Fronius 8,045,368, Operating Instructions Manual

Page 1: ...FDV 22 MF EN 42 0410 1645 V09 03082016 Operating Instructions Carriage Perfect Welding Solar Energy Perfect Charging...

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Page 3: ...k 14 AC ACvoltage transformer 15 Welding position and seam tracking 16 Possible welding positions 16 Guidance of the carriage 17 Second torch holder 20 Preparing the driving vehicle 21 Fitting the han...

Page 4: ...le 41 Oscillation 42 Maintenance and care 43 Personnel 43 Maintenance record 43 Maintenance operations and intervals 43 Recommended lubricants 43 Horizontal torch adjustment unit 44 Vertical torch adj...

Page 5: ...ple Driving vehicle FDV 22 MF is a portable battery powered longitudinal truck with 4 wheel drive The driving vehicle is used to execute mechanised butt and fillet welds in horizon tal or vertical wel...

Page 6: ...all times Clearly mark the place where the instructions are kept Ensure that all persons using the carriage know where the operating instructions are located The operating instructions will only be ab...

Page 7: ...safety rules Do not use the functions until you have fully read all the operating instructions Type Ser No Art No A 4600 Wels www fronius com U weight max load 14 4 VDC 15 kg 22 kg 2009 FDV 22 MF 8 04...

Page 8: ...Scope of supply 3 4 6 5 7 1 8 2 1 Driving vehicle FDV 22MF 2 Handle with hose pack holder 3 Battery pack 14 4 V 3 Ah 4 Charger FDV MF 5 Allen keys 2 5 3 4 6 Front guide rail 7 Rear guide rail 8 Conne...

Page 9: ...1425 This accessory comprises two parts Brush bracket and 1x brush Oscillation unit FOU 30 ML6 8 045 370 For workpieces with very rough surface Stainless steel drive wheel 48 0005 1603 article number...

Page 10: ...tions continued Lateral guides Additional torch holder for second torch 48 0005 1893 1 1 Lateral guide tiltable 48 0005 1890 2 Lateral guide for edge 48 0005 1888 3 Lateral guide magnetic 48 0005 1892...

Page 11: ...de with guiding rail 4 Guide arm for flexible rail 1850 mm 2 St ck 48 0005 1897 5 Flexible guiding rail 1850 mm 48 0005 1894 6 Magnetic block for guiding rail 48 0005 1895 IMPORTANT 10 magnetic blocks...

Page 12: ...oscillation unit Universal torch holder Vertical torch adjustment unit Horizontal torch adjustment unit On board control unit Hosepack holder Guide wheels Limit switch Truck with 4 wheel drive Batter...

Page 13: ...source control For connecting the cable to the power source 8 Welding ON OFF toggle switch For choosing whether to run the automatic program sequence with or without weld ing Welding can be deactivat...

Page 14: ...t is deactivated The display appears after the value 99 9 and before 0 5 Traversing speed display Display range 5 150 cm min The current step is signalled by the relevant LED lighting up Display flash...

Page 15: ...ence 2 Right dwell time potentiometer For setting the dwell time of the torch in the right reversal position Setting range 0 3 seconds 3 Oscillation speed potentiometer For setting the traversing spee...

Page 16: ...he battery pack 7 Battery release button For releasing the battery pack WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described until you hav...

Page 17: ...e system components especially the safety rules AC ACvoltage transformer AC AC voltage transformer 1 2 The voltage transformer allows the charger to be operated using 110 V and 120 V mains supplies A...

Page 18: ...t from falling The load securing device must be designed for the total weight of the vehicle The manufacturer accepts no liability for any damage to persons or property resulting from vertical use of...

Page 19: ...in the PE overhead position is prohibited Guidance of the carriage Guidance on outside vertical surface Guidance on inside vertical surface The guide wheels automatically track the torch in the fille...

Page 20: ...angle piece the welding torch must only be placed on the upper side Guidance of the carriage continued Guidance on outside vertical surface Guidance on angle piece vertical or rail Outside of curve wi...

Page 21: ...19 Guidance of the carriage with optional lateral guides Lateral guide tiltable Lateral guide for edge Standard lateral guide with magnet...

Page 22: ...or guiding rail Guide arm for flexible rail 1850 mm 72 84 in IMPORTANT 10 magnetic blocks per rail are necessary Lateral guide with guiding rail IMPORTANT Working with two welding torches is only poss...

Page 23: ...o the control panel housing 2 Tighten the screws using a size 5 allen key Fitting the guide rails 1 Use the M6 knurled screws to attach the guide rails to the driving vehicle 2 Tighten knurled screws...

Page 24: ...1 Remove the M6 knurled screws a 2 Attach the brush brackets as shown 3 Insert the M6 knurled screws a and tighten by hand 4 Fit the brush to the front or rear brush bracket using M6 screws b a NOTE T...

Page 25: ...ion All optinal lateral guides for the FDV 22 carriage are mounted with the M6 knurled screws The lateral guides are mounted on the front sides of the carriage Lateral guide tiltable Lateral guide for...

Page 26: ...10 magnet blocks are necessary for one rail 1850 mm 72 84 in to ensure a secure fit The rails can be mounted on the magnetic blocks in the following way by forming a butt joint by forming a lap joint...

Page 27: ...ge before the con trol panel 1 Remove the right knurled screw and the lifting eye 5 Tighten the knurled screw and the lifting eye into the two holes above the fixing screws 2 Place the recress a of th...

Page 28: ...rger is designed for a supply voltage of 230 V Directly con necting the charger to a 110 120 V mains supply can cause serious material damage Ensure that the charger is always operated using the corre...

