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

9
Options
(continued)
Lateral guide with guiding rail:
(4) Guide arm for exible rail, 1850 mm (2 Stück)
(48,0005,1897)
(5) Flexible guiding rail, 1850 mm
(48,0005,1894)
(6) Magnetic block for guiding rail
(48,0005,1895)
IMPORTANT! 10 magnetic blocks per rail are neccessary!
5
6
4

10
Driving vehicle components
Oscillation unit
FOU 30 / ML6
Universal torch holder
Horizontal torch
adjustment unit
On-board
control unit
Guide wheels
Limit switch
Lifting eye for securing the
driving vehicle
Truck
with 4-wheel drive
Battery pack
(14.4V / 3Ah)
Control lever for
permanent magnet
Conguration
FDV 22 MF with
oscillation unit
Universal torch
holder
Vertical torch
adjustment unit
Horizontal torch
adjustment unit
On-board control unit
Hosepack holder
Guide wheels
Limit switch
Truck
with 4-wheel drive
Battery pack (14.4V / 3Ah)
Control lever for
permanent magnet
Handle
Conguration
FDV 22 MF with-
out oscillation
unit
Lifting eye for securing
the driving vehicle
Driving vehicle FDV 22 MF with oscillation unit FOU 30 / ML6
Driving vehicle FDV 22 MF without oscillation unit
Handle
Vertical torch
adjustment unit
Hosepack holder

11
Controls, connections and add-ons
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
Driving vehicle
control panel
Driving vehicle FDV 22 MF control panel
(7)
(9)
(1)
(2)
(3)
(4)
(5)
(6)
(8)
(4) SELECT / ENTER button
- Press the button for 3 seconds to enable parameter entry
- To select the desired parameter (3)
- To accept the value set with the +/- buttons.
(5) Control unit ON/OFF toggle switch
For switching the driving vehicle control unit on and o󰀨.
(6) Connector for oscillation unit FOU30
For connecting the cable to the optional oscillation unit FOU 30.
(7) Connector for power source control
For connecting the cable to the power source.
(8) Welding ON/OFF toggle switch
For choosing whether to run the automatic program sequence with or without weld-
ing. Welding can be deactivated for test purposes.
(9) + / - button
For increasing or reducing the parameter value. Press the key for 2 seconds to
increase or reduce the parameter value quickly.
(10)
No. Function
(1) Traverse speed potentiometer
Used to adjust the traversing speed of
the driving vehicle.
Setting range: 5 - 150 cm/min
(2) Digital display
Shows the value of the currently se-
lected parameter. The digital display is
illuminated.
(3) Parameter selection display eld
The selected parameter is signalled
by the relevant LED lighting up. The
currently saved value appears in the
digital display.
Selectable parameters:
Welding segment [cm]
Setting range: 0.5 - 99.9 cm
Pause segment [cm]
Setting range: 0.5 - 99.9 cm
End-crater lling [s]
Setting range: 0.0 - 5 s
Back lling [s]
Setting range: 0.0 - 3 s
All 4 LEDs lit: Total path [cm]
Setting range: 1 - 999 cm

12
(10) Toggle switch Start LEFT / STOP / Start RIGHT
For starting and stopping the automatic program sequence.
Driving vehicle
control panel
(continued)
“Bat” display
“End“ display
Display during
program se-
quence
“Con” display
“InF” display InF ... Innite. The driving vehicle travels endlessly. The dis-
play appears after the value "999" and before "1".
Con ... Constant. The pause segment is deactivated. The
display appears after the value "99.9" and before "0.5".
"Traversing speed" display. Display range 5 - 150 cm /min.
The current step is signalled by the relevant LED lighting up.
Display ashes. The battery pack is nearly at. The battery
pack must be removed from the driving vehicle and re-
charged.
Total path active
display
The driving vehicle travels the dened distance.
Setting range 1 - 999 cm.
Program 'End' indication. All parameters have been com-
pleted.
A new automatic program sequence may be started using
the "Start LEFT / STOP / Start RIGHT" button (10).

