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FDV 15MF

Fronius FDV 15MF Operating Instruction [EN]

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FDV 15 MF
Operating Instructions
EN
Carriage
42,0410,1653 V07 - 04072016
Contents
Principle......................................................................................................................................................3
Machine concept ........................................................................................................................................ 3
Field of application ..................................................................................................................................... 3
Proper use .................................................................................................................................................. 3
Improper use .............................................................................................................................................. 4
Conversions or modications ..................................................................................................................... 4
Operating instructions ................................................................................................................................ 4
Instructions ................................................................................................................................................. 4
Warning notices on the driving vehicle ....................................................................................................... 5
Scope of supply .......................................................................................................................................... 6
Options ....................................................................................................................................................... 7
FDV 15 MF ................................................................................................................................................. 9
Control elements and connections ................................................................................................................ 10
Driving vehicle control panel .................................................................................................................... 10
AC-ACvoltage transformer ....................................................................................................................... 10
Charger and battery pack ......................................................................................................................... 11
Welding position and seam tracking ..............................................................................................................12
Possible welding positions ....................................................................................................................... 12
Guidance of the driving vehicle ................................................................................................................ 13
Guidance of the driving vehicle with optional lateral guides ..................................................................... 15
Preparing the driving vehicle ......................................................................................................................... 16
Fitting the guide rails ................................................................................................................................ 16
Fitting the brushes (option) ...................................................................................................................... 17
Fitting the lateral guides (Option) ............................................................................................................. 18
Fitting lateral guides with exible guide rail (Option) ................................................................................ 19
Connecting the charger to the mains supply ............................................................................................ 20
Charge the battery pack ........................................................................................................................... 20
Insert battery pack in driving vehicle docking station ............................................................................... 21
Adjusting the guide wheels ...................................................................................................................... 22
Check the surface of the workpiece and the driving vehicle to ensure they are clean ............................. 22
Placing the driving vehicle ........................................................................................................................ 22
Attach fall protection (vertical operation) .................................................................................................. 23
Mounting and adjusting the welding torch ................................................................................................ 23
Driving vehicle strain relief ....................................................................................................................... 24
Start-up .......................................................................................................................................................... 25
Check the connections ............................................................................................................................. 25
Switch on system components ................................................................................................................. 25
Dene driving vehicle parameters ............................................................................................................ 25
Loading a welding program ...................................................................................................................... 25
Carry out test run......................................................................................................................................26
Start the welding process ......................................................................................................................... 26
Troubleshooting ............................................................................................................................................. 27
General.....................................................................................................................................................27
Basic requirements for the system to work .............................................................................................. 27
Driving vehicle .......................................................................................................................................... 27
1
Maintenance and care ................................................................................................................................... 29
Personnel ................................................................................................................................................. 29
Maintenance record ................................................................................................................................. 29
Maintenance operations and intervals ..................................................................................................... 29
Recommended lubricants ........................................................................................................................ 29
Driving vehiclecomponents ...................................................................................................................... 30
FDV-MF charger ....................................................................................................................................... 31
Battery pack ............................................................................................................................................. 31
Disposal of components ........................................................................................................................... 31
Technical data ...............................................................................................................................................32
FDV 15 MF ............................................................................................................................................... 32
FDV MF charger + battery pack ............................................................................................................... 32
AC-AC-voltage transformer ...................................................................................................................... 32
FDV 15 MF dimensions ............................................................................................................................ 33
2
General
Principle Driving vehicle FDV 15 MF is a portable, battery-powered longitudinal truck with 4-wheel
drive. The driving vehicle is used to execute mechanised butt and llet welds in horizon­tal or vertical welding positions.
Machine concept
Field of applica­tion
Driving vehicle FDV 15 MF has been for
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 and robust yet lightweight design allow quick and easy positioning on the workpiece. The driving vehicle adheres to the com­ponent by means of a permanent magnet. This guarantees the best possible traction even in vertical use. The guide wheels automatically track the torch in the lled joint. The universal torch holder allows use of
Driving vehicle FDV 15 MF
Driving vehicle FDV 15 MF can be used in all situations where a high degree of exibility is required when executing longitudinal weld seams:
- Welding of longitudinal members
- Shipyards
- Bridge construction
- Workshops
- Production halls
- Building sites
both manual and machine welding torches. The driving vehicle is powered by the inter­changeable battery pack. The control unit is integrated into the driving vehicle.
