How it Works
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FDV 80
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Operating Instruction [EN]
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Operating Instruction [DE]
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Fronius FDV 80 Operating Instruction [EN]

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FDV 80
Operating Instructions
EN
Straight-line carriage
42,0426,0098,EN V03 - 04072016
Table of contents
Principle......................................................................................................................................................3
Device concept ........................................................................................................................................... 3
Field of application ..................................................................................................................................... 3
Proper use .................................................................................................................................................. 3
Warning notices on the carriage .................................................................................................................4
Standard equipment ................................................................................................................................... 5
Options and accessories ............................................................................................................................ 5
Overview .................................................................................................................................................... 6
Carriage connections ................................................................................................................................. 7
FRC-40 remote control ............................................................................................................................... 8
Possible welding positions ......................................................................................................................... 9
Guidance of the carriage ............................................................................................................................ 9
Preparing the carriage ................................................................................................................................... 10
Checking the surface of the workpiece and the carriage to ensure they are clean .................................. 10
Placing the carriage ................................................................................................................................. 10
Adjusting the guide roller .......................................................................................................................... 10
Option: setting the lateral guides .............................................................................................................. 11
Carriage strain relief ................................................................................................................................. 11
Commissioning .............................................................................................................................................. 12
Checking the connections ........................................................................................................................ 12
Switching on system components ............................................................................................................ 12
Dening carriage parameters ................................................................................................................... 12
Selecting and loading the welding program ............................................................................................. 12
Carrying out a test run .............................................................................................................................. 13
Starting the welding process .................................................................................................................... 13
Troubleshooting ............................................................................................................................................. 14
General.....................................................................................................................................................14
Basic requirements for the system to work .............................................................................................. 14
Carriage....................................................................................................................................................14
Control error messages ............................................................................................................................ 14
Maintenance and care ................................................................................................................................... 16
Personnel ................................................................................................................................................. 16
Maintenance record ................................................................................................................................. 16
Maintenance operations and intervals ..................................................................................................... 16
Recommended lubricants ........................................................................................................................ 16
Carriage components ............................................................................................................................... 17
Technical data ............................................................................................................................................... 18
Carriage FDV 80 ...................................................................................................................................... 18
Dimensions FDV 80 ................................................................................................................................. 18
Dimensions FDV 80 / S001 ...................................................................................................................... 19
Dimensions FDV 80 / S002 ...................................................................................................................... 19
Dimensions FDV 80 / S003 ...................................................................................................................... 20
Dimensions FDV 80 / S004 ...................................................................................................................... 20
Dimensions FDV 80 / S005 ...................................................................................................................... 21
Dimensions FDV 80 / S006 ...................................................................................................................... 21
Dimensions FDV 80 / S007 ...................................................................................................................... 22
Dimensions FDV 80 / S008 ...................................................................................................................... 22
1
Options and accessories ............................................................................................................................... 23
System overview ...................................................................................................................................... 23
Installation kits .......................................................................................................................................... 23
Wiring diagram .............................................................................................................................................. 35
EU-Declaration of conformity ........................................................................................................................ 41
2
General
Principle The FDV 80 carriage forms the basis of a mobile longitudinal welding system, consisting
of a straight-line carriage, control unit, torch head and weld tracking.
Device concept
Field of application
Proper use
The modular design enables the carriage to be equipped for a wide range of applications.
A exible system consisting of rails and swivelling units, along with a mechanical weld tracking system, enables welding to take place on parallel workpieces as well as on workpieces that are bent, diverge or are tapered.
The job is selected directly using the remote control. The carriage is powered by a mains cable.
The FDV 80 carriage can be used in all situations where a high degree of exibility is required when executing longitudinal weld seams:
- Welding of longitudinal members
- Shipyards
- Production halls
The FDV 80 carriage must only be used for creating mechanised butt and llet welds in a
horizontal welding position. Any other use shall be deemed improper and the manufacturer will assume no responsibility for any damages arising.
Can be used in the following welding processes:
- MIG / MAG process
Proper use also includes:
- Carrying out all maintenance work at the appropriate intervals
- Keeping a service book with the most important information (date, operator, activities
carried out)
- Using the spare parts stipulated by Fronius
- Following all the information in the operating instructions
- Using this document in combination with the operating instructions for the integrated
system components (power source, wire-feed unit, etc.)
NOTE! Any use of the machine other than for its intended purpose or any
unauthorised conversion or modications, shall be deemed improper use.