13
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
Control panel
oscillation
unit option
Oscillation unit FOU 30 / ML6 control panel
(1)
No. Function
(1) Oscillation mode toggle switch
MANUAL / OFF / AUTOMATIC
For selecting the oscillation mode of
the FOU 30.
MANUAL: Oscillation active immedi-
ately
OFF: Oscillation is deactivated
AUTOMATIC: Oscillation starts simul-
taneously with program sequence.
(2) Right dwell time potentiometer
For setting the dwell time of the torch
in the right reversal
position.
Setting range: 0 - 3 seconds
(3) Oscillation speed potentiometer
For setting the traversing speed of
the oscillation unit in mm / min. The
oscillation speed can only be adjusted
while the oscillation unit is running.
(4) Connection cable with male socket
For connection to the "Connector for
oscillation unit FOU30" of the driving
vehicle control panel.
(5) Support arm
For fastening the torch holder.
(6) Oscillation path potentiometer
To increase or reduce the oscillation
path (oscillation width).
The oscillation path can only be adjust-
ed while the oscillation unit is running.
Setting range: 1 - 30 mm
(2)
(5)
(6)
(7)
(3)
(4)
(7) Left dwell time potentiometer
For setting the dwell time of the torch in the left reversal position.
Setting range: 0 - 3 seconds

14
Charger and bat-
tery pack
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.
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
(6)
(4)
(7)
(5)
Ni MH
H
N
i C
d
+
+
(2)
(1)
(3)
CAUTION! The charger may be damaged if the wrong supply voltage
is used.
The FDV MF charger is designed for a supply voltage of 230 V. Directly con-
necting the charger to a 110 / 120 V mains supply can cause serious material
damage.
- Ensure that the charger is always operated using the correct supply vol-
tage.
- Always use the AC-AC voltage transformer when operating the charger
on a 110/120 V mains supply.

15
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
AC-ACvoltage
transformer
AC-AC voltage transformer
(1)
(2)
The voltage transformer allows the charger to be operated using 110 V and 120 V mains
supplies. A transformed voltage of 230 V is provided at the output of the AC-AC voltage
transformer for the FDV MF charger (4).
No. Function
(1) 110 / 120 V AC mains plug
For connection to the 110 / 120 V
AC mains supply.
(2) 230 V AC output
For connection to the FDV MF
charger.

16
Welding position and seam tracking
Possible
welding
positions
The 4-wheel drive and built-in permanent magnet ensure that the driving vehicle adheres
optimally to the workpiece and guarantee the best possible traction. The following weld-
ing positions are possible.
IMPORTANT! In vertical operation, the driving vehicle must be secured by a load secur-
ing device with a locking function to prevent it from falling. The load securing device must
be designed for the total weight of the vehicle. The manufacturer accepts no liability for
any damage to persons or property resulting from vertical use of the driving vehicle with-
out a load securing device.
SlopingHorizontal
Outside of container with min. diameter of 3000 mmVertical
NOTE! From an angle of 45° upwards, the driving vehicle must be secured by a
load securing device with a locking function to prevent it from falling.
NOTE! When used on the outside of a container, the container must be turned
in the opposite direction and at the same speed.

17
Possible
welding
positions
(continued)
Inside of container with minimum diameter of 2500 mm
NOTE! When used inside a container, the container must be turned in the op-
posite direction and at the same speed.
IMPORTANT! Use of the driving vehicle in the "PE" overhead position is prohibited.
Guidance of the
carriage
Guidance on outside vertical surfaceGuidance on inside vertical surface
The guide wheels automatically track the torch in the lled 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:

18
Guidance on angle piece (horizontal) or rail
NOTE! When guided on a hori-
zontal angle piece, the welding
torch must only be placed on the
upper side.
Guidance of the
carriage
(continued)
Guidance on outside vertical surfaceGuidance on angle piece (vertical) or rail
Outside of curve with minimum diameter of 5000 mm Inside of curve with minimum diameter of
5000 mm