TÄYDELLISTÄ HITSAUSTA

PLASMAMODULE 10/ Operating Instructions/ Spare Parts List

v.01/2012 ENG

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Dear Reader

Thank you for choosing Fronius - and congratulations on your new, technically high-

grade Fronius product! This instruction manual will help you get to know your new

machine. Read the manual carefully and you will soon be familiar with all the many

great features of your new Fronius product. This really is the best way to get the most

out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you

will help to ensure more safety at your product location. And of course, if you treat your

product carefully, this definitely helps to prolong its enduring quality and reliability - things

which are both essential prerequisites for getting outstanding results.

Introduction

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Safety rules

DANGER!

WARNING!

CAUTION!

“NOTE!” indicates a situation which implies a risk of impaired welding resultand damage to the equipment.

NOTE!

This equipment has been made in accordance with the state of the art andall recognised safety rules. Nevertheless, incorrect operation or misuse maystill lead to danger for- the life and well-being of the operator or of third parties,- the equipment and other tangible assets belonging to the owner/operator,- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing andmaintaining the equipment must- be suitably qualified- know about welding and- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. Inaddition to the instruction manual, copies of both the generally applicableand the local accident prevention and environmental protection rules must bekept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:- must be kept in a legible condition- must not be damaged, must not be removed- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings arelocated on the machine, please see the section of your machine’s instructionmanual headed “General remarks”.

General remarks

Important!

“DANGER!” indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury. This signal word is to belimited to the most extreme situations. This signal word is not used forproperty damage hazards unless personal injury risk appropriate to thislevel is also involved.

“WARNING!” indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury. This signal word is not usedfor property damage hazards unless personal injury risk appropriate to thislevel is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avo-ided, may result in minor or moderate injury. It may also be used to alertagainst unsafe practices that may cause property damage.

“Important!” indicates practical hints and other useful special-information. Itis no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay evencloser attention to the contents of the manual!

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Operation or storage of the power source outside the stipulated range isdeemed to be “not in accordance with the intended use”. The manufacturershall not be liable for any damage resulting herefrom.

Temperature range of ambient air:- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:- up to 50 % at 40 °C (104 °F)- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Ambientconditions

The machine may only be used for jobs as defined by the “Intendedpurpose”.

The machine may ONLY be used for the welding processes stated on therating plate.Utilisation for any other purpose, or in any other manner, shall be deemed tobe "not in accordance with the intended purpose". The manufacturer shall notbe liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises- complete reading and following of all the instructions given in this manual- complete reading and following of all the safety instructions and danger

warnings- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:- Thawing pipes- Charging batteries/accumulators- Starting engines

The machine is designed to be used in industrial and workshopenvironments. The manufacturer shall not be liable for any damage resultingfrom use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty workresults.

Utilisation forintended purposeonly

Any malfunctions which might impair machine safety must be eliminatedimmediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

The owner/operator undertakes to ensure that the only persons allowed towork with the machine are persons who- are familiar with the basic regulations on workplace safety and accident

prevention and who have been instructed in how to operate the machine- have read and understood the sections on “safety rules” and the “war-

nings“ contained in this manual, and have confirmed as much with theirsignatures

- be trained in such a way that meets with the requirements of the workresults

Regular checks must be performed to ensure that personnel are still workingin a safety-conscious manner.

Obligations ofowner/operator

General remarks(continued)

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Before starting work, all persons to be entrusted with carrying out work with(or on) the machine shall undertake- to observe the basic regulations on workplace safety and accident

prevention- to read the sections on “safety rules” and the “warnings” contained in this

manual, and to sign to confirm that they have understood these and willcomply with them.

Before leaving the workplace, personnel must ensure that there is no risk ofinjury or damage being caused during their absence.

Obligations ofpersonnel

Protection foryourself andother persons

When welding, you are exposed to many different hazards such as:- flying sparks and hot metal particles- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace-maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

Mains connection High-performance devices can affect the quality of the mains power due totheir current-input.This may affect a number of types of device in terms of:- connection restrictions- criteria with regard to maximum permissible mains impedance *)

- criteria with regard to minimum short-circuit power requirement *)

*) at the interface with the public mains network

see Technical Data

In this case, the plant operator or the person using the device should checkwhether or not the device is allowed to be connected, where appropriatethrough discussion with the power supply company.

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable pro-tective clothing with the following characteristics:- flame-retardant- isolating and dry- must cover whole body, be undamaged and in good condition- protective helmet- trousers with no turn-ups

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The fumes given off during welding contain gases and vapors that areharmful to health.

Welding fumes contain substances which may cause birth defects andcancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with anindependent air supply.

If you are not sure whether your fume-extraction system is sufficiently power-ful, compare the measured pollutant emission values with the permittedthreshold limit values.

Hazards fromnoxious gasesand vapours

Keep other people - especially children - well away from the equipment andthe welding operation while this is in progress. If there are still any otherpersons nearby during welding, you must- draw their attention to all the dangers (risk of being dazzled by the arc or

injured by flying sparks, harmful welding fumes, high noise immissionlevels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or- erect suitable protective partitions or curtains.

Protection foryourself andother persons(continued)

“Protective clothing” also includes:- protecting your eyes and face from UV rays, heat and flying sparks with

an appropriate safety shield containing appropriate regulation filter glass- wearing a pair of appropriate regulation goggles (with sideguards) behind

the safety shield- wearing stout footwear that will also insulate even in wet conditions- protecting your hands by wearing appropriate gloves (electrically insula-

ting, heat-proof)- To lessen your exposure to noise and to protect your hearing against

injury, wear ear-protectors!

Information onnoise emissionvalues

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 maximumpermissible operating point under maximum rated load conditions according toEN 60974-1.

It is not possible to provide a workplace-related emission value during welding(or cutting) as this is influenced by both the process and the environment. Allmanner of different welding parameters come into play, including the weldingprocess (MIG/MAG, TIG welding), the type of power selected (DC or AC), thepower range, the type of weld metal, the resonance characteristics of theworkpiece, the workplace environment, etc.

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Hazards frommains and weld-ing current

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from thearc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas throughsmall cracks and openings. Take suitable measures here to ensure that thereis no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion,or in enclosed tanks, barrels or pipes, unless these latter have beenprepared for welding in accordance with the relevant national andinternational standards.

Welding must NEVER be performed on containers that have had gases,fuels, mineral oils etc. stored in them. Even small traces of these substancesleft in the containers are a major explosion hazard.

Hazards fromflying sparks

An electric shock is potentially life-threatening, and can be fatal.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the driverollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or elseuse a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of adry base or cover that provides adequate insulation against the ground/framepotential. The base or cover must completely cover the entire area betweenyour body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properlyinsulated and adequately dimensioned. Immediately replace any looseconnections, scorched, damaged or underdimensioned cables or otherleads.

