FRO­NIUS Calibration system 2.0 User manual

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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0270,EN 008-29052019
Calibration system 2.0 Operating Instructions
Miscellaneous
EN

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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety notices DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.

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EN
Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 8
Risks from mains current and welding current...................................................................................... 9
EMC Device Classifications .................................................................................................................. 9
EMC measures ..................................................................................................................................... 9
EMF measures...................................................................................................................................... 10
Specific hazards.................................................................................................................................... 10
Danger from shielding gas cylinders..................................................................................................... 11
Safety measures at the installation location and during transport ........................................................ 11
Safety measures in normal operation ................................................................................................... 12
Commissioning, maintenance and repair.............................................................................................. 12
Safety inspection................................................................................................................................... 12
Calibration of the calibration system ..................................................................................................... 13
Disposal ................................................................................................................................................ 13
Safety symbol ....................................................................................................................................... 13
Data protection...................................................................................................................................... 13
Copyright............................................................................................................................................... 13
General information 15
General ...................................................................................................................................................... 17
Device concept ..................................................................................................................................... 17
Proper use / intended purpose.............................................................................................................. 17
Crane transport ..................................................................................................................................... 18
Required for calibration......................................................................................................................... 18
Accessories and options ............................................................................................................................ 19
Accessories........................................................................................................................................... 19
Options.................................................................................................................................................. 20
Controls, connections and mechanical components 21
Controls and connections on calibration system........................................................................................ 23
Front of device ...................................................................................................................................... 23
Rear of device (without trolley) ............................................................................................................. 24
Mechanical components on trolley............................................................................................................. 25
Calibration system trolley...................................................................................................................... 25
Installation 27
Installing the calibration system ................................................................................................................. 29
General ................................................................................................................................................. 29
TwinCat................................................................................................................................................. 29
USB to LAN driver................................................................................................................................. 29
TPS/i SmartCard driver......................................................................................................................... 30
LocalNet FTDI driver............................................................................................................................. 32
Desktop software installation ................................................................................................................ 32
Changing network settings.................................................................................................................... 33
Changing the network settings for USB calibration............................................................................... 33
Setting a TwinCat route ........................................................................................................................ 34
Setting the language, system information.................................................................................................. 36
Setting the language ............................................................................................................................. 36
Retrieving system information............................................................................................................... 36

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Calibrating welding systems 37
General information ................................................................................................................................... 39
Mains voltage measurement for single-phase power sources.............................................................. 39
Correcting set values and load resistances .......................................................................................... 39
Calibrating welding systems with LocalNet (TPS, TSt, MW, TT) ............................................................... 40
Overview - LocalNet.............................................................................................................................. 40
Connecting the power source and calibration system .......................................................................... 40
Connecting the welding wire calibration system ................................................................................... 43
Connecting the computer to the calibration system and signature pad ................................................ 44
Preparing the gas calibration system.................................................................................................... 45
Calibrating the welding system ............................................................................................................. 46
Calibrating welding systems with SpeedNet (TPSi)................................................................................... 49
Overview - SpeedNet............................................................................................................................ 49
Connecting the power source and calibration system .......................................................................... 49
Connecting the welding wire calibration system ................................................................................... 49
Connecting the computer to the calibration system and signature pad ................................................ 50
Preparing the gas calibration system.................................................................................................... 50
Calibrating the welding system ............................................................................................................. 51
Calibrating welding systems with USB / SpeedNet.................................................................................... 55
Overview - USB .................................................................................................................................... 55
Connecting the power source and calibration system .......................................................................... 55
Connecting the welding wire calibration system ................................................................................... 56
Connecting the computer to the calibration system and signature pad ................................................ 56
Preparing the gas calibration system.................................................................................................... 56
Calibrating the welding system ............................................................................................................. 57
Calibrating other Fronius welding systems ................................................................................................ 61
Overview - other Fronius devices ......................................................................................................... 61
Connecting the power source and calibration system .......................................................................... 61
Connecting the welding wire calibration system ................................................................................... 62
Connecting the computer to the calibration system and signature pad ................................................ 62
Preparing the gas calibration system.................................................................................................... 62
Calibrating the TransPocket welding system ........................................................................................ 62
Calibrating TransTig 1750 Puls............................................................................................................. 66
Calibrating VarioSynergic 3400 ............................................................................................................ 69
Troubleshooting 75
Troubleshooting ......................................................................................................................................... 77
The status indicator is not lit up ............................................................................................................ 77
The status indicator lights up red .......................................................................................................... 77
No connection ....................................................................................................................................... 77
No USB/SpeedNet connection.............................................................................................................. 77
Technical data 79
Technical data............................................................................................................................................ 81
Calibration system 2.0 .......................................................................................................................... 81
Wire speed measuring system.............................................................................................................. 81
Interface box ......................................................................................................................................... 82
Gas measurement option...................................................................................................................... 82

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EN
Safety rules
General The device is manufactured using state-of-the-art technology and according to recognised
safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- 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 and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applica-
ble and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- 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" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for unexpected or incorrect results.
Environmental
conditions Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age arising from such usage.
Ambient air temperature range:
- during operation: 0 °C to + 40 °C (32 °F to 104 °F)
- during transport 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)

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The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed 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.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance *)
- Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power sup-
ply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your-
self and others For your personal safety, take the following precautions:
Use suitable protective clothing
Protective clothing refers to a variety of different items. Operators should:
- protect their eyes with the specified protective goggles;
- wear stout footwear that provides insulation even in wet conditions;
- protect their hands by wearing suitable gloves (electrically insulated, heat-proof, pro-
tection from cut injuries);
- wear ear protection to reduce the harmful effects of noise and to prevent injury.
Keep all persons, especially children, out of the working area while any devices are in op-
eration or calibration is in progress. If, however, there are people in the vicinity,
- warn them of all the dangers
- provide suitable protective equipment or
- erect suitable safety screens/curtains

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EN
Risks from mains
current and weld-
ing current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
Make sure that you and others are protected with an adequately insulated, dry base or cov-
er for the earth or ground potential. This base or cover must extend over the entire area
between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimen-
sioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.
If the device is operated on a grid without a ground conductor and in a socket without a
ground conductor contact, this will be deemed gross negligence. The manufacturer shall
not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
EMC Device Clas-
sifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential 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.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sen-
sitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situ-
ation.