Any liability or warranty from the manufacturer is hereby invalidated.
3
Warning notices on the carriage
A number of safety symbols can be seen on the rating plate a󰀩xed to the carriage. The
safety symbols must not be removed or painted over.
FDV 80
A-4600 Wels
www.fronius.com
Art.No.:
Ser.No.:
8,045,278
FDV 80 rating plate
YM:2010
1~
50/60 Hz
U
1
230 V
max. load
80 kg
EN 12100
I1
1,3 A
weight
70 kg
v
max
300 cm/min
P
300 VA
L x W x H
800 x 1260 x 245 mm
Do not use the functions until you have fully read all the operating instructions.
Do not dispose of used devices with domestic waste. Dispose of them according to safety rules.
4
Carriage components
Standard equipment
Options and accessories
- 4-wheel drive via pulse motor
- Wheels with polyurethane tread, one side with a groove
- Integrated distance measurement system
- Reinforcement with mounting pin for wire-feed unit
- 4 transportation lugs
- Power supply and PLC power module
- Mains cable with plug (12m)
- Control line to power source (10m)
- FRC-40 remote control with cable (3m)
- Holder for FRC-40 remote control
- Mechanical weld tracking system
- Torch holder and adjustment units
- FRR reducing rings for torch holder
- Steel guide rollers with / without groove
- Linear axis unit FAU 50 -100 / SD 600 or FAU 50 - 100 SD 1100
- FAU 50-100 cradle I-kit (needed when 2 torches are used)
- Limit position function I-kit
- Guide rollers, with lateral adjustment
- VR holder for two wire-feed units
Wire-feed unit
Conguration 1
FDV 80 accessories
Conguration 1: Use of one torch:
Linear axis unit FAU 50 - 100 / SD 600 / ML 20 (Cradle I-kit included)
Conguration 2 and 3: Use of two torches:
Linear axis unit FAU 50 - 100 / SD 1100 / ML 20
Cradle I-kit for the second torch
FDV 80
Conguration 2
Conguration 3
Remote control
5
Congurations
Overview Depending on the individual requirements and composition of the components, a wide
range of workpieces can be processed.
FDV 80/S001 FDV 80 / S002
FDV 80 / S003
FDV 80 / S005
FDV 80 / S007
FDV 80 / S004
FDV 80 / S006
6
Controls and connections
Carriage connections
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here 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
(1)
(2)
(3)
(4)
(5)
FDV 80 connections
No. Function
(4) Power source control
to connect the power source
(5) Optional: Control I-kit of second power source (job changeover)
to connect a second power source
No. Function
(1) Remote control connection
(control unit)
to connect the manual remote con­trol (e.g. FRC-4 control unit)
(2) On/O󰀨 mains switch
to switch the carriage and connect-
ed remote control on and o󰀨
(3) Mains connection with fuse
to connect the mains cable
7
FRC-40 remote control
The FRC-40 remote control allows you to load and save up to 100 programs.
NOTE! Detailed information about loading and saving programs and using the remote control can be found in the FRC-40 operating instructions.
(1)
No. Function
(1) Touchscreen display
for menu navigation
(2)
(2) Emergency Stop button
for immediate stoppage in an
(3)
emergency
(3) Multi-function wheel
to select and edit the welding parameters
(4) "STOP" button
stops the automatic program sequence
(5)(6)(7)
FRC-40 remote control
(4)
No. Function
(5) "Welding ON/OFF" selector switch
to select automatic program sequence with or without welding
(6) "Manual mode" button
to manually position the carriage
(7) "START" button
to start an automatic program sequence
8
Welding position and seam tracking
Possible
welding positions
Guidance of the carriage
Its 4-wheel drive gives the carriage exceptional directional stability and the best possible
traction. A groove in the tread of the wheels on one side of the carriage also ensures stable handling properties.
The following welding positions are possible:
- Horizontal
The adjustable guide roller on the carriage provide optimum seam tracking.
Depending on the carriage components and the workpiece to be welded, di󰀨erent roller
positions are possible:
9
Preparing the carriage
Checking the
surface of the
workpiece and
the carriage to ensure they are clean
Placing the carriage
Adjusting the
guide roller
Before positioning the carriage, check the following:
- The surface of the workpiece must be clean (no sand, shavings, etc.)
