FRO­NIUS FOH 8-40 Instructions for use

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

3
These operating instructions will help you familiarise yourself with the machine. It is in
your interest to read these instructions carefully and to observe the directions contained
in them. This will prevent faults and incorrect operation or possible damage to installed
components.
Please also obey the safety rules; doing so will ensure greater safety when using the
product. Careful handling of the entire system will repay you with years of safe and relia-
ble operation. These are essential prerequisites for excellent results.
Dear reader,
Introduction

4

5
Contents
General information 9
Safety rules ................................................................................................................................................... 11
General remarks....................................................................................................................................... 11
Proper use................................................................................................................................................ 11
Environmental conditions ......................................................................................................................... 12
Obligations of the operator....................................................................................................................... 12
Obligations of the personnel .................................................................................................................... 12
Mains connection ..................................................................................................................................... 12
Protecting yourself and others ................................................................................................................. 13
Information on noise emission values ...................................................................................................... 13
Dangers posed by mains current and welding current............................................................................. 14
EMC device classications....................................................................................................................... 14
EMC measures......................................................................................................................................... 15
EMF measures with implants ................................................................................................................... 15
Specic hazards....................................................................................................................................... 16
Impairment of the welding results ............................................................................................................ 16
Danger from shielding gas cylinders ........................................................................................................ 17
Safety measures at installation location and during transport.................................................................. 17
Safety measures in normal operation ...................................................................................................... 18
Maintenance and repair ........................................................................................................................... 18
Safety inspection...................................................................................................................................... 19
Disposal.................................................................................................................................................... 19
Safety labelling......................................................................................................................................... 19
Data protection......................................................................................................................................... 19
Copyright.................................................................................................................................................. 19
About this document...................................................................................................................................... 20
Function of this document ........................................................................................................................ 20
Explanation of safety symbols.................................................................................................................. 20
Qualied technicians ................................................................................................................................ 20
Copyright.................................................................................................................................................. 20
General remarks............................................................................................................................................ 21
Principle.................................................................................................................................................... 21
Device concept and applications.............................................................................................................. 21
Safety 23
Operational reliability and tips for the user .................................................................................................... 25
Proper use................................................................................................................................................ 25
Foreseeable misuse................................................................................................................................. 25
Conversions or modications ................................................................................................................... 25
Duty to provide instruction........................................................................................................................ 25
Operating instructions .............................................................................................................................. 26
Personal protective equipment................................................................................................................. 26
Local regulations ...................................................................................................................................... 26
Additional overarching policies and regulations ....................................................................................... 26
Spare parts, wearing parts and auxiliary materials .................................................................................. 27
Transportation and storage ...................................................................................................................... 27
Danger points and safety precautions........................................................................................................... 28
Safety instructions.................................................................................................................................... 28

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Description of the open weld heads 31
Scope of supply............................................................................................................................................. 33
Open weld head conguration ................................................................................................................. 33
Accessories ............................................................................................................................................. 33
Open weld head components........................................................................................................................ 35
FOH open weld head ............................................................................................................................... 35
Hosepack for FOH open weld head ......................................................................................................... 36
Controls and connections.............................................................................................................................. 37
Connections ............................................................................................................................................. 37
Controls for open weld head .................................................................................................................... 38
Welding position ............................................................................................................................................ 40
Welding position ....................................................................................................................................... 40
Commissioning 41
Starting up the open weld head..................................................................................................................... 43
Positioning the open weld head on the workpiece .................................................................................. 43
Setting the external wirefeed ................................................................................................................... 45
Threading the welding wire ..................................................................................................................... 47
Operation 49
Before welding............................................................................................................................................... 51
Safety ....................................................................................................................................................... 51
Checking the connections ........................................................................................................................ 51
Switching on the system components ..................................................................................................... 51
Selecting the type of orbital open weld head ........................................................................................... 52
Welding process ........................................................................................................................................... 53
Creating a program ................................................................................................................................. 53
Starting the welding process .................................................................................................................... 53
After the welding process ............................................................................................................................. 55
Removing the open weld head................................................................................................................. 55
Troubleshooting, maintenance and disposal 57
Troubleshooting............................................................................................................................................. 59
General..................................................................................................................................................... 59
Basic requirements for the system to work .............................................................................................. 59
Troubleshooting........................................................................................................................................ 59
Error messages in the system control unit .............................................................................................. 60
Error messages on the power source ..................................................................................................... 60
Maintenance.................................................................................................................................................. 61
Maintenance personnel............................................................................................................................ 61
Maintenance record ................................................................................................................................. 61
Maintenance intervals and procedures .................................................................................................... 61
Opening the welding head ....................................................................................................................... 62
Replacing the plastic coupling.................................................................................................................. 64
Technical data 65
Technical data ............................................................................................................................................... 67
Open weld head FOH 8-40 ...................................................................................................................... 67
Open weld head FOH 10-76 .................................................................................................................... 67
Open weld head FOH 20-114................................................................................................................... 67
Open weld head FOH 40-168 .................................................................................................................. 67
Orbital welding torch ................................................................................................................................ 67
FOH dimensions....................................................................................................................................... 68
Rating plates ............................................................................................................................................ 68
Environmental conditions ......................................................................................................................... 69

