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Translation of original
Operating Instructions
ArcRover 22
Operating Instructions
EN
Welding carriage
42,0426,0297,EN 19112019
Contents
About this document ........................................................................................................................................ 5
Function of this document .......................................................................................................................... 5
Explanation of safety information ............................................................................................................... 5
General ............................................................................................................................................................ 6
Application area ......................................................................................................................................... 6
Duty to provide instruction .......................................................................................................................... 7
Dangers from the rechargeable battery pack ............................................................................................. 8
Use of charger and rechargeable battery pack .......................................................................................... 9
Warning notices on the carriage ...............................................................................................................10
Scope of supply ........................................................................................................................................ 11
ArcRover 22 conguration with oscillation unit ........................................................................................ 12
ArcRover 22 conguration without oscillation unit ................................................................................... 13
Accessories and options ............................................................................................................................... 14
Control panel ............................................................................................................................................ 19
Main menu................................................................................................................................................20
Charger and rechargeable battery pack ................................................................................................... 21
Menu navigation and parameter entry ........................................................................................................... 22
CAR menu ................................................................................................................................................ 23
Preparing the carriage ................................................................................................................................... 31
Mounting and setting up the guide rails ................................................................................................... 31
Fitting the carriage brushes (option) ........................................................................................................ 32
Fitting the lateral guides (option) .............................................................................................................. 33
Fitting the second torch holder (option) .................................................................................................... 35
Charging the rechargeable battery pack .................................................................................................. 35
Inserting rechargeable battery pack into carriage .................................................................................... 37
Connecting the external power supply (option) ........................................................................................ 38
Setting up the carriage .................................................................................................................................. 39
Checking the workpiece surface and carriage ......................................................................................... 39
Placing the carriage ................................................................................................................................. 39
Attaching fall protection (only for vertical operation) ................................................................................ 40
Mounting and adjusting the welding torch ................................................................................................ 41
Disengaging the carriage ......................................................................................................................... 42
Starting up the carriage ................................................................................................................................. 43
Checking the connections ........................................................................................................................ 43
Switching on the system components ...................................................................................................... 43
Setting the carriage parameters .................................................................................................................... 44
Parameter list ........................................................................................................................................... 44
Setting the carriage parameters ............................................................................................................... 45
Setting the oscillation parameters ............................................................................................................ 47
Saving a program ..................................................................................................................................... 49
Loading a program ................................................................................................................................... 50
Retrieving parameter record (JOB) on the power source ........................................................................ 51
Loading the carriage program .................................................................................................................. 51
Performing a test run ................................................................................................................................ 52
Starting the welding process .................................................................................................................... 53
Correcting the Travel Speed .................................................................................................................... 53
Correcting the FMS oset ........................................................................................................................ 54
End of welding .......................................................................................................................................... 54
Oscillation unit .......................................................................................................................................... 57
FMS 50/100 motor slide ........................................................................................................................... 57
Maintenance record ................................................................................................................................. 58
Horizontal welding torch adjustment unit ................................................................................................. 59
Vertical welding torch adjustment unit ...................................................................................................... 60
Carriage front ........................................................................................................................................... 61
Carriage back ........................................................................................................................................... 62
Disposal of components ........................................................................................................................... 64
Technical Data ............................................................................................................................................... 65
Spare parts .................................................................................................................................................... 69
Spare parts, wearing parts and auxiliary materials .................................................................................. 69
EU Declaration of Conformity ........................................................................................................................ 80
About this document
Function of this
document
Explanation
of safety
information
These Operating Instructions explain how to commission and operate the carriage. Look
after the Operating Instructions carefully; they must always be to hand at the location
where the carriage is being used. They can be used as a reference should any operational or functional problems occur in the future.
DANGER!
Indicates an imminent danger. If not avoided, death or serious injury will result.
WARNING!
Indicates a possibly dangerous situation. If not avoided, death or serious injury may
result.
CAUTION!
Indicates a possibly harmful situation. If not avoided, minor or minor injury may result.
NOTE!
Indicates a risk of awed results and possible damage to the equipment.
