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

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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

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Contents
General information 9
Safety rules ................................................................................................................................................... 11
General remarks....................................................................................................................................... 11
Proper use................................................................................................................................................ 11
Environmental conditions ......................................................................................................................... 12
Obligations of the operator....................................................................................................................... 12
Obligations of the personnel .................................................................................................................... 12
Mains connection ..................................................................................................................................... 12
Protecting yourself and others ................................................................................................................. 13
Information on noise emission values ...................................................................................................... 13
Dangers posed by mains current and welding current............................................................................. 14
EMC device 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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General information

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