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Fronius FlexTrack 45, Operating Instructions/Spare Parts List, Page: 21 / 90

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Fronius FlexTrack 45 Operating Instructions/Spare Parts List Download Page 21

21

Scope of supply

Basic 

configuration

(2)

(7)

(3)

(1)

(4)

(5)

(6)

(1)

Control box

(2)

FlexTrack welding carriage

(3)

2 connecting cables: 1x between carriage and control box, 1x between carriage 

and remote control 

(4)

Hosepack holder

(5)

Connecting cable, control box - power source

(6)

Tool kit

(7)

Remote control

Summary of Contents for FlexTrack 45

Page 1: ...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...

Page 2: ......

Page 3: ...ained 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 C...

Page 4: ...4...

Page 5: ...ns 22 Welding carriage components 23 Configuration welding carriage with oscillation unit 23 Configuration welding carriage without oscillation unit 24 Operating elements and connections 25 Connection...

Page 6: ...ng 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...

Page 7: ...7 General information...

Page 8: ...8...

Page 9: ...se 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 Deat...

Page 10: ...n be used on rigid or flexible rails and on rigid or flexible guide rings m i n 1 5 0 0 m m m i n 1 1 0 0 m m The compact welding carriage can be used in a wide range of applications Three differ ent...

Page 11: ...11 Device concept and applications continued 200 6060 m m RING application...

Page 12: ...12...

Page 13: ...13 Safety...

Page 14: ...14...

Page 15: ...ping 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 instruct...

Page 16: ...ials 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 o...

Page 17: ...17 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...

Page 18: ...18...

Page 19: ...19 Description of the welding carriage...

Page 20: ...20...

Page 21: ...7 3 1 4 5 6 1 Control box 2 FlexTrack welding carriage 3 2 connecting cables 1x between carriage and control box 1x between carriage and remote control 4 Hosepack holder 5 Connecting cable control box...

Page 22: ...22 11 10 9 8 Accessories and options 8 Oscillation unit 9 Adjustment unit Torch holder depending on welding process 10 FTH 18 11 FTH 21...

Page 23: ...nfiguration welding carriage with oscillation unit Oscillation unit Rail Magnetic bridge Coupling Locking lever Guide rollers Remote control Torch adjustment unit Hosepack holder Torch holder Limit sw...

Page 24: ...4 Configuration welding carriage without oscillation unit Rail Magnetic bridge Adjustment unit Coupling Remote control Torch adjust ment unit Hosepack holder Torch holder Limit switch Carrying handles...

Page 25: ...ns 1 5 2 3 4 1 Control box mains cable 2 Control line between welding carriage and control box 3 Control line between welding carriage and remote control 4 Connecting lead between control box and powe...

Page 26: ...ng elements 1 Coupling on off Locks unlocks the welding carriage on the rail Allows rapid positioning of the carriage 2 Guide rollers locking lever Fixes and releases the internal guide rollers 3 Limi...

Page 27: ...low symbol Return travel path Return time at the end of the welding path in seconds s 3b White symbol Oscillation dwell time middle Regulates the oscillation dwell time in the middle of the weaving mo...

Page 28: ...itional segment welding function orange symbols IMPORTANT The welding process cannot start until the weaving mode adjusting knob 9 is set to one of the white function parameters 10 White symbol Weavin...

Page 29: ...on request 2 4 kg Rigid guide rail 1884 mm 11 kg Flexible guide rail 1884 mm 5 5 kg Flexible guide rail 1695 mm 4 8 kg Flexible guide rail 1130 mm 3 3 kg Rigid guide ring 200 300 mm 8 8 kg Rigid guid...

Page 30: ...ferent segment lengths for different diameter ranges Segment type Length I 1130 mm II 1695 mm III 1884 mm For workpiece 200 840 mm Guide ring rigid 200 300 mm Guide ring rigid 300 480 mm Guide ring ri...

Page 31: ...d for rigid rings up to 840 mm in diameter IMPORTANT All bridges include a metric adjustment unit and a distance block Structure of a bridge Standard bridge Bridge with distance block Bridge with metr...

Page 32: ...stable foot metric adjust ment unit and distance block Bridge with adjustable feet M6x14 screws M6x14 screws M6x14 screws Configuration rail and guide rings 200 840mm 840 1380mm 1380 1560 mm 200 840mm...

Page 33: ...33 Configuration rail and guide rings continued l 1130 mm l 1695 mm l 1884 mm 1380 1560 mm 1560 6060 mm on request...

Page 34: ...the total weight of the welding carriage and rail structure The manufacturer accepts no liability for any damage to persons or property resulting from vertical use of the welding carriage without a l...

