip-</p><p>ment.</p><p>IMPORTANT! Indicates tips for correct operation and other particularly useful informa-</p><p>tion. It does not indicate a potentially damaging or dangerous situation.</p><p>Special care is required if you see any of the symbols shown.</p><p>Copyright of these operating instructions remains with Fronius International GmbH. The</p><p>text and illustrations are all technically correct at the time of going to</p><p>print. Fronius reserves the right to make changes. The contents of the operating instruc-</p><p>tions shall not provide the basis for any claims whatsoever on the part of the purchaser.</p><p>Copyright</p><p>10</p><p>11</p><p>Safety</p><p>12</p><p>13</p><p>Proper use</p><p>Operational reliability and tips for the user</p><p>Any unauthorised conversions or modifications made to the welding carriage by the user</p><p>shall invalidate all liability or warranty obligations on the part of the manufacturer.</p><p>The electromagnetic characteristics of the welding carriage can be adversely affected by</p><p>additions or modifications of any kind. No modifications or upgrades should therefore be</p><p>undertaken without first consulting the manufacturer and obtaining written approval.</p><p>Conversions or</p><p>modifications</p><p>The Arcing Equipment is concepted to carry out hard-faced layers on sugar cane</p><p>crushing rolls.</p><p>Any use above and beyond this purpose is deemed improper – the manufacturer shall</p><p>not be responsible for any damage resulting from such improper use.</p><p>The welding carriage can be used in the following welding processes:</p><p>- Arcing process</p><p>Proper use also includes:</p><p>- Carrying out all maintenance work at the stipulated intervals</p><p>- Keeping a service book with the necessary information (date, operator, activities car-</p><p>ried out, etc.)</p><p>- Using the spare parts stipulated by Fronius</p><p>- Following all the instructions, particularly the safety instructions, in the operating</p><p>instructions</p><p>- Using this document in conjunction</p><p>with the operating instructions for the integrated</p><p>system components (power source, etc.)</p><p>Foreseeable</p><p>misuse</p><p>Any use other than for the intended purpose shall be deemed improper use. This in-</p><p>cludes:</p><p>- Riding on the welding carriage, transporting loads</p><p>- Hoisting processes (hoisting, manoeuvring of loads, animals or persons)</p><p>- Use as a tray for tools</p><p>- Use outside of the permitted technical operating limits (e.g. exceeding the max. per-</p><p>mitted load)</p><p>- Use in hazardous areas</p><p>Duty to instruct Before they start work, the system operator must instruct or train all persons working with</p><p>the welding carriage in:</p><p>- the theoretical and practical aspects of operation</p><p>- the safety regulations.</p><p>IMPORTANT! The duty to instruct also applies in particular to those who only occasion-</p><p>ally work with the welding carriage (e.g. during set-up, maintenance, etc.).</p><p>14</p><p>The operating instructions help you to use the welding carriage safely and efficiently, and</p><p>must therefore be to hand at all times.</p><p>- Keep the various sections of the operating instructions at the location where the weld-</p><p>ing carriage is being used at all times.</p><p>- Clearly mark the place where the instructions are kept.</p><p>- Ensure that all persons working with the welding carriage know where the operating</p><p>instructions are located.</p><p>- The operating instructions will only be able to help you in the event of a problem if</p><p>they are at hand!</p><p>IMPORTANT! The manufacturer shall not be liable for any damage that arises from fail-</p><p>ure to observe the operating instructions.</p><p>Operating in-</p><p>structions</p><p>Personal protec-</p><p>tive equipment</p><p>Local regulations In some countries, local statutory regulations may apply that are not included in these</p><p>operating instructions. It is the duty of the operator to be aware of and comply with any</p><p>local statutory regulations. This relates primarily to regulations concerning:</p><p>- Accident prevention</p><p>- Machine safety</p><p>- Protection of personnel (protective equipment)</p><p>- Environmental protection</p><p>- Electrical system</p><p>The operator alone is responsible for the immediate working environment.</p><p>The following safety measures must be put in place and employed:</p><p>- Welding goggles</p><p>- Welding shield</p><p>- Welding gloves</p><p>- Welding apparel</p><p>- Welding footwear</p><p>Spare parts,</p><p>wearing parts</p><p>and auxiliary</p><p>materials</p><p>Use of third-party spare and wearing parts may pose risks. Use approved Fronius origi-</p><p>nal spare parts only.</p><p>The manufacturer cannot accept any liability for damage resulting from the use of spare</p><p>or wearing parts or auxiliary materials that are not approved by the manufacturer.</p><p>15</p><p>Description of the welding carriage</p><p>16</p><p>17</p><p>Welding carriage principe and components</p><p>Carriage</p><p>configuration</p><p>1. Carriage Arcing Track 1200</p><p>2. FRC-1200 Remote control without cable</p><p>3. Control line ArcingTrack 23,5m (925,195inch)</p><p>4. Control line e-cabinet - power source 2m ArcingTrack (78,740inch)</p><p>5. Power source TPS 600i</p><p>6. Mounting set e-cabinet ArcingTrack 1200</p><p>7. HP 120i CON /W/20m</p><p>8. Wire feeder WF 15i /4R/W/FSC</p><p>9. Water cooled hosepack MHP 700i W ML M /FSC/4,35m</p><p>10. Torch body MTB 400i W ML /15°/L194/H23</p><p>11. I-kit Roll rotation sensor for current coupling 1200A,</p><p>incl. Control line to e-cabinet 20m (787,400inch)</p><p>12. Holding clamp Arcing 2xø38</p><p>13. Protective tube</p><p>14. Rail 3000mm ArcingTrack 1200</p><p>15. I-kit Actuating cam rail ArcingTrack 1200</p><p>16. Mounting system rail ArcingTrack 1200</p><p>Principe The Arcing Equipment is concepted to carry out hard-faced layers on sugar cane</p><p>crushing rolls. The carriage travels on a rail, parallel to the axis of the rotating roll. The</p><p>hardfacing process is performed using arc welding with two 38 mm diameter torches.