Subscribe to Our Youtube Channel
Related Manuals for Fronius Acerios
Summary of Contents for Fronius Acerios
- Page 1 Operating instructions Acerios EN-US Operating instructions 42,0426,0326,EA 003-21032022...
-
Page 3: Table Of Contents
Safety Control Panel Shortcut Keys - Special Functions General Key Lock Show Software Version, Runtime, and Coolant Flow Connections, Switches, and Mechanical Components Acerios Connections Installation and Startup Before installation and initial operation Safety Minimum Equipment Intended Use Setup regulations... - Page 4 General Installation Commissioning Connecting the Gas Cylinder Connecting the Plasma Torch Plasma Surface Treatment Overloaded Electrode Overloaded Electrode Description of operating modes 2-Step Mode 4-Step Mode Plasma Surface Treatment Safety Process Parameters Plasma Surface Treatment Special Functions and Options Arc Break Monitoring Function Ignition Time-Out Function Plasma Pulsing Hold-Function...
- Page 5 Safety Displayed Service Codes Power Source Troubleshooting Service, maintenance and disposal General Safety At every start-up Every 2 Months Every 6 Months Disposal Appendix Technical data Special Voltage Acerios Explanation of Footnotes...
-
Page 6: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ▶ Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 7: Intended Use
Intended Use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose". -
Page 8: Grid Connection
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current consumption. This may affect a number of device types in terms of: connection restrictions criteria regarding maximum permissible grid impedance criteria regarding the minimum required short-circuit power both at the interface with the public grid See technical data In this case, the operator or the person using the device should check whether or... -
Page 9: Danger From Toxic Gases And Vapors
A work station-specific emission value cannot be specified because this value de- pends on the process and the environmental conditions. It depends on differing parameters, such as the power range, the component geometry, the material, the resonance properties of the workpiece, the work station environment, and many other factors. -
Page 10: Hazards From Grid Current And Process Current
Only ever perform the plasma surface treatment in areas at risk of fire and ex- plosion, on sealed tanks, drums, or pipes if these have been prepared in accord- ance with corresponding national and international standards. Do not perform the plasma surface treatment on containers in which gases, fuels, mineral oils, and the like are/were stored. -
Page 11: Stray Currents
Stray Currents If the following instructions are not observed, stray currents may occur, which pose a risk of the following: Fire Overheating of components connected to the workpiece Destruction of ground conductors Damage to the device and other electrical equipment Ensure a proper connection between the hosepack and the plasma power source. -
Page 12: Emf Measures
EMF Measures Electromagnetic fields may cause health problems that are not yet known: Effects on the health of persons close by, e.g., those with pacemakers and hearing aids Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the plasma process Keep distances between hosepacks and the head/torso of the operator as great as possible for safety reasons Do not carry hosepacks over your shoulder or wrap them around your body... -
Page 13: Impaired Plasma Surface Treatment
al damage, corrosion, or changes due to other environmental influences). The test interval and scope must at least comply with the respective valid nation- al standards and guidelines. There is a risk of colorless, odorless gas escaping unnoticed if an adapter is used for the gas connection. -
Page 14: Safety Measures At The Setup Location And During Transport
Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour Observe the safety and maintenance information on the gas cylinder or the main gas supply When no plasma surface treatment is being performed, close the valve of the gas cylinder or the main gas supply. -
Page 15: Maintenance And Repair
Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.). Only use appropriate original coolant from the manufacturer. Do not mix original coolant from the manufacturer with other coolants. Only connect system components from the manufacturer to the cooling unit cir- cuit. -
Page 16: Safety Symbols
Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you... -
Page 17: General Information
General information... -
Page 19: General
The plasma pulsed arc function with a wide frequency range provides additional process-stabilizing options. The Acerios plasma power source has an optimized high-frequency ignition pro- cess for short cycle times and high repeatability. NOTE! The plasma surface treatment process will simply be referred to as the plasma process in the rest of these instructions. -
Page 20: Application Areas
Dry lubricant on aluminum Oil on steel System Config- Plasma power source and cooling unit installed on an upright console urations Acerios plasma power source Robot interface FK 9000 R cooling unit TU Podium upright console Gas control 5 - 30 l... -
Page 21: Operating Controls And Connections
Operating controls and connec- tions... -
Page 23: Control Panel
Control Panel General The key feature of the control panel is the logical arrangement of the controls. All parameters essential for day-to-day work can be easily selected with buttons changed using the selection dial shown on the digital display during the plasma process. NOTE! Because of software updates, certain functions may be available for your device but not described in these Operating Instructions or vice versa. -
Page 24: Control Panel
Control Panel (6) (7) (10) (11) (15) (14) (13) (12) Function Left parameter selection button Right parameter selection button Buttons (1) and (2) are used to select the following process parameters: Starting current for the plasma process UpSlope Period of time it takes to rise from the starting current I to the spe- start cified main current I... - Page 25 When a parameter is selected, the LED at the corresponding parameter symbol illuminates. Special indicators Pulsing indicator Illuminates when the F-P setup parameter has been set to a pulse fre- quency Electrode overloaded indicator Illuminates when the tungsten electrode is overloaded Further information on the electrode overloaded indicator can be found in the section headed "Overloaded Electrode"...