Page 35: ...lat position PB horizontal vertical position PC horizontal position PG descending position PF ascending position Positions on ring rail rigid or flexible Possible welding positions PA flat position PB...

Page 36: ...36...

Page 37: ...37 Commissioning...

Page 38: ...38...

Page 39: ...rews supplied 2 Connect the connecting lead for the oscillation unit to the carriage and lock it in place 3 Push the welding torch holder onto the oscillation unit 4 Tighten the screws 5 Fit the horiz...

Page 40: ...d for the oscillation unit from the welding carriage 2 Undo the six M6 screws and remove the oscillation unit 3 Place the protective cap onto the socket for the oscillation unit 4 Fasten the adjustmen...

Page 41: ...t unit Bridges with an adjustment unit are installed with the M6x14 screws supplied Straight rigid rails For a rail length of 1884 mm use 3 bridges Straight flexible rails For a rail length of 1884 mm...

Page 42: ...F 6 Push the next section of rail with the groove 4 between the joining element 2 and the screw 3 7 Tighten both M6 screws 3 8 Align the rail if necessary then set the levers on the magnetic bridges t...

Page 43: ...ibration units on the bridges Refer to the settings table for the recommended setting M plus 3 mm 1 Open the locks on the ring rail Loosen the M6 screws a Release the locking hook b b a c Securing the...

Page 44: ...component 5 Engage the locking hook a tighten the screws b 6 Using the adjusting screws c on the bridges fit the ring rail evenly around the component 7 When using magnetic bridges Set all the levers...

Page 45: ...in 3 12 1200 1380 mm 47 2 54 3 in 3 15 1380 1560 mm 54 3 61 4 in 4 16 1 Join two rail segments Tighten the top four M6x20 screws a slightly 2 Lock the locking hook b on the lower guide section Tighte...

Page 46: ...to set the distance on the calibration units on the bridges For the recommended setting M please refer to the settings table When installing the rings set them initially to 3 mm more than is shown on...

Page 47: ...2460 mm 5x type II 25 2460 2640 mm 3x type III 2x type II 25 2640 2820 mm 5x type II 1x type I 25 2820 3000 mm 6x type II 28 3000 3180 mm 3x type III 3x type II 30 3180 3360 mm 6x type III 30 3360 354...

Page 48: ...ains at a constant distance from the workpiece If the distance is not constant set the correct distance M on the relevant bridges 7 Push the welding carriage along the rail At the same time set the co...

Page 49: ...the lever for the stationary pressure rollers to ON Reverse the procedure for removal 7 Tighten the three M6 mounting screws on both sides 8 Manually pull the welding carriage along the full length of...

Page 50: ...rol box to the grid 4 12 Set the mains switch on the control box to ON Regulating the pressure rollers The four pressure rollers are non positively connected with the guide rails by means of disk spri...

Page 51: ...lay the hosepack as straight as possible 1 Undo the knurled screw a on the clamp 2 Insert the hose pack as illustrated IMPORTANT Do not kink the hosepack This can cause wirefeed problems 3 Tighten the...

Page 52: ...52...

Page 53: ...53 Operation...

Page 54: ...54...

Page 55: ...ggle switch on the welding carriage remote control is set to the O position With oscillation Travel speed Weaving path Oscillation speed Dwell time left Dwell time middle Dwell time right End crater f...

Page 56: ...welding Dwell time elapses Carriage starts to move If value is negative flying start s Carriage starts to move The arc does not ignite until the flying start time has expired Return travel path Retur...

Page 57: ...ion Set the traversing direction toggle switch to the central position 0 Saving a program Press the travel speed knob and end crater filling time knob at the same time and hold for 4 seconds memX appe...

Page 58: ...To load a saved program mem and the number of the last used program must be shown on the display NOTE The remote control has a factory saved read only program mem0 which contains the working paramete...

Page 59: ...The welding carriage moves according to the programmed para meters but without welding The welding carriage s current speed is then shown on the display All parameters can be changed during operation...

Page 60: ...e switch to the position required Set the traversing direction toggle switch to the position required forwards or backwards The welding process starts IMPORTANT Never leave the device unattended durin...

Page 61: ...61 Maintenance and disposal...

Page 62: ...62...

Page 63: ...e Cre ating and saving welding programs section under Changing the units of measurement inch Imperial system selected mem0 mem9 Save or load a welding program Indication Description Remedy err1 Error...

Page 64: ...s with solid lubricant additives e g MoS2 graphite and PTFE are not suitable for guiding systems Lubricant DIN DIN number Comment Grease KP 2 K 51502 51825 Lithium soap grease Lubricating oil CLP32 10...

Page 65: ...hly 1 2 y Half yearly Y Yearly Maintenance intervals and procedures NOTE Use a dry cleaning cloth to clean the machine components Only use a cleaning agent if this is indicated in the maintenance proc...