- The bottom plate of the carriage must be clean and free of shavings
- The drive wheels must not be damaged and must be clean
- The guide roller and guide rails must be clean, undamaged and free of welding spatter
1. Place the carriage on the workpiece.
If guide rollers with grooves are used: Ensure that the size of the guide rail is suitable
for the guide rollers.
2. Place the lateral guide rollers on the workpiece. Correct their position if necessary.
The holders (c) for the guide rollers (a)
(c)
(b)
(b)
have ve slots in which the guide rollers
can be secured:
1. Loosen the xing screw (b) at the de- sired slot.
2. Position the guide roller (a) and extend it to the desired length.
(a)
3. Tighten the xing screw (b).
(a)
10
Option: setting
the lateral guides
(b)
(a)
Some carriage congurations have, in addition to the guide rollers, two lateral guides (a) that guide the carriage. The guides and rollers can be installed facing towards the centre,
or even swapped over or rotated so that both rollers face outwards.
To adjust the guides, proceed as follows:
1. Loosen the two xing screws (b) on both lateral guides.
2. Extend the lateral guides to the desired length.
Carriage strain relief
3. Tighten the xing screws (b).
To attain optimum wirefeed, observe the following when connecting and routing the
hosepack:
- Do not allow the hosepack to become kinked
- Always lay the hosepack as straight as possible
- Suspend hosepack if necessary. Use balancer and hosepack holder.
Hosepack handling
11
Commissioning
Checking the
connections
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here 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
components:
- 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.
Switching on system components
Dening carriage
parameters
Selecting and loading the
welding program
IMPORTANT! There are no xed rules for the sequence in which the system
components are switched on. They can be switched on in any order.
Switch the main switch on the following system components to the "ON - 1" position:
- Carriage control unit
- Power source
- Wire-feed unit (if power is not supplied from the power source)
Determine the following settings for the welding process:
- Traversing speed
- Path
- Select the correct welding program
Further information and a detailed description of the carriage parameters can be found in the operating instructions for the FRC-40 remote control.
IMPORTANT! For each workpiece a corresponding welding program must be created.
This contains a list of welding parameters that is saved under a specic program number (job number). These programs can be reloaded at any time, and corrected as required.
The programs are managed from the FRC 40 remote control.
Load the relevant welding program. More detailed information on "Managing welding programs" can be found in the operating instructions for the FRC 40 remote control.
12
Carrying out a test run
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 "Welding ON / OFF" selector switch (1) to the "OFF" position.
2. Press the "START" button (2). The automatic program sequence starts.
IMPORTANT! Never leave the
machine unattended, particularly when
it is moving automatically.
Starting the
welding process
(2)
(1)
NOTE! After you have pressed the "START" button, the carriage only starts to
move once the predetermined start-up delay time has elapsed.
3. Carry out a visual check during the process.
4. If necessary, make the relevant corrections (welding torch position, direction of travel of carriage, traversing speed, etc.).
5. After the test, move the carriage back to its original position.
Start the welding process:
1. Set the "Welding ON / OFF" selector switch (1) to the "ON" position.
2. Press the "START" button (2). The automatic program sequence starts.
13
Troubleshooting
General
Basic requirements for the system to
work
Carriage
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 is as
specied (see rating plate)
Drive wheels slip during travel
Cause: Wheels dirty (with oil)
Remedy: Clean the wheels
Cause: Carriage overloaded (e.g. the torch cables pull the carriage up)
Remedy: Relieve cable strain (suspend)
Play on the torch
Cause: Play on the handles
Remedy: Tighten handles
Control error messages
Cause: Play on the guide rails
Remedy: Tighten the pressure screws
Errors or malfunctions associated with the FRC 40 remote control appear on its display.
EMERGENCY STOP
Cause: Emergency stop signal activated by the Emergency Stop protection
device. All controls are disabled during an emergency stop
Remedy: Rectify the Emergency Stop situation and release the Emergency
Stop button
Limit reached - adjust with manual mode button
Cause: The relevant limit switch on the carriage has been activated
Remedy: Leave the limit position using the manual mode button
Cause: The limit switch was actuated unintentionally
Remedy: Leave the limit position using the manual mode button
Cause: Mechanical fault on limit switch
Remedy: Replace the limit switch (spare parts list, carriage)
14
Control error messages
(continued)
No current ow signal
Cause: Current ow signal activated in system parameters, but no
ROB 3000 or digital power source in use
Remedy: Deactivate current ow signal in system parameters
Cause: Fault on the power source
Remedy: Check the settings on the power source
Correct if necessary
Cause: Fault on the power source
Remedy: Check the settings on the power source
Correct if necessary
Cause: No robot interface in use (digital power source only.)
