FRO­NIUS FlexTrack 45 User manual

FlexTrack 45
8,045,565
Operating instructions
Spare parts list
Welding carriage
EN
/ Perfect Welding / Solar Energy / Perfect Charging
42,0426,0205,EN V03-03032015

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These operating instructions will help you familiarise yourself with the device. It is in
your interest to read these instructions carefully and to observe the directions contained
in them. This will prevent faults and incorrect operation or possible damage to installed
components.
Please also obey the safety rules; doing so will ensure greater safety when using the
product. Careful handling of the entire system will repay you with years of safe and reli-
able operation. These are essential prerequisites for excellent results.
Dear reader,
Introduction

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Contents
General information 7
About this document........................................................................................................................................ 9
Function of this document .......................................................................................................................... 9
Explanation of safety symbols.................................................................................................................... 9
Qualied technicians .................................................................................................................................. 9
Copyright.................................................................................................................................................... 9
General.......................................................................................................................................................... 10
Principle.................................................................................................................................................... 10
Device concept and applications.............................................................................................................. 10
Safety 13
Operational reliability and tips for the user .................................................................................................... 15
Proper use................................................................................................................................................ 15
Foreseeable misuse................................................................................................................................. 15
Conversions or modications ................................................................................................................... 15
Duty to instruct ......................................................................................................................................... 15
Operating instructions .............................................................................................................................. 16
Personal protective equipment................................................................................................................. 16
Local regulations ...................................................................................................................................... 16
Spare parts, wearing parts and auxiliary materials .................................................................................. 16
Transportation and storage ...................................................................................................................... 17
Description of the welding carriage 19
Scope of supply............................................................................................................................................. 21
Basic conguration................................................................................................................................... 21
Accessories and options .......................................................................................................................... 22
Welding carriage components....................................................................................................................... 23
Conguration: welding carriage with oscillation unit................................................................................. 23
Conguration: welding carriage without oscillation unit............................................................................ 24
Operating elements and connections............................................................................................................ 25
Connections ............................................................................................................................................. 25
Control box operating elements ............................................................................................................... 26
Welding carriage operating elements....................................................................................................... 26
Remote control elements ......................................................................................................................... 27
Rails and bridges........................................................................................................................................... 29
Weights of rails and bridges..................................................................................................................... 29
Fittings...................................................................................................................................................... 29
Rigid rails.................................................................................................................................................. 30
Flexible rails ............................................................................................................................................. 30
Bridge types ............................................................................................................................................. 31
Structure of a bridge................................................................................................................................. 31
Conguration: rail and guide rings ........................................................................................................... 32
Welding position and weld seam tracking ..................................................................................................... 34
Possible welding positions ....................................................................................................................... 34
Commissioning 37
Preparing the welding carriage...................................................................................................................... 39
Installing the welding carriage with oscillation unit................................................................................... 39
Replacing oscillation unit with adjustment unit......................................................................................... 40
Preparing and installing rails ......................................................................................................................... 41
Number of bridges required ..................................................................................................................... 41
Installing the bridges ................................................................................................................................ 41
Straight rails ............................................................................................................................................. 42

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Installing the contact cams....................................................................................................................... 42
Securing the rail structure ........................................................................................................................ 43
Closed ring rail ......................................................................................................................................... 43
Closed ring rail ......................................................................................................................................... 44
Rigid ring segments ................................................................................................................................. 45
Flexible ring segments ............................................................................................................................. 47
Commissioning the welding carriage............................................................................................................. 48
Placing the welding carriage on a straight rail.......................................................................................... 48
Placing the welding carriage on a ring rail ............................................................................................... 49
Regulating the pressure rollers ................................................................................................................ 50
Disengaging the welding carriage ............................................................................................................ 51
Operation 53
Creating and saving welding programs ......................................................................................................... 55
Switching on system components............................................................................................................ 55
Setting the welding carriage parameters.................................................................................................. 55
Selecting additional functions................................................................................................................... 56
Saving a program..................................................................................................................................... 57
Loading a welding program...................................................................................................................... 58
Changing the units of measurement ........................................................................................................ 58
Work procedure............................................................................................................................................. 59
Working with or without oscillation ........................................................................................................... 59
Performing a test run................................................................................................................................ 59
Starting the welding process .................................................................................................................... 60
Maintenance and disposal 61
Troubleshooting............................................................................................................................................. 63
General..................................................................................................................................................... 63
Basic requirements for the system to work .............................................................................................. 63
Event codes ............................................................................................................................................. 63
Error codes............................................................................................................................................... 63
Maintenance.................................................................................................................................................. 64
Maintenance personnel............................................................................................................................ 64
Maintenance record ................................................................................................................................. 64
Recommended lubricants ........................................................................................................................ 64
Maintenance intervals and procedures .................................................................................................... 65
Technical data 67
Technical data ............................................................................................................................................... 69
FlexTrack 45 welding carriage ................................................................................................................. 69
Control box............................................................................................................................................... 69
Oscillation unit.......................................................................................................................................... 69
Dimensions............................................................................................................................................... 69
Rating plates ............................................................................................................................................ 70
Weights of rails and bridges..................................................................................................................... 71
Ring rail settings table.............................................................................................................................. 72
Flexible rail segments settings table ........................................................................................................ 73
Spare parts, circuit diagram 75
Spare parts.................................................................................................................................................... 77
Spare parts, wearing parts and auxiliary materials .................................................................................. 77
Ordering details........................................................................................................................................ 77
Circuit diagram .............................................................................................................................................. 85