IMPORTANT! Indicates usage tips and other particularly useful information. It is not a
signal word for a harmful or dangerous situation.
Copyright
Qualied
personnel
Special care is required if you see any of the symbols shown.
Copyright of these Operating Instructions remains with Fronius International GmbH. The
text and illustrations are all technically correct at the time of going to press. We reserve
the right to make changes. The content of the Operating Instructions shall not give rise to
any claims whatsoever on the part of the purchaser.
-These Operating Instructions are designed for trained personnel or persons with
practical welding experience. Personnel must be trained through veriable regular
instruction.
-Maintenance and repair of the carriage may likewise only be carried out by trained
technicians and in compliance with the specied maintenance activities and maintenance intervals.
-The manufacturer accepts no liability for damage caused by insucient knowledge of
how to use the device.
5
General
PrincipleThe ArcRover 22 carriage is a portable, battery-powered welding carriage with 4-wheel
drive. The carriage is used to execute mechanised butt and llet welds in horizontal or
vertical welding positions, with or without oscillation.
Device concept
The ArcRover 22 carriage has been
designed for exibility and to improve
productivity in the execution of longitudinal
weld seams. A spatter guard mounted on
the working side and powder coating of all
housing components enable use in harsh
operating conditions.
A large holding and carrying handle coupled with a robust yet lightweight design
allows quick and easy positioning on the
workpiece.
The carriage adheres to the workpiece
by means of a permanent magnet. This
guarantees the best possible traction even
in vertical use.
Adjustable guide rollers on the side of the
carriage ensure optimal tracking of the
ArcRover 22 carriage
The carriage can be equipped with a torch oscillation unit.
The carriage, together with the optional oscillation unit, is powered by the interchangeable rechargeable battery pack.
The control unit is integrated into the carriage. The control panel has an illuminated display allowing simple and user-friendly parameter setting for the carriage.
weld seam.
The universal torch holder allows use of
both manual and machine welding torches.
Application areaThe ArcRover 22 carriage can be used in all situations where a high degree of exibility
is required when executing longitudinal weld seams:
- Shipyards
- Bridge construction
- Workshops
- Production halls
- Building sites
Proper use/
intended purpose
The ArcRover 22 carriage must only be used for performing mechanised butt and llet
welds in horizontal or vertical welding positions. Any other use shall be deemed improper
and the manufacturer will assume no responsibility for any resulting damages.
The carriage can be used in the following welding processes:
- MIG / MAG process
Proper use also includes:
- Use of the charger and rechargeable battery pack included with the carriage
- Use of the permanent magnet with a minimum sheet thickness of 5 mm
6
Proper use/intended purpose
(continued)
- Use of MIG/MAG welding torches with a holder diameter of up to 28 mm
- Use in welding position PA with the "stainless steel drive wheel" option
- Carrying out all maintenance work at the specied maintenance intervals
- Keeping a service book with the most important data (date, operator, activities carried
out)
- Using the spare parts stipulated by Fronius
- Following all the instructions contained in the Operating Instructions
- Using this document in conjunction with the operating
- instructions of the integrated system components (power source, wirefeeder, etc.)
Foreseeable
misuse
Conversions or
modications
Operating
Instructions
Any use other than for the intended purpose shall be deemed improper use. This includes:
-Operation on preheated components > 50 °C without stainless steel drive wheels
-Transporting people
-Use outside the permitted technical operating limits
-Use in hazardous areas
Any unauthorised conversions or modications made to the carriage by the user shall
invalidate all liability or warranty obligations on the part of the manufacturer!
The electromagnetic characteristics of the carriage can be adversely aected by additions or modications of any kind. No modications or additions should therefore be
undertaken without rst consulting the manufacturer and obtaining written approval.
The Operating Instructions help you to use the carriage safely and eciently, and must
therefore be to hand at all times:
-The Operating Instructions must always be kept near the carriage.
-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 able to help you in the event of a problem if
they are at hand!
Duty to provide
instruction
IMPORTANT! The manufacturer shall not be liable for any damage that arises from fail-
ure to observe the Operating Instructions!
