Fronius FlexTrack 45 Operating Instructions/Spare Parts List
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Fronius FlexTrack 45 Operating Instructions/Spare Parts List

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

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Summary of Contents for Fronius FlexTrack 45

  • Page 1 / Perfect Welding / Solar Energy / Perfect Charging Operating instructions FlexTrack 45 Spare parts list 8,045,565 Welding carriage 42,0426,0205,EN V03-03032015...
  • Page 3 Dear reader, Introduction 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.

  • Page 5: Table Of Contents

    Contents General information About this document ............................9 Function of this document .......................... 9 Explanation of safety symbols ........................9 Qualified technicians ..........................9 Copyright ..............................9 General ................................10 Principle..............................10 Device concept and applications ......................10 Safety Operational reliability and tips for the user ....................15 Proper use ..............................
  • Page 6 Maintenance record ..........................64 Recommended lubricants ........................64 Maintenance intervals and procedures ....................65 Technical data Technical data ............................... 69 FlexTrack 45 welding carriage ......................... 69 Control box ............................... 69 Oscillation unit ............................69 Dimensions............................... 69 Rating plates ............................70 Weights of rails and bridges ........................

  • Page 7: General Information

    General information...

  • Page 9: About This Document

    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...

  • Page 10: General

    General Principle The FlexTrack 45 welding carriage is intended for welding of butt and fillet welds in the MIG/MAG or CMT process, with or without oscillation. It can be used on rigid or flexible rails and on rigid or flexible guide rings.
  • Page 11 Device concept RING application: and applications (continued)

  • Page 13: Safety

    Safety...

  • Page 15: Operational Reliability And Tips For The User

    Operational reliability and tips for the user Proper use The FlexTrack 45 welding carriage must only be used for welding butt and fillet welds in a horizontal or vertical welding position. Any use above and beyond this purpose is deemed im- proper –...

  • Page 16: Operating Instructions

    Protection of personnel (protective equipment) Environmental protection Electrical system Spare parts, Use of third-party spare and wearing parts may pose risks. Use approved Fronius origi- wearing parts nal spare parts only. and auxiliary The manufacturer cannot accept any liability for damage resulting from the use of spare materials or wearing parts or auxiliary materials that are not approved by the manufacturer.

  • Page 17: Transportation And Storage

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

  • Page 19: Description Of The Welding Carriage

    Description of the welding carriage...

  • Page 21: Scope Of Supply

    Scope of supply Basic configuration Control box FlexTrack welding carriage 2 connecting cables: 1x between carriage and control box, 1x between carriage and remote control Hosepack holder Connecting cable, control box - power source Tool kit Remote control...

  • Page 22: Accessories And Options

    Accessories and Oscillation unit options Adjustment unit Torch holder, depending on welding process: (10) FTH 18 (11) FTH 21 (10) (11)

  • Page 23: Welding Carriage Components

    Welding carriage components Configuration: Torch adjustment unit welding carriage with oscillation unit Remote control Oscillation unit Carrying handles Torch holder Limit switch Contact cam Coupling Locking lever Guide rollers Hosepack holder Rail Magnetic bridge...

  • Page 24: Configuration: Welding Carriage Without Oscillation Unit

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

  • Page 25: Operating Elements And Connections

    Operating elements and connections Connections Control box mains cable Control line between welding carriage and control box Control line between welding carriage and remote control Connecting lead between control box and power source Connecting lead for oscillation unit...

  • Page 26: Control Box Operating Elements

    Control box ON/OFF switch operating switches the control box on and off elements Welding carriage operating elements Coupling on/off Locks/unlocks the welding carriage on the rail. Allows rapid positioning of the carriage. Guide rollers locking lever Fixes and releases the internal guide rollers. Limit switch (both sides, in and against direction of travel) For automatic stopping or changing of direction.

  • Page 27: Remote Control Elements

    Remote control elements (11) (3a) (3b) (3c) (10) Numerical display, 4 digits (metric / imperial) Displays welding parameters and error codes. Limit switch function, change direction / stop Depending on the switch position, the welding carriage changes direction or stops as soon as the limit switch is activated. (3a) White symbol: Oscillation dwell time, left Regulates the oscillation dwell time on the left.
  • Page 28 Remote control Traversing direction elements Selects the traversing direction. (continued) Travel speed Regulates the travel speed of the welding carriage. Welding mode 3 welding modes can be selected: Test Without arc (O) With arc (I) White symbols: Weaving mode Four weaving modes can be selected: No weaving Trapezoidal weaving Box weaving...

