FRO­NIUS FDV 80 User manual

FDV 80 Operating Instructions
Straight-line carriage
EN
42,0426,0098,EN V03 - 04072016
/ Perfect Welding / Solar Energy / Perfect Charging

1
Table of contents
General............................................................................................................................................................ 3
Principle...................................................................................................................................................... 3
Device concept........................................................................................................................................... 3
Field of application ..................................................................................................................................... 3
Proper use.................................................................................................................................................. 3
Warning notices on the carriage................................................................................................................. 4
Carriage components ...................................................................................................................................... 5
Standard equipment................................................................................................................................... 5
Options and accessories............................................................................................................................ 5
Congurations ................................................................................................................................................. 6
Overview .................................................................................................................................................... 6
Controls and connections................................................................................................................................ 7
Carriage connections ................................................................................................................................. 7
FRC-40 remote control............................................................................................................................... 8
Welding position and seam tracking................................................................................................................ 9
Possible welding positions ......................................................................................................................... 9
Guidance of the carriage............................................................................................................................ 9
Preparing the carriage................................................................................................................................... 10
Checking the surface of the workpiece and the carriage to ensure they are clean.................................. 10
Placing the carriage ................................................................................................................................. 10
Adjusting the guide roller.......................................................................................................................... 10
Option: setting the lateral guides.............................................................................................................. 11
Carriage strain relief................................................................................................................................. 11
Commissioning.............................................................................................................................................. 12
Checking the connections ........................................................................................................................ 12
Switching on system components............................................................................................................ 12
Dening carriage parameters................................................................................................................... 12
Selecting and loading the welding program ............................................................................................. 12
Carrying out a test run.............................................................................................................................. 13
Starting the welding process .................................................................................................................... 13
Troubleshooting............................................................................................................................................. 14
General..................................................................................................................................................... 14
Basic requirements for the system to work .............................................................................................. 14
Carriage.................................................................................................................................................... 14
Control error messages............................................................................................................................ 14
Maintenance and care................................................................................................................................... 16
Personnel ................................................................................................................................................. 16
Maintenance record ................................................................................................................................. 16
Maintenance operations and intervals ..................................................................................................... 16
Recommended lubricants ........................................................................................................................ 16
Carriage components............................................................................................................................... 17
Technical data ............................................................................................................................................... 18
Carriage FDV 80 ...................................................................................................................................... 18
Dimensions FDV 80 ................................................................................................................................. 18
Dimensions FDV 80 / S001...................................................................................................................... 19
Dimensions FDV 80 / S002...................................................................................................................... 19
Dimensions FDV 80 / S003...................................................................................................................... 20
Dimensions FDV 80 / S004...................................................................................................................... 20
Dimensions FDV 80 / S005...................................................................................................................... 21
Dimensions FDV 80 / S006...................................................................................................................... 21
Dimensions FDV 80 / S007...................................................................................................................... 22
Dimensions FDV 80 / S008...................................................................................................................... 22

2
Options and accessories ............................................................................................................................... 23
System overview ...................................................................................................................................... 23
Installation kits.......................................................................................................................................... 23
Wiring diagram .............................................................................................................................................. 35
EU-Declaration of conformity ........................................................................................................................ 41

3
Field of
application
The FDV 80 carriage can be used in all situations where a high degree of exibility is
required when executing longitudinal weld seams:
- Welding of longitudinal members
- Shipyards
- Production halls
General
The modular design enables the carriage to be equipped for a wide range of
applications.
A exible system consisting of rails and swivelling units, along with a mechanical weld
tracking system, enables welding to take place on parallel workpieces as well as on
workpieces that are bent, diverge or are tapered.
The job is selected directly using the remote control.
The carriage is powered by a mains cable.
Principle The FDV 80 carriage forms the basis of a mobile longitudinal welding system, consisting
of a straight-line carriage, control unit, torch head and weld tracking.
Device concept
The FDV 80 carriage must only be used for creating mechanised butt and llet welds in a
horizontal welding position.
Any other use shall be deemed improper and the manufacturer will assume no
responsibility for any damages arising.
Can be used in the following welding processes:
- MIG / MAG process
Proper use also includes:
- Carrying out all maintenance work at the appropriate intervals
- Keeping a service book with the most important information (date, operator, activities
carried out)
- Using the spare parts stipulated by Fronius
- Following all the information in the operating instructions
- Using this document in combination with the operating instructions for the integrated
system components (power source, wire-feed unit, etc.)
Proper use
NOTE! Any use of the machine other than for its intended purpose or any
unauthorised conversion or modications, shall be deemed improper use.
Any liability or warranty from the manufacturer is hereby invalidated.