The operator must inform all people working with the carriage about the following before
starting work:
-Theoretical and practical aspects of operation
-Safety regulations
IMPORTANT! The duty to provide instruction applies in particular for people who only
work on the carriage occasionally.
7
Dangers from
the rechargeable
battery pack
The substances contained in the battery used in this device can be harmful
to the environment and to human and animal health. If the device becomes
damaged, please observe the following points:
-Make sure that leaking uids cannot get into the soil or groundwater
- If pollution has already occurred, it must be removed in accordance with
relevant national regulations
The battery can catch re if overheated. Do not expose the device to heat
(e.g. a permanent heat source or re).
If the battery is damaged or subjected to improper use, dangerous vapours
may be given o which can irritate the airways.
Measures:
- Ensure an adequate supply of fresh air
- Seek medical attention in case of discomfort
With a faulty battery, liquid may leak out of the device.
- Avoid contact with the liquid
- Hand the device over to a Fronius Service Partner for repair
- Clean and check any parts that have come into contact with the liquid
Do not operate or store the device in a potentially explosive atmosphere.
Special regulations apply in rooms at risk of re or explosion:
-Observe relevant national and international regulations
To comply with European Directive 2006/66/EC on batteries and accumulators and its implementation in national law, batteries and rechargeable
batteries that have reached the end of their life must be collected separately
and returned to an approved recycling facility.
-Be sure to return any device that you no longer require to your dealer, or
nd out about the approved collection and recycling facilities in your area.
Ignoring this European Directive may be harmful to the environment and
your own health!
Devices with mechanically undamaged rechargeable batteries may be
returned to the relevant Fronius Service Partner for repair or battery replacement.
As soon as it becomes evident that the rechargeable battery has been mechanically damaged (e.g. electrolyte is escaping), dispose of the device at
your nearest recycling centre in accordance with national laws and guidelines.
If anything is unclear or you have any questions about disposal, contact your
Fronius Service Partner.
8
Use of charger
and rechargeable
battery pack
- The charger and the rechargeable battery pack are designed for each other. Therefore
you should only ever use the supplied charger to charge the battery pack.
-Recharge the rechargeable battery pack after every discharge. Do not wait until the
rechargeable battery pack is completely discharged before recharging it.
-Objects must not be passed through the ventilation openings of the charger.
-Charging/discharging of the battery must be carried out according to the relevant
requirements for the environmental conditions (technical data).
-Should unusual temperatures, odours, discolorations or deformations occur during the
charging process, halt the process immediately.
-Disconnect the charger from the mains and rechargeable battery pack when not in
use.
-When handling the battery, check the packaging and/or the battery itself for obvious
signs of damage.
-Do not open, crush, dismantle or drop the rechargeable battery pack from a large
height.
-Do not short-circuit the rechargeable battery pack or expose it to high temperatures.
-Keep the rechargeable battery pack away from direct sunlight and other heat sources.
-Do not place the rechargeable battery pack or the charger on moist or wet surfaces.
-Do not operate the rechargeable battery pack and charger in environments where they
are exposed to dust, ammable gases, steam or solvents. Do not use in environments
with strong vibrations and magnetic elds.
Environmental
conditions
Operating, storing or transporting the system outside the specied area or environmental ranges is regarded as not complying with the intended purpose. The manufacturer
shall not be liable for any damage or loss resulting from this.
Ambient air temperature range:
-during operation: 0 °C to +40 °C (32 °F to 104 °F)
-during transport and storage: -10 °C to+45 °C (14 °F to 113 °F)
-Recommended temperature range during charging: +5 °C to +40 °C (41 °F to
104 °F)
Relative humidity:
-up to 65% +/- 20%
Environmental conditions:
-Surrounding air is free from dust and ammable vapours, solvents or gases.
-No strong vibrations and magnetic elds around the rechargeable battery pack.
-No direct sunlight on the rechargeable battery pack.
-No storing the rechargeable battery pack on moist or wet surfaces.