</p><p>4</p><p>33</p><p>1</p><p>2</p><p>10</p><p>10</p><p>9</p><p>9</p><p>8</p><p>8</p><p>7</p><p>7</p><p>5</p><p>5</p><p>4</p><p>6</p><p>1</p><p>15 15</p><p>14</p><p>16 16</p><p>11</p><p>13</p><p>13</p><p>12</p><p>12</p><p>18</p><p>Carriage</p><p>configuration</p><p>(continued)</p><p>Tools</p><p>6mm hex wrench</p><p>10mm angled socket wrench</p><p>Accessoires</p><p>Custom fitting metal transport box</p><p>19</p><p>Operating elements and connections</p><p>Connections</p><p>1</p><p>2</p><p>3 4</p><p>(1) Control box mains cable</p><p>(2) Control line between welding carriage and control box</p><p>(3) Control line between control box and remote control</p><p>(4) Roboter interface connections</p><p>(1) ON/OFF switch</p><p>switches the control box on and off</p><p>Control box</p><p>operating</p><p>elements</p><p>(1)</p><p>20</p><p>1</p><p>3</p><p>2</p><p>(1) Coupling lever: for mounting the carraige on rail</p><p>(2) Carrying handle</p><p>(3) Torch clamping levers</p><p>Carriage</p><p>operating</p><p>elements</p><p>3</p><p>21</p><p>Remote control</p><p>elements</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>(1) OSC speed</p><p>(red symbol)</p><p>Allows setting the number of oscillations (hertz per mi-</p><p>nute) in lateral mode.</p><p>Arc ON time</p><p>(yellow symbol)</p><p>Allows setting the time to turn on the arc in picot mode</p><p>(we assume that the roll is moving</p><p>constantly during the picot and the arc must be turned</p><p>on and off for periods whose duration</p><p>will depend on the number of teeth, roll speed, etc.).</p><p>(2) Numerical display 4 digits (metric / imperial), displays welding parameters</p><p>and error codes.</p><p>(3) Imediate Stop</p><p>button</p><p>Pressing the button interrupts an active arc, and the</p><p>torches are moving into their park position.</p><p>(4) Automatic / Setup: Allows selecting the operation mode (automatic process</p><p>or setup).</p><p>22</p><p>Remote control</p><p>elements</p><p>(continued)</p><p>(5) Start tooth</p><p>(white symbol)</p><p>Allows setting the number of the tooth from which the</p><p>carriage should start the process.</p><p>START</p><p>(green symbol)</p><p>2nd function allows setting the start position of the arc-</p><p>ing or lateral for single tooth.</p><p>Distance</p><p>(orange symbol)</p><p>3rd function allows setting the distance between teeth.</p><p>(6) Step</p><p>(white symbol)</p><p>Allows choosing the number of steps in arcing mode.</p><p>Stop</p><p>(green symbol)</p><p>2nd function allows setting the length</p><p>of the tooth side surface where arcing or lateral will be</p><p>performed for single tooth. The</p><p>maximum value will be limited automatically by the</p><p>value set by button (5).</p><p>Arc OFF time</p><p>(yellow symbol)</p><p>Alternative function allows setting the time to turn off the</p><p>arc in picot mode (we assume that the roll is moving</p><p>constantly during the picot and the arc must be turned</p><p>on and off for periods whose duration will depend on the</p><p>number of teeth, roll speed, etc.).</p><p>(7) End tooth</p><p>(white symbol)</p><p>Allows setting the number of the tooth on which the car-</p><p>riage should end the process.</p><p>Hold</p><p>(green symbol)</p><p>2nd function allows setting the safe position of the arc-</p><p>ing or lateral for single tooth.</p><p>Center offset</p><p>(orange symbol)</p><p>3rd function allows torch fine setting exactly to the</p><p>center of teeth.</p><p>(8) Power correction Allows correcting the power of the first welding source in</p><p>relation to the welding power that is set globally.</p><p>Setting the value to 0 or over minus 30 in P mode</p><p>switches off the power source.</p><p>IMPORTANT! For description of further functions, see</p><p>next chapter.</p><p>(9) Power correction</p><p>2nd power source</p><p>Allows correcting the power of the second welding</p><p>source in relation to the welding power that is set</p><p>globally.</p><p>Setting the value to 0 or over minus 30 in P mode</p><p>switches off the power source.</p><p>IMPORTANT! For description of further functions, see</p><p>next chapter.</p><p>(10) Welding mode</p><p>selection switch</p><p>Allows selecting the following operating modes:</p><p>Lateral Mode</p><p>Base Mode</p><p>Picote Mode</p><p>Arcing mode</p><p>Green symbol: Second level: must be selected, to retrieve the functions</p><p>of the green symbols.</p><p>Orange symbol: Third level: must be selected, to retrieve the functions of</p><p>the orange symbols.</p><p>(11) Roll speed Allows setting the number of roll rotations per minute.</p><p>(12) Selector switch</p><p>Test welding / No</p><p>welding / Start weld-</p><p>ing</p><p>Allows the carriage to ignite an arc permanently (posi-</p><p>tion ‘I’) or for a short while</p><p>(pos. TEST). Position ‘0’ allows simulating the move-</p><p>ment with the arc turned off.</p><p>23</p><p>Remote control</p><p>elements</p><p>(continued)</p><p>(13) POWER Allows setting the welding power of both welding power</p><p>sources, globally.</p><p>Power correction mode M0: POWER button has no</p><p>function.</p><p>Power correction mode M2: switching between jobs</p><p>with POWER button.</p><p>Power correction mode M8: Power</p><p>adjustment with</p><p>POWER button.</p><p>IMPORTANT! Power correction modes are described in</p><p>the following chapter.</p><p>(14) Welding direction Function in SETUP mode:</p><p>switching the button to left or right position references</p><p>the carriage to the left or right limit switch.</p><p>Function in AUTOMATIC mode:</p><p>switching into left or right position starts the welding</p><p>process in the choosen direction.</p><p>If the operator switches into the middle position while</p><p>welding, welding process will be interrupted.</p><p>Switching into the previously selected position again</p><p>continues the interrupted welding program.</p><p>POWER</p><p>CORRECTION</p><p>buttons: further</p><p>functions</p><p>The POWER CORRECTION buttons (8 and 9) have some more function, which are</p><p>described below.</p><p>The description is available for both buttons.</p><p>IMPORTANT! These parameters can only be selected, if the roll rotation sensor is active!