The harmfulness of the welding fumes will depend on e.g. the followingcomponents:- the metals used in and for the workpiece- the electrodes- coatings- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheetsand the information given by the manufacturer regarding the componentslisted above.

Keep all flammable vapors (e.g. from solvents) well away from the arcradiation.

Hazards fromnoxious gasesand vapours(continued)

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If the following instructions are ignored, stray welding currents may occur.These can cause:- fires- overheating of components that are connected to the workpiece- destruction of PE conductors- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a waythat it is sufficiently insulated from the floor.

Stray weldingcurrents

Hazards frommains and weld-ing current(continued)

Do not loop any cables or other leads around your body or any part of yourbody.

Never immerse the welding electrode (rod electrode, tungsten electrode,welding wire, ...) in liquid in order to cool it, and never touch it when thepower source is ON.

Twice the open-circuit voltage of one single welding machine may occurbetween the welding electrodes of two welding machines. Touching thepotentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by aqualified electrician to ensure that the PE (protective earth) conductor isfunctioning correctly.

Only run the machine on a mains network with a PE conductor, and pluggedinto a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor andplugged into a power outlet socket without a protective-conductor contact,this counts as gross negligence and the manufacturer shall not be liable forany resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece issufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from themains.

Put up a clearly legible and easy-to-understand warning sign to stop anybodyinadvertently plugging the machine back into the mains and switching it backon again.

After opening up the machine:- discharge any components that may be storing an electrical charge- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a secondperson on hand to immediately switch off the machine at the main switch inan emergency.

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When using current supply distributors, twin head wire feeder fixtures etc.,please note the following: The electrode on the unused welding torch/weldingtongs is also current carrying. Please ensure that there is sufficient insula-ting storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulatedfiller wire is routed from the welding wire drum, large wirefeeder spool orwirespool to the wirefeeder.

Stray weldingcurrents(continued)

EMC deviceclassifications

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 thepublic low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures In certain cases, even though a device complies with the standard limit valuesfor 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 thedevice is installed is close to either radio or television receivers).If this is the case, then the operator is obliged to take appropriate action torectify the situation.

Examine and evaluate any possible electromagnetic problems that mayoccur on equipment in the vicinity, and the degree of immunity of thisequipment, in accordance with national and international regulations:- safety features- mains, signal and data-transmission leads- IT and telecoms equipment- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply- If electromagnetic interference still occurs, despite the fact that the mains

connection is in accordance with the regulations, take additionalmeasures (e.g. use a suitable mains filter).

b) Welding cables- Keep these as short as possible- Arrange them so that they run close together (to prevent EMI problems

as well)- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)- where necessary, run the connection to ground (earth) via suitable

capacitors.

e) Shielding, where necessary- Shield other equipment in the vicinity- Shield the entire welding installation.

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Power sources for use in spaces with increased electrical danger (e.g.boilers) must be identified by the (for “safety”) mark.However, the power source should not be in such rooms.

Allow welding torches - and other items of equipment that are used at highoperating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observeall relevant national and international regulations.

Risk of scalding from accidental discharge of hot coolant. Before unpluggingthe connectors for coolant forward flow and return flow, switch off the coolingunit.

When the welding wire emerges from the torch, there is a high risk of injury(the wire may pierce the welder’s hand, injure his face and eyes ...). For thisreason, when feeder-inching etc., always hold the torch so that it is pointingaway from your body (machines with wirefeeder).

While the machine is in use:- ensure that all the covers are closed and that all the sideguards are

properly mounted ...- ... and that all covers and sideguards are kept closed.

Do not touch the workpiece during and after welding - risk of injury fromburning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,continue to wear the regulation protective gear, and to ensure that otherpersons are suitably protected, when doing post-weld finishing onworkpieces.

Electromagnetic fields may cause as yet unknown damage to health.- Effects on the health of persons in the vicinity, e.g. users of heart pace-

makers and hearing aids- Users of heart pacemakers must take medical advice before going

anywhere near welding equipment or welding workplaces- Keep as much space as possible between welding cables and head/body

of welder for safety reasons- Do not carrywelding cables and hose pack over shoulder and do not loop

around body or or any part of body

EMI Precautions

Keep your hands, hair, clothing and tools well away from all moving parts,e.g.:- fans- toothed wheels, rollers, shafts- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of thewirefeed drive.0

Covers and sideguards may only be opened or removed for as long as isabsolutely necessary to carry out maintenance and repair work.

Particular dangerspots

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Shielding-gas cylinders contain pressurized gas and may explode if they aredamaged. As shielding-gas cylinders are an integral part of the overallwelding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessiveheat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such away that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gascylinder.

Use only shielding-gas cylinders that are suitable for the application inquestion, together with matching, suitable accessories (pressure regulators,hoses and fittings, ...). Only use shielding-gas cylinders and accessories thatare in good condition.

When opening the valve of a shielding-gas cylinder, always turn your faceaway from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in placeon the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national andinternational rules applying to shielding-gas cylinders and accessories.

Danger fromshielding-gascylinders

Particular dangerspots(continued)

When hoisting the machines by crane, only use suitable manufacturer-supplied lifting devices.- Attach the chains and/or ropes to all the hoisting points provided on the

suitable lifting device.- The chains and/or ropes must be at an angle which is as close to the

vertical as possible.- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG

units).

When hoisting the wirefeed unit by crane during welding, always use asuitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember thatthis strap is ONLY to be used for lifting and carrying the machine by hand.The carrying strap is NOT suitable for transporting the machine by crane,fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, whenusing an adapter for the inert gas protection. Seal the adapter thread for theinert gas connection using Teflon tape before assembly.

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Only operate the machine if all of its protective features are fully functional. Ifany of the protective features are not fully functional, this endangers:- the life and well-being of the operator or other persons- the equipment and other tangible assets belonging to the owner/operator- efficient working with the equipment.

Any safety features that are not fully functional must be put right before youswitch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered byyour doing so.

- At least once a week, check the machine for any damage that may bevisible from the outside, and check that the safety features all functioncorrectly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogetherbefore hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frost-proofing, materials-compatibility, combustibility etc.), only original coolantof the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.- Do not mix original coolant of the manufacturer with other coolants.

Safety precau-tions in normaloperation

Safety precauti-ons at the instal-lation site andwhen beingtransported

A machine that topples over can easily kill someone! For this reason, alwaysplace the machine on an even, firm floor in such a way that it stands firmly.- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observeall relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace andthe area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with theprotection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national andregional guidelines and accident protection regulations are followed. Thisapplies in particular to guidelines in respect of dangers during transportationand carriage.