- Page 26 mm indicator Illuminates when the electrode diameter setup parameter has been selec- s indicator Illuminates when parameters t and t have been selected, along with down the following setup parameters: GPr / G-L / G-H / t-S / t-E / C-t / HFt / Ito / Arc % indicator Illuminates when parameters I and I...
-
Page 27: Shortcut Keys - Special Functions
Shortcut Keys - Special Functions General Pressing buttons on the control panel simultaneously or repeatedly can access the functions described below. Key Lock Activate key lock: Keeping the store button pressed, press the right parameter selection button. The lock message "CLo|SEd" appears briefly on the digital displays. The key lock special indicator illuminates on the control panel Now if a button is pressed, the lock message "CLo|SEd"... -
Page 28: Show Software Version, Runtime, And Coolant Flow
Show Software Show software version: Version, Keeping the store button pressed, press the left parameter selection button. Runtime, and The software version appears on the digital displays. Coolant Flow Show runtime: Press the left parameter selection button again The runtime records the actual plasma time since starting for the first time. -
Page 29: Connections, Switches, And Mechanical Components
Connections, Switches, and Mechanical Compon- ents Acerios Connec- tions Function (+) Current socket with bayonet latch Connect the plasma torch here LocalNet connection Standardized connection socket for system add-ons Torch control connection Input for the collision protection signal if connecting a robot interface or... -
Page 31: Installation And Startup
Installation and Startup... -
Page 33: Before Installation And Initial Operation
Digital, external gas regulator Intended Use The plasma power source is intended exclusively for automated plasma surface treatment in conjunction with Fronius components. Any other use does not constitute proper use. The manufacturer accepts no responsibility for any damage resulting from im- proper use. -
Page 34: Grid Connection
dust must not be allowed to get sucked directly into the device (e.g. from grind- ing work). Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the mains cable or mains plug has not been attached to your version of the appli- ance, these must be installed according to national standards. -
Page 35: Installation
A standard configuration is used to describe the installation and start-up of the plasma system. The standard configuration consists of the following system components: Acerios plasma power source (including robot interface) FK 9000 R cooling unit PCT 2000 plasma torch... - Page 36 IMPORTANT! A flow controller must not be fitted upstream of the external gas regulator. Connect the robot interface to the robot control system Equip the plasma torch with the correct wearing parts NOTE! Do not use pure tungsten electrodes for the Acerios plasma power source (color code: green).
-
Page 37: Commissioning
Commissioning Connecting the WARNING! Gas Cylinder Danger of severe injury and damage to property if gas cylinders fall over. ▶ Place gas cylinders on a solid, level surface in such a way that they remain stable. ▶ Secure the gas cylinders to prevent them from falling over: the retaining strap must be attached at the height of the upper part of the gas cylinder. -
Page 39: Plasma Surface Treatment
Plasma Surface Treatment... -
Page 41: Overloaded Electrode
Overloaded Electrode Overloaded If the electrode is overloaded, there is a risk that an oversized cap could form on Electrode the tungsten electrode. An oversized cap has a negative effect on the ignition properties. If the electrode is overloaded, the "electrode overloaded" indicator illuminates on the control panel. -
Page 42: Description Of Operating Modes
Description of operating modes 2-Step Mode 0 ... 1 Trigger signal (from the robot control system) 1 ... 0 Reset trigger signal 0 ... 1 1 ... 0 main start down GPr = gas pre-flow time, I start = starting current, t-S = starting current time, t up = UpSlope, I main = main current, t down = DownSlope, I end = final current, t-E = final current time 4-Step Mode 0 ... -
Page 43: Plasma Surface Treatment
Plasma Surface Treatment Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 44: Plasma Surface Treatment
Plasma Surface Insert mains plug Treatment CAUTION! Danger of injury and damage from electric shock. When the power switch is set to position - I -, the tungsten electrode of the plasma torch is live. ▶ Ensure that the tungsten electrode is not touching any people or electrically conductive or grounded parts (housing, etc.). -