  • Page 29: Rails And Bridges

    Rails and bridges Weights of rails Magnetic bridge 2.5 kg and bridges Vacuum bridge (on request) 1.6 kg Magnetic bridge with spacers 2.7 kg Vacuum bridge with spacers (on request) 1.8 kg Magnetic bridge with spacer and metric calibration unit 3.4 kg Magnetic bridge with metric calibration unit 3.2 kg...

  • Page 30: Rigid Rails

    Rigid rails STRAIGHT ► Straight rails with aluminium reinforce- ment ► For horizontal and vertical use ► With two joining elements to extend the rail Length: 1884 mm Weight: 5.5 kg RING (external use) ► Rigid rails with aluminium reinforce- ment ►...

  • Page 31: Bridge Types

    Bridge types Magnetic bridge Bridge with adjustable feet For magnetic components, heat-resistant Recommended for rigid rings up to 840 to 180°C. mm in diameter. The magnetic force is controlled by a lever. Maximum holding force of a magnetic bridge: 750 N IMPORTANT! All bridges include a metric adjustment unit and a distance block.

  • Page 32: Configuration: Rail And Guide Rings

    Structure of a Bridge with adjustable feet bridge (continued) Bridge with adjustable foot, metric adjust- Bridge with adjustable foot and ment unit and distance block metric adjustment unit M6x14 screws M6x14 screws M6x14 screws Configuration: on request rail and guide rings on request Ø200-840mm...
  • Page 33 Configuration: on request rail and guide rings (continued) Ø 1560 - 6060 mm Ø 1380 - 1560 mm...

  • Page 34: Welding Position And Weld Seam Tracking

    Welding position and weld seam tracking Possible welding IMPORTANT! In vertical applications, the rail structure must be secured by a load arres- positions tor with a locking function to prevent it from falling. The load arrestor must be designed for the total weight of the welding carriage and rail structure.
  • Page 35 Possible welding Positions on flexible rail: positions (continued) Possible welding positions: PA (flat 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 (horizontal-vertical position) PC (horizontal position) PG (descending position) PF (ascending position)

  • Page 37: Commissioning

    Commissioning...

  • Page 39: Preparing The Welding Carriage

    Preparing the welding carriage Installing the welding carriage with oscillation unit Assembling the welding carriage with oscillation unit: Connect the oscillation unit to the welding carriage using the six screws supplied. Connect the connecting lead for the oscillation unit to the carriage and lock it in place.

  • Page 40: Replacing Oscillation Unit With Adjustment Unit

    Replacing oscillation unit with adjustment unit Replacing the oscillation unit with an adjustment unit: Disconnect the connecting lead for the oscillation unit from the welding carriage. Undo the six M6 screws and remove the oscillation unit. Place the protective cap onto the socket for the oscillation unit. Fasten the adjustment unit to the welding carriage using four M6 screws.

  • Page 41: Preparing And Installing Rails

    Preparing and installing rails Number of Straight, rigid rails: bridges required ► For a rail length of 1884 mm: use 3 bridges. Straight, flexible rails: ► For a rail length of 1884 mm: use 5 bridges. ► For a rail length of 1695 mm: use 4 bridges. ►...

  • Page 42: Straight Rails

    Straight rails Both rigid and flexible straightw rails can easily be extended using the joining elements supplied. Set the levers on the magnetic bridges (1) to OFF. Place the rail section on the workpiece and set the levers on the magnetic bridges to ON.

  • Page 43: Securing The Rail Structure

    Securing the rail IMPORTANT! In vertical applications, the rail structure must be secured by a load arres- structure tor with a locking function to prevent it from falling. The load arrestor must be designed for the total weight of the welding carriage and rail structure.

  • Page 44: Closed Ring Rail

    Closed ring rail Install the ring rail on the component. Engage the locking hook (a), tighten the screws (b). Using the adjusting screws (c) on the bridges, fit the ring rail evenly around the component. When using magnetic bridges: Set all the levers on the magnetic bridges to the ON position.

  • Page 45: Rigid Ring Segments

    Rigid ring Rigid ring segments can be joined to create guide rings with a maximum diameter of segments 1560 mm (4 segments). The individual segments are joined to form a guide ring using locking catches and M6x20 socket screws: 1. Join two rail segments. Tighten the top 2.
  • Page 46 Rigid ring It is recommended that two people should work together when installing a guide segments ring made from rail segments. (continued) When using magnetic bridges: Set the lever on the bridges to OFF. Use the adjusting screw (d) to set the distance on the calibration units on the bridges.