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Spare parts, circuit diagram 71
Spare parts.................................................................................................................................................... 73
Spare parts, wearing parts and auxiliary materials .................................................................................. 73
Ordering details........................................................................................................................................ 73
FOH 8-40.................................................................................................................................................. 74
FOH 10-76................................................................................................................................................ 77
FOH 20-114.............................................................................................................................................. 80
FOH 20-114.............................................................................................................................................. 81
FOH 20-114.............................................................................................................................................. 82
FOH 40-168.............................................................................................................................................. 83
Orbital welding torch TTWO 2000 F++..................................................................................................... 86
Wire adjustment unit FOH........................................................................................................................ 86
Wire feeding Orbital TTWO 2000 ............................................................................................................ 87
Extension hose pack FCH / FOH 10m .................................................................................................... 87
Motor control cable................................................................................................................................... 88
Transport case FOH................................................................................................................................. 88
Wearing parts box TTWO 2000 F++ ............................................................................................................. 89
Original spare parts.................................................................................................................................. 89
Content of wearing parts box ................................................................................................................... 89
Circuit diagrams ............................................................................................................................................ 91
EU Declaration of conformity......................................................................................................................... 93

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9
General information

10

11
Safety rules
General remarks
Proper
use
The device is manufactured using state-of-the-art technology and according to r
ecognised 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 operator,
- inefcient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualied,
- have sufcient 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
applicable 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 remarks" in the operating instructions for the device. Before switching
on the device, remove any faults that could compromise safety.
The device is to be used exclusively for its intended purpose.
The device is intended for the welding process described on the rating plate only.
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 also 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.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
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.

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Environmental
conditions
Obligations of
the operator
Obligations of
the personnel
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer shall not be held liable for any
damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
- free from dust, acids, corrosive gases and substances, etc.
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
Altitudes above sea level:
- up to 2000 m (6561 ft. 8.16 in.)
Environment:
- Under no circumstances may the device be operated in rainy or snowy environments.
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 conrmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Before 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
conrm 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 of types of device 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 operator or user of the device should check whether the device may be
connected, discussing the matter with the power supply company where appropriate.
NOTE! Ensure that the mains connection is earthed properly

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Protecting your-
self and others
Persons involved with welding expose themselves to numerous risks, e.g.:
- arc radiation, which can damage eyes and skin
- hazardous electromagnetic elds, which can endanger the lives of those using
cardiac pacemakers
- risk of electrocution from mains current and welding current
- greater noise pollution
- harmful welding fumes and gases
Anyone working on the workpiece whilst welding is taking place must wear suitable pro-
tective clothing with the following properties:
- ame-resistant
- insulating and dry
- covers the whole body, is undamaged and in good condition
- safety helmet
- trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- protect eyes and face from UV rays, heat and sparks using a protective visor and
regulation lter.
- wear regulation protective goggles with side protection behind the protective visor.
- wear stout footwear that provides insulation even in wet conditions.
- protect the hands with suitable gloves (electrically insulated and providing protection
against heat).
- 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
operation or welding is in progress. If, however, there are people in the vicinity,
- make them aware of all the dangers (risk of dazzling by the arc, injury from ying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.),
- provide suitable protective equipment or
- erect suitable safety screens/curtains.
Information on
noise
emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling
and in the cooling phase following operation at the maximum permissible operating point
under maximum rated load conditions according to EN 11201.

