FRO­NIUS ArcRover 22 Wiring diagram

ArcRover 22
Welding carriage
EN
/ Perfect Welding / Solar Energy / Perfect Charging
Operating Instructions
Translation of original
Operating Instructions
42,0426,0297,EN 19112019

Contents
About this document........................................................................................................................................ 5
Function of this document .......................................................................................................................... 5
Explanation of safety information ............................................................................................................... 5
Copyright.................................................................................................................................................... 5
Qualied personnel .................................................................................................................................... 5
General............................................................................................................................................................ 6
Principle...................................................................................................................................................... 6
Device concept........................................................................................................................................... 6
Application area ......................................................................................................................................... 6
Proper use/intended purpose..................................................................................................................... 6
Foreseeable misuse................................................................................................................................... 7
Conversions or modications ..................................................................................................................... 7
Operating Instructions ................................................................................................................................ 7
Duty to provide instruction.......................................................................................................................... 7
Dangers from the rechargeable battery pack............................................................................................. 8
Use of charger and rechargeable battery pack .......................................................................................... 9
Environmental conditions ........................................................................................................................... 9
Warning notices on the carriage............................................................................................................... 10
Scope of supply........................................................................................................................................ 11
Carriage components .................................................................................................................................... 12
ArcRover 22 conguration with oscillation unit ........................................................................................ 12
ArcRover 22 conguration without oscillation unit ................................................................................... 13
Accessories and options ............................................................................................................................... 14
Accessories.............................................................................................................................................. 14
Options..................................................................................................................................................... 16
Control and display elements, connections................................................................................................... 17
Carriage.................................................................................................................................................... 17
Control panel............................................................................................................................................ 19
Main menu................................................................................................................................................ 20
Charger and rechargeable battery pack................................................................................................... 21
Menu navigation and parameter entry........................................................................................................... 22
General..................................................................................................................................................... 22
Turning/pressing the adjusting dial........................................................................................................... 22
Carriage parameters ..................................................................................................................................... 23
CAR menu................................................................................................................................................ 23
OSC menu................................................................................................................................................ 24
Welding position and weld seam tracking ..................................................................................................... 26
Possible welding positions ....................................................................................................................... 26
Guidance of the carriage.......................................................................................................................... 27
Optional lateral guides ............................................................................................................................. 29
Additional torch holder ............................................................................................................................. 30
Preparing the carriage................................................................................................................................... 31
Mounting and setting up the guide rails ................................................................................................... 31
Fitting the carriage brushes (option) ........................................................................................................ 32
Fitting the lateral guides (option).............................................................................................................. 33
Fitting the second torch holder (option).................................................................................................... 35
Charging the rechargeable battery pack .................................................................................................. 35
Inserting rechargeable battery pack into carriage .................................................................................... 37
Connecting the external power supply (option)........................................................................................ 38
Setting up the carriage .................................................................................................................................. 39
Checking the workpiece surface and carriage ......................................................................................... 39
Placing the carriage ................................................................................................................................. 39
Attaching fall protection (only for vertical operation) ................................................................................ 40
Mounting and adjusting the welding torch................................................................................................ 41
Disengaging the carriage ......................................................................................................................... 42