4
FDV 80 rating plate
Warning notices
on the carriage
A number of safety symbols can be seen on the rating plate a󰀩xed to the carriage. The
safety symbols must not be removed or painted over.
Do not dispose of used devices with domestic waste. Dispose of them according to
safety rules.
Do not use the functions until you have fully read all the operating instructions.
800 x1260 x245 mm
LxWxH
P
70 kg
weight
300 VA
80 kg
max. load
1~
50/60 Hz
I1
1,3 A
U1
230 V
vmax
300 cm/min
EN 12100
Ser.No.:
Art.No.:
A-4600 Wels
www.fronius.com
FDV 80
8,045,278
YM:2010

5
Carriage components
Standard
equipment
Options and
accessories
- 4-wheel drive via pulse motor
- Wheels with polyurethane tread, one side with a groove
- Integrated distance measurement system
- Reinforcement with mounting pin for wire-feed unit
- 4 transportation lugs
- Power supply and PLC power module
- Mains cable with plug (12m)
- Control line to power source (10m)
- FRC-40 remote control with cable (3m)
- Holder for FRC-40 remote control
- Mechanical weld tracking system
- Torch holder and adjustment units
- FRR reducing rings for torch holder
- Steel guide rollers with / without groove
- Linear axis unit FAU 50 -100 / SD 600 or FAU 50 - 100 SD 1100
- FAU 50-100 cradle I-kit (needed when 2 torches are used)
- Limit position function I-kit
- Guide rollers, with lateral adjustment
- VR holder for two wire-feed units
FDV 80 Remote
control
Wire-feed
unit
Conguration 1
Conguration 2
Conguration 3
FDV 80 accessories
Conguration 1: Use of one torch:
Linear axis unit FAU 50 - 100 / SD 600 / ML 20 (Cradle I-kit included)
Conguration 2 and 3: Use of two torches:
Linear axis unit FAU 50 - 100 / SD 1100 / ML 20
Cradle I-kit for the second torch

6
Congurations
FDV 80 / S007
FDV 80 / S004
FDV 80 / S005
FDV 80 / S003
FDV 80/S001 FDV 80 / S002
FDV 80 / S006
Overview Depending on the individual requirements and composition of the components, a wide
range of workpieces can be processed.

7
Controls and connections
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here 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
Carriage
connections
FDV 80 connections
(1)
(2)
(3)
(4)
(5)
No. Function
(1) Remote control connection
(control unit)
to connect the manual remote con-
trol (e.g. FRC-4 control unit)
(2) On/O󰀨 mains switch
to switch the carriage and connect-
ed remote control on and o󰀨
(3) Mains connection with fuse
to connect the mains cable
No. Function
(4) Power source control
to connect the power source
(5) Optional: Control I-kit of second power source (job changeover)
to connect a second power source

8
No. Function
(5) "Welding ON/OFF" selector switch
to select automatic program sequence with or without welding
(6) "Manual mode" button
to manually position the carriage
(7) "START" button
to start an automatic program sequence
FRC-40
remote control
FRC-40 remote control
The FRC-40 remote control allows you to load and save up to 100 programs.
(1)
(2)
(3)
(4)
(5)(6)(7)
NOTE! Detailed information about loading and saving programs and using the
remote control can be found in the FRC-40 operating instructions.
No. Function
(1) Touchscreen display
for menu navigation
(2) Emergency Stop button
for immediate stoppage in an
emergency
(3) Multi-function wheel
to select and edit the welding
parameters
(4) "STOP" button
stops the automatic program
sequence

