FRO­NIUS FDV 15 MF User manual

FDV 15 MF Operating Instructions
Carriage
EN
42,0410,1653 V07 - 04072016
/ 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 ............................................................................................................................ 9
FDV 15 MF................................................................................................................................................. 9
Control elements and connections ................................................................................................................ 10
Driving vehicle control panel .................................................................................................................... 10
AC-ACvoltage transformer ....................................................................................................................... 10
Charger and battery pack......................................................................................................................... 11
Welding position and seam tracking.............................................................................................................. 12
Possible welding positions ....................................................................................................................... 12
Guidance of the driving vehicle ................................................................................................................ 13
Guidance of the driving vehicle with optional lateral guides..................................................................... 15
Preparing the driving vehicle ......................................................................................................................... 16
Fitting the guide rails ................................................................................................................................ 16
Fitting the brushes (option) ...................................................................................................................... 17
Fitting the lateral guides (Option) ............................................................................................................. 18
Fitting lateral guides with exible guide rail (Option)................................................................................ 19
Connecting the charger to the mains supply............................................................................................ 20
Charge the battery pack........................................................................................................................... 20
Insert battery pack in driving vehicle docking station ............................................................................... 21
Adjusting the guide wheels ...................................................................................................................... 22
Check the surface of the workpiece and the driving vehicle to ensure they are clean............................. 22
Placing the driving vehicle........................................................................................................................ 22
Attach fall protection (vertical operation).................................................................................................. 23
Mounting and adjusting the welding torch................................................................................................ 23
Driving vehicle strain relief ....................................................................................................................... 24
Start-up.......................................................................................................................................................... 25
Check the connections............................................................................................................................. 25
Switch on system components................................................................................................................. 25
Dene driving vehicle parameters............................................................................................................ 25
Loading a welding program...................................................................................................................... 25
Carry out test run......................................................................................................................................26
Start the welding process......................................................................................................................... 26
Troubleshooting............................................................................................................................................. 27
General..................................................................................................................................................... 27
Basic requirements for the system to work .............................................................................................. 27
Driving vehicle.......................................................................................................................................... 27

2
Maintenance and care................................................................................................................................... 29
Personnel ................................................................................................................................................. 29
Maintenance record ................................................................................................................................. 29
Maintenance operations and intervals ..................................................................................................... 29
Recommended lubricants ........................................................................................................................ 29
Driving vehiclecomponents ...................................................................................................................... 30
FDV-MF charger....................................................................................................................................... 31
Battery pack ............................................................................................................................................. 31
Disposal of components........................................................................................................................... 31
Technical data ............................................................................................................................................... 32
FDV 15 MF............................................................................................................................................... 32
FDV MF charger + battery pack ............................................................................................................... 32
AC-AC-voltage transformer...................................................................................................................... 32
FDV 15 MF dimensions............................................................................................................................ 33
FDV 15 MF ...................................................................................................................................................... 4
EU-Declaration of conformity .......................................................................................................................... 5

3
Field of applica-
tion
Driving vehicle FDV 15 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 15 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.
The driving vehicle is powered by the inter-
changeable battery pack. The control unit
is integrated into the driving vehicle.
Driving vehicle FDV 15 MF
Principle Driving vehicle FDV 15 MF is a portable, battery-powered longitudinal truck with 4-wheel
drive. The driving vehicle is used to execute mechanised butt and llet welds in horizon-
tal or vertical welding positions.
Machine concept
Driving vehicle FDV 15 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 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 4 mm
- use of MIG / MAG welding torches with a holder diameter of 16 - 22 mm
- 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
Proper use

4
- 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.)
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.