9
Warning notices
on the carriage
A number of safety symbols can be seen on the rating plate axed to the carriage. The
rating plate and safety symbols must not be removed or painted over.
www.fronius.com
Froniusstraße 1
Pettenbach 4643
Uweight
25,4 VDC 10,7 kg
ArcRover 22
Type:
Art.No.:
Ser.No.:
22 kg
ArcRover 22
8,045,642
XXXXXXXX
max. load
11 kg
Do not use the functions until you have fully read the Operating Instructions.
Do not dispose of used devices with domestic waste. Dispose of them according to safety rules.
WARNING!
Risk of burns from hot surfaces!
The protective plate for the wheels heats up during long periods of welding
operation. Touching the plate may cause burns.
-Do not touch the protective plate.
- Wear protective gloves and suitable safety goggles or a protective
helmet.
10
Scope of supply
(1)(2)(3)
(4)
(5)
ArcRover 22 scope of supply
(1)Connecting cable to power source
(2)ArcRover 22 carriage
(3)Universal welding torch holder
(4)Hosepack holder
(5)Guide rails
(6)Allen keys: 2 / 2.5 / 3 / 4
(7)Rechargeable battery pack
25.4 V / 3.35 Ah
(8)Charger
(7)(8)
(6)
11
Carriage components
ArcRover 22
conguration
with oscillation
unit
Handle
Rechargeable
battery pack
25.4 V / 3.35 Ah
Vertical welding
torch adjustment
unit
Hosepack holder
Oscillation unit
FOU 30/ ML6
Horizontal
welding torch
adjustment unit
On-board
control unit
Chassis with
4-wheel drive
Control lever for
permanent magnet
ArcRover 22 carriage with oscillation unit
Universal
welding torch
holder
Guide rails
with rollers
Lashing point for
securing the carriage
Limit switch
12
ArcRover 22
conguration
without oscillation unit
Handle
Rechargeable
battery pack
25.4 V / 3.35 Ah
Vertical welding
torch adjustment
unit
Hosepack holder
Horizontal
welding torch
adjustment unit
On-board
control unit
Chassis with
4-wheel drive
Control lever for
permanent magnet
ArcRover 22 carriage without oscillation unit
Universal
welding torch
holder
Lashing point
for securing the
carriage
Guide rails
with rollers
Limit switch
13
Accessories and options
Accessories
Article:Item number:Designation:
48,0005,2582Stainless steel drive wheel
(for workpieces with particularly rough surfaces).
IMPORTANT! Use of the carriage with the "stainless steel drive wheel" accessory is
only permitted in the PA welding position. Please seek advice with Fronius service personnel if using pre-heated workpieces.
48,0005,2583Brushes (2 pcs)
48,0005,2600Rechargeable battery pack
25.4 V / 6.8 Ah
48,0005,2601Charger
100-240 V 50/60 Hz /
29.4 V DC
48,0005,0165External power supply
230V AC / 24V DC
38,0100,0433Remote control cable 10 m
38,0100,0476Extension cable 10 m
4,100,711I-set external start signal
VR5000
(necessary for use with TransSteel;
installed in the wirefeeder)
14
Accessories
(continued)
Article:Item number:Designation:
4,100,779,IKOPT/i WF external start
signal
(necessary in combination
with TPSi; installed in the WF
wirefeeder)
48,0005,2578Tiltable lateral guide
48,0005,2577Lateral guide for edge
(2)
(3)(1)
48,0005,2579Magnetic lateral guide
(1) 48,0005,2580 Guide arm for rail 1850 mm
(2 pcs)
(2) 48,0005,1894 Flexible guide rail 1850 mm
(3) 48,0005,1895 Magnetic guide rail base
15
Accessories
(continued)
Article:Item number:Designation:
48,0005,2581Additional welding torch
holder (for 2nd torch)
Options
Article:Item number:Designation:
8,045,644Oscillation unit
FOU 30/ML6/radial
8,045,599Motor slide
FMS 100/ML15/SE/ACC
8,045,618Motor slide
FMS 50/ML15/SE/ACC
16
38,0100,0459Connection cable 0,8 m:
-FMS/ML15/SE/ACC
-FOU 30/ML6/radial
Control and display elements, connections
Carriage
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
Do not use the functions described here until you have fully read and understood the
following documents:
-These Operating Instructions
-All operating instructions for the system components
(7)
(1)
(6)
ArcRover 22 carriage
No. Function
(1) Front limit switch
(2) Control panel
-For the complete operation of the carriage.