9
Welding position and seam tracking
Possible
welding positions
Its 4-wheel drive gives the carriage exceptional directional stability and the best possible
traction. A groove in the tread of the wheels on one side of the carriage also ensures
stable handling properties.
The following welding positions are possible:
- Horizontal
Guidance of the
carriage
The adjustable guide roller on the carriage provide optimum seam tracking.
Depending on the carriage components and the workpiece to be welded, di󰀨erent roller
positions are possible:

10
Preparing the carriage
Before positioning the carriage, check the following:
- The surface of the workpiece must be clean (no sand, shavings, etc.)
- The bottom plate of the carriage must be clean and free of shavings
- The drive wheels must not be damaged and must be clean
- The guide roller and guide rails must be clean, undamaged and free of
welding spatter
Checking the
surface of the
workpiece and
the carriage to
ensure they are
clean
Adjusting the
guide roller
(a)
(a)
(b)
(b)
(c)
The holders (c) for the guide rollers (a)
have ve slots in which the guide rollers
can be secured:
1. Loosen the xing screw (b) at the de-
sired slot.
2. Position the guide roller (a) and extend
it to the desired length.
3. Tighten the xing screw (b).
1. Place the carriage on the workpiece.
If guide rollers with grooves are used: Ensure that the size of the guide rail is suitable
for the guide rollers.
2. Place the lateral guide rollers on the workpiece. Correct their position if necessary.
Placing the
carriage

11
Carriage strain
relief
To attain optimum wirefeed, observe the following when connecting and routing the
hosepack:
- Do not allow the hosepack to become kinked
- Always lay the hosepack as straight as possible
- Suspend hosepack if necessary. Use balancer and hosepack holder.
Hosepack handling
Option: setting
the lateral guides
(a)
(b)
Some carriage congurations have, in addition to the guide rollers, two lateral guides (a)
that guide the carriage. The guides and rollers can be installed facing towards the centre,
or even swapped over or rotated so that both rollers face outwards.
To adjust the guides, proceed as follows:
1. Loosen the two xing screws (b) on both lateral guides.
2. Extend the lateral guides to the desired length.
3. Tighten the xing screws (b).

12
IMPORTANT! For each workpiece a corresponding welding program must be created.
This contains a list of welding parameters that is saved under a specic program number
(job number). These programs can be reloaded at any time, and corrected as required.
The programs are managed from the FRC 40 remote control.
Load the relevant welding program.
More detailed information on "Managing welding programs" can be found in the
operating instructions for the FRC 40 remote control.
Selecting and
loading the
welding program
Commissioning
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here 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
The following activities and work steps apply to the installed system. All connections
must be established. Before start-up, check the connections of the following system
components:
- Power source
- Cooling circuit
- Gas cylinder
- Wire-feed unit
- Welding torch with hosepack
- Workpiece
Precise information on the assembly and connection of the system components can be
found in the relevant system component operating instructions.
Checking the
connections
IMPORTANT! There are no xed rules for the sequence in which the system
components are switched on. They can be switched on in any order.
Switch the main switch on the following system components to the
"ON - 1" position:
- Carriage control unit
- Power source
- Wire-feed unit (if power is not supplied from the power source)
Switching on
system
components
Determine the following settings for the welding process:
- Traversing speed
- Path
- Select the correct welding program
Further information and a detailed description of the carriage parameters can be found in
the operating instructions for the FRC-40 remote control.
Dening carriage
parameters

13
NOTE! After you have pressed the "START" button, the carriage only starts to
move once the predetermined start-up delay time has elapsed.
Perform a test run to check that all system components work together correctly. This is
done without an arc and thus allows you to check all movements during the process.
Carrying out a
test run
Start the welding process:
1. Set the "Welding ON / OFF" selector switch (1) to the "ON" position.
2. Press the "START" button (2). The automatic program sequence starts.
Starting the
welding process
1. Set the "Welding ON / OFF" selector
switch (1) to the "OFF" position.
2. Press the "START" button (2).
The automatic program sequence
starts.
IMPORTANT! Never leave the
machine unattended, particularly when
it is moving automatically.
3. Carry out a visual check during the process.
4. If necessary, make the relevant corrections (welding torch position, direction of travel
of carriage, traversing speed, etc.).
5. After the test, move the carriage back to its original position.
(1)
(2)