Before transportation, completely drain any coolant and dismantle the follo-wing components:- Wire feed- Wire wound coil- Gas bottle

Before commissioning and after transportation, a visual check for damagemust be carried out. Any damage must be repaired by trained service per-sonnel before commissioning.

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With parts sourced from other suppliers, there is no certainty that these partswill have been designed and manufactured to cope with the stressing andsafety requirements that will be made of them. Use only original spares andwearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machinewithout getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and therelevant part number, as given in the spare parts list. Please also quote theserial number of your machine.

Preventive andcorrective main-tenance

- If any damage occurs in cases where other coolants have been used, themanufacturer shall not be liable for any such damage, and all warrantyclaims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport thecoolant in closed original containers, and keep it away from sources ofignition.

- Used coolant must be disposed of properly in accordance with therelevant national and international regulations. A safety data sheet isavailable from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check thecoolant level.

Safety precauti-ons in normaloperation(continued)

The manufacturer recommends that a safety inspection of the device isperformed at least once every 12 months.

The manufacturer recommends that the power source be calibrated duringthe 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 internationalstandards and directives.

Further details on safety inspection and calibration can be obtained from yourservice centre. They will provide you on request with any documents you mayrequire.

Safety inspection

Do not dispose of this device with normal domestic waste!To comply with the European Directive 2002/96/EC on Waste Electrical andElectronic Equipment and its implementation as national law, electricalequipment that has reached the end of its life must be collected separatelyand returned to an approved recycling facility Any device that you no longerrequire must be returned to our agent, or find out about the approved collec-tion and recycling facilities in your area.Ignoring this European Directive may have potentially adverse affects on theenvironment and your health!

Disposal

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Copyright to this instruction manual remains the property of themanufacturer.

The text and illustrations are all technically correct at the time of going toprint. The right to effect modifications is reserved. The contents of the in-struction manual shall not provide the basis for any claims whatever on thepart of the purchaser. If you have any suggestions for improvement, or canpoint out to us any mistakes which you may have found in the manual, weshould be most grateful for your comments.

Copyright

Equipment with CE-markings fulfils the basic requirements of the Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant productstandards according to EN 60 974). .

Safety markings

Equipment marked with the CSA-Test Mark fulfils the requirements made inthe relevant standards for Canada and the USA.

The user is responsible for the data security of changes made to factorysettings. The manufacturer is not liable, if personal settings are deleted.

Data security

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PlasmaModule 10

Gas pre-flow time - Plasma gas pre-flow timeGas post-flow time - Plasma gas post-flow timeGas Purger - Plasma gas purgingGas pre-flow amount - Amount of plasma gas during the plasma gas pre-flow timeand the plasma gas post-flow time

+Gas Setup

Control panel

Fronius International GmbH, www.fronius.com

Setup menu +I pilot arc - Pilot arc currentFactory - For resetting the plasma moduleSecond level of Setup menu

Flow monitoringCorrection - Gas correctionSetting - Country-specific setting (Standard / USA)Ignition Time-Out - Time until safety cut-out following an abortive ignition attemptArc - Arc break watchdog

Setup menulevel 2 (2nd) +

/

+

2

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Table of contentsGeneral remarks ........................................................................................................................................... 5

Device concept ......................................................................................................................................... 5Explanation of terms used ....................................................................................................................... 5The principle of plasma welding ............................................................................................................... 6Power sources for plasma welding .......................................................................................................... 6Advantages of plasma welding over TIG welding..................................................................................... 7Application areas ...................................................................................................................................... 7Options and accessories .......................................................................................................................... 7

Controls and connections .............................................................................................................................. 8General remarks ...................................................................................................................................... 8Housing front panel .................................................................................................................................. 8Housing rear panel ................................................................................................................................. 10

Before commissioning .................................................................................................................................. 11General remarks ..................................................................................................................................... 11Utilisation in accordance with „intended purpose“ ...................................................................................11Setup regulations .................................................................................................................................... 11Mains connection .................................................................................................................................... 11Generator-powered operation ................................................................................................................ 12Digital plasma gas control ...................................................................................................................... 12

Installation ................................................................................................................................................... 13General remarks .................................................................................................................................... 13Installation .............................................................................................................................................. 13Connecting the interconnecting hosepack to the TIG power source ...................................................... 13Connecting the plasma welding torch .................................................................................................... 14Connecting the shielding gas and plasma gas ....................................................................................... 15Connecting PlasmaModule 10 and TIG power source to the robot control ............................................ 15

Commissioning ........................................................................................................................................... 16General remarks .................................................................................................................................... 16Commissioning ...................................................................................................................................... 16Notes on operation ................................................................................................................................. 16Plasma welding process ........................................................................................................................ 17

The Setup menu.......................................................................................................................................... 18General remarks .................................................................................................................................... 18Gas Setup .............................................................................................................................................. 18Setup menu ............................................................................................................................................ 19Setup menu level 2 (2nd) ....................................................................................................................... 19Correction factors ................................................................................................................................... 21

Signals for robot welding ............................................................................................................................. 22General remarks .................................................................................................................................... 22Overview ................................................................................................................................................ 22Signals for robot welding ........................................................................................................................ 22Signal waveform..................................................................................................................................... 23Application example ............................................................................................................................... 23Important information for robot operation ............................................................................................... 24

Troubleshooting........................................................................................................................................... 25General remarks .................................................................................................................................... 25Service codes displayed ........................................................................................................................ 25Troubleshooting ..................................................................................................................................... 27

4

Care, maintenance and disposal ................................................................................................................. 28General remarks .................................................................................................................................... 28Every start-up ......................................................................................................................................... 28Every 2 months ...................................................................................................................................... 28Every 6 months ...................................................................................................................................... 28Disposal ................................................................................................................................................. 28

Configuration examples .............................................................................................................................. 29„Manual mode“ configuration ................................................................................................................. 29„Manual mode“ configuration - List of components ................................................................................ 30„Robot mode“ configuration.................................................................................................................... 31„Robot mode“ configuration - List of components .................................................................................. 32

Technical data ............................................................................................................................................. 33General remarks .................................................................................................................................... 33Technical data ........................................................................................................................................ 33

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General remarks

Device concept

Fig. 1 Digital PlasmaModule 10

Explanation ofterms used

PlasmaPlasma is a gas with positive charge carriers (ions) and negative charge carriers (elec-trons). The ions and electrons determine the properties of a plasma.Plasma can only be created at high temperature.Plasma is known as the „fourth aggregate state of matter“, besides solid, liquid andgaseous materials.