Page 45: Special Functions And Options
Special Functions and Options Arc Break Monit- If the arc breaks and no current flow takes place during the time set in the Setup oring Function menu, the plasma power source automatically switches off. The control panel displays the service code "no | Arc". Press any button on the control panel to resume the plasma process. -
Page 46: Hold-Function
Current flow during plasma pulsing 1/F-P main start down I start = starting current, I end = final current, t up = UpSlope, t down = DownSlope, F-P = pulse fre- quency, dcY = duty cycle, IG = base current, I main = main current *) (1/F-P = Time between two impulses) Hold-Function The current actual process current and process voltage values are saved each... -
Page 47: Job Mode
Job Mode General Job Mode raises quality and simplifies operation in automated plasma applica- tions. Up to 100 proven jobs (operating points) can be reproduced in Job Mode, with no need to manually document the parameters. Different jobs are preprogrammed, depending on the configuration. Another advantage is that because jobs are preprogrammed, the plasma power source is ready for use immediately. -
Page 48: Saving A Job
Saving a Job NOTE! Jobs cannot be created in Job Mode. Creating a new job: Set the desired process parameters to be saved as a job NOTE! Apart from specific settings in the 2nd level Setup menu, all the currently made settings are saved. -
Page 49: Job Retrieval
Job Retrieval NOTE! Before retrieving a job, make sure that the plasma power source is set up and installed in accordance with the job. Press the operating mode button to select Job Mode The last used job is displayed. Use the selection dial to select the desired job Use the left and right parameter selection buttons to view the settings pro- grammed in the job. -
Page 50: Copying/Overwriting A Job
Copying/Over- In Job Mode, it is possible to copy a job already saved to a program location to writing a Job any other program location: Press the operating mode button to select Job Mode The last used job is displayed. Use the selection dial to select the desired job Briefly press the store button to switch to the Job menu. - Page 51 Briefly press the store button to exit the Job menu The power source switches to the setting requested before the job was copied.
-
Page 52: Deleting A Job
Deleting a Job In Job Mode, briefly press the store button to switch to the Job menu. The first free program location is displayed. Use the selection dial to select the job to delete The "DEL" symbol illuminates on the gas-test button. Press and hold the gas-test button "dEL"... -
Page 53: Setup Settings
Setup Settings... -
Page 55: The Setup Menu
The Setup Menu General The Setup menu offers easy access to expert knowledge related to the plasma power source, as well as additional functions. The Setup menu makes it possible to easily adjust the parameters for various tasks. All setup parameters that directly affect the plasma process are located in the Setup menu. -
Page 56: Parameters In The Setup Menu
Parameters in Pulse frequency the Setup Menu OFF / 0, 20 Hz - 2.00 kHz) Factory setting: OFF IMPORTANT! If F-P is set to "OFF", Setup parameters dcY and I-G can- not be selected. The pulsing special display illuminates on the control panel if a value for the pulse frequency has been entered. -
Page 57: Parameters In The 2Nd Level Setup Menu
IMPORTANT! If the plasma power source is reset, all the personal set- tings in the Setup menu are lost. The jobs and parameter settings in the 2nd level Setup menu are not de- leted when the plasma power source is reset. 2nd level Setup menu Parameters in Cooling unit controls... - Page 58 See the "Displaying Plasma System Resistance r" section starting on page Plasma system inductance Microhenry See the "Displaying Plasma System Inductance L" section starting on page 62. Ignition time-out Period of time until the safety cut-out following failed ignition 0.1 - 9.9 s Factory setting: 5 s IMPORTANT! The ignition time-out function is a safety function and can- not be deactivated.
- Page 59 is automatically selected. The main current I can be adjusted immediately. main The last selected parameter remains selected during the plasma process. The last selected parameter can be adjusted immediately. The main cur- rent I is not automatically selected. main Gas correction For entering a gas correction factor for the process gas (only in conjunction with the "digital gas control"...