Starting up the carriage ................................................................................................................................. 43
Checking the connections ........................................................................................................................ 43
Switching on the system components...................................................................................................... 43
Setting the carriage parameters .................................................................................................................... 44
Parameter list ........................................................................................................................................... 44
Setting the carriage parameters............................................................................................................... 45
Setting the oscillation parameters ............................................................................................................ 47
Saving a program..................................................................................................................................... 49
Loading a program ................................................................................................................................... 50
Welding mode ............................................................................................................................................... 51
Retrieving parameter record (JOB) on the power source ........................................................................ 51
Loading the carriage program .................................................................................................................. 51
Performing a test run................................................................................................................................ 52
Starting the welding process .................................................................................................................... 53
Correcting the Travel Speed .................................................................................................................... 53
Correcting the FMS o󰀨set ........................................................................................................................ 54
End of welding.......................................................................................................................................... 54
Troubleshooting............................................................................................................................................. 55
General..................................................................................................................................................... 55
Displayed error messages ....................................................................................................................... 55
Carriage.................................................................................................................................................... 56
Oscillation unit.......................................................................................................................................... 57
FMS 50/100 motor slide ........................................................................................................................... 57
Maintenance.................................................................................................................................................. 58
Personnel ................................................................................................................................................. 58
Maintenance record ................................................................................................................................. 58
Cleaning ................................................................................................................................................... 58
Maintenance intervals .............................................................................................................................. 58
Recommended lubricants ........................................................................................................................ 58
Horizontal welding torch adjustment unit ................................................................................................. 59
Vertical welding torch adjustment unit ...................................................................................................... 60
Carriage front ........................................................................................................................................... 61
Carriage back........................................................................................................................................... 62
Charger .................................................................................................................................................... 63
Rechargeable battery pack ...................................................................................................................... 63
Disposal of components........................................................................................................................... 64
Technical Data............................................................................................................................................... 65
ArcRover 22 carriage ............................................................................................................................... 65
Oscillation unit FOU 30/ML6 .................................................................................................................... 66
FMS 100/ML15/SE/ACC (optional) .......................................................................................................... 66
FMS 50/ML15/SE/ACC (optional) ............................................................................................................ 66
ArcRover 22 dimensions .......................................................................................................................... 67
Environmental conditions ......................................................................................................................... 68
Spare parts.................................................................................................................................................... 69
Spare parts, wearing parts and auxiliary materials .................................................................................. 69
Ordering details........................................................................................................................................ 69
ArcRover 22 carriage ............................................................................................................................... 70
„External power supply“ option................................................................................................................. 72
FOU 30/ML6/radial oscillation unit ........................................................................................................... 73
Circuit Diagrams............................................................................................................................................ 75
EU Declaration of Conformity........................................................................................................................ 80

5
About this document
Function of this
document
These Operating Instructions explain how to commission and operate the carriage. Look
after the Operating Instructions carefully; they must always be to hand at the location
where the carriage is being used. They can be used as a reference should any opera-
tional or functional problems occur in the future.
Qualied
personnel
- These Operating Instructions are designed for trained personnel or persons with
practical welding experience. Personnel must be trained through veriable regular
instruction.
- Maintenance and repair of the carriage may likewise only be carried out by trained
technicians and in compliance with the specied maintenance activities and mainte-
nance intervals.
- The manufacturer accepts no liability for damage caused by insu󰀩cient knowledge of
how to use the device.
Explanation
of safety
information
IMPORTANT! Indicates usage tips and other particularly useful information. It is not a
signal word for a harmful or dangerous situation.
Special care is required if you see any of the symbols shown.
Copyright of these Operating Instructions remains with Fronius International GmbH. The
text and illustrations are all technically correct at the time of going to press. We reserve
the right to make changes. The content of the Operating Instructions shall not give rise to
any claims whatsoever on the part of the purchaser.
Copyright
WARNING!
Indicates a possibly dangerous situation. If not avoided, death or serious injury may
result.
DANGER!
Indicates an imminent danger. If not avoided, death or serious injury will result.
NOTE!
Indicates a risk of awed results and possible damage to the equipment.
CAUTION!
Indicates a possibly harmful situation. If not avoided, minor or minor injury may result.

Application area The ArcRover 22 carriage can be used in all situations where a high degree of exibility
is required when executing longitudinal weld seams:
- Shipyards
- Bridge construction
- Workshops
- Production halls
- Building sites
General
The ArcRover 22 carriage has been
designed for exibility 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 cou-
pled with a robust yet lightweight design
allows quick and easy positioning on the
workpiece.
The carriage adheres to the workpiece
by means of a permanent magnet. This
guarantees the best possible traction even
in vertical use.
Adjustable guide rollers on the side of the
carriage ensure optimal tracking of the
weld seam.
The universal torch holder allows use of
both manual and machine welding torches.
ArcRover 22 carriage
Principle The ArcRover 22 carriage is a portable, battery-powered welding carriage with 4-wheel
drive. The carriage is used to execute mechanised butt and llet welds in horizontal or
vertical welding positions, with or without oscillation.
Device concept
The ArcRover 22 carriage must only be used for performing mechanised butt and llet
welds in horizontal or vertical welding positions. Any other use shall be deemed improper
and the manufacturer will assume no responsibility for any resulting damages.
The carriage can be used in the following welding processes:
- MIG / MAG process
Proper use also includes:
- Use of the charger and rechargeable battery pack included with the carriage
- Use of the permanent magnet with a minimum sheet thickness of 5 mm
Proper use/
intended purpose
The carriage can be equipped with a torch oscillation unit.
The carriage, together with the optional oscillation unit, is powered by the interchange-
able rechargeable battery pack.
The control unit is integrated into the carriage. The control panel has an illuminated dis-
play allowing simple and user-friendly parameter setting for the carriage.
6