Plasma weldingPlasma welding is a welding process which uses a constricted arc as the heat source.The arc is constricted by a cooled nozzle.The following plasma welding processes are distinguished:- Microplasma welding- (Soft) plasma welding- Plasma keyhole welding- Plasma brazing

The digital PlasmaModule 10 can be usedwith all TIG power sources from Fronius.Together with an appropriate powersource, a cooling unit and a water-cooledplasma torch, it allows plasma weldingprocesses to be carried out.

Thanks to the modular concept designedby Fronius, PlasmaModule 10 can also beused with existing welding systems.

As a stand-alone unit, PlasmaModule 10can serve as a further component in acomplex welding system.

A self-explanatory, intuitive operatingconcept makes PlasmaModule 10 easy towork with. The welder can see the keyfunctions at a glance and adjust themaccordingly.

In view of the modular product design, thedigital PlasmaModule 10 is extremelyflexible and can be adapted to many typesof task.

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PlasmaModule 10 can be operated with the following power sources:- MagicWave 4000 / 5000- MagicWave 2600 / 2600 CEL / 3000- TransTig 2600 / 2600 CEL / 3000- TransTig 4000 / 5000

NOTE! Select the appropriate cooling unit for the existing plasma welding torchand the application.

NOTE! With plasma welding the duty cycle of the TIG power source is shor-tened depending on the application.

Power sourcesfor plasma wel-ding

The principle ofplasma welding

Fig. 2 The principle of plasma welding

(1) Shielding gas pressure regulator(2) TIG power Source(3) Cooling unit(4) Digital PlasmaModule 10 with digital plasma gas control(5) Plasma gas pressure regulator

(1)(4)(3)(2)

(5)

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Advantages ofplasma weldingover TIG welding

Fig. 3 TIG arc Fig. 4 Plasma arc

~ 45°

~ 5°

- Low component distortion thanks to the concentrated arc- Smaller heat-affected zone- Arc can be relatively long- Higher temperature in the arc: Plasma up to 25,000°C (45,032°F) - TIG up to

10,000°C (18,032°F)- No time-consuming seam preparation needed (e.g. square butt joint with material

thickness up to 10 mm)- Higher welding speed- Impossible for the tungsten electrode to dip into the weld pool- Longer torch service life (with optimum torch cooling)

Tungsten electrode Tungsten electrode

Shieldinggas

Shielding gasPlasma gas

Plasma nozzle

Application areas The digital PlasmaModule 10 is used in automated and manual applications, for example:- in the automotive and component supply industry,- in the manufacture of special vehicles and construction plant- in pipeline and equipment construction- in plant, container, machine and steel engineering- in rail vehicle construction and shipbuilding- in applications requiring the highest quality standards- for welding materials with a sheet thickness of 0.4 - 10 mm (0.02 - 0.39 in.)

PlasmaModule 10 is generator-compatible and exceptionally sturdy in operation, thanksto the protected controls and a powder-coated housing.

Options andaccessories

- PTW 1500: Plasma manual welding torch- Robacta PTW 1500: Plasma robot welding torch- PMW 350: Plasma welding torch for keyhole welding- PlasmaModule 10 - MagicWave / TransTig interconnecting hosepack- Air filter- PlasmaModule holder- PlasmaModule flow watch dog (for installation in the PlasmaModule holder)

NOTE! Where PlasmaModule 10 is operated on the PlasmaModule holder, thePlasmaModule flow watchdog option is also necessary.

8

Controls and connections

WARNING! Operating the equipment incorrectly can cause serious injury anddamage. You should not use the functions described until you have thoroughlyread and understood the following documents:- these Operating Instructions- all the operating instructions for the system components, especially the

safety regulations

General remarks

Housing frontpanel

Fig. 05 PlasmaModule 10 - Front panel

(1)

(16)

(15)

(14)

(13)(12)

(11) (10)

(9)

(8)

(7)

(6)

(5)

(4)(3)(2)

9

(1) Left digital display(2) Left unit display

Either CFH or l/min appears in the Setup menu depending on the country setting(3) Right digital display(4) Right unit display

Either CFH or l/min appears in the Setup menu depending on the country setting(5) Parameter unit display

Either % or s appears depending on which parameter is chosen in the Setup menu(6) Pilot flow LED

lights up when the pilot flow parameter is selected(7) Pilot arc on LED

lights up when the plasma process is active(8) Start/Stop button

- to start or end the plasma process manually- to access the Setup menu

(9) Gas test button- to test the plasma gas flow- to access the gas test menu

(10) Pilot flow (-) / plasma gas connectionto connect the pilot flow (-) / plasma gas cable from the plasma welding torch

(11) Pilot flow (+) connectionto connect the pilot flow (+) cable from the plasma welding torch

(12) Store button- to access the Setup menu- to access the gas test menu

(13) Adjusting dial (with LED)for setting parameter values; when the LED on the adjusting dial is lit, the selectedparameter can be set

(14) Plasma gas LEDlights up when the plasma gas parameter is selected

(15) Over-temperature indicatorlights up if the PlasmaModule overheats

(16) Operating instructions symbolObserve all safety instructions and notes on operation, care and maintenance in theoperating manual

Housing frontpanel(continued)

10

Housing rearpanel

(20)

(19)

(18)

(17)

Fig. 06 PlasmaModule 10 - Rear panel

(17) LocalNet connectionStandard connection socket for system add-ons (e.g. robot interface ROB 3000 orROB 4000)

(18) Plasma gas connectionincluding supply pressure regulator; max. supply pressure 9 bar (130 psi)

(19) Mains switch(20) Mains cable

11

Before commissioning

WARNING! Operating the equipment incorrectly can cause serious injury anddamage. You should not use the functions described until you have thoroughlyread and understood the following documents:- these Operating Instructions- all the operating instructions for the system components, especially the

safety regulations

Setup regulations

Mains connection The equipment is designed to run on the mains voltage given on the respective ratingplates. If your version of the machine does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. Thefuse protection of the mains supply is described in the Technical Data.

NOTE! Inadequately dimensioned electrical installations can lead to seriousdamage. The mains lead and its fuse protection must be rated accordingly. Thetechnical data shown on the rating plate shall apply.

General remarks

Utilisation inaccordance with„intended purpo-se“

The digital PlasmaModule 10 is intended to be used only in conjunction with a suitableTIG power source and a suitable plasma torch (e.g. Fronius PTW 1500).The following plasma welding processes can be carried out with the PlasmaModule 10:- Soft plasma welding (sheet thicknesses from 0.4 - 3.0 mm / 0.02 - 0.12 in.)- Plasma keyhole welding (sheet thicknesses from 3.0 - 10.0 mm / 0.12 - 0.39 in.)- Plasma brazing

Utilisation for any other purpose, or in any other manner, shall be deemed to be „not inaccordance with the intended purpose“. The manufacturer shall not be liable for anydamage resulting from such improper use.