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Dangers posed
by mains cur-
rent and welding
current
- An electric shock is potentially life threatening and can be fatal.
- Do not touch live parts either inside or outside the device.
- During TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of
metal that are in contact with the welding wire are live.
- Always set the wirefeeder up on a sufciently insulated surface or use a suitable,
insulated wirefeeder holder.
- Make sure that you and others are protected with an adequately insulated, dry tem-
porary backing or cover for the earth or ground potential. This temporary backing 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. Loose connectors, scorched, damaged or inadequately dimensioned cables
and leads must be replaced immediately.
- Do not loop cables or leads around the body or parts of the body.
- Never submerge the electrode (rod electrode, tungsten electrode, welding wire, etc.)
in uids to cool it.
- Never touch the electrode when the power source is switched on.
- Double the open circuit voltage of a power source can occur between the welding
electrodes of two power sources. Touching the potentials of both electrodes at the
same time may be fatal under certain circumstances.
- Arrange for the mains cable to be checked regularly by a qualied electrician to en-
sure 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 mains without a ground conductor and in a socket with-
out a ground conductor contact, this will be deemed gross negligence. The manufac-
turer 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.
- Wear a safety harness if working at height.
- 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
anyone from plugging the mains plug back in and switching it on again.
- After opening the device:
- Discharge all components that store electrical charges
- Ensure that all components of the device are currentless.
- If work on live parts is required, appoint a second person to switch off the main switch
at the right moment.
EMC device clas-
sications
EMC device classication according to the rating plate or the technical data.
Devices with emission class A:
- are only designed for use in an industrial setting.
- can cause conducted and emitted interference in other areas.
Devices with emission class B:
- satisfy the emissions criteria for residential and industrial areas.
This also applies to residential areas in which power is supplied from the public
low-voltage grid.

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EMC measures In certain cases, even though a device complies with the standard limit values for
emissions, it may affect the application area for which it was designed (e.g. when there
is sensitive equipment at the same location, or if the 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 situation.
Check and assess the immunity of equipment in the vicinity of the device in accordance
with national
and international regulations. Examples of equipment that may be susceptible to
interference 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 power supply
- If electromagnetic interference arises despite correct mains connection, additional
measures are necessary (e.g. use a suitable line lter).
2. Welding power-leads
- Keep the power-leads as short as possible
- Allow the power-leads to run close together (also to avoid EMF problems)
- Lay the power-leads far away from other lines
3. Equipotential bonding
4. Earthing the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if required
- Where necessary, shield other equipment in the vicinity.
- Shield off the entire welding installation
EMF measures
with implants
Electromagnetic elds may pose as yet unknown risks to health:
- Effects on the health of persons in the vicinity, e.g. those with pacemakers and hear-
ing aids
- Individuals with pacemakers must seek advice from their doctor before approaching
the device or any welding that is in progress
- For safety reasons, maintain as large a distance as possible between the welding
cables and the head/torso of the welder.
- Do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body

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Specic hazards Keep hands, hair, clothing and tools away from moving parts.
For example:
- Fans
- Cogs
- 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 or removed for as long as maintenance
or repair work is being carried out.
During operation:
► Ensure that all covers are closed and all side panels are tted properly.
►Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).
► Do not look into the contact tip
► Wear suitable protective goggles.
- Never touch the workpiece during or after welding - risk of burns.
- Welding torches and other parts with a high operating temperature must be allowed to
cool down before handling.
- Special provisions apply in areas at risk of re or explosion - observe relevant national
and international regulations.
- 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.
- Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting
coolant ow or return lines.
- Observe the information on the coolant safety data sheet when handling coolant. The
coolant safety data sheet may be obtained from your service centre or downloaded
from the manufacturer's website.
- The device is equipped with a carrying handle. This is only to be used for transport by
hand. The carrying handle is not suitable for use if transporting with a crane, counter-
balanced lift truck or other mechanical hoist.
- As a minimum, the test interval and scope of the test must comply with the relevant
valid national standards and guidelines.
- Odourless and colourless shielding gas may escape unnoticed if an adapter is used
for the shielding gas connection. Prior to assembly, seal the device-side thread of the
adapter for the shielding gas connection using suitable Teon tape.
The following requirements with regard to shielding gas quality must be met if the
welding system is to operate in a correct and safe manner:
- Solid particle size < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being used.
Impairment
of the welding
results