</p><p>Wire feed speed command value [P]</p><p>How to reach: press the button once</p><p>Symbol on display: P</p><p>Scale: 0,1</p><p>Range: -30 up to 30</p><p>Pulse/dynamic correction [D]</p><p>How to reach: press the button twice</p><p>Symbol on display: D</p><p>Scale: 0,1</p><p>Range: -9,9 up to 9,9 (Indicated on display: -99 up to 99)</p><p>Arc length correction [L]</p><p>How to reach: press the button three times</p><p>Symbol on display: L</p><p>Scale: 0,1</p><p>Range: -9,9 up to 9,9 (Indicated on display: -99 up to 99)</p><p>24</p><p>Wire retract correction [R]</p><p>How to reach: press the button four times</p><p>Symbol on display: R</p><p>Scale: 0,1</p><p>Range: 0,0 up to 9,9 (Indicated on display: -99 up to 99)</p><p>Power source mode [M0]</p><p>How to reach: press the button five times and turn it, until M0 appears on display</p><p>Symbol on display: M0</p><p>Function: POWER button on remote control is without function now.</p><p>The operator must select the required welding program directly</p><p>on power source display.</p><p>Job mode [M2]</p><p>How to reach: press the button five times and turn it, until M2 appears on display</p><p>Symbol on display: M2</p><p>Function: POWER button on remote control is used to choose a welding job</p><p>on power source display.</p><p>Remote control mode [M8]</p><p>How to reach: press the button five times and turn it, until M8 appears on</p><p>display.</p><p>Symbol on display: M8</p><p>Function: POWER button on remote control is used to regulate power</p><p>adjustment.</p><p>POWER</p><p>CORRECTION</p><p>buttons: further</p><p>functions</p><p>(continued)</p><p>Software</p><p>versions</p><p>These operating instructions are valid for the following software versions:</p><p>- official_TPSi_1.7.4-11696</p><p>- ArcingCarriage_CarriageUnit_v2_0_2230.mpu</p><p>- ArcingCarriage_ControlBox_v1_0_2228.hex</p><p>- ArcingCarriage_OscillatorUnit_v2_0_2232.mpu</p><p>- BETA_ArcingCarriage_RemoteController_v3_0_2835.hex</p><p>25</p><p>Commissioning and operation</p><p>26</p><p>27</p><p>Commissioning the carriage</p><p>Safety</p><p>Mounting the rail</p><p>► Stop the crushing roll before fixing the rail and installing the carriage on the rail.</p><p>► Before installing the carriage on the rail, make sure that the rail is clean and fixed</p><p>securely.</p><p>► Clean the carriage and the rail after every use.</p><p>Never use pressure washers for cleaning.</p><p>► Transport the carriage in the box. Never carry the carriage on the connecting cable.</p><p>► Never touch moving parts of the carriage.</p><p>► Never stay near the carriage during operation.</p><p>STEP 1: Position the rail parallel to the axis of the roll.</p><p>The rail must be positioned as specified in the following figure, maintaining a 780 mm</p><p>distance between the travel surface and the surface of the roll.</p><p>IMPORTANT! Modifications or setup only at machine standstill!</p><p>28</p><p>Mounting the rail</p><p>(Fortsetzung)</p><p>STEP 2: Use the 6 mm hex wrench to fix the rail using four M8x40 screws, M8 spring</p><p>washers, and M8 round washers.</p><p>Setting the angle Use the 6 mm hex wrench to loosen four side screws on the both ends of the rail, rotate</p><p>the rail, and tighten the screws.</p><p>Travel surface</p><p>loosen 4xM8 screws</p><p>Travel surface positioned vertically Travel surface rotated by 30°</p><p>29</p><p>STEP 1: The coupling lever must be set in left position!</p><p>Hold the carrying handle and place the carriage onto the rail, like shown in the detail</p><p>graphic below.</p><p>Positioning the</p><p>carriage on rail</p><p>Coupling lever</p><p>30</p><p>Positioning the</p><p>carriage on rail</p><p>(Fortsetzung)</p><p>STEP 2: Pull the coupling lever (1) and rotate it from its left position to right (2), which will</p><p>engage the gear and tighten the rollers to the rail.</p><p>IMPORTANT! Do not force the lever if it cannot be rotated easily. In such a case, set</p><p>the lever back to left position and move the carriage slightly left or right. Try to rotate the</p><p>lever again, to properly engage the gear of the carriage with the gear rack of the rail.</p><p>×</p><p>Gear not</p><p>engaged</p><p>Gear engaged</p><p>properly</p><p>1</p><p>2</p><p>31</p><p>Mounting</p><p>hosepack and</p><p>torch body</p><p>(a)</p><p>(c) (c)</p><p>(b) (b)</p><p>(b)</p><p>(c)</p><p>(d)</p><p>(c)</p><p>(b)</p><p>1. Unscrew the lock nut (a) from the hosepack.</p><p>2. Loosen the holding clamp screws on bottom side (b) and top side (c).</p><p>3. Push the hosepack through the holding clamps.</p><p>4. Replace the lock nut (a) and fasten it.</p><p>5. Fasten the holding clamp screws on bottom side (b).</p><p>6. If necessary, correct the hosepack position. Then fasten the holding clamp screws</p><p>on top side (c).</p><p>7. Mount the torch body (d).</p><p>(a)</p><p>32</p><p>3</p><p>Positioning the</p><p>torch holder</p><p>2</p><p>1</p><p>1. Open the clamping lever (1).</p><p>2. Push the mounting plate back-</p><p>wards (2), to the middle of the</p><p>torch holder.</p><p>3. Perform the same two steps on the</p><p>second torch holder.</p><p>4. Place the torches into the torch holders.</p><p>IMPORTANT! There are holes on the bottom side of the protective tube - one of</p><p>this holes must fit to the pin on the torch holder (3).</p><p>33</p><p>Positioning the</p><p>torch holder</p><p>(continued)</p><p>1</p><p>2</p><p>5. Push the mounting plate forwards</p><p>(1), to fix the torch.</p><p>6. Close the clamping lever (2).</p><p>7. Perform the same two steps on the</p><p>second torch holder.</p><p>1. Loosen the four screws (1) with the 10 mm angle socket wrench.</p><p>2. Adjust the angle of the torches with the adjusting screw (2).</p><p>3. After setting the proper angle, tighten the screws (1) again.</p><p>Adjusting the</p><p>angle between</p><p>the torches</p><p>1</p><p>1</p><p>1</p><p>2</p><p>1</p><p>34</p><p>1</p><p>2</p><p>Positioning the</p><p>contact cams</p><p>Place torches beside the first tooth of the sugar crush roll:</p><p>1. Use the remote control and move the torches to the left side (1) and forwards (2),</p><p>to place the first tooth of the sugar crush roll between the two torches.</p><p>2. Position the left contact cam on the rail, as shown at (3).</p><p>3. Slide the contact cam towards the</p><p>carriage, until the remote control</p><p>indicates the following message:</p><p>3</p><p>3</p><p>35</p><p>Positioning the</p><p>contact cams</p><p>(continued)</p><p>4. Retract the cam slightly, until the</p><p>remote control indicates the follow-</p><p>ing message:</p><p>5. Use the 6 mm hex wrench, to tighten</p><p>the left contact cam in this position</p><p>6. Install the right contact cam in the required position on the rail, right from the</p><p>carriage.