FDV 15 MF

TÄYDELLISTÄ HITSAUSTA
FDV 15 MF
/ Operating Instructions
/ Spare Parts List
v.01/2012 ENG
Safety rules
DANGER!
WARNING!
CAUTION!
“DANGER!” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.
“CAUTION!” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert
against unsafe practices that may cause property damage.
NOTE!
“NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.
Important!
“Important!” indicates practical hints and other useful special-information. It
is no signal word for a harmful or dangerous situation.
Whenever you see any of the symbols shown above, you must pay even
closer attention to the contents of the manual!
General remarks
This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/operator,
- efficient working with the equipment.
All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.
The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must be
kept on hand, and of course observed in practice.
All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over
For information about where the safety instructions and danger warnings are
located on the machine, please see the section of your machine’s instruction
manual headed “General remarks”.
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General remarks
(continued)
Any malfunctions which might impair machine safety must be eliminated
immediately - meaning before the equipment is next switched on.
It’s your safety that’s at stake!
Utilisation for
intended purpose
only
The machine may only be used for jobs as defined by the “Intended
purpose”.
The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall not
be liable for any damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises
- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.
The appliance must never be used for the following:
- Thawing pipes
- Charging batteries/accumulators
- Starting engines
The machine is designed to be used in industrial and workshop
environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.
ikewise the manufacturer will accept no liability for defective or faulty work
results.
Ambient
conditions
Operation or storage of the power source outside the stipulated range is
deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.
Temperature range of ambient air:
- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)
Relative atmospheric humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Ambient air: Free of dust, acids, corrosive gases or substances etc.
Elevation above sea level: Up to 2000 m (6500 ft)
Obligations of
owner/operator
The owner/operator undertakes to ensure that the only persons allowed to
work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood the sections on “safety rules” and the “warnings“ contained in this manual, and have confirmed as much with their
signatures
- be trained in such a way that meets with the requirements of the work
results
Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.
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Obligations of
personnel
Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.
Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.
Mains connection
High-performance devices can affect the quality of the mains power due to
their current-input.
This may affect a number of types of device in terms of:
connection restrictions
criteria with regard to maximum permissible mains impedance *)
criteria with regard to minimum short-circuit power requirement *)
*)
at the interface with the public mains network
see Technical Data
In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.
Protection for
yourself and
other persons
When welding, you are exposed to many different hazards such as:
- flying sparks and hot metal particles
- arc radiation which could damage your eyes and skin
-
harmful electromagnetic fields which may put the lives of cardiac pacemaker users at risk
-
electrical hazards from mains and welding current
-
increased exposure to noise
-
noxious welding fumes and gases.
Anybody working on the workpiece during welding must wear suitable protective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups
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Protection for
yourself and
other persons
(continued)
“Protective clothing” also includes:
- protecting your eyes and face from UV rays, heat and flying sparks with
an appropriate safety shield containing appropriate regulation filter glass
- wearing a pair of appropriate regulation goggles (with sideguards) behind
the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insulating, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!
Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.
Information on
noise emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum
permissible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.
Hazards from
noxious gases
and vapours
The fumes given off during welding contain gases and vapors that are
harmful to health.
Welding fumes contain substances which may cause birth defects and
cancers.
Keep your head away from discharges of welding fumes and gases.
Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable means.
Ensure a sufficient supply of fresh air.
Where insufficient ventilation is available, use a respirator mask with an
independent air supply.
If you are not sure whether your fume-extraction system is sufficiently powerful, compare the measured pollutant emission values with the permitted
threshold limit values.
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IV
Hazards from
noxious gases
and vapours
(continued)
The harmfulness of the welding fumes will depend on e.g. the following
components:
- the metals used in and for the workpiece
- the electrodes
- coatings
- cleaning and degreasing agents and the like
For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.
Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.
Hazards from
flying sparks
Flying sparks can cause fires and explosions!
Never perform welding anywhere near combustible materials.
Combustible materials must be at least 11 meters (35 feet) away from the
arc, or else must be covered over with approved coverings.
Have a suitable, approved fire extinguisher at the ready.
Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that there
is no risk of injury or fire.
Do not perform welding in locations that are at risk from fire and/or explosion,
or in enclosed tanks, barrels or pipes, unless these latter have been
prepared for welding in accordance with the relevant national and
international standards.