-
Page 60: Exiting The 2Nd Level Setup Menu
Exiting the 2nd Press the store button Level Setup Menu The power source is now located in the Setup menu Press the store button again to exit the Setup menu Exiting the Press the store button Setup Menu... -
Page 61: Displaying Plasma System Resistance R
Displaying Plasma System Resistance r General Measuring the plasma system resistance provides information on the total resist- ance of the plasma torch hosepack and the plasma torch. For example, if the plasma system resistance increases after the plasma torch is replaced, the following components may be faulty: Plasma torch hosepack Plasma torch... -
Page 62: Displaying Plasma System Inductance L
Displaying Plasma System Inductance L General Inform- The way that the hosepack is arranged has a significant effect on the properties ation on Plasma of the plasma arc. Depending on the length and arrangement of the hosepack, a System Induct- high plasma system inductance can be produced, especially during pulsing. -
Page 63: The Gas Menu
The Gas Menu General The gas menu gives easy access to the gas settings. Accessing the Press and hold the store button Gas Menu Press the gas-test button The power source in now located in the gas menu; the last selected paramet- er is displayed. -
Page 64: Exiting The Setup Menu
Set value for the flow of process gas ("Digital Gas Control" option) OFF / 5.0 - max l/min (OFF / 10.71 - max. cfh) Factory setting: 15 l/min (32.14 cfh) IMPORTANT! More detailed explanations of the "GAS" parameter can be found in the "Digital Gas Control"... -
Page 65: The Job Correction Menu
The Job Correction Menu General Setup parameters can be adapted to meet the specific requirements of individual jobs in the job correction menu. Accessing the Press the operating mode button to select "Job Mode" Job Correction Press and hold the store button Menu Press the operating mode button The power source is now located in the job correction menu. - Page 66 DownSlope t down Transition time from main current I to final current I main OFF / 0.01 - 9.9 s Factory setting: 1.0 s Final current I 0 - 100% (of main current I main Factory setting: 30% Set value for the flow of process gas ("Digital Gas Control"...
-
Page 67: Exiting The Job Correction Menu
Duty cycle Relationship between pulse duration and base current duration at the set pulse frequency 10 - 90% Factory setting: 50% Base current 0 - 100% (of main current I main Factory setting: 50% Operating mode selection 2t / 4t 2t = operating mode is 2-step mode 4t = operating mode is 4-step mode Starting current time... -
Page 69: Troubleshooting And Maintenance
Troubleshooting and Maintenance... -
Page 71: Troubleshooting
Troubleshooting General Digital power sources are equipped with an intelligent safety system, which com- pletely negates the need for fuses (except for the coolant pump fuse). After cor- recting a possible error, the power source can be properly operated again without having to change any fuses. - Page 72 tP1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Leave power source to cool tP2 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Leave power source to cool tP3 | xxx...
- Page 73 tSt | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the control circuit of the power source Remedy: Leave power source to cool Err | 049 Cause: Phase error in the power supply Remedy: Check the mains fuse, the grid lead and the mains plug Err | 050 Cause: Indirect symmetry error...
- Page 74 dSP | Sy Cause: Error in the central control and regulation unit Remedy: Contact After-Sales Service dSP | nSy Cause: Error in the central control and regulation unit Remedy: Contact After-Sales Service r | E30 Cause: r adjustment: There is no contact between the electrode and the plasma nozzle Remedy: Establish a proper connection between the electrode and the plasma...
-
Page 75: Power Source Troubleshooting
Power Source Power source not working Troubleshooting Power source switched on; displays and indicators do not illuminate Cause: Grid lead damaged or broken, mains plug not inserted Remedy: Check grid lead, insert mains plug if necessary Cause: Grid socket or mains plug faulty Remedy: Replace faulty parts Cause:... - Page 76 Plasma torch gets very hot Cause: Plasma torch is under-dimensioned Remedy: Observe duty cycle and load limits Cause: Coolant flow too low Remedy: Check coolant level, coolant flow rate, water contamination, etc. If coolant pump blocked: use a screwdriver to turn on the shaft of the coolant pump at the gland Cause: Parameter C-C is set to "OFF".
-
Page 77: Service, Maintenance And Disposal
Service, maintenance and disposal General The plasma power source only requires minimal care and maintenance under nor- mal operating conditions. However, several points must be observed in order for the plasma power source to remain operational for years to come. Safety WARNING! Danger from incorrect operation and work that is not carried out properly. -
Page 78: Every 6 Months
Every 6 Months CAUTION! Danger due to the effect of compressed air. This can result in damage to property. ▶ Do not bring the air nozzle too close to electronic parts. Dismantle device side panels and blow the inside of the device clean with dry, reduced compressed air Also clean the cooling air ducts if there is a large accumulation of dust WARNING! -
Page 79: Appendix
Appendix... -
Page 81: Technical Data
An inadequately dimensioned electrical installation can lead to serious damage. ▶ The grid lead and its fuse protection should be designed accordingly. ▶ The technical data on the rating plate should be followed. Acerios Mains voltage 3 x 400 V Mains voltage tolerance ±15%... - Page 84 SPAREPARTS ONLINE Fronius International GmbH Froniusstraße 1 4643 Pettenbach Austria contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the adresses of all Fronius Sales & Service Partners and locations.
Need help?
Do you have a question about the Acerios and is the answer not in the manual?
Questions and answers