FRO­NIUS FlexTrack 45 User manual

FlexTrack 45 Operating instructions,
Carriage
EN
/ Battery Charging Systems / Welding Technology / Solar Electronics

FCP 600 - II Spare parts recommendation,
Mechanical spare parts
D

© FRONIUS 2013 1
Contents
1.Proper use............................................................................................................................3
1.1Secure carriage against falling .....................................................................................3
1.2Improper use.................................................................................................................3
2.Technical data......................................................................................................................4
3.Weight of bridges and rails...................................................................................................5
4.Safety precautions ...............................................................................................................6
5.Dimensions of carriage with oscillation All measurements in mm.......................................8
6.Dimensions of carriage without oscillation All measurements in mm.................................10
7.Assembling carriage for the first time.................................................................................11
8.Description of carriage with oscillation ...............................................................................12
9.Description of carriage without oscillation ..........................................................................13
10.Remote control ................................................................................................................14
11.Wiring diagrams ..............................................................................................................16
12.Straight rails ....................................................................................................................19
1.3Straight rigid rail..........................................................................................................19
1.4Straight flexible rail .....................................................................................................19
13.Ring rail ...........................................................................................................................20
1.5Closed ring rail............................................................................................................20
1.6Sectional ring rail ........................................................................................................21
1.7Sectional flexible rails for pipes ..................................................................................22
14.Magnetic bridges and metrical scale ...............................................................................23
15.Screw feet bridge with or without distance block.............................................................24
16.Mounting of bridges.........................................................................................................25
1.8Mounting on orbital rails..............................................................................................25
1.9Mounting on rail segment ...........................................................................................25
1.10Mounting on rigid rail ..................................................................................................26
1.11Mounting on flexible rail ..............................................................................................26
17.Assembling an orbital track .............................................................................................27
18.Preparing for operation on straight rail ............................................................................29
19.Preparing for operation on the orbital rail ........................................................................30
20.Positioning the orbital rail onto pipe ................................................................................32
21.Adjusting pressing force of rollers ...................................................................................35
22.Mounting rail onto the pipe ..............................................................................................36
1.12Mounting ring rail ........................................................................................................36
1.13Mounting sectional rail (two persons required) ...........................................................36
1.14Mounting flexible rail onto pipe (two persons required) ..............................................37
23.Usage ..............................................................................................................................38

© FRONIUS 2013 2
1.15Saving a program .......................................................................................................38
1.16Loading a program......................................................................................................39
1.17Operation ....................................................................................................................39
1.18Changing the measurement system ...........................................................................40
1.19Alarm codes................................................................................................................41
24.Maintenance....................................................................................................................42
1.20Lubricating drive system gear.....................................................................................42
1.21Lubricating oscillator gear rack ...................................................................................43
1.22Lubricating oscillator rolling guide...............................................................................43

© FRONIUS 2013 3
1. Proper use
The FlexTrack 45 is a rail carriage designed to establish groove and fillet welds with
or without oscillation using MIG/MAG or CMT torches with handle diameter of
16-35 mm. The carriage can be fixed on straight, flexible orbital, and orbital rails.
It can travel horizontally, vertically, and orbitally, which is enable for welding in
almost all positions.
IMPORTANT! When using vacuum bridges, the workpiece must not be preheated!
1.1 Secure carriage against falling
In vertical operation, the rail construction must be secured with 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 rail construction with carriage. The
manufacturer accepts no liability for any damage to persons or property, resulting
from vertical use of the carriage without a load securing device.
1.2 Improper use
Any use of the machine other than for its intended purpose shall be deemed
improper use. This includes:
Using flexible (unreinforced) rails on flat surfaces
Using vacuum bridges on preheated workpieces
Use over head
Use as lifting tool (Transporting or maneuvering loads, animals, people)
Standing on the machine or using it as a work platform
Use as a storage surface for tools
Use outside the permitted technical operating limits
Use in hazardous areas