Page 66: ...ide rollers D M5 screws D D D B D Maintenance on the oscillation unit IMPORTANT The toothed rack on the oscillation unit must be lubricated once a month The guide rail must be lubricated every six mon...

Page 67: ...67 Technical data...

Page 68: ...68...

Page 69: ...kg Weight without welding torch holder 12 5 kg Protection class IP23 Oscillation speed 5 400 cm min Weaving path 2 30 mm Offset 0 50 mm Dwell time 0 3 seconds Weight without welding torch holder 2 kg...

Page 70: ...or modified without the consent of Fronius International GmbH Ensure that the rating plates remain legible 14 5 kg weight 24 VDC U Ser No Art No A 4600 Wels www fronius com max load 45 kg 30 kg Type...

Page 71: ...t unit 1 5 kg Bridge with adjustable foot and metric adjustment unit 1 3 kg Vacuum bridge with distance block and metric adjustment unit on request 2 6 kg Vacuum bridge with metric adjustment unit on...

Page 72: ...475 5 591 5 6 375 0 5 Dp 900 Vw Dp 560 660 555 5 671 5 335 0 5 Dp 660 840 660 760 655 5 771 5 8 365 0 5 Dp 1080 Vw Dp 740 840 735 5 851 5 325 0 5 Dp 840 1020 840 940 835 4 951 4 9 455 0 5 Dp 1260 Vw...

Page 73: ...80 2380 2275 2391 25 1235 0 5 Dp 2700 Vw Dp 2360 2460 2355 2471 1275 0 5 Dp 2460 2640 2460 2560 2455 2571 25 1325 0 5 Dp 2880 Vw Dp 2540 2640 2535 2651 1365 0 5 Dp 2640 2820 2640 2740 2634 2750 28 141...

Page 74: ...4620 4514 4630 2354 0 5 Dp 4620 4800 4620 4720 4613 4729 43 2404 0 5 Dp 5040 Vw Dp 4700 4800 4693 4809 2444 0 5 Dp 4800 4980 4800 4900 4793 4909 45 2494 0 5 Dp 5220 Vw Dp 4880 4980 4873 4989 2534 0 5...

Page 75: ...75 Spare parts circuit diagram...

Page 76: ...76...

Page 77: ...amage resulting from the use of spare or wearing parts or auxiliary materials that are not approved by the manufacturer NOTE Only trained technicians may change parts and may only do so after having r...

Page 78: ...tic bridge 2 48 0005 1760 Rigid ring 200 300mm 48 0005 1761 Rigid ring 300 480mm 48 0005 1762 Rigid ring 480 660mm 48 0005 1763 Rigid ring 660 840mm 48 0005 1764 Point support adjustable 48 0005 1765...

Page 79: ...005 1804 48 0005 1805 48 0005 1807 48 0005 1806 48 0005 1812 48 0005 1813 48 0005 1814 48 0005 1815 48 0005 1818 48 0005 1819 48 0005 1820 48 0005 1816 48 0005 1817 48 0005 1809 48 0005 1800 48 0005 1...

Page 80: ...80 48 0005 1823 8 045 578 8 045 581 FGU 9 SD28 Item no 8 045 581 FGU 8 SD80 28 Item no 8 045 578...

Page 81: ...81 48 0005 1839 48 0005 1841 48 0005 1843 48 0005 1798 48 0005 1840 48 0005 1842 48 0005 1845 48 0005 1846 FOU 30 ML 10 Item no 8 045 579...

Page 82: ...82 48 0005 1854 48 0005 1816 48 0005 1853 Remote control Item no 8 046 036...

Page 83: ...83 48 0005 1752 FTH 18 D16 25 Item no 48 0005 1752 FTH 21 Item no 48 0005 1777 48 0005 1777...

Page 84: ...84 48 0005 1827 48 0005 1838 48 0005 1838 48 0005 1824 48 0005 1825 48 0005 1826 48 0005 1838 Closed rings Straight rails rigid and flexible...

Page 85: ...85 Circuit diagram...

Page 86: ...86...

Page 87: ...87...

Page 88: ...FCP 600 II Spare parts recommendation Mechanical spare parts D...

Page 89: ...H TechSupport Automation www fronius com addresses 8QGHU KWWS ZZZ IURQLXV FRP DGGUHVVHV RX ZLOO IiQG DOO DGGUHVVHV RI RXU 6DOHV VHUYLFH SDUWQHUV DQG RFDWLRQV URQLXVSODW HOV XVWULD 7HO D 0DLO VDOHV IUR...

Page 90: ...FCP 600 II Spare parts recommendation Mechanical spare parts D...

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