- Use of MIG/MAG welding torches with a holder diameter of up to 28 mm
- Use in welding position PA with the "stainless steel drive wheel" option
- Carrying out all maintenance work at the specied maintenance 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 instructions contained in the Operating Instructions
- Using this document in conjunction with the operating
- instructions of the integrated system components (power source, wirefeeder, etc.)
Proper use/in-
tended purpose
(continued)
Any use other than for the intended purpose shall be deemed improper use. This in-
cludes:
- Operation on preheated components > 50 °C without stainless steel drive wheels
- Transporting people
- Use outside the permitted technical operating limits
- Use in hazardous areas
Foreseeable
misuse
Any unauthorised conversions or modications made to the carriage by the user shall
invalidate all liability or warranty obligations on the part of the manufacturer!
The electromagnetic characteristics of the carriage can be adversely a󰀨ected by ad-
ditions or modications of any kind. No modications or additions should therefore be
undertaken without rst consulting the manufacturer and obtaining written approval.
Conversions or
modications
Duty to provide
instruction
The operator must inform all people working with the carriage about the following before
starting work:
- Theoretical and practical aspects of operation
- Safety regulations
IMPORTANT! The duty to provide instruction applies in particular for people who only
work on the carriage occasionally.
The Operating Instructions help you to use the carriage safely and e󰀩ciently, and must
therefore be to hand at all times:
- The Operating Instructions must always be kept near the carriage.
- 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 in the event of a problem if
they are at hand!
IMPORTANT! The manufacturer shall not be liable for any damage that arises from fail-
ure to observe the Operating Instructions!
Operating
Instructions
7

Dangers from
the rechargeable
battery pack
The substances contained in the battery used in this device can be harmful
to the environment and to human and animal health. If the device becomes
damaged, please observe the following points:
- Make sure that leaking uids cannot get into the soil or groundwater
- If pollution has already occurred, it must be removed in accordance with
relevant national regulations
The battery can catch re if overheated. Do not expose the device to heat
(e.g. a permanent heat source or re).
If the battery is damaged or subjected to improper use, dangerous vapours
may be given o󰀨 which can irritate the airways.
Measures:
- Ensure an adequate supply of fresh air
- Seek medical attention in case of discomfort
With a faulty battery, liquid may leak out of the device.
- Avoid contact with the liquid
- Hand the device over to a Fronius Service Partner for repair
- Clean and check any parts that have come into contact with the liquid
Do not operate or store the device in a potentially explosive atmosphere.
Special regulations apply in rooms at risk of re or explosion:
- Observe relevant national and international regulations
To comply with European Directive 2006/66/EC on batteries and accumu-
lators and its implementation in national law, batteries and rechargeable
batteries that have reached the end of their life must be collected separately
and returned to an approved recycling facility.
- Be sure to return any device that you no longer require to your dealer, or
nd out about the approved collection and recycling facilities in your area.
Ignoring this European Directive may be harmful to the environment and
your own health!
Devices with mechanically undamaged rechargeable batteries may be
returned to the relevant Fronius Service Partner for repair or battery replace-
ment.
As soon as it becomes evident that the rechargeable battery has been me-
chanically damaged (e.g. electrolyte is escaping), dispose of the device at
your nearest recycling centre in accordance with national laws and guide-
lines.
If anything is unclear or you have any questions about disposal, contact your
Fronius Service Partner.
8