Utilisation in accordance with the „intended purpose“ also comprises- following all the instructions in this manual- performing all stipulated inspection and servicing work.

The machine is tested to “Degree of protection IP23”, meaning:- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.47 in.)- protection against direct sprays of water up to 60° from the vertical

The machine can be set up and operated outdoors in accordance with IP23. However,direct wetting (e.g. from rain) should be avoided.

The venting duct is a very important safety feature. When choosing the machine locati-on, ensure that the cooling air can enter and exit unhindered through the air ducts on thefront and back of the machine. Electrically conductive metallic dust (from grinding work,for example) must not be allowed to get sucked into the machine.

WARNING! If one of these devices topples over or falls it could cause seriousor even fatal injury. Place machine on a solid, level surface in such a way that itremains stable.

12

PlasmaModule 10 is generator-compatible, provided the maximum apparent powerdelivered by the generator is at least 1.5 kVA.

NOTE! The voltage delivered by the generator must never exceed the upper orlower limits of the mains voltage tolerance range. Details of the mains voltagetolerance are given in the section “Technical data”.

Generator-powered operati-on

Digital plasmagas control

Important! Before operating for the first time, mount the supply pressure regulator,supplied separately, on the rear of the PlasmaModule 10. When mounting, pay attentionto the sealing ring in the supply pressure regulator.

For the digital plasma gas regulator in PlasmaModule 10 to reach the maximum gasflow, the following requirements must be met:- If the plasma gas supply has a pressure regulator, open it fully after connecting the

gas hose.- The pressure regulator with metering tube (item number: 43,0011,0008) is not

suitable, as it does not allow a sufficient supply pressure.- Where the plasma and shielding gas are supplied by gas cylinders:

use separate gas cylinders for plasma gas and shielding gas.

The digital PlasmaModule 10 is fitted with a digital plasma gas regulator as standard.

WARNING! Plasma gas is colourless and odourless, is hazardous to healthand can cause asphyxiation. If the following instructions are not observed, afterwelding has finished there is a danger of the control valve not closing fully.Colourless and odourless plasma gas may escape undetected.- Use the digital PlasmaModule 10 only in conjunction with the standard

supply pressure regulator.- Never alter the adjusting screw on the supply pressure regulator. If the

adjusting screw is altered, Fronius accepts no liability for resulting damage.- Do not exceed the maximum supply pressure of 9 bar (130 psi).

13

Installation

General remarks The installation of a plasma welding system depends on many factors, e.g.:- the application- the material to be welded- the available space- influences of robots and robot control system or other automation apparatus- accessibility- Environmental conditions

For detailed information on the work steps, please refer to the documentation for theindividual components.

WARNING! An electric shock can be fatal. If the machine is plugged into themains electricity supply during installation, there is a high risk of very seriousinjury and damage. Only carry out work on the machine when- the mains switch is in the “O” position,- the machine is unplugged from the mains.

Installation

CAUTION! Falling equipment can cause injury. Make sure PlasmaModule 10and the PlasmaModule holder stand firmly.

1. Set up the individual components of the plasma welding system according to theintended application (see also the section „Configuration examples“)

Connecting theinterconnectinghosepack to theTIG power sour-ce

Fig. 7 Connecting the interconnecting hosepack to the TIG power source TransTig 2600 / 2600 CEL / 3000

TransTig 2600 / 2600 CEL / 3000

14

Connecting theinterconnectinghosepack to theTIG power source(continued)

TransTig 4000 / 5000 with FK 4000 R

Fig. 08 Connecting the interconnecting hosepack to the TIG power source TransTig 4000 / 5000 andcooling unit FK 4000 R

Connecting theplasma weldingtorch

Fig. 09 Connecting the plasma welding torch to PlasmaModule 10 and the PlasmaModule holder

15

Where the parameters required for the plasma welding process are supplied via a robotcontrol unit, a robot interface is required (e.g. ROB 3000, ROB 4000).

1. Connect a 10-pole remote control cable to the LocalNet connection on the rear ofPlasmaModule 10 and to the robot interface for PlasmaModule 10

2. Connect a 10-pole remote control cable to the LocalNet connection on the rear ofthe TIG power source and to the robot interface for the TIG power source

ConnectingPlasmaModule 10and TIG powersource to therobot control

Connecting theshielding gas andplasma gas

NOTE! Where the gas for a plasma welding system is supplied by gas cylin-ders, there must be one cylinder for plasma gas and another cylinder for shiel-ding gas. Never take plasma gas and shielding gas from one and the same gascylinder.

1. Connect the plasma gas to the plasma gas connection of PlasmaModule 10 (on therear of the unit), working pressure approx. 6 - 8 bar (86.99 - 115.99 psi.)

Important! Use only pure argon as plasma gas

2. Connect the shielding gas to the gas connection of the power source (on the rear ofthe unit)

Important! Use only inert gases as shielding gas (e.g. argon)

16

Commissioning

Commissioning

For detailed information on the work steps, please refer to the documentation for theindividual components.

General remarks

1. Insert a tungsten electrode in the plasma welding torch

Important! The tip angle of the tungsten electrode should be approx. 30°

2. Check the distance between the plasma nozzle and the tungsten electrode (approx.1 - 2.5 mm or 0.04 - 0.1 in.) with an adjusting gauge

3. Turn the main switch of the power source to the „I“ position4. Connect PlasmaModule 10 to the mains and turn the main switch to the „I“ position

Important! The PlasmaModule 10 must reach a certain operating temperature beforeit can regulate the gas accurately.If the ambient temperature is below 20°C (68°F), let the PlasmaModule 10 run forabout 10 - 15 minutes without any load to allow it to reach this operating temperature.

5. On the power source select current type „DC“6. Set the cooling unit to permanent operation (Setup menu on power source, parame-

ter C-C = ON )7. On MagicWave power sources, switch off „Reverse polarity ignition“ (Setup menu

on power source: Parameter rPi = OFF)8. On the TIG power source, set „High-frequency ignition“ to „Start with external arc

starters“ (Setup menu on power source, parameter HFt = EHF)9. Set welding parameters on TIG power source and on PlasmaModule 1010. Purge shielding gas and plasma gas for at least 30 seconds11. Ignite pilot arc on PlasmaModule 10 manually or via the robot control unit12. Start plasma welding by pressing the torch trigger or via the start signal from the

robot control unit

Notes on operati-on

To reduce wear, the pilot arc should burn throughout the operation.

Shielding gas flow rate in operation: at least 12 l/min (25.71 CFH)

The robot control unit should emit a permanent plasma gas command value- for the pilot arc,- so that the „Gas Test“ function can be performed on the PlasmaModule 10.

With robot control, if a hot wire power source is used, provide a separate „ground“ forthe hot wire power source.

