FRO­NIUS FDV 22 MF User manual

FDV 22 MF
EN
42,0410,1645 V09 - 03082016
Operating Instructions
Carriage
/ Perfect Welding / Solar Energy / Perfect Charging

1
Contents
General............................................................................................................................................................ 3
Principle...................................................................................................................................................... 3
Machine concept ........................................................................................................................................ 3
Field of application ..................................................................................................................................... 3
Proper use.................................................................................................................................................. 3
Improper use .............................................................................................................................................. 4
Conversions or modications ..................................................................................................................... 4
Operating instructions ................................................................................................................................ 4
Instructions................................................................................................................................................. 4
Warning notices on the driving vehicle....................................................................................................... 5
Scope of supply.......................................................................................................................................... 6
Options....................................................................................................................................................... 7
Driving vehicle components .......................................................................................................................... 10
Conguration FDV 22 MF with oscillation unit ........................................................................................ 10
Conguration FDV 22 MF without oscillation unit ................................................................................... 10
Controls, connections and add-ons............................................................................................................... 11
Driving vehicle control panel .................................................................................................................... 11
“Con” display ............................................................................................................................................ 12
“InF” display.............................................................................................................................................. 12
Total path active display ........................................................................................................................... 12
Display during program sequence ........................................................................................................... 12
“Bat” display ............................................................................................................................................. 12
“End“ display ............................................................................................................................................ 12
Control panel oscillation unit option ......................................................................................................... 13
Charger and battery pack......................................................................................................................... 14
AC-ACvoltage transformer ....................................................................................................................... 15
Welding position and seam tracking.............................................................................................................. 16
Possible welding positions ....................................................................................................................... 16
Guidance of the carriage.......................................................................................................................... 17
Second torch holder ................................................................................................................................. 20
Preparing the driving vehicle ......................................................................................................................... 21
Fitting the handle...................................................................................................................................... 21
Fitting the guide rails ................................................................................................................................ 21
Fitting the brushes (option) ...................................................................................................................... 22
Fitting lateral guides (Option) ................................................................................................................... 23
Fitting lateral guides with exible rail (Option).......................................................................................... 24
Fitting the additional torch holder (Option) ............................................................................................... 25
Connecting the charger to the mains supply............................................................................................ 26
Charge the battery pack........................................................................................................................... 26
Insert battery pack in driving vehicle docking station ............................................................................... 27
Adjusting the guide wheels ...................................................................................................................... 28
Check the surface of the workpiece and the driving vehicle to ensure they are clean............................. 28
Position the driving vehicle and activate the permanent magnet ............................................................. 28
Attach fall protection (vertical operation).................................................................................................. 29
Mounting and adjusting the welding torch................................................................................................ 29
Driving vehicle strain relief ....................................................................................................................... 30

2
Start-up.......................................................................................................................................................... 31
Check the connections............................................................................................................................. 31
Switch on system components................................................................................................................. 31
Dene driving vehicle parameters............................................................................................................ 31
Loading a welding program...................................................................................................................... 32
Carry out test run......................................................................................................................................32
Start the welding process......................................................................................................................... 32
Setting the driving vehicle parameters .......................................................................................................... 33
Continuous welding.................................................................................................................................. 33
Interval welding ........................................................................................................................................ 35
Path welding............................................................................................................................................. 38
Oscillation option ........................................................................................................................................... 40
Setting the oscillation ............................................................................................................................... 40
Troubleshooting............................................................................................................................................. 41
General..................................................................................................................................................... 41
Basic requirements for the system to work .............................................................................................. 41
Displayed error messages ....................................................................................................................... 41
Driving vehicle.......................................................................................................................................... 41
Oscillation................................................................................................................................................. 42
Maintenance and care................................................................................................................................... 43
Personnel ................................................................................................................................................. 43
Maintenance record ................................................................................................................................. 43
Maintenance operations and intervals ..................................................................................................... 43
Recommended lubricants ........................................................................................................................ 43
Horizontal torch adjustment unit............................................................................................................... 44
Vertical torch adjustment unit ................................................................................................................... 44
Driving vehicle front end........................................................................................................................... 44
Driving vehicle rear end ........................................................................................................................... 44
Driving vehicle drive unit .......................................................................................................................... 45
Charger .................................................................................................................................................... 45
Battery pack ............................................................................................................................................. 45
Disposal of components........................................................................................................................... 46
Technical data ............................................................................................................................................... 47
Driving vehicle FDV 22 MF....................................................................................................................... 47
FDV MF charger + battery pack ............................................................................................................... 47
AC-AC voltage transformer ...................................................................................................................... 47
Oscillation unit FOU 30 / ML6 .................................................................................................................. 48
Dimensions FDV 22 MF without oscillation unit ...................................................................................... 48
Dimensions FDV 22 MF with oscillation unit ........................................................................................... 49
Spare parts...................................................................................................................................................... 1
Circuit diagram ................................................................................................................................................ 6
EU-Declaration of conformity .......................................................................................................................... 7