</p><p>IMPORTANT! If the reference position is on the right side, perform the same ac-</p><p>tions for the right contact cam.</p><p>Hosepack</p><p>guidance</p><p>Recommended hosepack length: 3,35 m (131.88 in)</p><p>Maximum hosepack length: 4,35 m (171.25 in)</p><p>Wire diameter: ≤ 2,4 mm</p><p>IMPORTANT! Always lay the hosepack as straight as possible! Do not kink the</p><p>hosepack.</p><p>CORRECT!</p><p>WRONG!</p><p>36</p><p>Changing the</p><p>units of</p><p>measurement</p><p>Measurements can be displayed in either metric (cm), in imperial (inch) units or in mixed</p><p>units.</p><p>cm: all parameters in metric units, linear input for step parameter also in mm</p><p>inch: all parameters in imperial units, linear input for step parameter also in inch</p><p>mix: all parameter in metric units, but predefined input for step parameter in inch</p><p>To change the units, proceed as follows:</p><p>- Set the main switch on the control box to 0 (off).</p><p>- Press and hold the buttons (5) and (7) at the same time.</p><p>- Switch on the main switch on the control box. The unit of measurement selected (cm</p><p>or inch) is shown on the display.</p><p>- Select the setting required using the travel speed knob.</p><p>- Press the travel speed knob once to confirm and apply the setting.</p><p>O</p><p>FRC 1200</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>37</p><p>Configuring the robot interface</p><p>Safety</p><p>Indicators</p><p>WARNING!</p><p>Incorrect operation</p><p>or shoddy workmanship can cause serious injury or</p><p>damage!</p><p>All functions described in this document may only be carried out by trained</p><p>and qualified personnel after they have fully read and understood the following</p><p>documents:</p><p>- this document</p><p>- the operating instructions for the robot interface “RI FB Inside/i”</p><p>- all documents relating to the system components, especially the safety</p><p>rules</p><p>(1)</p><p>(2)</p><p>(1) LED ERR (error)</p><p>(2) LED RUN (operation)</p><p>LED RUN (operation)</p><p>Status Meaning</p><p>Off No power</p><p>Steady green Module status ‘operational’</p><p>Flashing green Module status ‘pre-operational’</p><p>Flashing green (briefly) Module status ‘stopped’</p><p>Flickering green Transmission speed detection running</p><p>Steady red When the Run LED and Error LED are lit, this indicates</p><p>a fatal event bringing the Interface to an exception state.</p><p>Contact After-Sales Service</p><p>38</p><p>Indicators</p><p>(continued)</p><p>LED ERR (error)</p><p>Status Meaning</p><p>Off No error (or no power)</p><p>Flashing red Warning limit reached</p><p>A bus error counter reached or exceeded its warning</p><p>level</p><p>Flickering red LSS services in progress</p><p>Flashing red (twice) Error Control Event</p><p>A guard (NMT-Slave or NMT-master) or heartbeat event</p><p>(Heartbeat consumer) has occurred</p><p>Steady red Bus off (Fatal Event)</p><p>DIP-switch</p><p>Setting the node</p><p>adresses for</p><p>power sorces</p><p>(1)</p><p>The DIP-switch (1) on the RI FB Inside/i</p><p>robot interface is used to set the node ad-</p><p>dress.</p><p>Position 2 of the DIP-switch is set by de-</p><p>fault in the ON position, all other switches</p><p>are in the OFF position.</p><p>IMPORTANT! Process is only working with: Node adress 6 for Power Source 1 and</p><p>Node adress 7 for Power Source 2.</p><p>DIP switch</p><p>8 7 6 5 4 3 2 1 Node adress Power source</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF O</p><p>N</p><p>O</p><p>N</p><p>O</p><p>FF 6 P1</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF</p><p>O</p><p>FF O</p><p>N</p><p>O</p><p>N</p><p>O</p><p>N 7 P2</p><p>Node adress is set, using the DIP switch positions 1 to 3.</p><p>Setting occurs in binary format.</p><p>NOTE! Whenever the DIP switch settings are changed, the interface must</p><p>be re- started in order to activate the new settings.</p><p>(Restart = disconnect and then reconnect the power supply)</p><p>39</p><p>Operation</p><p>IMPORTANT! There are fixed rules for the sequence in which the system components</p><p>are switched on.</p><p>On the following system components turn the main switch to the "ON - 1" position:</p><p>Switching on</p><p>system</p><p>components</p><p>Operation modes</p><p>WARNING!</p><p>Danger of injury from premature arc ignition.</p><p>The arc may be ignited accidentally. This can cause serious eye injuries.</p><p>- Before switching on the system components, ensure that the "Welding</p><p>mode" toggle switch on the welding carriage remote control is set to the "O"</p><p>position.</p><p>Picote</p><p>Base</p><p>Lateral</p><p>Arcing</p><p>The system supports 4 automatic operation modes:</p><p>- Lateral</p><p>- Base</p><p>- Picote</p><p>- Arcing.</p><p>1. Power sources</p><p>2. Welding carriage control box</p><p>40</p><p>Recommended</p><p>materials</p><p>Lateral: UTP AF DUR 600 MP Ø 1,2 mm</p><p>a FCAW metal cored of martensitic structure suitable for making the</p><p>lateral layers on roll teeth (Ø 1,2 mm).</p><p>Electrical parameters: Current (A): Voltage (V):</p><p>1,2 mm 150 – 200 22 - 28</p><p>Base: UTP AF DUR 600 MP Ø 1,6 mm</p><p>a FCAW metal cored of martensitic structure suitable for making the</p><p>base layer on top of roll teeth (Ø 1,6 mm).</p><p>Electrical parameters: Current (A): Voltage (V):</p><p>1,6 mm 160 - 240 24 - 32</p><p>Picote/Hook: UTP AF LEDURIT 68 Ø 1,6 mm</p><p>a FCAW with high content of chromium is used for marking hooks on</p><p>top of sugar cane roll teeth. Excellent characteristics for building up the</p><p>hooks.</p><p>Electrical parameters: Current (A): Voltage (V):</p><p>1,6 mm 150 - 220 22 - 26</p><p>Arcing: UTP AF VANADIUM 500 or UTP AF VANADIUM SG Ø 2,8 mm</p><p>FCAW for arcing on sugar mill rolls in the sugar cane industry.</p><p>A soft transfer with exact sizes of the drops, improves the grinding of</p><p>sugar cane. A special</p><p>Chrome/Vanadium alloy offers excellent resistance against abrasion. It</p><p>works with amperages lower than the conventional ones.