17

Sta

rting

cur

rent

Cur

rent

ups

lope

Mai

n cu

rren

t

Bas

e cu

rren

t

Cur

rent

dow

nslo

pe

Fina

l cur

rent

Welding current

Shielding gas

Pilot flow

Plasma gas

I (A)

Gas (l/min)

t (s)

Gas (l/min)

I (A)

t (s)

t (s)

t (s)

She

ildin

g ga

s pr

e-flo

w

Shi

eldi

ng g

as p

ost-f

low

Pla

sma

gas

pre-

flow

GpA GpA

Pla

sma

gas

post

-flow

Plasma weldingprocess

18

The Setup menu

General remarks

Parameters for plasma gas supply

GPrGas pre-flow time - Plasma gas pre-flow time

Unit sSetting range 0 - 9,9Factory setting 0,4

GPoGas post-flow time - Plasma gas post-flow time

Unit sSetting range 0 - 9,9Factory setting 5

GPUGas purger - Plasma gas purging

Unit minSetting range OFF / 0.1 - 10.0Factory setting OFF

Plasma gas purging begins as soon as GPU is allocated a value.

For safety reasons, plasma gas purging cannot be restarted until a new GPU value isentered.

Important! Plasma gas purging is necessary above all where condensation forms afterthe device has been left unused in a cold environment for a long time. Long hosepacksare most affected.

The Setup menu makes it easy to adapt the parameters saved in the unit to differenttypes of task:

- The plasma gas supply parameters are set in the Gas Setup.- The Setup menu contains parameters which have an immediate effect on the

plasma process.- Machine pre-sets are defined in the Setup menu level 2 (2nd).

Gas Setup 1. To enter Gas Setup, press the Store button and the Gas Testbutton simultaneously.

The plasma gas setting parameter last called is displayed.

2. Select parameter by pressing the Gas Test button

3. Change the parameter values by using the adjusting dial

4. Press the Store button to exit Gas Setup

+

19

1. To enter the Setup menu, press the Store button and the Start/Stopbutton simultaneously

The plasma process parameter last called is displayed.

2. Select parameters by pressing the Start / Stop button

3. Change the parameter values by using the adjusting dial

4. Press the Store button to exit the Setup menu

+Setup menu

Parameters for the plasma process

IPLI pilot arc - Pilot arc current

Unit ASetting range 3,0 - 30,0Factory setting 10

FACFactory - for resetting PlasmaModule 10Press and hold the Store button for 2 s to reset the machine to the factory settings. If„PrG“ appears on the display, the parameters of the PlasmaModule are reset to thefactory settings.

Important! The settings in the Setup menu will be lost when the PlasmaModule is reset.The parameter settings in the second level of the set-up menu (2nd) are not deletedeither.

2ndSecond level of Setup menu

Setup menu level2 (2nd) +

/+

GPAGas pre-flow amount - Plasma gas quantity during the plasma gas pre-flow time andplasma gas post-flow time

Unit l/minSetting range 0,2 - 10Factory setting 3

Gas Setup(continued)

1. Access the Setup menu by pressing the Store button and the Start/ Stop button simultaneously

The plasma process parameter last called is displayed.

2. Select „2nd“ parameter by pressing the Start / Stop button

3. To enter the Setup menu level 2, press the Store button and theStart/Stop button simultaneously

The machine pre-set parameter last called is displayed.

20

Setup menu level2 (2nd)(continued)

Parameters for machine pre-sets

C-CFlow monitoring

Unit -Setting range ON / OFFFactory setting ON

„ON“ position Flow monitoring remains permanently switched on„OFF“ position Flow monitoring remains permanently switched off

COrCorrection - Gas correction

Unit -Setting range AUT / 1.0 - 10.0Factory setting AUT (corresponds to a correction factor of 1.76 and therefore argon

100 %)

Other correction factors for other plasma gases can be found in the table of correctionfactors.

SEtSetting - Country-specific setting (Standard / USA)

Unit -Setting range Std / USFactory setting Standard version: Std (l/min)

USA-Version: US (cfh)

ItoIgnition Time-Out - Time until safety cut-out following an abortive ignition attempt

Unit sSetting range 0,1 - 9,9Factory setting 5

Important! „Ignition Time-Out“ is a safety function so cannot be deactivated. A descripti-on of the „Ignition Time-Out“ function may be found in the section headed „TIG welding“.

ArcArc - Arc break watchdog: Time until safety cut-out following an arc break

Unit sSetting range 0,1 - 9,9Factory setting 2

Important! The arc break watchdog is a safety function so cannot be deactivated.

4. Select parameters by pressing the Start / Stop button

5. Change the parameter values by using the adjusting dial

6. To exit Setup menu level 2: press the Store button twice- press once = return to Setup menu, „2nd“ parameter- press twice = return to normal mode

21

Plasma gas Composition DIN EN 439 COR Gas min.Ar He H

I1 100 % Ar 100 - - I1 1.76 0.2 lI3 Ar 50 % He 50 50 - I3 3.78 0.3 lI3 Ar 15 % He 85 15 - I3 1.94 0.4 lI3 Ar 25 % He 75 25 - I3 2.70 0.2 lI3 Ar 30 % He 70 30 - I3 2.72 0.2 lI3 Ar +75 % He 25 75 - I3 5.98 0.4 lVarigon He 10 90 - I3 8.35 0.5 lVarigon H2 98 - 2 R1 1.79 0.2 lVarigon H3 97 - 3 R1 1.77 0.2 lVarigon H5 95 - 5 R1 1.75 0.2 lVarigon H7.5 92.5 - 7.5 R1 1.72 0.2 l

The correction factor takes account of the lowest gas volume than can be set „Gasmin.“. This volume depends on the plasma gas mixture that is being used.

Correction fac-tors

22

Signals for robot welding

General remarks Robot operation of PlasmaModule 10 requires a robot interface. PlasmaModule 10 canbe controlled via the following interfaces:- Robot interface ROB 3000- Robot interface ROB 4000- Field bus

Signals for robotwelding

Signal I / O ROB 3000 ROB 4000 Field busArc on E x x x(welding start)Robot ready / quick stop E x x x(robot ready / quick stop)Gas test E - x xWelding simulation E - x x(welding simulation)Power input value E - x x(power input value)Arc stable A x x x(arc stable)Power source ready A x x x(power source ready)Welding current real value A - x x(welding current real value)

I = input signal (signal from the robot control unit)O = output signal (signal to the robot control unit)

Overview

Signals for robot-controlled plasma welding operation and their function on the Plasma-Module 10:

Welding startstarts the pilot arcRobot ready / quick stop24 V = Robot ready to weld / 0 V = quick stop; quick stop stops the welding processimmediatelyGas testactivates the Gas Test function on PlasmaModule 10Welding simulationThe welding simulation signal allows a programmed welding path to be simulated; an arcand shielding gas are not required.Power input valueSpecifies the plasma gas flow rate; 0 V = minimum plasma gas flow rate, 10 V = maxi-mum plasma gas flow rateArc stableThe „arc stable“ signal is set as soon as a stable arc is present after the pilot arc hasignited.

