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FDV 15 MF
Operating Instructions
EN
Carriage
42,0410,1653 V07 - 04072016
Contents
General ............................................................................................................................................................ 3
Principle......................................................................................................................................................3
Machine concept ........................................................................................................................................ 3
Field of application ..................................................................................................................................... 3
Proper use .................................................................................................................................................. 3
Improper use .............................................................................................................................................. 4
Conversions or modications ..................................................................................................................... 4
Operating instructions ................................................................................................................................ 4
Instructions ................................................................................................................................................. 4
Warning notices on the driving vehicle ....................................................................................................... 5
Scope of supply .......................................................................................................................................... 6
Options ....................................................................................................................................................... 7
Driving vehicle components ............................................................................................................................ 9
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
Dene 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
FDV 15 MF ...................................................................................................................................................... 4
EU-Declaration of conformity .......................................................................................................................... 5
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
modications
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 modication of the equipment, any
liability or warranty from the manufacturer is invalidated.
The electromagnetic characteristics of the equipment can be adversely aected by any
kind of addition or modication. No modications 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 eciently 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 axed 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
Possible
welding
positions
(continued)
Inside of container with minimum diameter of 2500 mm
NOTE! When used inside a container, the container must be turned in the opposite direction and at the same speed.
Guidance of the
driving vehicle
IMPORTANT! Use of the driving vehicle in the "PE" overhead position is prohibited.
The guide wheels automatically track the torch in the lled joint. They can be positioned
on either side of the driving vehicle. For detailed information about the correct setting of
the guide wheels, see the section "Preparing the driving vehicle". The guide wheels can
be set to the following positions:
Guidance on outside vertical surfaceGuidance on inside vertical surface
13
Guidance of the
driving vehicle
(continued)
Guidance on outside vertical surfaceGuidance on angle piece (vertical) or rail
Guidance on outside of curve with minimum diameter
of 5000 mm
Guidance on angle piece (horizontal) or rail
Guidance on inside of curve with minimum diameter
of 5000 mm
NOTE! When guided on a hori-
zontal angle piece, the welding
torch must only be placed on the
upper side.
14
Guidance of the
driving vehicle
with optional
lateral guides
Lateral guide, tiltable
Lateral guide for edge
Lateral guide, standard / with magnet
Lateral guide with exible guide rail
- Lateral guide for exible rail (2 pc.) (1850 mm / 72.84 in)
- Magnet block for guiding rail
- Guiding for exible rail (1850 mm / 72.84 in)
IMPORTANT! 10 magnet blocks per rail are necessary!
15
Preparing the driving vehicle
Fitting
the guide rails
FDV-15 MF driving vehicle
1. Use M5 x 14 allen screws and a 5.5 shim to attach the guide rails to the driving
vehicle.
2. Tighten the screws using a size 5 allen key. See „Adjusting the guide wheels“ for
information on how to set the guide wheels.
16
Fitting the
brushes (option)
(a)
(a)
(b)
FDV-15 MF driving vehicle with brushes
NOTE! The brush may be tted to either the front or rear of the driving vehicle.
1. Remove the M5 x 14 (a) screws using a size 5 allen key.
2. Attach the brush brackets as shown.
3. Fit and tighten the M5 x 14 screws (a) and the shims.
4. Fit the brush to the front or rear brush bracket using M6 screws (b).
17
Fitting the lateral
guides
(Option)
All lateral guides for the FDV 15 carriage are fastened with the M5 x 14 xing screws
with washer.
The lateral guides are mounted on both front sides of the carriage.
Tighten the xing screws with a size 5 allen key.
Lateral guide, tiltable
Lateral guide for edge
Lateral guide, magnetic
18
Fitting lateral
guides with
exible guide rail
(Option)
The lateral guides, which are used with guide rail, are xed with the M5 x 14 xing
screws with washers.
Tighten the screws with the 5 mm allen key.
The exible guide rail is xed with magnet blocks. 10 magnet blocks are necessary for
one rail (1850 mm / 72.84 in), to ensure a secure t.
The rails can be mounted on the magnetic blocks in the following way:
- by forming a butt joint
- by forming a lap joint
Mount the rails with the delivered M5x16 xing screws and a size 3 allen key.
M5x16
Butt joint Lap joint
Holding force of one magnet block, placed on a 5mm (0.2“)
thick ferromagnetic surface:
- up to a temperature of 100°C (212 °F): 90 N
- above a temperature of 180°C (356°F): 54 N
19
Connecting the
charger to the
mains supply
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.
110 / 120 V mains supply:
1. Plug the AC-AC voltage transformer
(a) into the 110 / 120 V socket.
2. Plug the charger into the AC-AC voltage transformer output (b).
The YELLOW signal lamp lights up.