  • Page 47: Flexible Ring Segments

    Flexible ring Flexible ring segments can be joined to create guide rings with a diameter of 1560 mm segments to 6060 mm (up to 11 segments). The individual segments are joined to form a guide ring using M6x20 socket screws. Flexible segments are available in the following lengths: SEGMENT LENGTH...

  • Page 48: Commissioning The Welding Carriage

    Commissioning the welding carriage Placing the Remove the remote control. The welding carriage must be installed on the guide welding carriage rail without the remote control. on a straight rail Coupling and levers for the rollers in the "OFF" position. Lift the welding carriage using the handles and place it on the rails.

  • Page 49: Placing The Welding Carriage On A Ring Rail

    Placing the Remove the remote control. The welding carriage must be installed on the guide welding carriage rail without the remote control. on a ring rail Coupling and levers for the rollers in the "OFF" position. Loosen the three M6x20 holding the pressure rollers in place, on both sides. Place the welding carriage horizontally on the rail above the centre of the work- piece and hold it by the handle.

  • Page 50: Regulating The Pressure Rollers

    Placing the 11. Connect the cables: welding carriage Plug in the connecting lead to the power source (1) at the control box and on a ring rail power source. (continued) Connect the remote control to the control box using the control line (2) (purple cable).

  • Page 51: Disengaging The Welding Carriage

    Disengaging the To attain optimum wirefeed, observe the following when laying the hosepack: welding carriage Do not kink the hosepack Always 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.

  • Page 53: Operation

    Operation...

  • Page 55: Creating And Saving Welding Programs

    Creating and saving welding programs Switching on WARNING! system Danger of injury from premature arc ignition. components The arc may be ignited accidentally. This can cause serious eye injuries. Before switching on the system components, ensure that the "Welding mode" toggle switch on the welding carriage remote control is set to the "O" position.

  • Page 56: Selecting Additional Functions

    IMPORTANT! After adjusting settings for the additional functions, turn the weaving mode Selecting additional knob (1) back to the weaving mode required (white markings), otherwise the welding functions process cannot start. Additional function - path measurement: 1. Set the weaving mode knob to the GREEN marking. 2.

  • Page 57: Saving A Program

    Saving a program Before saving a program: Set the toggle switch for the "Change direction/stop" limit switch functions to the lower position (change direction). Set the welding mode toggle switch to the 0 position. TEST 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.

  • Page 58: Loading A Welding Program

    Loading a NOTE! The remote control has a factory-saved, read-only program "mem0", welding program which contains the working parameters for the welding carriage and oscillation unit. The value “mem0” cannot be overwritten. To load a saved program, "mem" and the number of the last used program must be shown on the display.

  • Page 59: Work Procedure

    Work procedure Working with The welding carriage can work with and without oscillation. If the oscillation unit is not or without required, it should be removed according to the instructions in the "Preparing the welding oscillation carriage " section under "Replacing the oscillation unit with an adjustment unit". After the control box has been switched on, it automatically checks whether the oscilla- tion unit is connected and the current status appears on the display.

  • Page 60: Starting The Welding Process

    Starting the Set the welding mode toggle switch to the "I" position. welding process TEST Set the change direction/stop toggle 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 during the weld- ing process.

  • Page 61: Maintenance And Disposal

    Maintenance and disposal...

  • Page 63: Troubleshooting

    If necessary, replace damaged control lines. err4 Communication error between remote control and control box. err5 Error while saving or reading, Contact your FRONIUS service memory error on the remote con- engineer. trol. err6 Operating temperature exceeded Allow device to cool down. Operate or ambient temperature too high.

  • Page 64: Maintenance

    Maintenance Maintenance WARNING! personnel Risk of injury and damage if maintenance work is not carried out cor- rectly. It is essential to adhere to the maintenance intervals and maintenance proce- dures. The manufacturer accepts no liability for any damage caused by inad- equate or poorly performed maintenance.

  • Page 65: Maintenance Intervals And Procedures

    Maintenance NOTE! Use a dry cleaning cloth to clean the machine components. Only intervals and use a cleaning agent if this is indicated in the maintenance procedure for a procedures specific part. Item Component Procedure Interval Linear guides Clean, check oil film Gearbox Clean, regrease Rack and pinion...
  • Page 66 Maintenance Clean and lubricate the gearbox: intervals and IMPORTANT! The gearbox must be procedures cleaned and lubricated once a month (continued) (B): Undo four M5 screws and remove the wheel cover. Clean the gearbox with a brush. Lubricate with grease. Maintenance on the underside of the welding carriage: Clean the guide rollers (D)

  • Page 67: Technical Data

    Technical data...