23

Signals for robotwelding(continued)

Power source readyThe “Power source ready” signal remains on as long as PlasmaModule 10 is ready toweld.Welding current real valueVia the „Welding current real value“ signal, the actual plasma gas value is indicated by avoltage of 0 - 10 V on the analog output.

For further information about the signals, refer to the relevant operating instructions forthe robot interface.

Signal waveform

0

1

0

1

0

1

0

1

Power input value(power input value)

Robot ready(robot ready)

Welding start(welding start)

Arc stable(arc stable)

Power source ready(power source ready)

0 V

10 V

t (s)

t (s)

t (s)

t (s)

t (s)

Applicationexample

Example of how to connect the robot interface to the robot control:

DI Welding start (*)

DO Arc stable (*)

AI Power input value + (*)

AI Power input value - (*)

Not in use

DI Robot ready / quick stop (*)

DO Power source ready

+24 V secondary (*)

GND secondary (*)

Supply voltage (*)Not in use

DI Welding simulation

X2:4

X2:12

X2:1

X2:8

X2:6

X2:5

X2:14

X12:1

X12:2

X14:1

X2:13

X14:2

+24 V Robot PlasmaModule 10

0 - 10 V

+24 V = Pulse 0 V = Standard

+24 V

GND

or external (+24 V)+ 24 V

DI = digital in DO = digital out AI = analog in AO = analog out

(*) = required for robot operation

Plasma gas pre-flow time Plasma gas post-flow time

Pilot arc

24

Important infor-mation for robotoperation

NOTE! If the connection between the power source and the robot interfacegoes down, all digital and analog output signals on the robot interface will be setto “0”.

The power supply for the power sourceis available in the robot interface (24 V secondary).The 24 V secondary supply is electrically isolated from the LocalNet. A suppressor circuitlimits excess voltages to 100 V.

Use pin X14/1 to select which voltage is to be connected to the digital outputs of therobot interface.a) 24 V external voltage from the digital output card of the robot control

orb) Power source supply voltage (24 V secondary):

Place a jumper between X14/1 and X14/7.

WARNING! Risk of injury and damage if welding starts unexpectedly. The “Arcon” signal must not be set while the error is being rectified, otherwise weldingwill start as soon as the error is fixed.

25

Troubleshooting

WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine from the mains- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again- Using a suitable measuring instrument, check to make sure that electrical-

ly charged components (e.g. capacitors) have been discharged

CAUTION! Failure to connect an appropriate earth lead may result in seriousinjury or damage. The housing screws provide a suitable PE conductor connec-tion for earthing (grounding) the housing and must NOT be replaced by anyother screws which do not provide a reliable PE conductor connection.

General remarks The digital PlasmaModule 10 is equipped with an intelligent safety system that does notrequire fuses.After a possible malfunction has been remedied, PlasmaModule 10 can be put back intonormal operation again without any fuses having to be changed.

Service codesdisplayed

If any error message that is not described here appears on the displays, then the fault isone that can only be put right by a service technician. Make a note of the error messageshown in the display, and of the serial number and configuration of the PlasmaModule,and get in touch with our after-sales service, giving them a detailed description of theerror.

tP1 | xxx

Cause: Overheating in the primary circuit of PlasmaModule 10Remedy: Allow PlasmaModule 10 to cool down

tS1 | xxx

Cause: Overheating in the secondary circuit of PlasmaModule 10Remedy: Allow PlasmaModule 10 to cool down

tSt | xxx

Cause: Overheating in the control circuit of PlasmaModule 10Remedy: Allow PlasmaModule 10 to cool down

Err | 051

Cause: Mains undervoltage: The mains voltage has dropped below the tolerancerange (see chapter „Technical data“)

Remedy: Check the mains voltage

Err | 052

Cause: Mains overvoltage: The mains voltage has exceeded the upper limit of thetolerance range (see chapter „Technical data“)

Remedy: Check the mains voltage

26

Service codesdisplayed(continued)

no | IGn

Cause: „Ignition time-out“ function is active: No current started flowing before theend of the time specified in the Setup menu. The safety cut-out of Plasma-Module 10 has tripped.

Remedy: Repeatedly press the Start / Stop button; clean the workpiece surface; ifnecessary, in „Setup menu level 2“ increase the time until the safety cut-out is triggered.

Err | IP

Cause: Primary overcurrentRemedy: Contact After-Sales Service

Err | bPS

Cause: Fault in power moduleRemedy: Contact After-Sales Service

dSP | Axx, dSP | Cxx, dSP | Exx, dSP | Sy, dSP | nSy

Cause: Fault in central control and regulation unitRemedy: Contact After-Sales Service

no | Arc

Cause: Break in pilot arcRemedy: Clean the workpiece surface, clean the plasma nozzle

no | H2O

Cause: Flow watchdog in the PlasmaModule PM 10 holder has respondedRemedy: Check the cooling unit; if necessary, top up the coolant and vent the water

flow hose as described in „Putting the cooling unit into service“

-St | oP-where the power source is operated with a robot interface or a field bus

Cause: Robot not readyRemedy: Initialise „Robot ready“ signal, initialise „Source error reset“ signal (N.B.

„Source error reset“ only available in conjunction with ROB 5000 and fieldbus coupler for robot control)

Err | 70.1

Cause: Gas flow sensor not foundRemedy: Check connections of the signal cable for the gas flow sensor

no | GAS

Cause: Plasma gas supply absent or inadequateRemedy: Establish the plasma gas supply (e.g. open the gas cylinder valve and

pressure regulator fully), reset no | GAS by pressing the Store button;when using a ROB 5000 robot interface or field bus coupler, reset „Sourceerror reset“ via digital input signal.

Err | 70.3

Cause: Calibration error:Supply pressure at pressure regulating valve is too highor pressure regulating valve is faulty.