Proper use
Driving vehicle FDV 15 MF must only be used for performing mechanised butt and llet welds in horizontal or vertical welding positions. Any other use shall be deemed to be im-
proper use and the manufacturer will assume no responsibility for any damages arising.
The following welding processes are possible:
- MIG/MAG process
Proper use also includes:
- use of the charger FDV MF and battery pack (14.4V / 3 Ah) included with the driving vehicle
- use of the permanent magnet with a minimum sheet thickness of 4 mm
- use of MIG / MAG welding torches with a holder diameter of 16 - 22 mm
- use with the „Drive wheel stainless steel“ option in PA welding position
- carrying out all maintenance work at the appropriate intervals
- keeping a service book with the most important data (date, operator, activities carried out)
- using the spare parts stipulated by Fronius
3
Proper use
(continued)
- following all the information in the operating instructions
- using this document in conjunction with the operating
instructions of the integrated system components (power source, wire-feed unit, etc.)
Improper use
Conversions or
modications
Operating instructions
Any use of the machine other than for its intended purpose shall be deemed improper
use. This includes:
- using on preheated workpieces > 50 ° C
- Transporting people
- Standing on the machine or using it as a work platform
- As a storage surface for tools
- Use outside the permitted technical operating limits
- Use in hazardous areas
If the user carries out any unauthorised conversion or modication of the equipment, any
liability or warranty from the manufacturer is invalidated.
The electromagnetic characteristics of the equipment can be adversely a󰀨ected by any kind of addition or modication. No modications or upgrades to the equipment should therefore be undertaken without rst consulting the manufacturers and receiving written
approval.
The operating instructions help you to use the carriage e󰀩ciently and must be accessible
at all times.
- Keep the operating instructions near the corresponding parts of the carriage at 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 able to help you if you can get to them when there is a problem!
IMPORTANT! The manufacturer shall not be liable for any damage that arises from failu­re to observe the operating instructions.
Instructions The system operator must, before they start, tell all people working on the carriage
about:
- the theoretical and practical aspects of operating the system
- the safety regulations applicable to the system.
IMPORTANT! This obligation applies in particular to persons who only work occasionally on the carriage.
4
Warning notices
Type:
Ser.No.:
Art.No.:
A-4600 Wels
www.fronius.com
U weight max. load
14,4 VDC 5 kg 15 kg
2009
FDV 15/MF
8,045,369
20 25 9502
on the driving vehicle
A number of safety symbols can be seen on the rating plate a󰀩xed to the driving vehicle. The safety symbols must NOT be removed or painted over.
Do not use the functions until you have fully read all the operating instructions.
Do not dispose of used chargers with domestic waste. Dispose of them according to
safety rules.
Rating plate FDV 15 MF
WARNING! Risk of burns from hot surfaces.
The protective plate covering the battery pack heats up over
extended periods of welding. Touching the plate may cause burns.
- Do not touch the protective plate.
- Wear protective gloves and suitable safety goggles or a protec­tive helmet.
5
Scope of supply
(3)
(1) (2)
(4)
(5)
(7)
FDV 15 MF scope of supply
(1) Driving vehicle FDV -15 MF (2) Rear guide rail (3) Front guide rail (4) Universal torch holder
(6)
(5) Allen keys 5 / 4 / 3 / 2 (6) Battery pack 14.4 V / 3 Ah (7) Charger FDV MF
6
Options
The optional equipment of the driving vehicle comprises:
- AC-AC voltage transformer (38,0006,0164)
- Driving vehicle brush (48,0005,1424) This accessory comprises two parts.
Brush bracket and 1x brush.
For workpieces with very rough surface:
- Stainless steel drive wheel (48,0005,1602), article number inclu­des 1 pc. stainless steel wheel.