Welding must NEVER be performed on containers that have had gases,
fuels, mineral oils etc. stored in them. Even small traces of these substances
left in the containers are a major explosion hazard.
Hazards from
mains and welding current
An electric shock is potentially life-threatening, and can be fatal.
Do not touch any live parts, either inside or outside the machine.
In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.
Always place the wirefeeder on an adequately insulated floor or base, or else
use a suitable insulating wirefeeder holder.
Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/frame
potential. The base or cover must completely cover the entire area between
your body and the ground/frame potential.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.
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Hazards from
mains and welding current
(continued)
Do not loop any cables or other leads around your body or any part of your
body.
Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.
Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.
Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.
Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.
If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.
Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).
Switch off any appliances that are not in use.
Wear a safety harness if working at height.
Before doing any work on the machine, switch it off and unplug it from the
mains.
Put up a clearly legible and easy-to-understand warning sign to stop anybody
inadvertently plugging the machine back into the mains and switching it back
on again.
After opening up the machine:
- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.
If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.
Stray welding
currents
If the following instructions are ignored, stray welding currents may occur.
These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment
Ensure that the workpiece clamp is tightly connected to the workpiece.
Attach the workpiece clamp as close as possible to the area to be welded.
On electrically conductive floors, the machine must be set up in such a way
that it is sufficiently insulated from the floor.
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Stray welding
currents
(continued)
When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/welding
tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs.
In the case of automated MIG/MAG applications, ensure that only insulated
filler wire is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.
EMC device
classifications
Devices with emission class A:
are only designed for use in an industrial setting
can cause conducted and emitted interference in other areas.
Devices with emission class B:
satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.
EMC device classification as per the rating plate or technical specifications
EMC measures
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to
rectify the situation.
Examine and evaluate any possible electromagnetic problems that may
occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices
Ancillary measures for preventing EMC problems:
a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the mains
connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).
b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.
c) Equipotential bonding
d) Workpiece grounding (earthing)
- where necessary, run the connection to ground (earth) via suitable
capacitors.
e) Shielding, where necessary
- Shield other equipment in the vicinity
- Shield the entire welding installation.
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EMI Precautions
Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pacemakers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/body
of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not loop
around body or or any part of body
Particular danger
spots
Keep your hands, hair, clothing and tools well away from all moving parts,
e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires
Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.0
Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.
While the machine is in use:
- ensure that all the covers are closed and that all the sideguards are
properly mounted ...
- ... and that all covers and sideguards are kept closed.
When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...). For this
reason, when feeder-inching etc., always hold the torch so that it is pointing
away from your body (machines with wirefeeder).
Do not touch the workpiece during and after welding - risk of injury from
burning!
Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.
Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.
Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.
Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.
Risk of scalding from accidental discharge of hot coolant. Before unplugging
the connectors for coolant forward flow and return flow, switch off the cooling
unit.
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Particular danger
spots
(continued)
When hoisting the machines by crane, only use suitable manufacturersupplied lifting devices.
- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).
When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).
If a machine is fitted with a carrying strap or carrying handle, remember that
this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.
Danger of colourless and odourless inert gas escaping unnoticed, when
using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.
Danger from
shielding-gas
cylinders
Shielding-gas cylinders contain pressurized gas and may explode if they are
damaged. As shielding-gas cylinders are an integral part of the overall
welding outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).
Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).
Never hang a welding torch on a shielding-gas cylinder.
Never touch a shielding-gas cylinder with a welding electrode.
Explosion hazard - never perform welding on a pressurized shielding-gas
cylinder.
Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories that
are in good condition.
When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.
Close the shielding-gas cylinder valve when no welding is being carried out.
When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.
Observe the manufacturer’s instructions and all relevant national and
international rules applying to shielding-gas cylinders and accessories.
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Safety precautions at the installation site and
when being
transported
A machine that topples over can easily kill someone! For this reason, always
place the machine on an even, firm floor in such a way that it stands firmly.
- An angle of inclination of up to 10° is permissible.
Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.
By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.
The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.
When installing the appliance, please ensure a clearance radius of 0.5 m
(1.6ft.) , so that cool air can circulate freely.
When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportation
and carriage.
Before transportation, completely drain any coolant and dismantle the following components:
- Wire feed
- Wire wound coil
- Gas bottle
Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by trained service personnel before commissioning.
Safety precautions in normal
operation
Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:
- the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.
