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FDV-22 MF

Fronius FDV-22 MF Operating Instruction [EN]

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FDV 22 MF
Operating Instructions
EN
Carriage
42,0410,1645 V09 - 03082016
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
Driving vehicle components .......................................................................................................................... 10
Conguration FDV 22 MF with oscillation unit ........................................................................................ 10
Conguration FDV 22 MF without oscillation unit ................................................................................... 10
Controls, connections and add-ons ............................................................................................................... 11
Driving vehicle control panel .................................................................................................................... 11
“Con” display ............................................................................................................................................ 12
“InF” display..............................................................................................................................................12
Total path active display ........................................................................................................................... 12
Display during program sequence ........................................................................................................... 12
“Bat” display ............................................................................................................................................. 12
“End“ display ............................................................................................................................................ 12
Control panel oscillation unit option ......................................................................................................... 13
Charger and battery pack ......................................................................................................................... 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 handle ...................................................................................................................................... 21
Fitting the guide rails ................................................................................................................................ 21
Fitting the brushes (option) ...................................................................................................................... 22
Fitting lateral guides (Option) ................................................................................................................... 23
Fitting lateral guides with exible rail (Option) .......................................................................................... 24
Fitting the additional torch holder (Option) ............................................................................................... 25
Connecting the charger to the mains supply ............................................................................................ 26
Charge the battery pack ........................................................................................................................... 26
Insert battery pack in driving vehicle docking station ............................................................................... 27
Adjusting the guide wheels ...................................................................................................................... 28
Check the surface of the workpiece and the driving vehicle to ensure they are clean ............................. 28
Position the driving vehicle and activate the permanent magnet ............................................................. 28
Attach fall protection (vertical operation) .................................................................................................. 29
Mounting and adjusting the welding torch ................................................................................................ 29
Driving vehicle strain relief ....................................................................................................................... 30
1
Start-up .......................................................................................................................................................... 31
Check the connections ............................................................................................................................. 31
Switch on system components ................................................................................................................. 31
Dene driving vehicle parameters ............................................................................................................ 31
Loading a welding program ...................................................................................................................... 32
Carry out test run......................................................................................................................................32
Start the welding process ......................................................................................................................... 32
Setting the driving vehicle parameters .......................................................................................................... 33
Continuous welding .................................................................................................................................. 33
Interval welding ........................................................................................................................................ 35
Path welding ............................................................................................................................................. 38
Oscillation option ........................................................................................................................................... 40
Setting the oscillation ............................................................................................................................... 40
Troubleshooting ............................................................................................................................................. 41
General.....................................................................................................................................................41
Basic requirements for the system to work .............................................................................................. 41
Displayed error messages ....................................................................................................................... 41
Driving vehicle .......................................................................................................................................... 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 adjustment unit ................................................................................................................... 44
Driving vehicle front end ........................................................................................................................... 44
Driving vehicle rear end ........................................................................................................................... 44
Driving vehicle drive unit .......................................................................................................................... 45
Charger .................................................................................................................................................... 45
Battery pack ............................................................................................................................................. 45
Disposal of components ........................................................................................................................... 46
Technical data ...............................................................................................................................................47
Driving vehicle FDV 22 MF....................................................................................................................... 47
FDV MF charger + battery pack ............................................................................................................... 47
AC-AC voltage transformer ...................................................................................................................... 47
Oscillation unit FOU 30 / ML6 .................................................................................................................. 48
Dimensions FDV 22 MF without oscillation unit ...................................................................................... 48
Dimensions FDV 22 MF with oscillation unit ........................................................................................... 49
Spare parts ...................................................................................................................................................... 1
Circuit diagram ................................................................................................................................................ 6
EU-Declaration of conformity .......................................................................................................................... 7
2
General
Principle
Machine concept
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 llet welds in horizon­tal or vertical welding positions, with or without oscillation.
Driving vehicle FDV 22 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 22 MF
both manual and machine welding torches.
Field of applica­tion
Proper use
The FDV 22 MF can be equipped with a torch oscillation unit. The driving vehicle together with the optional oscillation unit is powered by the inter-
changeable battery pack. The control unit is integrated into the driving vehicle. The control panel has an illuminated
display allowing simple and user-friendly parameter setting for the driving vehicle.
Driving vehicle FDV 22 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
Driving vehicle FDV 22 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 im­proper 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 5 mm
- use of MIG / MAG welding torches with a holder diameter of 16 - 22 mm
3
Proper use
(continued)
- 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
- 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 15 kg 22 kg
2009
FDV 22/MF
8,045,368
20 25 9503
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 22 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
(1)(8) (2)
(3)
(4)(6) (5)(7)
FDV 22 MF scope of supply
(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) Connecting cable to power source
6
Options The optional equipment of the driving vehicle comprises:
- AC-AC voltage transformer
(38,0006,0164)
- Driving vehicle brush (48,0005,1425) 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 inclu­des 1 pc. stainless steel wheel.
IMPORTANT! Using the „Stain­less steel drive wheel“ option is permitted only in PA welding
position.