Remedy: Integrate ROB 3000 robot interface
Cause: Faulty connection to power source
Remedy: Check the power source function
Cause: No earth connection: earthing cable loose or not connected
Remedy: Check the earth connection
15
Maintenance and care
Personnel
Maintenance record
Maintenance operations and intervals
WARNING! Risk of injury and damage from incorrectly performed maintenance.
All maintenance work on the FDV 80 carriage 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! Before beginning maintenance work, switch o󰀨 device and disconnect
from mains supply.
Item Part Action Interval
A
Linear guides Clean, check oil lm M
B
Thread play Clean, regrease M
C
Rack and pinion Clean, regrease M
D
Toothed belt Pretension, check for tears M
E
Rollers and rails Clean, check position M
F
Ventilation openings Clean W
G
Terminal contacts Clean W
H
Wheels / rollers, underbody,
Clean D
guide rails
Recommended lubricants
D Daily
W Weekly
M Monthly
1/2 y 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 soap-based
grease
Lubricating oil CLP32-100 51517 Part 3 ISO VG 32-100
Conductive paste --- --- Item no. 48,0009,0157
16
Carriage components
E
A
Conguration example
E
H
H
G
H
C
H
D
H
17
Technical data
Carriage FDV 80
Dimensions FDV 80
Max. load 80 kg
Welding signal 2-step/4-step mode Welding position PA Travel speed 1-300 cm/min Track width 380 mm Net weight (without remote control and weld tracking) 70 kg Mains voltage/frequency 230 V / 50-60 Hz Control voltage 24 V DC Power consumption 300 VA
A
A 800 mm
B 450 mm
C 245 mm
C
B
18
Dimensions
A
C
C
FDV 80 / S001
A min. 210 mm / max. 810 mm
C min. 30 mm / max. 380 mm
Weight: approx. 107 kg
Dimensions
FDV 80 / S002
FDV 80/S001
B
A
A min. 335 mm / max. 700 mm
B min. 210 mm / max. 575 mm
C min. 30 mm / max. 380 mm
Weight: approx. 153 kg
FDV 80 / S002
19
Dimensions
C
C
FDV 80 / S003
Dimensions FDV 80 / S004
FDV 80 / S003
A1
A2
B1
B2
A 1 300 mm
A 2 510 mm
B 1 175 mm
B 2 635 mm
C 90 mm
Weight: approx. 120 kg
B
A
A min. 335 mm / max. 1900 mm
B min. 210 mm / max. 1775 mm
C min. 30 mm / max. 380 mm
Weight: approx. 188 kg
FDV 80 / S004
20
Dimensions
C
FDV 80 / S005
Dimensions FDV 80 / S006
FDV 80 / S005
A1
A2
B2B1
A 1 300 mm
A 2 510 mm
B 1 175 mm
B 2 635 mm
C min. 30 mm / max. 380 mm
Weight: approx. 169 kg
C
A1
B1
D
A2
B2
A 1 455 mm
A 2 335 mm
B 1 330 mm
B 2 460 mm
C 31 mm
D 362.5 mm
Weight: approx. 147 kg
FDV 80 / S006
21
Dimensions
C
A
FDV 80 / S007
Dimensions FDV 80 / S008
FDV 80 / S007
A1
A2
B1
B2
A 1 300 mm
A 2 510 mm
B 1 175 mm
B 2 635 mm
C 90 mm
Weight: approx. 120 kg
Weight of trailer +
approx. 180 kg
power sources:
C
A min. 125 mm / max. 415 mm
C 215 mm
Weight: approx. 161 kg
FDV 80 / S008
22
Options and accessories
System overview
Start for
external device
KD 4010:
38,0100,0128
38,0100,0188
FCU-11 / FCU-12 / FRC-12:
1
Pneumatic cylinder FPT 100 8,045,228
or
FRC-40
FPT 150 8,045,227
38,0100,0081
24V + DC
2
38,0100,0035
Rob
3000
38,0101,0014
TUCHEL
38,0100,0018
Power source
A
Installation Kits FDV 80:
1
I-Kit ROB A: 8,100,138
2
I-Kit ROB A/B: 8,100,142
Rob
3000
38,0101,0014
38,0100,0281
Power source
B
LEGEND:
------- -- Option ______ Standard
(included in delivery)
Installation kits ROB A installation kit
Item number: 8,100,138
ROB A/B installation kit for controlling two power sources:
Item number: 8,100,142
23
24
Spare parts list,
EN
circuit diagram
FDV 80
8,045,278 FDV 80 carriage (Drawing number: 48-0385-0001)
FDV-80
Ersatzteilliste / Spare parts list
27
8,045,278 FDV 80 carriage (Drawing number: 48-0385-0001)
Designation: Item number:
Control unit 48,0385,0005
Shaft 2 48,0385,0102
Spur gear 1 48,0385,0103
Spur gear 2 48,0385,0104
FDV / 3/ PU guide roller with groove 48,0385,0107
Base frame 48,0385,1001
Side cover 48,0385,1309
Motor holder 48,0385,2000
Y pedestal 48,0008,0052
Polyurethane wheel with steel core 48,0007,0037
Washer 68-0000-0064
Pulse motor 48,0006,0053
Vibration damper 48,0006,0052
Toothed belt wheel 48,0003,0146
Taper clamping socket 48,0003,0147
Toothed belt 48,0003,0145
EB plug with lter 38,0003,0114
10-pin amphenole socket housing 43,0003,0255
Main switch, green 43,0002,0305
Flange socket 38,0003,0109
Eye bolt 42,0401,0142
Plug for moulded tube 48,0009,0099
Spring 48,0009,0097
Spring 48,0009,0032
48-0385-C000 I-kit Limit switch
Designation: Item number:
Limit switch 90° 38,0002,0166
Cable connection 38,0004,0090
FDV-80
Ersatzteilliste / Spare parts list
28
Electric parts
(1)
(2)
(3)
(4)
Pos.Nr. Designation: Item number:
(1) Print Step motor 38,0102,0043
(2) Print SMP 4,085,183
(3) FPA NT 1 4,085,158
(4) SPS FX3G 38,0102,0047
FDV-80
Ersatzteilliste / Spare parts list
29
58,0070,0000 Linear axis unit FAU 50-100 / SD 600 / ML 20
58,0070,0303
58,0070,1000
58,0070,0301
Designation: Item number:
Mounting plate 58,0070,0301
Moulded tube 58,0070,0303
FAU 50-100 cradle I-kit 58,0070,1000
Sliding block 68-0000-0555
FDV-80
Ersatzteilliste / Spare parts list
30
58,0070,0000 Linear axis unit FAU 50-100 / SD 1100 / ML 20
58,0070,0301
58,0070,1000
58,0070,0302
Designation: Item number:
Mounting plate 58,0070,0301
Moulded tube 58,0070,0302
FAU 50-100 cradle I-kit 58,0070,1000
Sliding block 68-0000-0555
FDV-80
Ersatzteilliste / Spare parts list
31
58-0732-1100 Guide, right
48,0314,0115
48,0314,0116
58-0732-1200 Guide, left
Designation: Item number:
Guide roller 48,0314,0115
Guide roller 48,0314,0116
ZUS adjustment unit 58-0732-1500
48,0314,0115
48,0314,0116
Designation: Item number:
Guide roller 48,0314,0115
Guide roller 48,0314,0116
ZUS adjustment unit 58-0732-1600
FDV-80
Ersatzteilliste / Spare parts list
32
48,0385,0107 PU guide roller with groove
Used for:
- Round steel, diameter 15
- Hexagon bar steel, width a/f 13
- Square steel 15
48,0385,0105 Steel guide roller with groove
Used for:
- Round steel, diameter 15
- Hexagon bar steel, width a/f 13
- Square steel 15
FDV-80
Ersatzteilliste / Spare parts list
33
48,0385,0106 Steel guide roller, smooth
For using the carriage on a smooth surface. The carriage is then primarily moved to the left and right by the lateral guides.
FDV-80
Ersatzteilliste / Spare parts list
34
Wiring diagram
FDV-80
Ersatzteilliste / Spare parts list
35
FDV-80
Ersatzteilliste / Spare parts list
36
FDV-80
Ersatzteilliste / Spare parts list
37
FDV-80
Ersatzteilliste / Spare parts list
38
FDV-80
Ersatzteilliste / Spare parts list
39
FDV-80
Ersatzteilliste / Spare parts list
40
EU-Declaration of conformity
41
FRONIUS INTERNATIONAL GMBH
TechSupport Automation
www.fronius.com
www.fronius.com/addresses
42
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