Any safety features that are not fully functional must be put right before you
switch on the machine.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered by
your doing so.
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At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
Owing to its special properties (in terms of electrical conductivity, frostproofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
Only use suitable original coolant of the manufacturer.
Do not mix original coolant of the manufacturer with other coolants.
X
Safety precautions in normal
operation
(continued)
-
Preventive and
corrective maintenance
If any damage occurs in cases where other coolants have been used, the
manufacturer shall not be liable for any such damage, and all warranty
claims shall be null and void.
Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
Before starting welding - while the machine is still cool - check the
coolant level.
With parts sourced from other suppliers, there is no certainty that these parts
will have been designed and manufactured to cope with the stressing and
safety requirements that will be made of them. Use only original spares and
wearing parts (this also applies to standard parts).
Do not make any alterations, installations or modifications to the machine
without getting permission from the manufacturer first.
Replace immediately any components that are not in perfect condition.
When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.
Safety inspection
The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.
The manufacturer also recommend the same (12-month) interval for regular
calibration of power sources.
A safety inspection, by a trained and certified electrician, is prescribed:
- after any alterations
- after any modifications or installations of additional components
- following repairs, care and maintenance
- at least every twelve months.
Observe the relevant national and international standards and directives in
connection with the safety inspection.
More detailed information on safety inspections and calibration is available
from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request.
Disposal
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility Any device that you no longer
require must be returned to our agent, or find out about the approved collection and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
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Safety markings
Equipment with CE-markings fulfils the basic requirements of the LowVoltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .
Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.
Data security
The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.
Copyright
Copyright to this instruction manual remains the property of the
manufacturer.
The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.
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Table of contents
General............................................................................................................................................................ 2
Principle...................................................................................................................................................... 2
Machine concept ........................................................................................................................................ 2
Field of application ..................................................................................................................................... 2
Proper use .................................................................................................................................................. 2
Warning notices on the driving vehicle ....................................................................................................... 3
Scope of supply .......................................................................................................................................... 4
Driving vehicle components ............................................................................................................................ 5
Driving vehicle FDV 15 MF......................................................................................................................... 5
Control elements and connections .................................................................................................................. 6
Driving vehicle control panel ...................................................................................................................... 6
Charger and battery pack ........................................................................................................................... 6
Welding position and seam tracking ................................................................................................................ 8
Possibleweldingpositions ........................................................................................................................... 8
Guidance of the driving vehicle .................................................................................................................. 9
Preparing the driving vehicle ......................................................................................................................... 11
Charge the battery pack ........................................................................................................................... 11
Insert battery pack in driving vehicle docking station ............................................................................... 11
Adjusting the guide wheels ...................................................................................................................... 12
Check the surface of the workpiece and the driving vehicle to ensure they are clean ............................. 12
Placing the driving vehicle ........................................................................................................................ 13
Attach fall protection (vertical operation) .................................................................................................. 13
Mounting and adjusting the welding torch ................................................................................................ 14
Driving vehicle strain relief ....................................................................................................................... 14
Start-up.......................................................................................................................................................... 16
Check the connections ............................................................................................................................. 16
Switch on system components ................................................................................................................. 16
Define driving vehicle parameters ............................................................................................................ 16
Loading a welding program ...................................................................................................................... 16
Carry out test run...................................................................................................................................... 17
Start the welding process ......................................................................................................................... 17
Troubleshooting ............................................................................................................................................. 18
General..................................................................................................................................................... 18
Basic requirements for the system to work .............................................................................................. 18
Driving vehicle .......................................................................................................................................... 18
Maintenance and care ................................................................................................................................... 20
Personnel ................................................................................................................................................. 20
Maintenance record ................................................................................................................................. 20
Maintenance operations and intervals ..................................................................................................... 20
Recommended lubricants ........................................................................................................................ 20
Driving vehicle components ..................................................................................................................... 21
Charger and battery pack ......................................................................................................................... 22
Technical data ............................................................................................................................................... 23
Driving vehicle FDV 15 MF....................................................................................................................... 23
Dimensions FDV 15 MF ........................................................................................................................... 23
Spare parts list, circuit diagram
1
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 fillet welds in horizontal or vertical welding positions.
Machine concept
Driving vehicle FDV 15 MF has been for
designed for flexibility 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 filled joint.
The universal torch holder allows use of
both manual and machine welding torches.