</p><p>Electrical parameters: Current (A): Voltage (V):</p><p>2,8 mm 260 - 400 30 - 38</p><p>41</p><p>Welding workflow 1. The carriage moves to the respective tooth, which is set as start tooth. Arcing</p><p>starts from the bottom of the tooth and moves up, while the roll is turning - ac-</p><p>cording to the selected configuration.</p><p>Start Pos.</p><p>Stop Pos.</p><p>Hold Pos.</p><p>Home Pos.</p><p>2. After finishing one tooth, the torch holder arm moves to the Hold position and the</p><p>carriage moves one step further.</p><p>This operation will be repeated, until the carriage reaches the opposite contact</p><p>cam. Then the process stops, and the torch holder arm move into the Home posi-</p><p>tion.</p><p>Start Pos.</p><p>Stop Pos.</p><p>Hold Pos.</p><p>Home Pos.</p><p>42</p><p>Teaching mode</p><p>settings</p><p>2. Set the welding direction selector switch to STOP.</p><p>Activating the teaching mode:</p><p>1. Position the carriage in the base position on the track (with “home” text shown on</p><p>the display). Carriage is positioned correctly, when “home” text stops blinking.</p><p>Moving carriage</p><p>to reference</p><p>position</p><p>1. Switch the Automatic / Setup switch in position Setup.</p><p>2. Choose the required direction with the Welding direction selector</p><p>switch.</p><p>Direction depends on which contact cam the operator wants to</p><p>reach. The carriage stops automatically after reaching the contact</p><p>cam and recognizes this reached position as reference.</p><p>4</p><p>14</p><p>14</p><p>Teaching mode allows manually moving the torch holder arm or the carriage to select the</p><p>required positions and process settings for automatic mode.</p><p>1. Choose a process using the welding mode</p><p>selection switch</p><p>2. Rotate the button Start tooth or Stop tooth. The carriage will now move to the</p><p>start or stop tooth (white symbols on remote control).</p><p>Selecting a start/stop tooth:</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>or</p><p>43</p><p>Teaching mode</p><p>settings</p><p>(continued)</p><p>3. Switch the Automatic / Setup switch in position Setup.</p><p>4</p><p>IMPORTANT! After teaching all required parameters, move the carriage to reference</p><p>position again.</p><p>1. Set the welding mode selection switch to posi-</p><p>tion “3rd”</p><p>Changing the distance between teeth</p><p>1. Set the welding mode selection switch to posi-</p><p>tion “2nd”</p><p>2. Use the the button Start tooth, Step or Stop tooth to set the reference position</p><p>and safe position of the torch holder arm (green symbols on remote control).</p><p>IMPORTANT! Proceed with caution! Don´t move the torches too far towards</p><p>the roll.</p><p>Moving the torch holder arm manually:</p><p>2. Rotate the button Start tooth or Stop tooth, to set the required distance (orange</p><p>symbols on remote control).</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>O</p><p>FRC 1200</p><p>V0</p><p>2/</p><p>20</p><p>16</p><p>2</p><p>1 4</p><p>12 14</p><p>13</p><p>3</p><p>5 6 7</p><p>8 9</p><p>10 11</p><p>or</p><p>44</p><p>Saving a welding</p><p>program</p><p>3. Turn the POWER button, to select the required program</p><p>number.</p><p>4. Press the POWER button, to save the program with this</p><p>number.</p><p>2. memX appears on the display. X stands for the program number that has not yet</p><p>been selected.</p><p>Saving a program:</p><p>1. Press the POWER button and the OSC speed button together and hold for</p><p>4 seconds.</p><p>3. Set the welding direction selector switch to the central position 0.</p><p>2. Set the welding mode selector switch to the 0 position.</p><p>1. Set the operation mode selector switch to the lower position.</p><p>Before saving a program:</p><p>4</p><p>14</p><p>13</p><p>13</p><p>together with</p><p>1</p><p>O</p><p>12</p><p>Teaching mode</p><p>settings</p><p>(continued)</p><p>4. Choose the required direction with the Welding direction selector</p><p>switch.</p><p>Direction depends on which contact cam the operator wants to</p><p>reach. The carriage stops automatically after reaching the contact</p><p>cam and recognizes this reached position as reference.</p><p>14</p><p>45</p><p>Loading a</p><p>welding program</p><p>NOTE! The remote control has a factory-saved, read-only program “mem0”,</p><p>which contains the working parameters for the welding carriage. The value</p><p>“mem0” cannot be overwritten.</p><p>Loading a program:</p><p>IMPORTANT! To load a saved program, “mem” and the number of the last used pro-</p><p>gram must be shown on the display.</p><p>5. Turn the POWER button, to select a program.</p><p>6. To load the</p><p>selected program, press the POWER briefly</p><p>once.</p><p>4. Press the POWER button and the Power correction button P1 for 4 seconds.</p><p>3. Set the operation mode selector switch to the lower position.</p><p>2. Set the welding direction selector switch to the central position.</p><p>1. Set the welding mode selector switch to the 0 position.</p><p>4</p><p>14</p><p>13</p><p>13</p><p>together with</p><p>8</p><p>O</p><p>12</p><p>46</p><p>1. Set the operation mode selector switch to the lower position.</p><p>4</p><p>Starting a</p><p>welding process</p><p>Start offset</p><p>1. Load or set up the required welding program.</p><p>4. Choose the welding direction with the welding direction selection</p><p>switch.</p><p>2. Select the required function with the welding</p><p>mode selection switch.</p><p>3. Switch the Automatic / Setup switch in position Automatic.</p><p>4</p><p>14</p><p>With this function, the operator has the possibility, to adjust torch position over tooth</p><p>in manual mode. The operator is able to position exactly on the first tooth even if limit</p><p>switch activator is not on perfect position.</p><p>IMPORTANT! Never correct the torches towards the limit switch. Always correct them</p><p>inwards!</p><p>To activate this functionality, proceed as follows:</p><p>2. Choose the required direction with the Welding direction selector</p><p>switch.</p><p>Direction depends on which contact cam the operator wants to</p><p>reach. The carriage stops automatically after reaching the contact</p><p>cam and recognizes this reached position as reference.</p><p>14</p><p>47</p><p>Start offset</p><p>(continued)</p><p>4. Set the welding mode selection switch to posi-</p><p>tion “3rd”</p><p>5. Press the button once.