(a)
Charge the
battery pack
(b)
AC-AC voltage transformer
230 V mains supply:
Plug the charger into the 230 V socket. The YELLOW signal lamp lights up.
IMPORTANT! The mains voltage and frequency must be as indicated on the rating plate.
1. Insert the battery pack with the ridge
in the lower recess (a) of the charger
docking station.
IMPORTANT! The charging time for
the battery pack is 45 minutes. If a
warm NiMH battery pack (> 37°C) is
used, charging takes place at a reduced charging current. In this case
the charging time for the battery pack
at 3.0 Ah is approx. 100 minutes.
(a)
Place battery pack in charger docking station
20
Charge the
battery pack
(continued)
Lock the battery pack in place
(b)
(c)
2. Push the battery pack into the charger
docking station until it engages with
the retainer (b) in the upper recess.
The battery pack charges up. The
signal lamp ashes 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 the battery has nished charging, press the battery release button
(c) and remove the battery pack from
the charger.
Insert battery
pack in driving
vehicle docking
station
(a)
Place battery pack in driving vehicle docking station
(d)
(b)
1. Insert the battery pack with the ridge
in the lower recess (a) of the driving
vehicle docking station.
2. Push the battery pack into the driving
vehicle docking station until it engages
with the retainer (b) in the upper recess.
3. To release, press the battery release
button (d) and remove the battery pack
from the driving vehicle.
Lock the battery pack in place
21
Adjusting the
guide wheels
5 - 10 mm
(b)
(b)
(a)
Adjusting the guide wheels
(a)
Direction of travel
1. Undo the fastening screws (a)
2. Extend the guide wheels (b) to the desired length. To ensure that the driving vehicle
keeps to the chosen direction, the extended guide wheels must be extended by at
least 5 - 10 mm (see diagram).
3. Tighten the fastening screws (a)
Check the surface of the workpiece and the
driving vehicle to
ensure they are
clean
Placing the
driving vehicle
Before positioning the driving vehicle, check the following:
- The surface of the workpiece must be clean (no sand, swarf etc.)
- The bottom plate of the driving vehicle must be free of objects which can be attracted
by the magnet
- The rubber elements of the drive wheels must be undamaged and free of swarf
- The guide wheels must be clean, undamaged and free of welding spatter
WARNING! Risk of injury due to permanent magnet
There is a danger of injury to the ngers when positioning the driving vehicle.
Only hold the driving vehicle by the handle and not by the bottom plate.
1. Place the driving vehicle on the workpiece. Adjust the side guide wheels to
the workpiece (a).
2. If necessary, correct the position of the
(a)
guide wheels
(a)
Placing the driving vehicle
22
Attach fall
protection
(vertical
operation)
IMPORTANT! In vertical operation, the driving vehicle must be secured by a load secur-
ing 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.
1. Attach the snap hook of the load
securing device to the securing ring of
the driving vehicle
NOTE! Do not stand beneath a
suspended driving vehicle.
Attach load securing device
2. Make sure the cable is kept permanently taut
Mounting and
adjusting the
welding torch
Check the cable
(c)
(b)
(d)
(a)
1. Undo the fastening screw (a) on the
torch holder
2. Insert the welding torch and tighten the
fastening screw (a)
3. Adjust the torch angle:
- Loosen the fastening screw (b)
with an Allen key
- Turn the clamp block and
set the desired angle
- Tighten the fastening screw (b)
4. Turn the adjusting wheel on the
relevant mechanical adjustment unit
(c), (d) until the correct welding torch
position is reached.
Fitting the welding torch
23
Driving vehicle
strain relief
To attain optimum wirefeed, observe the following 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 oor), use balancers
and hose pack holders (e.g. Universal hose pack holder)
Hose pack handling
Fixing the hose pack
(a)
Fix the hose pack as illustrated.
IMPORTANT! Make sure the hose pack
does not become kinked - this can lead to
wire feed problems.
IMPORTANT! Please note the
maximum tension load on the
hosepack holder (see chapter
„Technical Data“). This must not
be exceeded.
24
Start-up
Check the
connections
Switch on
system components
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
The following activities and work steps apply to the installed system. All connections
must be established. Before start-up, check the connections of the following system com-
ponents:
- Power source
- Cooling circuit
- Gas cylinder
- Wire-feed unit
- Welding torch with hosepack
- Workpiece
Precise information on the assembly and connection of the system components can be
found in the relevant system component operating instructions.
IMPORTANT! There are no xed rules for the sequence in which the system 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 unit (if power is not supplied from the power source)
Dene driving
vehicle parameters
Loading a welding program
Carry out the following settings for the welding process:
- Traversing speed
IMPORTANT! For each workpiece a corresponding welding program must be created.
This contains a list of welding parameters that is saved under a specic program number
(job number). These programs can be reloaded at any time, and corrected as required.