Driving vehicle FDV 15 MF
The driving vehicle is powered by the interchangeable battery pack. The control unit is
integrated into the driving vehicle.
Field of application
Driving vehicle FDV 15 MF can be used in all situations where a high degree of flexibility
is required when executing longitudinal weld seams:
- Welding of longitudinal members
- Shipyards
- Bridge construction
- Workshops
- Production halls
- Building sites
Proper use
Driving vehicle FDV 15 MF must only be used for performing mechanised butt and fillet
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 / 2 Ah) included with the driving
vehicle
- use of the permanent magnet with a minimum sheet thickness of 4 mm
2
Proper use
(continued)
-
Warning notices
on the driving
vehicle
use of MIG / MAG welding torches with a holder diameter of 16 - 25 mm
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.)
A number of safety symbols can be seen on the rating plate affixed to the driving vehicle.
The safety symbols must NOT be removed or painted over.
Type:
A-4600 Wels
www.fronius.com
FDV 15/MF
Art.No.:
8,045,369
Ser.No.:
20 25 9502
U
weight
max. load
14,4 VDC
5 kg
15 kg
2009
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
3
Scope of supply
(3)
(1)
(2)
(4)
(5)
(7)
(6)
FDV 15 MF scope of supply
(1)
(2)
(3)
(4)
Driving vehicle FDV -15 MF
Rear guide rail
Front guide rail
Universal torch holder
(5) Allen keys 5 / 4 / 2
(6) Battery pack 14.4 V / 2 Ah
(7) Charger FDV MF
4
Driving vehicle components
Driving vehicle
FDV 15 MF
Vertical torch
adjustment unit
On-board control unit
Handle
Universal torch
holder
Horizontal torch
adjustment unit
Battery pack
(14.4V / 2Ah)
Guide wheels
Truck with
Lifting eye for securing the
4-wheel drive
driving vehicle
Driving vehicle FDV 15 MF
5
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
2
(1)
SPEED
(4)
(2)
(3)
Driving vehicle FDV 15 MF control panel
6
No. Function
(1) Traverse speed potentiometer
Used to adjust the traversing speed of
the driving vehicle.
Setting range: 0 - 150 cm/min
(2) Control unit ON/OFF toggle switch
For switching the driving vehicle control unit on and off.
(3) Control unit ON signal lamp
Permanently lit: Control unit ready for
use Flashing: Battery pack is nearly
flat
(4) Toggle switch Start LEFT / STOP /
Start
RIGHT
For starting and stopping the automatic program sequence.
Charger and
battery pack
(1)
(7)
+
+
Ni Cd
(2)
(3)
Ni MH
H
(6)
(5)
(4)
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.
7
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.
Horizontal
Sloping
Vertical
Outside of container with minimum diameter of
1000 mm
Inside of container with minimum diameter of 1000 mm
NOTE! When used inside a container, the container must be turned in the opposite direction and at the same speed.
8
Guidance of the
driving vehicle
The guide wheels automatically track the torch in the filled 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 inside vertical surface
Guidance on outside vertical surface
Guidance on angle piece (vertical) or rail
Guidance on outside vertical surface
Guidance on outside of curve with minimum diameter
Guidance on inside of curve with minimum diameter
of 5000 mm
of 5000 mm
9
Guidance of the
driving vehicle
(continued)
NOTE! When guided on a horizontal angle piece, the welding
torch must only be placed on the
upper side.
Guidance on angle piece (horizontal) or rail
10
Preparing the driving vehicle
Charge the
battery pack
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.
1. Connect the charger to the power supply. The YELLOW signal lamp comes on.
Important! The mains voltage and frequency must be as indicated on the rating
plate.
2. Insert the battery pack with the ridge
in the lower recess (a) of the charger
docking station.
(a)
Place battery pack in charger docking station
(c)
(b)
Lock the battery pack in place
Insert battery
pack in driving
vehicle docking
station
3. 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 flashes 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.
4. Once the battery has finished charging, press the battery release button
(c) and remove the battery pack from
the charger.
1. Insert the battery pack with the ridge
in the lower recess (a) of the driving
vehicle docking station.
(a)
Place battery pack in driving vehicle docking station
11
Insert battery
pack in driving
vehicle docking
station
(continued)
(d)
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.