</p><p>Now turn the button, to correct the position of the</p><p>torches.7</p><p>3. Set the welding mode selection switch to posi-</p><p>tion “2nd”</p><p>The torches move unto their start position.</p><p>48</p><p>49</p><p>Maintenance and disposal</p><p>50</p><p>51</p><p>Troubleshooting</p><p>General</p><p>Event codes</p><p>Machine state</p><p>codes</p><p>Basic</p><p>requirements for</p><p>the system to</p><p>work</p><p>In the event of faults, note that the functioning of the entire system depends on many</p><p>additional components (power source, wire-feed unit, etc.) that are also potential sources</p><p>of problems.</p><p>If an error occurs: a message "Err" and the corresponding error number appears on the</p><p>display.</p><p>► Connections have been established between the separate system components</p><p>► System components are supplied with electricity and the mains voltage for each</p><p>component complies with the rating plate.</p><p>Indication Description Remedy</p><p>cLs Welding carriage has reached one</p><p>of the contact cams on the rail.</p><p>Release the limit switch using the</p><p>traversing direction toggle switch.</p><p>oLs The oscillation arm has reached a</p><p>limit position.</p><p>The limit switch will be released</p><p>automatically in few seconds.</p><p>cm Metric system selected. To change the setting: see “Chang-</p><p>ing the units of measurement”</p><p>section.inch Imperial system selected.</p><p>mem0…9 Save or load a welding program. –</p><p>Indication Description</p><p>init Initialization of the system components.</p><p>stop Immediate stop button is depressed. Welding process and the mo-</p><p>tion of all axes stop. The carriage arm with the torches retracts fully.</p><p>Turn the button to unlock and continue.</p><p>hold No move in all axes.</p><p>home (flashing) The carriage is travelling to the base position.</p><p>home The carriage is stopped in the base position.</p><p>ref The carriage is travelling to the set position in automatic mode.</p><p>refX The carriage is stopped at the tooth X.</p><p>base Base welding process is being executed.</p><p>pico Picot welding process is being executed.</p><p>late Lateral welding process is being executed.</p><p>arcX Arcing welding process is being executed, where X denotes the</p><p>number of steps left.</p><p>manu (flashing) The carriage is manually moved to the set position.</p><p>manu The carriage is stopped after manual move.</p><p>52</p><p>Error codes Indication Description Remedy</p><p>err1 Error during initiation of the CAN</p><p>communication system.</p><p>Rectify short circuit between the lines</p><p>or communication ports.</p><p>err2 Communication error between</p><p>control box and remote control.</p><p>Check connections, tighten if neces-</p><p>sary. If necessary, replace damaged</p><p>control lines.</p><p>err3 Communication error between</p><p>remote control and oscillation</p><p>unit.</p><p>err4 Communication error between</p><p>remote control and control box.</p><p>err5 Error while saving or reading,</p><p>memory error on the remote</p><p>control.</p><p>Contact your FRONIUS service engi-</p><p>neer.</p><p>err6 Operating temperature exceeded</p><p>or ambient temperature too high.</p><p>Allow the device to cool down. Oper-</p><p>ate in a lower ambient temperature.</p><p>err7 Error in motor control unit. Contact your FRONIUS service engi-</p><p>neer.</p><p>err8 Error in oscillation control unit. Contact your FRONIUS service engi-</p><p>neer.</p><p>err9 Error in the control unit in the</p><p>control box.</p><p>Contact your FRONIUS service engi-</p><p>neer.</p><p>err10 Error in the display of the remote</p><p>control.</p><p>Contact your FRONIUS service engi-</p><p>neer.</p><p>err11 Communication error between</p><p>controller and robot interface.</p><p>Check connections, tighten if neces-</p><p>sary. If necessary, replace damaged</p><p>control lines.</p><p>err12 Robot Interface error. Check Troubleshooting section in</p><p>documentation of Robot Interface.</p><p>err13 Homing error of the carriage. Check positioning of the contact</p><p>cams.</p><p>err14 Homing error of the oscillator</p><p>arm.</p><p>Contact your FRONIUS service engi-</p><p>neer.</p><p>err15 Power source disconnected from</p><p>the Robot Interface.</p><p>Check connections, tighten if neces-</p><p>sary. If necessary, replace damaged</p><p>control lines. Use terminal connection</p><p>at the Robot Interface.</p><p>err16 Heartbeat protocol error with</p><p>power source communication</p><p>Tighten connectors to power source if</p><p>loose. Replace communication wires</p><p>if damaged. Reboot power source.</p><p>err17 Roll rotation sensor error or sen-</p><p>sor disconnected during work</p><p>Tighten connectors between control</p><p>box and roll sensor. Replace commu-</p><p>nication wires if damaged.</p><p>53</p><p>Maintenance</p><p>Maintenance</p><p>personnel WARNING!</p><p>Risk of injury and damage if maintenance work is not carried out cor-</p><p>rectly.</p><p>It is essential to adhere to the maintenance intervals and maintenance proce-</p><p>dures. The manufacturer accepts no liability for any damage caused by inad-</p><p>equate or poorly performed maintenance.</p><p>- All maintenance work on the welding carriage must be carried out by</p><p>trained technicians.</p><p>The following measures regarding maintenance must be put in place by the system</p><p>operator:</p><p>- a service book containing the required information (date, operator, maintenance work</p><p>carried out) must be kept.</p><p>Maintenance</p><p>record</p><p>Recommended</p><p>lubricants</p><p>IMPORTANT! Lubricants with solid lubricant additives (e.g.: MoS2, graphite and PTFE)</p><p>are not suitable for guiding systems.</p><p>Lubricant Article number</p><p>Isoflex Topas NB 5051 lubricating grease 40,0009,0169</p><p>Synteso-Glep lubricating grease 40,00090151</p><p>Electrically qualified person / technician:</p><p>Is a person who is able to evaluate the working steps, based on his specific technical</p><p>training, experiences and the well known relevant standards / regulations to recognize</p><p>possible risks / hazards.</p><p>Electrically instructed person:</p><p>Is a person who was trained by an electrically qualified person and was instructed</p><p>of the possible risks that can appear due to improper use / behaviour as well as the</p><p>necessary protective measures.