  • Page 69: Technical Data

    Technical data FlexTrack 45 Welding position PA, PB, PC, PF, PG welding carriage Material thickness min. 4 mm Traversing speed, horizontal 5 - 150 cm/min Traversing speed, vertical 5 - 135 cm/min End-crater filling time 0 - 5 seconds Max. load, horizontal/vertical...

  • Page 70: Rating Plates

    H (overall height with adjustable foot bridge) 317 - 415 mm Rating plates NOTE! The rating plates may not be removed or modified without the consent of Fronius International GmbH. Ensure that the rating plates remain legible. Type: FlexTrack 45...

  • Page 71: Weights Of Rails And Bridges

    Weights of rails Magnetic bridge 2.5 kg and bridges Vacuum bridge (on request) 1.6 kg Magnetic bridge with distance block 2.7 kg Vacuum bridge with distance block (on request) 1.8 kg Magnetic bridge with distance block and metric adjustment unit 3.4 kg Magnetic bridge with metric adjustment unit 3.2 kg...

  • Page 72: Ring Rail Settings Table

    Ring rail settings table IMPORTANT! A quick-reference summary of the settings table, showing the most important settings, can be found on the inside of the transport box lid.

  • Page 73: Flexible Rail Segments Settings Table

    Flexible rail segments settings table...
  • Page 74 Flexible rail segments settings table (continued)

  • Page 75: Spare Parts, Circuit Diagram

    Spare parts, circuit diagram...

  • Page 77: Spare Parts

    Spare parts Spare parts, Use of third-party spare and wearing parts may pose risks. Use approved Fronius origi- wearing parts nal spare parts only. and auxiliary The manufacturer cannot accept any liability for damage resulting from the use of spare materials or wearing parts or auxiliary materials that are not approved by the manufacturer.
  • Page 78 Order numbers for welding carriage, rails and accessories: 8,045,565 FlexTrack 45 8,045,578 FGU 8/SD80-28 8,045,579 FOU 30/ML10 8,045,581 FGU 9/SD28 8,046,036 FRC-45 8,100,224 I-kit, contact cam 48,0005,1752 FTH 18/D16-25 48,0005,1753 FTH 19/D22-35 48,0005,1754 Rail, straight 1884mm incl. joining elements 48,0005,1755...
  • Page 79 FlexTrack 45 welding carriage Item no.: 8,045,565 48,0005,1802 48,0005,1800 48,0005,1798 48,0005,1807 48,0005,1799 48,0005,1804 48,0005,1806 48,0005,1805 48,0005,1812 48,0005,1808 48,0005,1809 48,0005,1810 48,0005,1811 48,0005,1813 48,0005,1814 48,0005,1818 38,0100,0433 48,0005,1815 48,0005,1817 48,0005,1816 48,0005,1819 48,0005,1820...
  • Page 80 FGU 8/SD80-28 Item no.: 8,045,578 8,045,578 48,0005,1823 FGU 9 / SD28 Item no.: 8,045,581 8,045,581...
  • Page 81 FOU 30 / ML 10 Item no.: 8,045,579 48,0005,1839 48,0005,1840 48,0005,1842 48,0005,1841 48,0005,1843 48,0005,1845 48,0005,1798 48,0005,1846...
  • Page 82 Remote control Item no.: 8,046,036 48,0005,1853 48,0005,1816 48,0005,1854...
  • Page 83 FTH 18/D16-25 Item no.: 48,0005,1752 48,0005,1752 FTH 21 Item no.: 48,0005,1777 48,0005,1777...
  • Page 84 Closed rings 48,0005,1838 48,0005,1826 48,0005,1827 48,0005,1838 48,0005,1824 48,0005,1825 Straight rails (rigid and flexible) 48,0005,1838...

  • Page 85: Circuit Diagram

    Circuit diagram...
  • Page 88 Spare parts recommendation, FCP 600 - II Mechanical spare parts...
  • Page 89 FRONIUS INTERNATIONAL GMBH TechSupport Automation )URQLXVSODW]  $ :HOV $XVWULD 7HO     )D[     (0DLO VDOHV#IURQLXVFRP www.fronius.com www.fronius.com/addresses 8QGHU KWWSZZZIURQLXVFRPDGGUHVVHV \RX ZLOO IiQG DOO DGGUHVVHV RI RXU 6DOHV VHUYLFH SDUWQHUV DQG /RFDWLRQV...
  • Page 90 Spare parts recommendation, FCP 600 - II Mechanical spare parts...

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