The programs are managed from the power source control panel. When an analogue
power source is used, the requisite welding parameters must be set manually on the
power source.
Load the relevant welding program on the control panel for the power source. More detailed information on managing welding programs can be found in the operating instructions for the power source.
25
Carry out
test run
process
Perform a test run to check that all system components work together correctly. This is
done without an arc and thus allows you to check all movements during the process:
1. Set the "Start LEFT / STOP / Start RIGHT" toggle switch to the desired direction - The test run starts. To stop the process early, turn the
switch to the "STOP" (0) position.
IMPORTANT! Never leave the machine unattended, particularly when
it is moving automatically.
2. Carry out a visual check during the test run
3. Make any necessary corrections (welding torch position, direction of
travel, traversing speed, etc.)
Start the welding process:Start the welding
1. Set the "Start LEFT / STOP / Start RIGHT" toggle switch to the desired
direction - the welding process starts. To stop the process early, turn
the switch to the "STOP" (0) position.
IMPORTANT! Never leave the machine unattended, particularly when
it is moving automatically.
2. Press the torch trigger to start the welding process
26
Troubleshooting
General
Basic requirements for the
system to work
Driving vehicle
In the event of faults, note that the functioning of the entire system depends on many
additional components (power source, wire-feed unit, etc.) that are also potential sources
of problems.
- Connections established between separate system components
- System components are supplied with electricity and the mains voltage for each
component complies with the rating plate
"Control unit ON" signal lamp ashes
Cause: Battery warning - the battery pack is nearly at.
Remedy: Charge up the battery pack with charger FDV MF.
Drive wheels slip during travel
Cause: Wheels dirty (with oil)
Remedy: Clean the wheels
Cause: Vehicle overloaded (e.g. the torch cables pull the vehicle up from the oor)
Remedy: Relieve cable strain (suspend)
Cause: Insucient magnetic force: Sheet too thin - must be at least 4 mm thick)
Insucient magnetic force: Too big a gap (s < 6 mm) - vehicle raised from
the ground by an obstacle or unevenness
Remedy: Change the welding conditions
Cause: Magnet not eective (overheated - working temperature > 150°C)
Remedy: Change magnet.
Play at the torch
Cause: Play at the handles.
Remedy: Tighten handles.
Cause: Play at the guide rails.
Remedy: Tighten the pressure screws.
"Control unit ON" signal lamp does not light up
Cause: The "Control unit ON/OFF" toggle switch is in the "OFF" position.
Remedy: Turn the "Control unit ON/OFF" toggle switch to the "ON" position.
Cause: Battery pack discharged.
Remedy: Charge up the battery pack with charger FDV MF.
Cause: Electronic module - no power.
Remedy: Check the connections between the driving vehicle battery docking station
and the electronic module.
Cause: Electronic module damaged.
Remedy: Change the electronic module.
27
Driving vehicle
(continued)
"Control unit ON" signal lamp is lit but machine does not work
Cause: "Start LEFT / STOP / Start RIGHT" toggle switch is in the "STOP" position.
Remedy: Turn the toggle switch to the required direction.
Cause: Traversing 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.
28
Maintenance and care
Personnel
Maintenance
record
Maintenance operations and
intervals
WARNING! Risk of injury and damage from incorrectly performed maintenance.
All maintenance on the FDV 15 MF driving vehicle must only be carried out by
trained technicians. It is essential to adhere
to the maintenance intervals and maintenance procedures. The manufacturer
accepts no liability for any damage caused by inadequate or poorly performed
maintenance.
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, maintenance
activities carried out)
NOTE! Remove the battery pack before carrying out any maintenance operations.
Item Component Action Interval
Linear guides Clean, check oil lm M
A
Eliminate play: Tighten pressure screws
with Allen key
B
Threaded spindle Clean, grease M
C
--- --- ---
Drive belt Pretension, check for tears M
D
Rollers and rails Clean, check position M
E
F
--- --- ---
--- --- ---
G
H
--- --- ---
Ventilation openings Clean W
I
J
Terminal contacts Clean W
Wheels, underbody, Clean D
K
guide rails
Recommended
lubricants
D ..... Daily
W ......Weekly
M ..... Monthly
1/2Y.....Half-yearly
Y ..... Yearly
IMPORTANT! Lubricants with solid lubricant additives (e.g. MoS2, graphite and PTFE)
are not suitable for guiding systems.
Lubricant DIN DIN number Comment
Lubricating grease KP 2-K 51502 / 51825 Lithium-based grease
Lubricating oil CLP32-100 51517 Part 3 ISO VG 32-100
Conductive paste --- --- Item number:
48,0009,0157
29
Driving vehicle
components
B
B
E
K
K
K
K
A
A
K
K
E
30
K
E
FDV-MF charger These devices are largely maintenance-free. To ensure problem-free operation, observe
the following instructions:
J
I
- Keep the ventilation openings (I) clean
to ensure that cooling air is able to
circulate.