</p><p>Notice: instruction has to be recorded</p><p>Electrically ordinary person:</p><p>Is a layperson who is neither an electrically qualified person nor a electrically instructed</p><p>person.</p><p>54</p><p>Maintaining the</p><p>torch holder arm</p><p>1. Use the 2,5 mm hex wrench to unscrew the four fixing screws (a) on both sides of</p><p>the cover.</p><p>2. Clean the torch holder arm.</p><p>3. Mount the torch holder arm again with the screws (a).</p><p>a</p><p>Maintenance</p><p>intervals and</p><p>procedures</p><p>NOTE! Use a dry cleaning cloth to clean the machine components. Only</p><p>use a cleaning agent if this is indicated in the maintenance procedure for a</p><p>specific part.</p><p>Daily</p><p>maintenance</p><p>IMPORTANT! Never use pressure washers for cleaning. Before mounting the carriage</p><p>on the rail, always make sure, that the contact area, rolls and gear wheels are clean, dry</p><p>and free of weld spatter.</p><p>Clean the carriage and the rail after every use.</p><p>IMPORTANT! Modifications,</p><p>maintenance or setup only at machine standstill!</p><p>IMPORTANT! Modifications, maintenance or setup only at machine standstill!</p><p>55</p><p>Technical data</p><p>56</p><p>57</p><p>Technical data</p><p>Arcing carriage</p><p>Control box</p><p>Remote control</p><p>Dimensions</p><p>Mains voltage 115 / 230 V</p><p>Mains voltage frequency 50 - 60 hz</p><p>Power supply 24 V DC</p><p>Weight (without cables) 5,3 kg (11.7 lb)</p><p>Degree of protection IP 23</p><p>Weight (without cable) 1,5 kg (3.3 lb)</p><p>Degree of protection IP 23</p><p>Welding procedures Lateral, Base, Picote, Arcing</p><p>Weight (only carriage) 11,85 kg (4.07 lb)</p><p>Degree of protection IP 67</p><p>4.</p><p>3°</p><p>21</p><p>m</p><p>m</p><p>(0</p><p>.8</p><p>2</p><p>in</p><p>)</p><p>70</p><p>m</p><p>m</p><p>(2</p><p>.7</p><p>5</p><p>in</p><p>)</p><p>–0</p><p>.5</p><p>°</p><p>483 mm (19.01 in)</p><p>783 mm</p><p>(30.82 in)</p><p>58</p><p>Environmental</p><p>conditions</p><p>Operation or storage of the device outside the stipulated area will be deemed</p><p>as not in accordance with the intended purpose. The manufacturer shall not</p><p>be held liable for any damage arising from such usage.</p><p>Ambient temperature range:</p><p>- during operation: +5°C up to +40°C (41°F up to 104°F)</p><p>- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)</p><p>Relative humidity:</p><p>- up to 50% at 40 °C (104 °F)</p><p>- up to 90% at 20 °C (68 °F)</p><p>The surrounding air must be free from dust, acids, corrosive gases or substances, etc.</p><p>Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)</p><p>Rating plates NOTE! The rating plates may not be removed or modified without the consent</p><p>of Fronius International GmbH. Ensure that the rating plates remain legible.</p><p>All illustrations of rating plates are repre-</p><p>sentative images.</p><p>IP67</p><p>11,85 kg</p><p>weight</p><p>411 x 208 x 405 mm</p><p>L x W x H</p><p>240 cm/min</p><p>vmax</p><p>1~</p><p>50/60 Hz 13 A</p><p>I1</p><p>4 A</p><p>U1</p><p>115/230 VAC</p><p>24 VDC</p><p>U2</p><p>Ser.-No.:</p><p>Art.-No.:</p><p>A-4600 Wels</p><p>www.fronius.com</p><p>Arcing Track 1200</p><p>8,045,602</p><p>XXXXXX</p><p>59</p><p>Spare parts, circuit diagram</p><p>60</p><p>61</p><p>Ordering details</p><p>Spare parts,</p><p>wearing parts</p><p>and auxiliary</p><p>materials</p><p>Spare parts</p><p>Use of third-party spare and wearing parts may pose risks. Use approved Fronius origi-</p><p>nal spare parts only.</p><p>The manufacturer cannot accept any liability for damage resulting from the use of spare</p><p>or wearing parts or auxiliary materials that are not approved by the manufacturer.</p><p>NOTE! Only trained technicians may change parts and may only do so after</p><p>having read the installation and dismantling instructions supplied.</p><p>When ordering spare parts, you should provide the following data:</p><p>- Item number as per spare parts list</p><p>- Model name of the device</p><p>- Serial number of the device (shown on the rating plate)</p><p>Overview:</p><p>8,045,602</p><p>8,046,040</p><p>38,0100,0461 (13,5m)</p><p>38,0100,0460 (23,5m)</p><p>38,0100,0463 (2m)</p><p>62</p><p>Carriage Arcing Track Art. no.: 8,045,602</p><p>48,0005,2174</p><p>48,0005,2173</p><p>48,0005,2172</p><p>48,0005,2172</p><p>48,0005,2179</p><p>48,0005,2180</p><p>PC-board X-axis</p><p>48,0005,2181</p><p>Motor X-axis</p><p>48,0005,2163</p><p>48,0005,2503</p><p>PC-Board Y-axis</p><p>48,0005,2504</p><p>Motor Y-axis</p><p>48,0005,2175</p><p>48,0005,2175</p><p>48,0005,2184</p><p>48,0005,2176</p><p>42,0001,4761</p><p>44,0350,4341</p><p>incl. Screws</p><p>44,0350,4341</p><p>incl. Screws</p><p>48,0005,2176</p><p>48,0005,2177</p><p>48,0005,2178</p><p>Torch and hosepack:</p><p>see operating instructions</p><p>MTB 400i / MHP 700i</p><p>Art. Nr. 42,0410,2076</p><p>63</p><p>Control Box included in Art. Nr. 8,045,306</p><p>48,0005,1819</p><p>48,0005,1820</p><p>48,0005,1817</p><p>38,0102,0072</p><p>48,0005,1818</p><p>64</p><p>Remote control Art. no.: 8,046,040</p><p>48,0005,1854</p><p>48,0005,1816*</p><p>48,0005,1856</p><p>*only rocker switch, without switch element</p><p>48,0005,1857</p><p>48,0005,1855</p><p>48,0005,2183</p><p>48,0005,2182 48,0005,1928</p><p>65</p><p>Rail Arcing Track</p><p>48,0005,2162</p><p>8,100,251</p><p>8,100,251</p><p>48,0005,3161 (3m)</p><p>48,0005,2160 (2m)</p><p>66</p><p>Torch body MTB 3600S G ML (Arcing) Art. no.: 44,0350,3961</p><p>Torch body MTB 400i G ML (Lateral, Base, Picote) Art. no.: 44,0350,3156</p><p>42,0100,1424</p><p>42,0001,4642 (2.8)</p><p>42,0001,6472 (2.4)</p><p>42,0001,1982</p><p>42,0100,1429</p><p>42,0100,0530</p><p>42,0001,3975</p><p>42,0100,0575</p><p>42,0100,0532</p><p>42,0001,6469 (1.6)</p><p>42,0001,6467 (1.2)</p><p>42,0001,4045</p><p>Torch wear parts</p><p>67</p><p>Circuit diagram</p><p>CA</p><p>RR</p><p>IA</p><p>G</p><p>E</p><p>O</p><p>SC</p><p>IL</p><p>LA</p><p>TO</p><p>R</p><p>CO</p><p>N</p><p>TR</p><p>O</p><p>L</p><p>BO</p><p>X</p><p>CO</p><p>N</p><p>TR</p><p>O</p><p>L</p><p>PA</p><p>N</p><p>EL</p><p>FR</p><p>O</p><p>N</p><p>IU</p><p>S</p><p>RO</p><p>BO</p><p>T</p><p>IN</p><p>TE</p><p>RF</p><p>AC</p><p>E</p><p>RI</p><p>M</p><p>O</p><p>D</p><p>/i</p><p>CC</p><p>C</p><p>AN</p><p>op</p><p>en</p><p>FR</p><p>O</p><p>N</p><p>IU</p><p>S</p><p>RO</p><p>BO</p><p>T</p><p>IN</p><p>TE</p><p>RF</p><p>AC</p><p>E</p><p>RI</p><p>M</p><p>O</p><p>D</p><p>/i</p><p>CC</p><p>C</p><p>AN</p><p>op</p><p>en</p><p>A</p><p>CCANL</p><p>DGND</p><p>E+24V</p><p>BCANH</p><p>A</p><p>B CANH</p><p>C CANL</p><p>D GND</p><p>E +24V</p><p>A B</p><p>CA</p><p>N</p><p>H</p><p>C</p><p>CA</p><p>N</p><p>L</p><p>D</p><p>G</p><p>N</p><p>D</p><p>E</p><p>+</p><p>24</p><p>V</p><p>A B</p><p>CA</p><p>N</p><p>H</p><p>C</p><p>CA</p><p>N</p><p>L</p><p>D</p><p>G</p><p>N</p><p>D</p><p>E</p><p>+</p><p>24</p><p>V</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>A B C D E</p><p>2x</p><p>2x</p><p>0,</p><p>5</p><p>23</p><p>,5</p><p>m</p><p>U</p><p>N</p><p>IT</p><p>RO</p><p>N</p><p>IC</p><p>B</p><p>U</p><p>S</p><p>CA</p><p>N</p><p>F</p><p>D</p><p>P</p><p>54</p><p>9.