IMPORTANT! Using the „Stain­less steel drive wheel“ option is permitted only in PA welding position.
7
Options
(continued)
Lateral guides:
(1) Lateral guide, tiltable
(48,0005,1889)
1
(2) Lateral guide for edge
(48,0005,1887)
2
(3) Lateral guide, magnetic
(48,0005,1891)
3
Lateral guide with guide rail:
(4) Guiding arm for exible rail,
1850 mm / 72.84 in (2 pc.) (48,0005,1896)
(5) Flexible guide rail,
1850 mm / 72.84 in (48,0005,1894)
5
(6) Magnet block for guide rail
(48,0005,1895)
IMPORTANT! 10 magnet blocks for one rail are necessary!
4
6
8
Driving vehicle components
FDV 15 MF
On-board control unit
Horizontal torch
adjustment unit
Battery pack
(14.4V / 3Ah)
Handle
Vertical torch
adjustment unit
Universal torch
holder
Guide wheels
Truck with
4-wheel drive
Driving vehicle FDV 15 MF
Lifting eye for securing the
driving vehicle
9
SPEED
2
Control elements and connections
Driving vehicle control panel
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read
and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
(4)
(3)
Driving vehicle FDV 15 MF control panel
(1)
(2)
No. Function (1) Traverse speed potentiometer
Used to adjust the traversing speed of
the driving vehicle.
Setting range: 5 - 150 cm/min
(2) Control unit ON/OFF toggle switch
For switching the driving vehicle con-
trol unit on and o󰀨.
(3) Control unit ON signal lamp
Permanently lit: Control unit ready for
use Flashing: Battery pack is nearly at
(4) Toggle switch Start LEFT / STOP / Start RIGHT
For starting and stopping the automa-
tic program sequence.
AC-ACvoltage transformer
The voltage transformer allows the charger to be operated using 110 V and 120 V mains supplies. A transformed voltage of 230 V is provided at the output of the AC-AC voltage transformer for the FDV MF charger.
No. Function
(1) 110 / 120 V AC mains plug
For connection to the 110 / 120 V AC mains supply.
(2) 230 V AC output
For connection to the FDV MF charger.
(1)
(2)
AC-AC voltage transformer
10
Charger and
i C
d
+
battery pack
CAUTION! The charger may be damaged if the wrong supply voltage is used.
The FDV MF charger is designed for a supply voltage of 230 V. Directly con­necting the charger to a 110 / 120 V mains supply can cause serious material damage.
- Ensure that the charger is always operated using the correct supply vol­tage.
- Always use the AC-AC voltage transformer when operating the charger on a 110/120 V mains supply.
(1)
(7)
(6)
(5)
Overview of charging set
No. Function (1) Signal lamp YELLOW
Permanently lit: Charger is ready for use
(2) Signal lamp GREEN
Flashing: Battery pack is charging Permanently lit: Battery pack is charged, under conservation charge
(3) Signal lamp RED
Flashing - general error warning: incomplete contact,
short-circuit, battery pack faulty;
Permanently lit: battery temperature outside permitted limits (5° - 45° C)
(4) Mains cable
For connection to the mains supply (230 - 240V).
(5) Charger docking station lower recess
For inserting the battery pack.
(6) Charger docking station upper recess
For locking the battery pack.
(7) Battery release button
For releasing the battery pack.
(2)
(3)
(4)
11
Welding position and seam tracking
Possible welding positions
The 4-wheel drive and built-in permanent magnet ensure that the driving vehicle adheres optimally to the workpiece and guarantee the best possible traction. The following weld­ing positions are possible. IMPORTANT! In vertical operation, the driving vehicle 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 vehicle. The manufacturer accepts no liability for any damage to persons or property resulting from vertical use of the driving vehicle with­out a load securing device.
SlopingHorizontal
NOTE! From an angle of 45° upwards, the driving vehicle must be secured by a load securing device with a locking function to prevent it from falling.
Vertical
Outside of container with minimum diameter of
1500 mm
NOTE! When used on the outside of a container, the container must be turned in the opposite direction and at the same speed.
12
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