-For conguring carriage parameters and creating programs.
(3) Permanent magnet control lever ON/OFF
For switching the permanent magnet on and o during vertical operation.
(4) Connecting plug for FOU 30, FMSS 50/100, Service
-For connecting the cable to the optional oscillation unit FOU 30.
-For connecting the cable to the optional motor slide FMS 50 or FMS 100. Mo-
tor slide corrects the position of the welding torch.
-Connection for diagnostic and service purposes.
(5) Not used.
(6) Connecting plug for analogue power source control
For connecting the cable to the power source (analogue arc ignition).
(7) Rear limit switch
(3)(2)(4)(5)
17
Carriage
(continued)
(11)
(8)
(9)
(10)
ArcRover 22 carriage
No. Function
(8)Compartment for rechargeable battery pack
(9)Connecting plug for rechargeable battery pack
-for plugging in the rechargeable battery pack (Li-Ion 25.4V / 3.35Ah)
-for connecting the connection cable of the control box during mains operation
(external power supply)
(10) Control unit ON/OFF toggle switch
For switching the carriage control unit on and o.
(11) Lock knob for locking the battery
18
Control panel
000
(1)
ArcRover
(6)
TEST
22
Slot 0
CAR
OSC
000
O
O
I
(4)(5)
ArcRover 22 control panel
No. Function
(1) Display
For conguring parameters and creating programs using the menu adjusting dial
(6). The digital display is illuminated.
(2) FMS-Oset adjusting dial
-For correcting the welding torch position when a FMS 50 or FMS 100 motor
slide is installed.
-For returning to the main menu.
(3) Travel speed adjusting dial
Used to adjust the travel speed of the carriage. The currently set travel speed is
shown on the display.
Setting range: 5 - 200 cm/min
(4) Toggle switch Start LEFT/ 0/RIGHT
For starting and stopping the automatic program sequence in the relevant welding direction.
(5) Welding toggle switch I/0/TEST
For choosing whether to carry out the automatic program sequence with or without welding.
I ... Welding on preselection
0 ... Welding o preselection
TEST ... Arc immediately active (arc test)
(6) Adjusting dial menu
-For menu navigation and parameter entry.
-Pressing 2 seconds: for returning to the main menu.
(2)
(3)
19
000
Main menu
(1)
Slot 0
(8)
(7)
No. Function
CAR
OSC
000
(4)(5)(6)
(4) Front limit switch active display
(5) Welding ON/OFF display
(6) Rear limit switch active display
(7) OSC menu
Opens the OSC menu for setting the parameters for the oscillation unit FOU 30.
(8) CAR menu
Opens the CAR menu for setting the carriage parameters.
A correction of the welding torch
position is currently being carried
out.
(3)Travel speed display
Displays the currently set travel
speed in cm/min.
20
Charger and
rechargeable
battery pack
(1)
(2)
(3)
(5)
(4)
(7)(7)
(6)
Overview of charging set
No. Function
(1) Fuse holder with glass-tube fuse
(2) LED1
Steady red light ... Mains on.
(3) LED2
-Steady red light ... Charging process active
-Steady green light ... Battery nished charging
(4) Charging cable with plug
(5) Mains connection with integrated glass-tube fuse
(6) Mains cable
(7) Housing screws (Allen screws)
For guiding the rechargeable battery pack into the compartment.
(8) Connecting plug for charging lead
(8)
21
Menu navigation and parameter entry
Slot 0
CAR
45%
45%
000
GeneralGeneral rules for entering parameters:
-Do not enter numbers; values must be entered using the relevant adjusting dial
-Changed parameters become active after the adjusting dial has been pressed, however they will not yet have been saved
Turning/pressing
the adjusting dial
Turn the adjusting dial to:
- Turning right highlights the next element (menu or parameter).