Remedy: Reduce supply pressure at pressure regulating valve to no more than 9bar (130 psi.)or replace pressure regulating valveReset Err | 70.3 by pressing the Store button

27

Service codesdisplayed(continued)

No functionMains switch is ON, but indicators are not lit upCause: No connection to the mainsRemedy: Check mains lead, mains plug and mains cable

Cause: mains fuse is faultyRemedy: Replace mains fuse

Cause Mains outlet socket or plug is faultyRemedy: Replace faulty components

No pilot arcMains switch is on, digital displays are lit up

Cause: Short-circuit between tungsten electrode and plasma nozzleRemedy: Readjust electrode with adjusting gauge

Cause: Plasma torch faultyRemedy: Replace plasma torch

Troubleshooting

Err | 70.4

Cause: Control valve faultyRemedy: Replace control valve

Err | 70.5

Cause: Control valve not foundRemedy: Check connections of the signal cable for the control valve

28

Under normal operating conditions, PlasmaModule 10 requires only a minimum of careand maintenance. However, it is vital to observe some important points to ensure theplasma welding system remains in a usable condition for many years.

- Check mains plug, mains cable, plasma torch, interconnecting hosepack and earthconnection for damage

- Check that there is a gap of 0.5 m (19.69 in.) all around the machine to ensure thatcooling air can flow and escape unhindered.

NOTE! Air inlets and outlets must never be covered, not even partially.

- Dismantle machine side panels and clean machine inside with dry reduced com-pressed air

NOTE! Risk of damage to electronic components. Do not bring the air nozzletoo close to the electronic components.

- If a lot of dust has accumulated, clean the cooling-air ducts.

Dispose of in accordance with the applicable national and local regulations.

WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine from the mains- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again- Using a suitable measuring instrument, check to make sure that electrical-

ly charged components (e.g. capacitors) have been discharged

Care, maintenance and disposal

General remarks

Every start-up

Every 6 months

Disposal

- Optional: Clean air filterEvery 2 months

29

Fig. 10 „Manual mode“ configuration: Plasma welding system for manual use

(10)(11)

(20)

Configuration examples

(30)

(50)(40)

(60)(61)

(70)

Plasma gas

Shielding gas

(80)

(90)

„Manual mode“configuration

30

„Manual mode“configuration -List of compon-ents

(10) „PickUp“ trolley(11) „Duo cylinder holder“ installation set(20) Cooling unit FK 2600 R(30) TIG power source TransTig 2600 W / F(40) Swivel pin receptor installation set VR 4000(50) Interconnecting hosepack W / 2 m / 70 mm²(60) PlasmaModule holder installation set(61) Flow watchdog installation set PM 10(70) PlasmaModule 10(80) Plasma manual welding torch PTW 1500 F++ / FG / UD / 4 m(90) Grounding (earthing) cable 50 mm² / 4 m / 400 A / Plug 50 mm²

31

„Robot mode“configuration

(10)

(20)

(30)(31)

(40)(50)

(60)

(70)(71)

(80)

(32)

(90)

(81)

(82)

(100)(101)

(110)(111)(112)(113)(120)

(121)

(130)(131)

Plasma gas

Shielding gas

(140)

Robot control

Fig. 11 „Robot mode“ configuration: Plasma welding system for automated use

(91)

(40a)

(113a)

32

„Robot mode“configuration -List of compon-ents

(10) Upright console(20) Cooling unit FK 4000-R FC

NOTE! Filler neck, filter and connections for water supply and return must beon the same side.

(30) TIG power source TransTig 4000 Job G / F(31) KD-Digital / LocalNet installation set(32) Remote control cable 10-pole, 10 m(40) Interconnecting hosepack W / 2 m / 70 mm²(40a) LocalNet cable 3.5 m (from Interconnecting hosepack)(50) Swivel pin receptor installation set VR 4000(60) Twin-head feeder mount VR 4000(70) Cold wire feeder KD 7000 D-11(71) KD-Drive installation set(80) Hot wire power source TransPocket 1500 RC HD(81) Grounding (earthing) cable 25 mm² / 6 m / hot wire(82) Connecting cable for TP 1500 RC HD(90) PlasmaModule 10(91) Remote control cable 10-pole, 10 m(100) PlasmaModule holder installation set(101) Flow watchdog installation set PM 10(110) Plasma robot welding torch Robacta PTW 1500 F++ / FG / 4 m(111) Robacta Plasma KD Drive, 0 - 6 m(112) Original equipment TIG RO(113) Hot wire option(113a) Power cable G / 25 mm² / 6 m / hot wire plasma(120) Installation set Rob 4000 LocalNet interface(121) Installation set TIG Rob 4000 cable harness 1.5 m(130) Installation set Rob 5000 LocalNet interface(131) Installation set TIG Rob 5000 cable harness 1.5 m(140) Grounding (earthing) cable 95 mm² / 10 m

33

Mains voltage 230 VMains voltage tolerance -20% / +15%Mains fuse protection (slow-blow) 16 AMains connection 1) Zmax on PCC 2) = 142 mOhmPrimary contin. power (100% d.c. 3)) 0.9 kVACos phi 0,99Plasma current range 3.0 - 30.0 APilot current at 10 min / 40°C (104°F) 100% d.c. 3) 30 AOpen-circuit voltage 88 VStandardised working voltage 10.1 - 11.2 VStriking voltage (Up) 9.5 kVThe arc striking voltage is designed for manual guided operation.Protection IP 23Type of cooling AFInsulation class BDimensions l/w/h 505/180/344 mm

19.88/7.09/13.54 in.Weight 14,2 kg

33.31 lbs.Marks of conformity S, CE

1) To 230/400 V, 50 Hz public supply mains2) PCC = point of common coupling3) d.c. = duty cycle

Technical data

NOTE! Inadequately dimensioned electrical installations can lead to seriousdamage. The mains lead and its fuse protection must be rated accordingly. Thetechnical data shown on the rating plate shall apply.

Technical data

General remarks

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

PlasmaModule 10

1/2

el_fr_st_pl_01118 032006

PlasmaModule 10 4,075,146

12,0405,0365

45,0200,1151

BE2,0201,1329

42,0409,3124

45,0405,0002

43,0001,3293

33,0005,4142

33,0010,0326

43,0001,0600

43,0001,1232

43,0004,051943,0004,1993 - US

41,0003,0203

43,0002,0295

42,0300,0648

32,0405,0183

42,0001,3662

42,0001,0550

42,0406,0315

42,0406,0093

40,0001,0310 - *

43,0004,2650

42,0405,0421

42,0407,027312,0405,0365

43,0001,1273

AM2,0201,1327

41,0012,0033

44,0001,1300

43,0001,1272

42,0401,0867

44,0001,1299

42,0001,3541 - US

43,0001,1271

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

PlasmaModule 10

2/2

el_fr_st_pl_01118 032006

UST2

BPS

HFF22

4,070,960,Z - UST2C

4,070,812,Z - HFF22

41,0009,0057

4,070,798,Z - BPS17

43,0004,1122 - 26pol.

41,0001,0627

42,0405,0420

43,0001,1138

43,0006,0134

41,0012,0080

43,0001,0600

42,0300,7085

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