7
Options
(continued)
- Additional torch holder for second
torch (48,0005,1893)
Lateral guides:
(1) Lateral guide, tiltable
(48,0005,1890)
1
(2) Lateral guide for edge
(48,0005,1888)
2
(3) Lateral guide, magnetic
(48,0005,1892)
3
8
Options
(continued)
5
4
Lateral guide with guiding rail:
(4) Guide arm for exible rail, 1850 mm (2 Stück)
(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 per rail are neccessary!
6
9
Driving vehicle components
Conguration
FDV 22 MF with oscillation unit
Handle
Hosepack holder
On-board
control unit
Horizontal torch
adjustment unit
Battery pack
(14.4V / 3Ah)
Truck
with 4-wheel drive
Driving vehicle FDV 22 MF with oscillation unit FOU 30 / ML6
Lifting eye for securing the driving vehicle
Vertical torch
adjustment unit
Limit switch
Oscillation unit
FOU 30 / ML6
Control lever for
permanent magnet
Universal torch holder
Guide wheels
Conguration
FDV 22 MF with­out oscillation unit
Handle
On-board control unit
Horizontal torch
adjustment unit
Truck
with 4-wheel drive
Battery pack (14.4V / 3Ah)
Driving vehicle FDV 22 MF without oscillation unit
Vertical torch
adjustment unit
Lifting eye for securing the driving vehicle
Hosepack holder
Control lever for
permanent magnet
Universal torch
holder
Guide wheels
Limit switch
10
Controls, connections and add-ons
Driving vehicle control panel
(10)
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
No. Function (1) Traverse speed potentiometer
Used to adjust the traversing speed of
(1)
(2)
(3)
the driving vehicle.
Setting range: 5 - 150 cm/min
(2) Digital display
Shows the value of the currently se-
lected parameter. The digital display is illuminated.
(3) Parameter selection display eld
The selected parameter is signalled
by the relevant LED lighting up. The currently saved value appears in the digital display.
Selectable parameters:
(9)
(8)
(7)
Driving vehicle FDV 22 MF control panel
(4) SELECT / ENTER button
- Press the button for 3 seconds to enable parameter entry
- To select the desired parameter (3)
- To accept the value set with the +/- buttons.
(5) Control unit ON/OFF toggle switch
For switching the driving vehicle control unit on and o󰀨.
(6) Connector for oscillation unit FOU30
For connecting the cable to the optional oscillation unit FOU 30.
(7) Connector for power 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 deactivated for test purposes.
(9) + / - button
For increasing or reducing the parameter value. Press the key for 2 seconds to
increase or reduce the parameter value quickly.
(4)
(5)
(6)
Welding segment [cm]
Setting range: 0.5 - 99.9 cm
Pause segment [cm]
Setting range: 0.5 - 99.9 cm
End-crater lling [s] Setting range: 0.0 - 5 s
Back lling [s] Setting range: 0.0 - 3 s
All 4 LEDs lit: Total path [cm]
Setting range: 1 - 999 cm
11
Driving vehicle control panel
(continued)
(10) Toggle switch Start LEFT / STOP / Start RIGHT
For starting and stopping the automatic program sequence.
“Con” display
Con ... Constant. The pause segment is deactivated. The
display appears after the value "99.9" and before "0.5".
“InF” display InF ... Innite. The driving vehicle travels endlessly. The dis-
play appears after the value "999" and before "1".
Total path active display
The driving vehicle travels the dened distance. Setting range 1 - 999 cm.
Display during program se­quence
“Bat” display
“End“ display
"Traversing speed" display. Display range 5 - 150 cm /min. The current step is signalled by the relevant LED lighting up.
Display ashes. The battery pack is nearly at. The battery
pack must be removed from the driving vehicle and re­charged.
Program 'End' indication. All parameters have been com­pleted.
A new automatic program sequence may be started using
the "Start LEFT / STOP / Start RIGHT" button (10).
12
Control panel oscillation unit option
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
(7)
(6)
Oscillation unit FOU 30 / ML6 control panel
(1)
(2)
(3)
(4)
(5)
No. Function (1) Oscillation mode toggle switch MANUAL / OFF / AUTOMATIC
For selecting the oscillation mode of
the FOU 30. MANUAL: Oscillation active immedi­ately
OFF: Oscillation is deactivated AUTOMATIC: Oscillation starts simul­taneously with program sequence.
(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 speed of
the oscillation unit in mm / min. The oscillation speed can only be adjusted
while the oscillation unit is running.
(4) Connection cable with male socket
For connection to the "Connector for
oscillation unit FOU30" of the driving vehicle control panel.
(5) Support arm
For fastening the torch holder.
(6) Oscillation path potentiometer
To increase or reduce the oscillation
path (oscillation width). The oscillation path can only be adjust-
ed while the oscillation unit is running.
Setting range: 1 - 30 mm
(7) Left dwell time potentiometer
For setting the dwell time of the torch in the left reversal position.
Setting range: 0 - 3 seconds
13
Charger and bat-
i C
d
+
tery pack
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
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.
(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.
(1)
(2)
(3)
(4)
14
AC-ACvoltage transformer
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 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 (4).
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
15
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 weld-
ing positions are possible.
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 with-
out 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.
Outside of container with min. diameter of 3000 mmVertical
NOTE! When used on the outside of a container, the container must be turned in the opposite direction and at the same speed.
16
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