Use of charger
and rechargeable
battery pack
- The charger and the rechargeable battery pack are designed for each other. Therefore
you should only ever use the supplied charger to charge the battery pack.
- Recharge the rechargeable battery pack after every discharge. Do not wait until the
rechargeable battery pack is completely discharged before recharging it.
- Objects must not be passed through the ventilation openings of the charger.
- Charging/discharging of the battery must be carried out according to the relevant
requirements for the environmental conditions (technical data).
- Should unusual temperatures, odours, discolorations or deformations occur during the
charging process, halt the process immediately.
- Disconnect the charger from the mains and rechargeable battery pack when not in
use.
- When handling the battery, check the packaging and/or the battery itself for obvious
signs of damage.
- Do not open, crush, dismantle or drop the rechargeable battery pack from a large
height.
- Do not short-circuit the rechargeable battery pack or expose it to high temperatures.
- Keep the rechargeable battery pack away from direct sunlight and other heat sources.
- Do not place the rechargeable battery pack or the charger on moist or wet surfaces.
- Do not operate the rechargeable battery pack and charger in environments where they
are exposed to dust, ammable gases, steam or solvents. Do not use in environments
with strong vibrations and magnetic elds.
Environmental
conditions
Operating, storing or transporting the system outside the specied area or environmen-
tal ranges is regarded as not complying with the intended purpose. The manufacturer
shall not be liable for any damage or loss resulting from this.
Ambient air temperature range:
- during operation: 0 °C to +40 °C (32 °F to 104 °F)
- during transport and storage: -10 °C to+45 °C (14 °F to 113 °F)
- Recommended temperature range during charging: +5 °C to +40 °C (41 °F to
104 °F)
Relative humidity:
- up to 65% +/- 20%
Environmental conditions:
- Surrounding air is free from dust and ammable vapours, solvents or gases.
- No strong vibrations and magnetic elds around the rechargeable battery pack.
- No direct sunlight on the rechargeable battery pack.
- No storing the rechargeable battery pack on moist or wet surfaces.
9

Warning notices
on the carriage
A number of safety symbols can be seen on the rating plate a󰀩xed to the carriage. The
rating plate and safety symbols must not be removed or painted over.
ArcRover 22
Do not use the functions until you have fully read the Operating Instruc-
tions.
Do not dispose of used devices with domestic waste. Dispose of them ac-
cording to safety rules.
Type:
Ser.No.:
Art.No.:
U weight max. load
25,4 VDC 10,7 kg 22 kg 11 kg
www.fronius.com
Froniusstraße 1
Pettenbach 4643
ArcRover 22
8,045,642
XXXXXXXX
WARNING!
Risk of burns from hot surfaces!
The protective plate for the wheels heats up during long periods of welding
operation. Touching the plate may cause burns.
- Do not touch the protective plate.
- Wear protective gloves and suitable safety goggles or a protective
helmet.
10

ArcRover 22 scope of supply
Scope of supply
(1) Connecting cable to power source
(2) ArcRover 22 carriage
(3) Universal welding torch holder
(4) Hosepack holder
(5) Guide rails
(6) Allen keys: 2 / 2.5 / 3 / 4
(7) Rechargeable battery pack
25.4 V / 3.35 Ah
(8) Charger
(1) (2) (3)
(7)(8) (6)
(4)
(5)
11

ArcRover 22 carriage with oscillation unit
Carriage components
Oscillation unit
FOU 30/ ML6
Universal
welding torch
holder
Vertical welding
torch adjustment
unit
Horizontal
welding torch
adjustment unit
On-board
control unit
Hosepack holder
Guide rails
with rollers
Limit switch
Lashing point for
securing the carriage
Chassis with
4-wheel drive
Rechargeable
battery pack
25.4 V / 3.35 Ah
Control lever for
permanent magnet
Handle
ArcRover 22
conguration
with oscillation
unit
12

Universal
welding torch
holder
Vertical welding
torch adjustment
unit
Horizontal
welding torch
adjustment unit
On-board
control unit
Hosepack holder
Guide rails
with rollers
Limit switch
Lashing point
for securing the
carriage
Chassis with
4-wheel drive
Rechargeable
battery pack
25.4 V / 3.35 Ah
Control lever for
permanent magnet
Handle
ArcRover 22 carriage without oscillation unit
ArcRover 22
conguration
without oscilla-
tion unit
13

Accessories Article: Item number: Designation:
48,0005,2582 Stainless steel drive wheel
(for workpieces with particu-
larly rough surfaces).
IMPORTANT! Use of the carriage with the "stainless steel drive wheel" accessory is
only permitted in the PA welding position. Please seek advice with Fronius service per-
sonnel if using pre-heated workpieces.
48,0005,2583 Brushes (2 pcs)
48,0005,2600 Rechargeable battery pack
25.4 V / 6.8 Ah
48,0005,2601 Charger
100-240 V 50/60 Hz /
29.4 V DC
48,0005,0165 External power supply
230V AC / 24V DC
38,0100,0433 Remote control cable 10 m
38,0100,0476 Extension cable 10 m
4,100,711 I-set external start signal
VR5000
(necessary for use with TransSteel;
installed in the wirefeeder)
Accessories and options
14