3
Field of applica-
tion
Driving vehicle FDV 22 MF can be used in all situations where a high degree of exibility
is required when executing longitudinal weld seams:
- Welding of longitudinal members
- Shipyards
- Bridge construction
- Workshops
- Production halls
- Building sites
General
Driving vehicle FDV 22 MF has been for
designed for exibility and to improve pro-
ductivity 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 com-
ponent by means of a permanent magnet.
This guarantees the best possible traction
even in vertical use.
The guide wheels automatically track the
torch in the lled joint.
The universal torch holder allows use of
both manual and machine welding torches.
Driving vehicle FDV 22 MF
Principle Driving vehicle FDV 22 MF is a portable, battery-powered longitudinal truck with 4-wheel
drive. The driving vehicle is used to execute mechanised butt and llet welds in horizon-
tal or vertical welding positions, with or without oscillation.
Machine concept
Driving vehicle FDV 22 MF must only be used for performing mechanised butt and llet
welds in horizontal or vertical welding positions. Any other use shall be deemed to be im-
proper use and the manufacturer will assume no responsibility for any damages arising.
The following welding processes are possible:
- MIG/MAG process
Proper use
The FDV 22 MF can be equipped with a torch oscillation unit.
The driving vehicle together with the optional oscillation unit is powered by the inter-
changeable battery pack.
The control unit is integrated into the driving vehicle. The control panel has an illuminated
display allowing simple and user-friendly parameter setting for the driving vehicle.
Proper use also includes:
- use of the charger FDV MF and battery pack (14.4V / 3 Ah) included with the driving
vehicle
- use of the permanent magnet with a minimum sheet thickness of 5 mm
- use of MIG / MAG welding torches with a holder diameter of 16 - 22 mm

4
Proper use
(continued)
Any use of the machine other than for its intended purpose shall be deemed improper
use. This includes:
- using on preheated workpieces > 50 ° C
- Transporting people
- Standing on the machine or using it as a work platform
- As a storage surface for tools
- Use outside the permitted technical operating limits
- Use in hazardous areas
Improper use
If the user carries out any unauthorised conversion or modication of the equipment, any
liability or warranty from the manufacturer is invalidated.
The electromagnetic characteristics of the equipment can be adversely a󰀨ected by any
kind of addition or modication. No modications or upgrades to the equipment should
therefore be undertaken without rst consulting the manufacturers and receiving written
approval.
Conversions or
modications
The operating instructions help you to use the carriage e󰀩ciently and must be accessible
at all times.
- Keep the operating instructions near the corresponding parts of the carriage at all
times.
- Clearly mark the place where the instructions are kept
- Ensure that all persons using the carriage know where the operating instructions are
located.
- The operating instructions will only be able to help you if you can get to them when
there is a problem!
IMPORTANT! The manufacturer shall not be liable for any damage that arises from failu-
re to observe the operating instructions.
Operating
instructions
Instructions The system operator must, before they start, tell all people working on the carriage
about:
- the theoretical and practical aspects of operating the system
- the safety regulations applicable to the system.
IMPORTANT! This obligation applies in particular to persons who only work occasionally
on the carriage.
- use with the „Drive wheel stainless steel“ option in PA welding position
- carrying out all maintenance work at the appropriate intervals
- keeping a service book with the most IMPORTANT data (date, operator, activities
carried out)
- using the spare parts stipulated by Fronius
- following all the information in the operating instructions
- using this document in conjunction with the operating
instructions of the integrated system components (power source, wire-feed unit, etc.)

5
Rating plate FDV 22 MF
Warning notices
on the driving
vehicle
A number of safety symbols can be seen on the rating plate a󰀩xed to the driving vehicle.
The safety symbols must NOT be removed or painted over.
Do not dispose of used chargers with domestic waste. Dispose of them according to
safety rules.
Do not use the functions until you have fully read all the operating instructions.
Type:
Ser.No.:
Art.No.:
A-4600 Wels
www.fronius.com
U weight max. load
14,4 VDC 15 kg 22 kg
2009
FDV 22/MF
8,045,368
20 25 9503
WARNING!
Risk of burns from hot surfaces.
The protective plate covering the battery pack heats up over
extended periods of welding. Touching the plate may cause burns.
- Do not touch the protective plate.
- Wear protective gloves and suitable safety goggles or a protec-
tive helmet.

6
FDV 22 MF scope of supply
Scope of supply
(3)
(4)(6) (5)(7)
(1)(8) (2)
(1) Driving vehicle FDV-22MF
(2) Handle with hose pack holder
(3) Battery pack 14.4 V / 3 Ah
(4) Charger FDV MF
(5) Allen keys 2.5 / 3 / 4
(6) Front guide rail
(7) Rear guide rail
(8) Connecting cable to power source

7
Options The optional equipment of the driving vehicle comprises:
- AC-AC voltage transformer
(38,0006,0164)
- Driving vehicle brush (48,0005,1425)
This accessory comprises two parts.
Brush bracket and 1x brush.
- Oscillation unit FOU 30 / ML6
(8,045,370)
For workpieces with very rough surface:
- Stainless steel drive wheel
(48,0005,1603), article number inclu-
des 1 pc. stainless steel wheel.
IMPORTANT! Using the „Stain-
less steel drive wheel“ option
is permitted only in PA welding
position.

8
Options
(continued)
Lateral guides:
- Additional torch holder for second
torch (48,0005,1893)
1
(1) Lateral guide, tiltable
(48,0005,1890)
(2) Lateral guide for edge
(48,0005,1888)
(3) Lateral guide, magnetic
(48,0005,1892)
2
3