(b)
Lock the battery pack in place
Adjusting the
guide wheels
5 mm
(b)
(b)
(a)
(a)
Direction of travel
Adjusting the guide wheels
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 12 mm (see diagram).
3. Tighten the fastening screws (a)
Check the surface of the workpiece and the
driving vehicle to
ensure they are
clean
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
12
Placing the
driving vehicle
WARNING! Risk of injury due to permanent magnet
There is a danger of injury to the fingers when positioning the driving vehicle.
Only hold the driving vehicle by the handle and not by the bottom plate
(a)
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
guide wheels
(a)
Placing the driving vehicle
Attach fall
protection
(vertical operation)
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.
1. Attach the snap hook of the load
securing device to the securing ring of
the driving vehicle
Attach load securing device
2. Make sure the cable is kept permanently taut
Check the cable
13
Mounting and
adjusting the
welding torch
(d)
(c)
(b)
(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
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 floor), use balancers
and hose pack holders (e.g. Universal hose pack holder)
Hose pack handling
14
Driving vehicle
strain relief
(continued)
Fix the hose pack as illustrated Important! Make sure the hose pack does not
become kinked - this can lead to wire feed
problems.
(a)
Fixing the hose pack
15
Start-up
Check the
connections
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 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.
Switch on
system components
Important! There are no fixed rules for the sequence in which the system components
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)
Def ne driving
vehicle parameters
Carry out the following settings for the welding process:
- Traversing speed
Loading a welding program
Important! For each workpiece a corresponding welding program must be created. This
contains a list of welding parameters that is saved under a specific 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.
16
Carry out
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 "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 process:
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
17
Troubleshooting
General
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.
Basic requirements for the
system to work
-
Driving vehicle
"Control unit ON" signal lamp f ashes
Connections established between separate system components
System components are supplied with electricity and the mains voltage for each
component complies with the rating plate
Cause:
Remedy:
Battery warning - the battery pack is nearly flat.
Charge up the battery pack with charger FDV MF.
Drive wheels slip during travel
Cause:
Remedy:
Wheels dirty (with oil)
Clean the wheels
Cause:
Remedy:
Vehicle overloaded (e.g. the torch cables pull the vehicle up from the floor)
Relieve cable strain (suspend)
Cause:
Insufficient magnetic force: Sheet too thin - must be at least 4 mm thick)
Remedy:
Insufficient magnetic force: Too big a gap (s < 6 mm) - vehicle raised from
the ground by an obstacle or unevenness
Change the welding conditions
Cause:
Remedy:
Magnet not effective (overheated - working temperature > 150°C)
Change magnet.
Play at the torch
Cause:
Remedy:
Play at the handles.
Tighten handles.
Cause:
Remedy:
Play at the guide rails.
Tighten the pressure screws.
"Control unit ON" signal lamp does not light up
Cause:
Remedy:
The "Control unit ON/OFF" toggle switch is in the "OFF" position.
Turn the "Control unit ON/OFF" toggle switch to the "ON" position.
Cause:
Remedy:
Battery pack discharged.
Charge up the battery pack with charger FDV MF.
Cause:
Remedy:
Electronic module - no power.
Check the connections between the driving vehicle battery docking station
and the electronic module.
Cause:
Remedy:
Electronic module damaged.
Change the electronic module.
18
Driving vehicle
(continued)
"Control unit ON" signal lamp is lit but machine does not work
Cause:
Remedy:
"Start LEFT / STOP / Start RIGHT" toggle switch is in the "STOP" position.
Turn the toggle switch to the required direction.
Cause:
Remedy:
Traversing speed is set to "0".
Set the traversing speed.
Cause:
Remedy:
Drive system faulty.
Remove the cover and check the operation of the drive system.
19
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
A Linear guides
B
C
D
E
F
G
H
I
J
K
Action
Interval
Clean, check oil film
M
Eliminate play: Tighten pressure screws
with Allen key
Clean, grease
M
----Pretension, check for tears
M
Clean, check position
M
------------Clean
W
Clean
W
Clean
D
Threaded spindle
--Drive belt
Rollers and rails
------Ventilation openings
Terminal contacts
Wheels, underbody,
guide rails
D ..... Daily
W ......Weekly
M ..... Monthly
1/2Y.....Half-yearly
Y ..... Yearly
Recommended
lubricants
Important! Lubricants with solid lubricant additives (e.g. MoS2, graphite and PTFE) are
not suitable for guiding systems.