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General information

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About this document
Function of this
document
These operating instructions explain how to commission and operate the device in
conjunction with the installed system components. Look after the operating instructions
carefully; they must always be to hand at the location where the device is being used.
They can be used as a reference should any operational or functional problems occur in
the future.
Qualied
technicians
- These operating instructions are designed for trained technicians or persons with
practical welding experience. Personnel must be trained through veriable regular
instruction.
- Maintenance and repair of the device 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 insufcient knowledge of
how to use the device.
Explanation of
safety
symbols
DANGER! Indicates immediate and real danger. If it is not avoided, death or
serious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. Minor
injury and/or damage to property may result if appropriate precautions are not
taken.
NOTE! Indicates a risk of awed results and possible damage to the equip-
ment.
IMPORTANT! Indicates tips for correct operation and other particularly useful informa-
tion. It does not indicate a potentially damaging 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
print. Fronius reserves the right to make changes. The contents of the operating instruc-
tions shall
not provide the basis for any claims whatsoever on the part of the purchaser.
Copyright

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General
Principle
Device concept
and applications
The FlexTrack 45 welding carriage is intended for welding of butt and llet welds in the
MIG/MAG or CMT process, with or without oscillation.
It can be used on rigid or exible rails and on rigid or exible guide rings.
min. 1500 mm
min. 1100 mm
The compact welding carriage can be used in a wide range of applications. Three differ-
ent rail types are available to suit differing requirements and surface geometries.
The carriage is entirely remote-controlled, making it perfect for universal use.
STRAIGHT application:
FLEXIBLE application:

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Device concept
and applications
(continued)
200 - 6060 mm
RING application:

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Safety

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Proper use
Operational reliability and tips for the user
Any unauthorised conversions or modications made to the welding carriage by the user
shall invalidate all liability or warranty obligations on the part of the manufacturer.
The electromagnetic characteristics of the welding carriage can be adversely affected by
additions or modications of any kind. No modications or upgrades should therefore be
undertaken without rst consulting the manufacturer and obtaining written approval.
Conversions or
modications
The FlexTrack 45 welding carriage must only be used for welding butt and llet welds in
a horizontal or vertical welding position.
Any use above and beyond this purpose is deemed im-
proper – the manufacturer shall not be responsible for any damage resulting from such
improper use.
The welding carriage can be used in the following welding processes:
- MIG/MAG process
- CMT process
Proper use also includes:
- Carrying out all maintenance work at the stipulated intervals
- Keeping a service book with the necessary information (date, operator, activities car-
ried out, etc.)
- Using the spare parts stipulated by Fronius
- Following all the instructions, particularly the safety instructions, in the operating
instructions
- Using this document in conjunction with the operating instructions for the integrated
system components (power source, etc.)
Foreseeable
misuse
Any use other than for the intended purpose shall be deemed improper use. This in-
cludes:
- Riding on the welding carriage, transporting loads
- Using the exible (non-reinforced) rails on level surfaces
- Use above head height
- Hoisting processes (hoisting, manoeuvring of loads, animals or persons)
- Use as an aid to climbing
- Use as a tray for tools
- Use outside of the permitted technical operating limits (e.g. exceeding the max. per-
mitted load)
-Use in hazardous areas
Duty to instruct Before they start work, the system operator must instruct or train all persons working with
the welding carriage in:
- the theoretical and practical aspects of operation
- the safety regulations.
IMPORTANT! The duty to instruct also applies in particular to those who only occasion-
ally work with the welding carriage (e.g. during set-up, maintenance, etc.).

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The operating instructions help you to use the welding carriage safely and efciently, and
must therefore be to hand at all times.
- Keep the various sections of the operating instructions at the location where the weld-
ing carriage is being used at all times.
- Clearly mark the place where the instructions are kept.
- Ensure that all persons working with the welding 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 in-
structions
Spare parts,
wearing parts
and auxiliary
materials
Use of third-party spare and wearing parts may pose risks. Use approved Fronius origi-
nal spare parts only.
The manufacturer cannot accept any liability for damage resulting from the use of spare
or wearing parts or auxiliary materials that are not approved by the manufacturer.
Personal protec-
tive equipment
Local regulations In some countries, local statutory regulations may apply that are not included in these
operating instructions. It is the duty of the operator to be aware of and comply with any
local statutory regulations. This relates primarily to regulations concerning:
- Accident prevention
- Machine safety
- Protection of personnel (protective equipment)
- Environmental protection
- Electrical system
The operator alone is responsible for the immediate working environment.
The following safety measures must be put in place and employed:
- Welding goggles
- Welding shield
- Welding gloves
- Welding apparel
- Welding footwear

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Transportation
and storage
The complete system, including tool kit, is supplied in a specially designed metal trans-
port box. The rails must be stored separately.

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Description of the welding carriage

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