5
Rating plate FDV 15 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.
Type:
Ser.No.:
Art.No.:
A-4600 Wels
www.fronius.com
U weight max. load
14,4 VDC 5 kg 15 kg
2009
FDV 15/MF
8,045,369
20 25 9502
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.
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 15 MF scope of supply
Scope of supply
(6)
(7)
(5)
(1) (2) (4)
(3)
(1) Driving vehicle FDV -15 MF
(2) Rear guide rail
(3) Front guide rail
(4) Universal torch holder
(5) Allen keys 5 / 4 / 3 / 2
(6) Battery pack 14.4 V / 3 Ah
(7) Charger FDV MF

7
The optional equipment of the driving vehicle comprises:
- AC-AC voltage transformer
(38,0006,0164)
- Driving vehicle brush (48,0005,1424)
This accessory comprises two parts.
Brush bracket and 1x brush.
Options
For workpieces with very rough surface:
- Stainless steel drive wheel
(48,0005,1602), 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
Lateral guides:
1
(1) Lateral guide, tiltable
(48,0005,1889)
(2) Lateral guide for edge
(48,0005,1887)
(3) Lateral guide, magnetic
(48,0005,1891)
2
3
Lateral guide with guide rail:
(4) Guiding arm for exible rail,
1850 mm / 72.84 in (2 pc.)
(48,0005,1896)
(5) Flexible guide rail,
1850 mm / 72.84 in
(48,0005,1894)
(6) Magnet block for guide rail
(48,0005,1895)
IMPORTANT! 10 magnet blocks
for one rail are necessary!
5
6
4
Options
(continued)

9
Driving vehicle components
Vertical torch
adjustment unit
Horizontal torch
adjustment unit
On-board control unit
Guide wheels
Lifting eye for securing the
driving vehicle
Truck with
4-wheel drive
Battery pack
(14.4V / 3Ah)
Driving vehicle FDV 15 MF
Handle
FDV 15 MF
Universal torch
holder

10
SPEED
2
Control elements and connections
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read
and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
Driving vehicle
control panel
Driving vehicle FDV 15 MF control panel
(1)
(2)
(3)
(4)
No. Function
(1) Traverse speed potentiometer
Used to adjust the traversing speed of
the driving vehicle.
Setting range: 5 - 150 cm/min
(2) Control unit ON/OFF toggle switch
For switching the driving vehicle con-
trol unit on and o󰀨.
(3) Control unit ON signal lamp
Permanently lit: Control unit ready for
use Flashing: Battery pack is nearly
at
(4) Toggle switch Start LEFT / STOP /
Start RIGHT
For starting and stopping the automa-
tic program sequence.
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.
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.

11
Charger and
battery pack
Overview of charging set
(6)
(4)
(7)
(5)
Ni MH
H
N
i C
d
+
+
(2)
(1)
(3)
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.
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.

12
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 minimum diameter of
1500 mm
Vertical
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.

13
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
driving vehicle
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:

14
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
driving vehicle
(continued)
Guidance on outside vertical surfaceGuidance on angle piece (vertical) or rail
Guidance on outside of curve with minimum diameter
of 5000 mm
Guidance on inside of curve with minimum diameter
of 5000 mm

15
Lateral guide, tiltable
Lateral guide for edge
Lateral guide, standard / with magnet
- Lateral guide for exible rail (2 pc.) (1850 mm / 72.84 in)
- Magnet block for guiding rail
- Guiding for exible rail (1850 mm / 72.84 in)
IMPORTANT! 10 magnet blocks per rail are necessary!
Lateral guide with exible guide rail
Guidance of the
driving vehicle
with optional
lateral guides

16
FDV-15 MF driving vehicle
1. Use M5 x 14 allen screws and a 5.5 shim to attach the guide rails to the driving
vehicle.
2. Tighten the screws using a size 5 allen key. See „Adjusting the guide wheels“ for
information on how to set the guide wheels.
Preparing the driving vehicle
Fitting
the guide rails

17
Fitting the
brushes (option)
FDV-15 MF driving vehicle with brushes
1. Remove the M5 x 14 (a) screws using a size 5 allen key.
2. Attach the brush brackets as shown.
3. Fit and tighten the M5 x 14 screws (a) and the shims.
4. Fit the brush to the front or rear brush bracket using M6 screws (b).
NOTE! The brush may be tted to either the front or rear of the driving vehicle.
(b)
(a)
(a)

18
Fitting the lateral
guides
(Option)
All lateral guides for the FDV 15 carriage are fastened with the M5 x 14 xing screws
with washer.
The lateral guides are mounted on both front sides of the carriage.
Tighten the xing screws with a size 5 allen key.
Lateral guide, tiltable
Lateral guide for edge
Lateral guide, magnetic