Lubricant DIN
Lubricating grease
Lubricating oil
Conductive paste
KP 2-K
CLP32-100
---
20
DIN number
51502 / 51825
51517 Part 3
---
Comment
Lithium-basedgrease
ISO VG 32-100
Item number:
48,0009,0157
Driving vehicle
components
B
B
K
K
K
K
A
A
K
K
K
E
E
21
Charger and battery pack
These devices are largely maintenance-free. To ensure problem-free operation, observe
the following instructions:
I
J
-
-
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
-
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 flat 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.
22
Technical data
Driving vehicle
FDV 15 MF
Supply voltage
Battery charging time
Min. battery capacity
Max. load
Pulling force (horizontal/vertical)
Welding position
Minimum thickness of material
Gap
Travel speed horizontal (load = 50 N)
Travel speed vertical (load = 50 N)
Torch holder diameter
Adjustable range of torch (horizontal/vertical)
Adjustable range of guide wheels
Max. thermal stress of drive wheels
Max. weight of torch hose pack horizontal
Max. weight of torch hose pack vertical
Net weight (without battery)
14.4V / 2Ah rechargeable battery
45 min
4h
15 kg
120 N / 80 N
PA, PB, PC, PF, PG
4 mm
4 mm
0 - 150 cm/min (+/- 6%)
0-130 cm/min (+/- 6%)
16 - 25 mm
28 mm / 28 mm
72 mm
150 °C
12 kg
8 kg
5 kg
Dimensions FDV
15 MF
F
G
H
E
B
I
C
A
D
A
B
C
D
E
220 mm
220 - 248 mm
208 - 280 mm
28.5 mm
24 mm
23
F
G
H
I
228 - 256 mm
29 mm
24 mm
16 mm
FDV 15 MF
EU-KONFORMITÄTSERKLÄRUNG 2009
EC-DECLARATION OF CONFORMITY 2009
DECLARATION DE CONFORMITE DE LA CE, 2009
Wels, 2009-11-19
Die Firma
Manufacturer
La compagnie
FRONIUS INTERNATIONAL GMBH
Buxbaumstrasse 2, A-4600 Wels
erklärt in alleiniger Verantwortung,
dass folgendes Produkt:
Hereby certifies on it´s sole
responsibility that the following
product:
se déclare seule responsable du fait
que le produit suivant:
FDV15/MF
FDV15/MF
FDV15/MF
Schweißzubehör
Arc welding equipment
Accessoires de soudage
auf das sich diese Erklärung
bezieht, mit folgenden Richtlinien
bzw. Normen übereinstimmt:
which is explicitly referred to by this
Declaration meet the following
directives and standard(s):
qui est l’objet de la présente
déclaration correspondent aux
suivantes directives et normes:
Richtlinie 2006/95/EG
Elektrische Betriebsmittel
Niederspannungsrichtlinie
Directive 2006/95/EC
Electrical Apparatus
Low Voltage Directive
Directive 2006/95/CE
Outillages électriques
Directive de basse tension
Richtlinie 2004/108/EG
Elektromag. Verträglichkeit
Directive 2004/108/EC
Electromag. compatibility
Directive 2004/108/CE
Électromag. Compatibilité
Richtlinie 98/37/EG
Maschinenrichtlinie
Directive 98/37/EC
Machinery Directive
Directive 98/37/CE
Directive aux machines
Europäische Normen inklusive
zutreffende Änderungen
DIN EN ISO 12100-1
DIN EN ISO 14121
European Standards including
relevant amendments
DIN EN ISO 12100-1
DIN EN ISO 14121
Normes européennes avec
amendements correspondants
DIN EN ISO 12100-1
DIN EN ISO 14121
Die oben genannte Firma hält
Dokumentationen als Nachweis der
Erfüllung der Sicherheitsziele und
die wesentlichen Schutzanforderungen zur Einsicht bereit.
Documentation evidencing
conformity with the requirements of
the Directives is kept available for
inspection at the above
Manufacture´s.
En tant que preuve de la satisfaction
des demandes de sécurité la
documentation peut être consultée
chez la compagnie susmentionnée.
2009
ppa. Mag.Ing.H.Hackl
Maahantuonti ja myynti:
Pronius Oy
Keisarinviitta 20 B
33960 Pirkkala
+358 (0)44 200 9060
[email protected]
www.pronius.fi