Page 29: ...rges up The signal lamp flashes GREEN during the charging process IMPORTANT The battery pack is fully charged after a charging time of 45 minutes The GREEN signal lamp is then lit permanently 3 Once t...

Page 30: ...warf The guide wheels must be clean undamaged and free of welding spatter Check the sur face of the work piece and the driving vehicle to ensure they are clean 1 Place the driving vehicle on the work...

Page 31: ...securing device must be designed for the total weight of the vehicle The manufacturer accepts no liability for any damage to persons or property resulting from vertical use of the driving vehicle with...

Page 32: ...when laying the hose pack Do not allow the hose pack to become kinked Always lay the hose pack as straight as possible Suspend the hose pack it must not come into contact with the floor use balancers...

Page 33: ...stem compo nents are switched on They can be switched on in any order On the following system components turn the main switch to the ON 1 position Driving vehicle control unit Power source Wire feed u...

Page 34: ...oggle switch to the OFF position Start the welding process Start the welding process 2 Set the Start LEFT STOP Start RIGHT toggle switch to the de sired direction The test run starts To stop the proce...

Page 35: ...ing Welding is stopped through actuation of the front or rear limit switch or through operation of the tog gle switch 13 on the control panel STOP position of the driving vehicle For continu ous weldi...

Page 36: ...to the STOP 0 position IMPORTANT The welding process stops automatically once the relevant limit switch on the driving vehicle is actuated 5 Press the buttons and set the desired end crater time e g...

Page 37: ...lected 4 Press the buttons and set the desired pause segment e g 5 0 cm Press the SELECT ENTER button to accept the value The next parameter is selected 3 sec For interval welding the welding segment...

Page 38: ...ress the buttons and set the desired back fill time e g 1 0 s Press the SELECT ENTER button to accept the value The next parameter is selected Interval welding continued 5 Press the buttons and set th...

Page 39: ...4 cm Total path 55 cm Welding Welding Welding 5 cm 5 cm 10 cm 1 2 2 3 1 Setting 1 Total path e g 43 cm or 45 cm If the total path finishes in a pause segment S6 the driving vehicle stops after complet...

Page 40: ...ly For this it is necessary to set the total path The welding process stops automatically once this programmed total path has been travelled The following parameters must be set for path welding Durat...

Page 41: ...lding path is reached Welding is also stopped as soon as a limit switch on the driving vehicle is actuated Path welding continued 5 Press the buttons and set the desired back fill time e g 1 0 s Press...

Page 42: ...ram sequence IMPORTANT If the driving vehicle has been configured for interval welding the oscillation motion is only active in the welding seg ment In the pause segment during crater filling and back...

Page 43: ...g them a detailed description of the error BAt flashing display Cause Battery warning the battery pack is nearly flat Remedy Charge up the battery pack with charger FDV MF Displayed error messages Dri...

Page 44: ...aversing speed is set to 0 Remedy Set the traversing speed Cause Drive system faulty Remedy Remove the cover and check the operation of the drive system Power source does not start Cause Welding ON OF...

Page 45: ...tenance Personnel The operator must put the following organisational measures in place with regard to maintenance keeping a service book with the most IMPORTANT data date operator mainte nance activit...

Page 46: ...44 Horizontal torch adjustment unit Vertical torch adjustment unit Driving vehicle front end Driving vehicle rear end K K K F K K K K F K E A B A A A B E...

Page 47: ...se self discharge Charger FDV MF with battery pack J I J The alignment of the driving vehicle depends on the setting of the play between the toothed belt and the drive wheel If there is too much play...

Page 48: ...d personnel Ensure that all machine components and electrical parts are separated according to type and disposed of properly drained or defective battery packs are disposed of by the dealer Fronius Cu...

Page 49: ...Adjustable range of guide wheels 100 mm Net weight without battery 14 kg Technical data Driving vehicle FDV 22 MF AC AC voltage transformer Input voltage 110 120 V AC Output voltage 230 V AC Mains fre...

Page 50: ...R 150 1 30 mm Oscillation frequency R 150 oscillation path 10 mm 12 110 strokes min Dwell time 0 3 sec Oscillation unit FOU 30 ML6 Dimensions FDV 22 MF without oscillation unit A 308 416 mm B 266 mm C...

Page 51: ...V 22 MF with oscillation unit A 305 415 mm B 112 162 mm C 29 mm D 40 mm E 30 mm F 271 421 mm G 288 398 mm H 157 mm I 52 mm J 10 mm K 40 mm L 60 200 mm M 398 mm N 312 mm O 5 mm P 369 mm A E D C B F G I...

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Page 53: ...1 Spare parts...

Page 54: ...2...

Page 55: ...3 Carriage FDV 22 MF Art Nr 8 045 368 incl 48 0005 1217 nur Stecker plug only 48 0005 1182...

Page 56: ...4 Torch holder for second torch Additional torch holder Art Nr 48 0005 1893 Carriage FDV 22 MF Art Nr 8 045 368...

Page 57: ...gnetic 2 pc Art Nr 48 0005 1892 2 3 5 6 4 Lateral guide with guiding rail 4 Guide arm for flexible rail 1850 mm 72 84 in 2 pc Art Nr 48 0005 1897 5 Guiding rail flexible 1850 mm 72 84 in Art Nr 48 000...

Page 58: ...6 Circuit diagram...

Page 59: ...7 EU Declaration of conformity...

Page 60: ...FRONIUS INTERNATIONAL GMBH TechSupport Automation www fronius com addresses www fronius com...