© FRONIUS 2013 4
2. Technical data
Power supply 24 V DC, 100 W
Travel direction Forward, backward (along the rail)
Drive Gear motor with gear and rail guide
Guiding mechanism 4 guide rollers
Rail type
Rigid, L = 1884mm
Flexible, L = 1884mm
(inner/outer curvature radius at least
1500/1100mm)
Orbital (for pipes Ø200–1560mm)
Sectional (for pipes Ø1560–3360mm)
Rail fixing Magnetic bridge, resistive bridge
Minimum workpiece type and thickness Ferromagnetic steel of 5 mm
Torch type MIG/MAG, CMT
Torch diameter 16-35 mm
Welding direction
Horizontal
Vertical
Orbital (180⁰from bottom to top)
Travel speed 5–150 cm/min horizontally
5–135 cm/min vertically
Direction change / stop Stops after reaching the limit switch
Changes direction after reaching the limit switch
End crater filling 0–5 s
Torch position
adjustment range
up-down 28 mm
left-right 28 mm
Oscillation
OSC type linear
OSC modes straight, trapezoid, triangle, rectangle
OSC offset 0–50 mm
OSC amplitude 2–30 mm
OSC speed 5-400 cm/min
OSC dwell
time
left 0–3 s
center 0–3 s
right 0–3 s
Maximum pulling force 450 N (horizontally)
300 N (vertically)
Dimensions with OSC 543 (L) × 352 (W) × 304 (H)
Dimensions without OSC 480 (L) × 314 (W) × 334 (H)
Carriage weight with OSC
(without remote control) 14.5 kg
Carriage weight without OSC(without remote
control) 12.5 kg
Remote control weight 1.5 kg
Control box without cable 5,3 kg
Welding device cable 1,5 kg

© FRONIUS 2013 5
3. Weight of bridges and rails
Magnetic bridge 2.5 kg
Vacuum bridge 1.6 kg
Magnetic bridge with distance block 2.7 kg
Vacuum bridge with distance block 1.8 kg
Magnetic bridge with distance block and fixing
mechanism
3.4 kg
Magnetic bridge with fixing mechanism 3.2 kg
Screw feet bridge with distance block and fixing
mechanism
1.5 kg
Screw feet bridge with fixing mechanism 1.3 kg
Vacuum bridge with distance block and fixing
mechanism
2.6 kg
Vacuum bridge with fixing mechanism 2.4 kg
Rigid rail 1884 mm 11 kg
Flexible rail 1884 mm 5.5 kg
Flexible rail 1695 mm 4.8 kg
Flexible rail 1130 mm 3.3 kg
Ring rail Ø200-300 mm 8.8 kg
Ring rail Ø300-480 mm 11 kg
Ring rail Ø480-660 mm 14 kg
Ring rail Ø660-840 mm 16 kg
Rail segment Ø840-1020 mm 19 kg
Rail segment Ø1020-1200 mm 22 kg
Rail segment Ø1200-1380 mm 24 kg
Rail segment Ø1380-1560 mm 27 kg
MAGNETIC BRIDGE
For magnetic workpieces.
Heat resistant up to 180°C
(356 °F). Adjustable
magnetic force.
VACUUM BRIDGE
(2 Versions)
For non-magnetic
workpieces. A vacuum
pump is required.
Version 1: Heat resistant
up to max. 80° (176°F)
Version 2: Heat resistant
up to max. 250°C (480°F).
SCREW FEET BRIDGE
Recommended for rigid
ring rails up to 840 mm
(33.1 in) diameter.

© FRONIUS 2013 6
4. Safety precautions
1. Before starting, read Operator’s Manual and complete proper occupational safety
and health training.
2. Carriage must be used only in applications specified in Operator’s Manual.
3. Carriage must be complete and all parts must be genuine and fully operational.
4. Power supply specifications must conform to those specified on rating plate.
5. Power supply socket must be equipped with grounding pin.
6. Never carry Carriage by cord or yank it to disconnect plug from socket. It can
cause power cord to break and result in electric shock.
7. Untrained bystanders must not be present near Carriage.
8. Before starting, check condition of Carriage and electrical installation, including
power cord, plug, control panel, guiding rollers, and gear.
9. Keep Carriage dry. Exposing it to rain, snow, or frost is prohibited.
10. Keep work area well lit, clean, and free of obstacles.
11. Never use Carriage near flammable fluids or gases, nor in explosive environments.
12. Make sure gear and guiding rollers are clean and not damaged.
13. Mount carriage only on the supplied rails.
14. Transport and position Carriage using carrying handles.
15. Do not stay below Carriage placed at heights.
16. Plug power cord into power supply only when power switch on the control box is
set in lower position.
17. Keep sockets clean. Do not use compressed air for cleaning.
18. Mounting torches other than specified in technical data is prohibited.
19. Mount cables in cable holder. They must be suspended to avoid damage and
reduce carriage load.
20. Operating in PD (horizontal overhead) and PE (overhead) welding positions, as
well as on curvatures with inner/outer radius lower than 1500/1100 mm is
prohibited.
21. When operating at heights, use safety line to protect Carriage from dropping.