14
Troubleshooting
In the event of faults, note that the functioning of the entire system depends on many
additional components (power source, wire-feed unit, etc.) that are also potential sources
of problems.
General
- Connections established between separate system components
- System components are supplied with electricity and the mains voltage is as
specied (see rating plate)
Basic
requirements for
the system to
work
Carriage
Control error
messages
Errors or malfunctions associated with the FRC 40 remote control appear on its display.
Drive wheels slip during travel
Cause: Wheels dirty (with oil)
Remedy: Clean the wheels
Cause: Carriage overloaded (e.g. the torch cables pull the carriage up)
Remedy: Relieve cable strain (suspend)
Play on the torch
Cause: Play on the handles
Remedy: Tighten handles
Cause: Play on the guide rails
Remedy: Tighten the pressure screws
EMERGENCY STOP
Cause: Emergency stop signal activated by the Emergency Stop protection
device. All controls are disabled during an emergency stop
Remedy: Rectify the Emergency Stop situation and release the Emergency
Stop button
Limit reached - adjust with manual mode button
Cause: The relevant limit switch on the carriage has been activated
Remedy: Leave the limit position using the manual mode button
Cause: The limit switch was actuated unintentionally
Remedy: Leave the limit position using the manual mode button
Cause: Mechanical fault on limit switch
Remedy: Replace the limit switch (spare parts list, carriage)

15
Control error
messages
(continued)
No current ow signal
Cause: Current ow signal activated in system parameters, but no
ROB 3000 or digital power source in use
Remedy: Deactivate current ow signal in system parameters
Cause: Fault on the power source
Remedy: Check the settings on the power source
Correct if necessary
Cause: Fault on the power source
Remedy: Check the settings on the power source
Correct if necessary
Cause: No robot interface in use (digital power source only.)
Remedy: Integrate ROB 3000 robot interface
Cause: Faulty connection to power source
Remedy: Check the power source function
Cause: No earth connection: earthing cable loose or not connected
Remedy: Check the earth connection

16
Maintenance and care
WARNING! Risk of injury and damage from incorrectly performed
maintenance.
All maintenance work on the FDV 80 carriage must only be carried out by
trained technicians. It is essential to adhere
to the maintenance intervals and maintenance procedures. The manufacturer
accepts no liability for any damage caused by inadequate or poorly performed
maintenance.
Personnel
The operator must put the following organisational measures in place with regard to
maintenance:
- keeping a service book with the most important data (date, operator, maintenance
activities carried out)
Maintenance
record
Recommended
lubricants
IMPORTANT! Lubricants with solid lubricant additives (e.g.: MoS2, graphite and PTFE)
are not suitable for guiding systems.
Maintenance
operations and
intervals
NOTE! Before beginning maintenance work, switch o󰀨 device and disconnect
from mains supply.
Lubricant DIN DIN number Comment
Lubricating grease KP 2-K 51502 / 51825 Lithium soap-based
grease
Lubricating oil CLP32-100 51517 Part 3 ISO VG 32-100
Conductive paste --- --- Item no. 48,0009,0157
D Daily
W Weekly
M Monthly
1/2 y Half-yearly
Y Yearly
Item Part Action Interval
Linear guides Clean, check oil lm M
Thread play Clean, regrease M
Rack and pinion Clean, regrease M
Toothed belt Pretension, check for tears M
Rollers and rails Clean, check position M
Ventilation openings Clean W
Terminal contacts Clean W
Wheels / rollers, underbody,
guide rails
Clean D
A
B
C
D
E
F
G
H

17
Carriage
components
E
H
H
A
E
H
G
H
H
C
D
Conguration example

18
Max. load 80 kg
Welding signal 2-step/4-step mode
Welding position PA
Travel speed 1-300 cm/min
Track width 380 mm
Net weight (without remote control and weld tracking) 70 kg
Mains voltage/frequency 230 V / 50-60 Hz
Control voltage 24 V DC
Power consumption 300 VA
Technical data
Carriage
FDV 80
Dimensions
FDV 80
A
B
C
A 800 mm
B 450 mm
C 245 mm