- Turning left highlights the previous element (menu or parameter).
To change values:
- Turning right increases the value to be set.
- Turning left decreases the value to be set.
Press the adjusting dial once:
OSC
Press the adjusting dial for 2 seconds,
Press the FMS-Oset adjusting dial once:
Slot 0
CAR
OSC
000
-Opens the highlighted menu (white frame)
-Activates parameter entry
-Deactivates parameter entry
-Return to main menu
22
000
Carriage parameters
CAR menu
Slot 0
CAR
OSC
000
ParameterFunction
Travel Speed
Denes the traversing speed of the carriage in cm/min.
Unit: cm/min
Setting range: 5 to 200 cm/min
40cm/min
Total Path
The total path for welding. Once this distance has been reached,
the program will stop automatically.
Unit: cm
Setting range: 0 to 9999 cm
Menu entry:
1. Turn menu adjusting dial and highlight the CAR
menu (white frame).
2. Press the menu adjusting dial once.
0cm
0cm
0cm
0.0s
Segment Width
Denes the length of the segments to be welded.
Unit: cm
Setting range: 0 to 99.9 cm
Segment Gap
Denes the length of the segments not to be welded.
Unit: cm
Setting range: 0 to 99.9 cm
Start Delay / Flying Start
Unit: s
-Setting range: 0 to +5 s ... Start Delay:
Denes the time between ignition of the arc and commencement of carriage movement.
-Setting range: 0 to -5 s ... Flying Start:
Denes the time between commencement of carriage movement and ignition of the arc.
23
000
CAR menu
(continued)
ParameterFunction
Back Filling
Denes for how long the torch should weld backwards at the end
of the weld.
Setting range: 0 to 5 s / ON / OFF
0.0s
End Crater Filling
Length of time that the carriage pauses at the end of the weld
seam to ll the end-crater. Value must be the same or higher
than the entered value on the power source (nal current duration).
Setting range: 0 to 5 s
0.0s
Change direction / Stop
-ON ... Once the limit switch has been reached, the carriage
reverses and runs to the other limit switch.
-OFF ... Once the limit switch has been reached, the carriage
stops
O
OSC menu
Slot 0
CAR
OSC
000
ParameterFunction
50%
Menu entry:
1. Turn menu adjusting dial and highlight the OSC
menu (white frame).
2. Press the menu adjusting dial once.
Oscillation Speed
Traversing speed for oscillation in %.
Setting range: 5 to 100%
Oscillation Path
Denes the distance between left and right reversal points of the
oscillation motion.
Setting range: 5 to 100%
30%
24
OSC menu
(continued)
ParameterFunction
Dwell time Left
Oscillation dwell time in the left-hand limit position.
Setting range: 0.0 to 3 s
1,5s
Dwell time Middle
Oscillation dwell time in the middle position.
Setting range: 0.0 to 3 s
1.5s
Dwell time Right
Oscillation dwell time in the right-hand limit position.
Setting range: 0.0 to 3 s
1.5s
Triangle
Oscillation Mode
No oscillation
Trapezoidal oscillation
Triangular oscillation
Rectangular oscillation
25
Welding position and weld seam tracking
Possible welding
positions
The 4-wheel drive and built-in permanent magnet ensure that the carriage adheres to the
workpiece and guarantee the best possible traction. The following welding positions are
possible:
SlopingHorizontal
NOTE!
From an angle of 45° upwards, the carriage must be secured by a load securing device
with a locking function to prevent it from falling.
Vertical
IMPORTANT! In vertical operation, the carriage must be secured by a load securing
device with a locking function to prevent it from falling. The load securing device must be
designed for the total weight of the carriage. The manufacturer accepts no liability for any
damage to persons or property resulting from vertical use of the carriage without a load
securing device.
NOTE!
When used on the “outside of a container”, the container must be turned in the opposite direction and at the same speed.
26
Outside of container with minimum diameter of
1500 mm
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