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Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interfer-
ence from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the de-
vice or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened / removed while maintenance or repair work
is being carried out.
During operation
- Ensure that all covers are closed and all side 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 in-
jury (piercing of the hand, injuries to the face and eyes, etc.).
For this reason, always keep the wire speed measuring system away from the head and
body and wear suitable protective goggles.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.

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EN
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains or ropes onto all suspension points provided on the load-carrying equip-
ment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or chang-
es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Danger from
shielding gas cyl-
inders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan-
ical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylin-
ders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
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 must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Safety measures
at the installation
location and dur-
ing transport
A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.

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Safety measures
in normal opera-
tion
Commissioning,
maintenance and
repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12-
month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and di-
rectives.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safe-
ty devices are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper func-
tioning of safety devices.
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- When ordering, please give the 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.
Only use original housing screws in the correct number and torque to 3 Nm.

13
EN
Further details on safety inspection and calibration can be obtained from your service cen-
tre. They will provide you on request with any documents you may require.
Calibration of the
calibration sys-
tem
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!
Safety symbol Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives. Further details can be found in the appendix or the
section headed "Technical data" in your documentation.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba-
sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.
Regular calibration is required to guarantee the traceability to national or inter-
national standards of calibrations performed with this calibration system.
Fronius recommends a 12-month calibration interval. For more information,
please contact your Fronius partner.

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General information

17
EN
General
Device concept The calibration system 2.0 is designed for
calibrating power sources.
All types of power sources, regardless of
manufacturer, can be calibrated under
static load using this system.
Both DC and AC devices can be calibrated.
The calibration system is suitable for quick
and easy calibration of the power source in
situ.
The calibration system can also be used for
servicing to test or check the power sources
(e.g. after repairs, troubleshooting, etc.).
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 manufacturer shall not
be liable for any damage resulting from such use.
Proper use also includes
- carefully reading these Operating Instructions
- following all the instructions and safety rules in these Operating Instructions
- performing all stipulated inspection and maintenance work
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.

18
Crane transport WARNING!
Risk of injury due to falling device or device parts.
► Do not walk under the device when it is being suspended in an elevated position or
dwell in hazardous locations
► Exclusively use load-carrying equipment approved by Fronius
► Attach 4 chains 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 regula-
tions
WARNING!
Risk of injury due to falling device or device parts.
When transporting by crane, make sure that:
► There are no objects on the shelf or in the storage compartments
► All accessory drawers are closed and locked
4 suspension points for transporting by crane
Required for cali-
bration
- Computer, laptop
- Calibration software (available from the Fronius Download Center)

19
EN
Accessories and options
Accessories
Item Designation Item no.
(1) 1 x mains cable, 5 m 43,0004,2862
(2) 1 x Euro/central connector adapter with Tuchel socket 44,0350,5407
(3) 1 x Fronius/central connector adapter 44,0350,4504
(4) 1 x (+) power cable with sense lead (red) 43,0004,5883
(5) 1 x LocalNet passive splitter 4,100,261
(6) 1 x (-) power cable with sense lead (blue) 43,0001,5882
(7) 1 x cooling unit bridging hose
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) 1 x USB connection cable to PC/laptop 43,0004,5963
(10) 2 x high-current socket to bayonet adapter 42,0001,4482
(11) 1 x LocalNet/USB converter 4,101,026
(12) 2 x bayonet adapter 25 mm2 to 50 mm24,001,549
(1) (2) (3) (4) (5) (6) (7) (8)
(9)
(13)(14) (12) (11) (10)

20
Further accessories (not pictured)
Options
(13) 1 x Tuchel adapter cable 43,0004,5884
(14) 1 x welding wire calibration system
+
5 m connection cable
4,050,210
43,0004,5997
Designation Item no.
1 x power adapter 4,051,091
1 x connection cable for gas sensor, 5 m 43,0004,5914
1 x 1.6 m SpeedNet cable 4,051,021
2 x 5 m SpeedNet cable 4,051,022
2 x insulating sleeve adapter 42,0100,1411
1 x 2.5 m 8-pin data cable, PUR 43,0004,4361
1 x LocalNet 6-pin cable with Molex Microfit socket 43,0004,4850
2 x USB Ethernet adapter EU 4306 43,0004,5688
Item Designation Item no.
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
10 m gas hose, 2 x 1/4" 44,0001,3423
Double nipple 1/4" 42,0401,0874
Gas fitting connection, 1/4" 44,0450,0281
Gas hosepack adapter, external 1/4" - internal 5/8-18 UNF 42,0001,3540
Gas fitting 5 /8" - 8400 + 8411 42,0001,6601
Removable cable tie, 180 mm 42,0407,0558
Calibration system trolley 4,077,022
TU Car 4 Basic trolley 4,077,009