- Risk of short-circuit: - make sure that
no metal objects such as metal chips
get into the charger or into the battery
holder, or penetrate the interior of the
device through the ventilation openings.
J
Charger FDV MF with battery pack
Battery pack
- The charger and the battery pack are designed for each other. Therefore you should
only ever use the supplied charger FDV MF to charge the battery pack.
- Storing the battery pack in the live charger keeps the battery pack in the charged
state by means of a permanent conservation charge.
- Do not leave at battery packs in the charger for longer than 1 month if the charger is
unplugged from the mains, in view of the risk of exhaustive discharge.
- A new battery pack or one that has not been used for a long time only reaches its full
capacity after about 5 charging and discharge cycles.
- If possible, drain the battery pack completely before recharging. Starting the charging
process repeatedly with a charged battery reduces its service life.
- Avoid prolonged warming of the battery pack by sunlight or radiators -
temperatures above 45°C reduce service life and increase self-discharge.
Special notes on NiMH battery packs:
- The performance of NiMH battery packs is considerably reduced in ambient tempe-
ratures outside a range of 0° C to 45° C.
- Do not overload the driving vehicle (do not place the vehicle under so much strain
that it comes to a complete stop).
- To maintain their full capacity, NiMH battery packs must be recharged every four
months, even if they have not been used.
- After every 10th charging process, NiMH battery packs should remain in the char-
ger for an extra hour after the quick-charge process has been completed in order to
equalise any capacity discrepancies across the cells.
- Owing to their self-discharging properties, store NiMH battery packs at ambient tem-
peratures of between 0° C and 25° C.
Disposal of components
WARNING!
Danger of environmental damage
Incorrect disassembly and disposal of the separate driving vehicle components
can result in serious environmental damage.
The product must only be disposed of by trained and qualied 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 Customer
Service or at ocially-authorised disposal sites. The battery packs are then recycled.
NOTE! If you have any further questions about disposal / recycling please address them to the manufacturer.
31
Technical data
FDV 15 MF
IMPORTANT! Standard version of FDV 15 MF carriage is not suitable for preheated
workpieces from 50°C (122°F)!
Driving vehicle supply voltage 14.4V / 3Ah (battery pack)
Max. load 15 kg
Pulling force (horizontal/vertical) 150 N / 100 N
Welding position PA, PB, PC, PF, PG
Minimum thickness of material 4 mm
Gap 4 mm
Travel speed horizontal (load = 50 N) 0 - 150 cm/min (+/- 6%)
Travel speed vertical (load = 50 N) 0-130 cm/min (+/- 6%)
Torch holder diameter 16 - 22 mm
Adjustable range of torch (horizontal/vertical) 28 mm / 28 mm
Adjustable range of guide wheels 72 mm
Net weight (without battery) 5,5 kg
Maximum tension load on hosepack holder:
80 mm
50 mm
FDV MF charger
+ battery pack
AC-AC-voltage
transformer
50 mm
80 mm
Charger supply voltage 230V AC
Battery charging time 45 min
Min. battery capacity 4 h
Input voltage 110-120 V AC
Output voltage 230 V AC
Mains frequency 50 - 60 Hz
Max. output power 100 W
32
FDV 15 MF
dimensions
F
G H
E
B
C
I
A
D
A 220 mm
B 220 - 248 mm
C 208 - 280 mm
D 28,5 mm
E 24 mm
F 228 - 256 mm
G 29 mm
H 24 mm
I 16 mm
33
34
Spare parts list,
GB
circuit diagram
FDV-15 MF
1
2
Carriage FDV 15 MF 8,045,369
1
Carriage FDV 15 MF 8,045,369
48,0005,1207
48,0005,1691
2
Lateral guides
(1) Lateral guide, tiltable (2 pc.)
Art. Nr. 48,0005,1889
1
(2) Lateral guide for edge (2 pc.)
Art. Nr. 48,0005,1887
2
(3) Lateral guide, magnetic (2 pc.)
Art. Nr. 48,0005,1891
3
Lateral guide with guide rail:
(4) Guide arm for exible guide rail
1850 mm / 72.84 in (2 pc.)
Art. Nr. 48,0005,1896
(5) Flexible guide rail, 1850 mm / 72.84 in
Art. Nr. 48,0005,1894
5
(6) Magnet block for guide rail
Art. Nr. 48,0005,1895
IMPORTANT! 10 magnet blocks per rail are necessary!
4
6
3
FDV 15 MF
4
EU-Declaration of conformity
5
FRONIUS INTERNATIONAL GMBH
TechSupport Automation
www.fronius.com
www.fronius.com/addresses
6
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