© FRONIUS 2013 7
22. Always use eye protection (helmet, shield, and screen), hearing protection,
gloves, and protective clothing during operation. Do not wear loose clothing.
23. Before every use, inspect Carriage to ensure it is not damaged. Check whether
any part is cracked or improperly fitted. Make sure to maintain proper conditions
that can affect Carriage operation.
24. Never try to manually stop motion of Carriage. For this purpose set travel
direction switch in neutral position.
25. Never toggle engaging lever to OFF if Carriage is unprotected from dropping.
26. Perform maintenance only when Carriage is unplugged from power supply.
27. Perform all repairs only in service center appointed by seller.
28. If Carriage falls on hard surface, from height, is wet, or has other damage that
could affect technical state of Carriage, stop operation and immediately send
Carriage to service center for inspection.
29. Never leave Carriage unattended during operation.
30. Remove from worksite and store in isolated and dry location when not in use.
Safety rules must be closely observed.

© FRONIUS 2013 8
5. Dimensions of carriage with oscillation
All measurements in mm.
Carriage on a flexible track

© FRONIUS 2013 9
Carriage with magnetic bridge on a straight rigid track:
Carriage with magnetic bridge, with support and fixing mechanism:
Carriage with screw-feet bridge, with supporting unit and fixing mechanism:

© FRONIUS 2013 10
6. Dimensions of carriage without oscillation
All measurements in mm.

© FRONIUS 2013 11
7. Assembling carriage for the first time
1
2
7
5
3
4
9
8
10
11
12
6

© FRONIUS 2013 12
8. Description of carriage with oscillation
The carriage with oscillation consists of a drive system, pressing roller units,
oscillation, cross slide, torch holder, remote control, and a control box. The drive
system comprises a gear motor that drives the gear. The fixed roller unit lever and
rotational roller unit lever are used for fixing the carriage by clamping four hardened
steel rotational rollers to the guide using disk springs.
The clutch enables the gear to engage or disengage with the holes of the hardened
spring steel rail guide. The cross slide enables for precise control of the torch position
in both horizontal and vertical axis. The carriage travels according to parameters
programmed on the controller. The controller with the magnetic foot can be
positioned on the carriage, on the pipe, on flat ferromagnetic surfaces, or can be hold
in hands. The controller enables for programming and adjusting all welding
parameters as well as positioning of the torch during welding. The control box
assures communication between the controller and the welding device.
Remote control
cable holder
fixed pressing roller unit
fixed pressing roller lever
rotational pressing roller lever
rotational pressing roller unit
oscillator
torch vertical guide
torch holder
Clutch ON / OFF
welding device cable
control box
Main switch
Connection cable
Remote control and
drive system cables
drive system
oscillator cable

© FRONIUS 2013 13
9. Description of carriage without oscillation
To dismount the oscillation unit, proceed according to the following instructions:
1. Unplug the oscillation cable.
2. Dismount the oscillation unit by unscrewing six M6 screws.
3. Screw the cap onto the oscillator socket.
4. Mount the guide arm in place of the oscillation unit.
(1)
(2)
(3)
(4)

© FRONIUS 2013 14
10. Remote control
The remote control consists of a magnetic foot, an aluminum body, and a control
panel. It can be fixed to the drive system or to the ferromagnetic surface and is used
to program and control all parameters of the carriage.
Four position display shows current and adjusted operating parameters. Additionally
it indicates if the stoppage of the carriage or oscillator has been triggered by the limit
switches.
body
control panel
magnetic foot

© FRONIUS 2013 15
Description:
A – Travel direction switch with neutral (middle) ‘stop’ position.
B – Travel speed adjustment (5–150 cm/min).
C – Oscillation modes: no oscillation, trapezoid, rectangular or triangular.
D – OSC offset
E – OSC amplitude (2–30 mm).
F – OSC speed (5–400 cm/min).
G – OSC dwell time left (0–3 s).
H – OSC dwell time middle (0–3 s).
I – OSC dwell time right (0–3 s).
J – Direction change/stop: changes direction or stops, when limit switch gets
activated
K – End crater filling (0–5 s).
L – Welding modes: Test (left position), No Arc (middle pos.) Arc (right pos.)
M – 4-position numeric display. Indication selectable between metric or imperial
measure units.
Note: To change the value of a parameter, press the required button lightly. Once it
is pressed, the current value of the parameter will show on the display along with the
corresponding symbol of the parameter.

© FRONIUS 2013 16
11. Wiring diagrams

© FRONIUS 2013 17

© FRONIUS 2013 18