Accessories
(continued) Article: Item number: Designation:
4,100,779,IK OPT/i WF external start
signal
(necessary in combination
with TPSi; installed in the WF
wirefeeder)
48,0005,2578 Tiltable lateral guide
48,0005,2577 Lateral guide for edge
48,0005,2579 Magnetic lateral guide
(2)
(3)(1)
(1) 48,0005,2580 Guide arm for rail 1850 mm
(2 pcs)
(2) 48,0005,1894 Flexible guide rail 1850 mm
(3) 48,0005,1895 Magnetic guide rail base
15

Accessories
(continued)
Options Article: Item number: Designation:
8,045,644 Oscillation unit
FOU 30/ML6/radial
8,045,599 Motor slide
FMS 100/ML15/SE/ACC
8,045,618 Motor slide
FMS 50/ML15/SE/ACC
38,0100,0459 Connection cable 0,8 m:
- FMS/ML15/SE/ACC
- FOU 30/ML6/radial
Article: Item number: Designation:
48,0005,2581 Additional welding torch
holder (for 2nd torch)
16

Control and display elements, connections
Carriage
ArcRover 22 carriage
No. Function
(1) Front limit switch
(2) Control panel
- For the complete operation of the carriage.
- For conguring carriage parameters and creating programs.
(3) Permanent magnet control lever ON/OFF
For switching the permanent magnet on and o󰀨 during vertical operation.
(4) Connecting plug for FOU 30, FMSS 50/100, Service
- For connecting the cable to the optional oscillation unit FOU 30.
- For connecting the cable to the optional motor slide FMS 50 or FMS 100. Mo-
tor slide corrects the position of the welding torch.
- Connection for diagnostic and service purposes.
(5) Not used.
(6) Connecting plug for analogue power source control
For connecting the cable to the power source (analogue arc ignition).
(7) Rear limit switch
(1)
(7)
(3) (2)(4)(5)
(6)
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
Do not use the functions described here until you have fully read and understood the
following documents:
- These Operating Instructions
- All operating instructions for the system components
17

Carriage
(continued)
ArcRover 22 carriage
No. Function
(8) Compartment for rechargeable battery pack
(9) Connecting plug for rechargeable battery pack
- for plugging in the rechargeable battery pack (Li-Ion 25.4V / 3.35Ah)
- for connecting the connection cable of the control box during mains operation
(external power supply)
(10) Control unit ON/OFF toggle switch
For switching the carriage control unit on and o󰀨.
(11) Lock knob for locking the battery
(10)
(11)
(8)
(9)
18

Control panel
No. Function
(1) Display
For conguring parameters and creating programs using the menu adjusting dial
(6). The digital display is illuminated.
(2) FMS-O󰀨set adjusting dial
- For correcting the welding torch position when a FMS 50 or FMS 100 motor
slide is installed.
- For returning to the main menu.
(3) Travel speed adjusting dial
Used to adjust the travel speed of the carriage. The currently set travel speed is
shown on the display.
Setting range: 5 - 200 cm/min
(4) Toggle switch Start LEFT/ 0/RIGHT
For starting and stopping the automatic program sequence in the relevant weld-
ing direction.
(5) Welding toggle switch I/0/TEST
For choosing whether to carry out the automatic program sequence with or with-
out welding.
I ... Welding on preselection
0 ... Welding o󰀨 preselection
TEST ... Arc immediately active (arc test)
(6) Adjusting dial menu
- For menu navigation and parameter entry.
- Pressing 2 seconds: for returning to the main menu.
O
TEST
O
I
ArcRover 22
Slot 0
CAR
OSC
000
000
(6)
(1)
(2)
(3)
(4)(5)
ArcRover 22 control panel
19

CAR
OSC
000
000
Slot 0
Main menu No. Function
(1) Header
The following information is dis-
played:
- Currently loaded carriage pro-
gram (program 0 - 9)
- Battery power level
- In the event of malfunction:
Error 1 - 11
(2) FMS-O󰀨set active status display
A correction of the welding torch
position is currently being carried
out.
(3) Travel speed display
Displays the currently set travel
speed in cm/min.
No. Function
(4) Front limit switch active display
(5) Welding ON/OFF display
(6) Rear limit switch active display
(7) OSC menu
Opens the OSC menu for setting the parameters for the oscillation unit FOU 30.
(8) CAR menu
Opens the CAR menu for setting the carriage parameters.
(1)
(2)
(3)
(7)
(8)
(4)(5)(6)
20