</p><p>14</p><p>.0</p><p>0.</p><p>00</p><p>.0</p><p>ye</p><p>llo</p><p>w</p><p>gr</p><p>ee</p><p>n</p><p>br</p><p>ow</p><p>n</p><p>w</p><p>hi</p><p>te</p><p>2x</p><p>2x</p><p>0,</p><p>5</p><p>23</p><p>,5</p><p>m</p><p>U</p><p>N</p><p>IT</p><p>RO</p><p>N</p><p>IC</p><p>B</p><p>U</p><p>S</p><p>CA</p><p>N</p><p>F</p><p>D</p><p>P</p><p>54</p><p>9.</p><p>14</p><p>.0</p><p>0.</p><p>00</p><p>.0</p><p>yellow</p><p>green</p><p>brown</p><p>white</p><p>A B C D E</p><p>A</p><p>BCANH</p><p>CCANL</p><p>DGND</p><p>E+24V</p><p>A</p><p>BCANH</p><p>CCANL</p><p>DGND</p><p>E+24V</p><p>B</p><p>C</p><p>D</p><p>E</p><p>A</p><p>2x</p><p>2x</p><p>0,</p><p>5</p><p>2</p><p>m</p><p>U</p><p>N</p><p>IT</p><p>RO</p><p>N</p><p>IC</p><p>B</p><p>U</p><p>S</p><p>CA</p><p>N</p><p>F</p><p>D</p><p>P</p><p>54</p><p>9.</p><p>15</p><p>.0</p><p>0.</p><p>00</p><p>.0</p><p>yellow</p><p>green</p><p>brown</p><p>white</p><p>2x</p><p>2x</p><p>0,</p><p>5</p><p>2</p><p>m</p><p>U</p><p>N</p><p>IT</p><p>RO</p><p>N</p><p>IC</p><p>B</p><p>U</p><p>S</p><p>CA</p><p>N</p><p>F</p><p>D</p><p>P</p><p>54</p><p>9.</p><p>15</p><p>.0</p><p>0.</p><p>00</p><p>.0</p><p>yellow</p><p>green</p><p>brown</p><p>white</p><p>B</p><p>C</p><p>D</p><p>E</p><p>A</p><p>CA</p><p>N</p><p>H</p><p>CA</p><p>N</p><p>L</p><p>G</p><p>N</p><p>D</p><p>+</p><p>24</p><p>V</p><p>CANH</p><p>CANL</p><p>GND</p><p>+24V</p><p>CANH</p><p>CANL</p><p>GND</p><p>+24V</p><p>68</p><p>PO</p><p>W</p><p>ER</p><p>SU</p><p>PP</p><p>LY</p><p>CO</p><p>N</p><p>TR</p><p>O</p><p>L</p><p>BO</p><p>X</p><p>br</p><p>ow</p><p>n</p><p>bl</p><p>ue</p><p>CA</p><p>N</p><p>1</p><p>CA</p><p>N</p><p>2</p><p>EX</p><p>TE</p><p>N</p><p>SI</p><p>O</p><p>N</p><p>B</p><p>O</p><p>AR</p><p>D</p><p>CA</p><p>N</p><p>3</p><p>CA</p><p>N</p><p>4</p><p>PE</p><p>L N PE</p><p>+ -</p><p>88</p><p>-2</p><p>64</p><p>VA</p><p>C</p><p>24</p><p>VD</p><p>C</p><p>+</p><p>24</p><p>V</p><p>G</p><p>N</p><p>D</p><p>+</p><p>IN</p><p>AN</p><p>AL</p><p>O</p><p>G</p><p>IN</p><p>PU</p><p>T</p><p>1</p><p>AG</p><p>N</p><p>D</p><p>IN</p><p>D</p><p>IG</p><p>IT</p><p>AL</p><p>IN</p><p>PU</p><p>T</p><p>1</p><p>+</p><p>24</p><p>V</p><p>CA</p><p>N</p><p>_L</p><p>O</p><p>W</p><p>CA</p><p>N</p><p>_H</p><p>IG</p><p>H</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>1</p><p>2</p><p>3</p><p>4</p><p>49</p><p>6.</p><p>20</p><p>.1</p><p>3.</p><p>00</p><p>.0</p><p>49</p><p>6.</p><p>20</p><p>.0</p><p>8.</p><p>00</p><p>.0</p><p>bl</p><p>ue</p><p>br</p><p>ow</p><p>n</p><p>49</p><p>6.</p><p>20</p><p>.0</p><p>9.</p><p>00</p><p>.0</p><p>bl</p><p>ac</p><p>k</p><p>re</p><p>d</p><p>49</p><p>6.</p><p>20</p><p>.1</p><p>1.</p><p>00</p><p>.0</p><p>re</p><p>d</p><p>bl</p><p>ac</p><p>k</p><p>49</p><p>6.</p><p>20</p><p>.1</p><p>4.</p><p>00</p><p>.0</p><p>w</p><p>hi</p><p>te</p><p>gr</p><p>ee</p><p>n</p><p>49</p><p>6.</p><p>20</p><p>.0</p><p>7.</p><p>00</p><p>.0</p><p>white</p><p>green</p><p>black</p><p>red</p><p>white</p><p>green</p><p>black</p><p>red</p><p>54</p><p>9.</p><p>12</p><p>.0</p><p>3.</p><p>00</p><p>.0</p><p>blue</p><p>black</p><p>brown</p><p>C</p><p>10</p><p>0n</p><p>F/</p><p>1k</p><p>VD</p><p>C</p><p>R</p><p>1M</p><p>oh</p><p>m</p><p>C</p><p>10</p><p>0n</p><p>F/</p><p>1k</p><p>VD</p><p>C</p><p>R</p><p>1M</p><p>oh</p><p>m</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>white</p><p>green</p><p>black</p><p>red</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E-4</p><p>96</p><p>.2</p><p>0.</p><p>07</p><p>.0</p><p>0.</p><p>0</p><p>white</p><p>green</p><p>black</p><p>red</p><p>C</p><p>10</p><p>0n</p><p>F/</p><p>1k</p><p>VD</p><p>C</p><p>R</p><p>1M</p><p>oh</p><p>m</p><p>C</p><p>10</p><p>0n</p><p>F/</p><p>1k</p><p>VD</p><p>C</p><p>R</p><p>1M</p><p>oh</p><p>m</p><p>69</p><p>CO</p><p>N</p><p>TR</p><p>O</p><p>L</p><p>PA</p><p>N</p><p>EL</p><p>CO</p><p>N</p><p>TR</p><p>O</p><p>L</p><p>M</p><p>O</p><p>D</p><p>U</p><p>LE</p><p>AR</p><p>C</p><p>EN</p><p>AB</p><p>LE</p><p>SW</p><p>IT</p><p>CH</p><p>TR</p><p>AV</p><p>EL</p><p>S</p><p>W</p><p>IT</p><p>CH</p><p>S3</p><p>S1</p><p>S2</p><p>S5</p><p>O</p><p>SC</p><p>IL</p><p>LA</p><p>TI</p><p>O</p><p>N</p><p>M</p><p>O</p><p>D</p><p>E</p><p>SE</p><p>LE</p><p>CT</p><p>O</p><p>R</p><p>S4</p><p>D</p><p>IR</p><p>EC</p><p>TI</p><p>O</p><p>N</p><p>CH</p><p>AN</p><p>G</p><p>E</p><p>SW</p><p>IT</p><p>CH</p><p>S6</p><p>A</p><p>B</p><p>C</p><p>D</p><p>E</p><p>1CANL</p><p>2CANH</p><p>3+24V</p><p>4GND</p><p>1GND</p><p>2WeldON</p><p>3WeldTest</p><p>1DirNeg</p><p>2DirPos</p><p>3GND</p><p>A9</p><p>8</p><p>4</p><p>3</p><p>2</p><p>1</p><p>6</p><p>3</p><p>4</p><p>2</p><p>1</p><p>5</p><p>1GND</p><p>4OSCRectan</p><p>5OSCTrain</p><p>6OSCSlope</p><p>7OSCNoWawe</p><p>1GND</p><p>2DirChange</p><p>3</p><p>2</p><p>1</p><p>1</p><p>2</p><p>3</p><p>21</p><p>49</p><p>6.</p><p>03</p><p>.0</p><p>4.</p><p>34</p><p>.1</p><p>blue</p><p>green</p><p>grey</p><p>brown</p><p>white</p><p>49</p><p>6.</p><p>03</p><p>.0</p><p>4.</p><p>31</p><p>.0</p><p>blue</p><p>white</p><p>brown</p><p>54</p><p>9.</p><p>11</p><p>.0</p><p>2.</p><p>05</p><p>.0</p><p>grey</p><p>green</p><p>blue</p><p>49</p><p>6.</p><p>03</p><p>.0</p><p>4.</p><p>33</p><p>.0</p><p>blue</p><p>white</p><p>49</p><p>6.</p><p>03</p><p>.1</p><p>2.</p><p>00</p><p>.0</p><p>green</p><p>white</p><p>red</p><p>blue</p><p>3SegmentWeld</p><p>2TotalPath</p><p>yellow</p><p>red</p><p>C</p><p>10</p><p>0n</p><p>F/</p><p>1k</p><p>VD</p><p>C</p><p>R</p><p>1M</p><p>oh</p><p>m</p><p>3</p><p>G</p><p>N</p><p>D</p><p>2</p><p>Q</p><p>ST</p><p>O</p><p>P</p><p>1</p><p>n/</p><p>c</p><p>11 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