17
Danger from
shielding gas
cylinders
Safety measures
at
installation loca-
tion
and during
transport
Shielding gas cylinders contain gas under pressure and can explode
if damaged. As shielding gas cylinders form part of the welding equipment,
they must be handled with great care.
- Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked ames, 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.
- Only use shielding gas cylinders suitable for the application in hand, along with the
correct and appropriate accessories (regulator, hoses and ttings). Only use shielding
gas cylinders 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
international regulations for shielding gas cylinders and accessories.
- Place the device on a solid, level surface.
The maximum permissible tilt angle is 10°.
- Special provisions apply in areas at risk of re 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.
- Only set up and operate the device in accordance with the degree of protection 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 ow in and out freely.
- When transporting the device, observe the relevant national and local guidelines and
accident prevention regulations. This applies especially to guidelines regarding the
risks arising during transport.
- Before transporting the device, allow coolant to drain completely.
- After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before
commissioning the device.

18
Safety measures
in normal opera-
tion
Maintenance and
repair
Only operate the device if all safety devices are fully functional. If the safety 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,
- inefcient 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 functioning of
safety devices.
Always secure the shielding gas cylinder to prevent it from falling over.
Only the manufacturer's original coolant is suitable for use with our devices due to its
properties (electrical conductibility, anti-freeze agent, material compatibility, ammability,
etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
The manufacturer accepts no liability for damage resulting from use of a different coolant.
In addition, all warranty claims will be forfeited.
The coolant can ignite under certain conditions. Transport the coolant
only in its original, sealed containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your ser-
vice centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
With parts sourced from third-parties, there is no guarantee that they are constructed and
manufactured so
as to meet the demands and safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
Do not carry out any modications, alterations, etc. to the device without the manufactur-
er's consent.
Parts that are not in perfect condition must be replaced immediately.
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.

19
Safety
inspection
Disposal
Safety
labelling
Data protection
Copyright
- 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 carried out by a qualied electrician is recommended
- after modication
- after installing or converting components
- after repairs, updates and maintenance
- at least every twelve months.
- For safety inspections, follow the appropriate national and international standards and
directives.
- Further details on safety inspection and calibration can be obtained from your service
centre. They will provide you on request with any documents you may require.
Do not dispose of this device with normal domestic waste! To comply with the European
Directive 2012/19/EC on Waste Electrical and Electronic Equipment and its implemen-
tation as national law, electrical equipment that has reached the end of its life must be
collected separately and returned to an approved recycling facility. Be sure to return any
device that you no longer require to your dealer, or nd out about the approved collection
and recycling facilities in your area. Ignoring this European Directive may be harmful to
the environment and your own health!
Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards from the EN 60 974
series).
Devices with the CSA test mark satisfy the requirements of the relevant standards in
Canada and the USA.
The user is responsible for backing up any changes made to the factory settings.
The manufacturer shall not be liable in the event that personal settings are deleted.
Copyright of these operating instructions remains with the manufacturer.
Text and illustrations were accurate at the time of printing.
Fronius reserves the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser.
We are grateful for any suggestions for improvement and for drawing our attention
to any errors in these operating instructions.

20
About this document
Function of this
document
These operating instructions explain how to commission and operate the device in
conjunction with the installed system components.
Look after the operating instructions carefully; they must always be to hand at the loca-
tion where the device is being used. They can be used as a reference should any
operational or functional problems occur in the future.
Qualied
technicians
- These operating instructions are designed for trained technicians or persons with
practical welding experience. Personnel must be trained through veriable regular
instruction.
- Maintenance and repair of the machine may likewise only be carried out by trained
technicians and in compliance with the specied maintenance activities and mainte-
nance intervals.
- The manufacturer accepts no liability for damage caused by insufcient knowledge
of how to use the device.
Explanation of
safety
symbols
DANGER! Indicates immediate and real danger. If it is not avoided, death or
serious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of awed results and possible damage to the
equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful informa-
tion. It does not indicate a potentially damaging or dangerous situation.
Special care is required if you see any of the symbols shown.
Copyright of these operating instructions remains with Fronius International GmbH.
Text and illustrations were accurate at the time of printing. Fronius reserves the right
to make changes. The contents of the operating instructions shall
not provide the basis for any claims whatsoever on the part of the purchaser.
Copyright