Related Manuals for Fronius FlexTrack 45
Summary of Contents for Fronius FlexTrack 45
- Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating instructions, FlexTrack 45 Carriage...
- Page 2 Spare parts recommendation, FCP 600 - II Mechanical spare parts...
-
Page 3: Table Of Contents
21. Adjusting pressing force of rollers ................... 35 22. Mounting rail onto the pipe ....................36 1.12 Mounting ring rail ......................36 1.13 Mounting sectional rail (two persons required) ............36 1.14 Mounting flexible rail onto pipe (two persons required) ..........37 23. Usage ..........................38 © FRONIUS 2013... - Page 4 1.16 Loading a program ...................... 39 1.17 Operation ........................39 1.18 Changing the measurement system ................40 1.19 Alarm codes ........................ 41 24. Maintenance ........................42 1.20 Lubricating drive system gear ..................42 1.21 Lubricating oscillator gear rack ................... 43 1.22 Lubricating oscillator rolling guide ................43 © FRONIUS 2013...
-
Page 5: Proper Use
1. Proper use The FlexTrack 45 is a rail carriage designed to establish groove and fillet welds with or without oscillation using MIG/MAG or CMT torches with handle diameter of 16-35 mm. The carriage can be fixed on straight, flexible orbital, and orbital rails. -
Page 6: Technical Data
480 (L) × 314 (W) × 334 (H) Carriage weight with OSC 14.5 kg (without remote control) Carriage weight without OSC(without remote 12.5 kg control) 1.5 kg Remote control weight Control box without cable 5,3 kg Welding device cable 1,5 kg © FRONIUS 2013... -
Page 7: Weight Of Bridges And Rails
VACUUM BRIDGE Version 1: Heat resistant (2 Versions) up to max. 80° (176°F) Version 2: Heat resistant up to max. 250°C (480°F). Recommended for rigid ring rails up to 840 mm SCREW FEET BRIDGE (33.1 in) diameter. © FRONIUS 2013... -
Page 8: Safety Precautions
20. Operating in PD (horizontal overhead) and PE (overhead) welding positions, as well as on curvatures with inner/outer radius lower than 1500/1100 mm is prohibited. 21. When operating at heights, use safety line to protect Carriage from dropping. © FRONIUS 2013... - Page 9 Carriage, stop operation and immediately send Carriage to service center for inspection. 29. Never leave Carriage unattended during operation. 30. Remove from worksite and store in isolated and dry location when not in use. Safety rules must be closely observed. © FRONIUS 2013...
-
Page 10: Dimensions Of Carriage With Oscillation All Measurements In Mm
5. Dimensions of carriage with oscillation All measurements in mm. Carriage on a flexible track © FRONIUS 2013... - Page 11 Carriage with magnetic bridge on a straight rigid track: Carriage with magnetic bridge, with support and fixing mechanism: Carriage with screw-feet bridge, with supporting unit and fixing mechanism: © FRONIUS 2013...
-
Page 12: Dimensions Of Carriage Without Oscillation All Measurements In Mm
6. Dimensions of carriage without oscillation All measurements in mm. © FRONIUS 2013... -
Page 13: Assembling Carriage For The First Time
7. Assembling carriage for the first time © FRONIUS 2013... -
Page 14: Description Of Carriage With Oscillation
Clutch ON / OFF rotational pressing roller unit welding device cable rotational pressing roller lever control box Remote control and Main switch drive system cables Connection cable © FRONIUS 2013... -
Page 15: Description Of Carriage Without Oscillation
To dismount the oscillation unit, proceed according to the following instructions: 1. Unplug the oscillation cable. 2. Dismount the oscillation unit by unscrewing six M6 screws. 3. Screw the cap onto the oscillator socket. 4. Mount the guide arm in place of the oscillation unit. © FRONIUS 2013... -
Page 16: Remote Control
Four position display shows current and adjusted operating parameters. Additionally it indicates if the stoppage of the carriage or oscillator has been triggered by the limit switches. body magnetic foot control panel © FRONIUS 2013... - Page 17 Note: To change the value of a parameter, press the required button lightly. Once it is pressed, the current value of the parameter will show on the display along with the corresponding symbol of the parameter. © FRONIUS 2013...
-
Page 18: Wiring Diagrams
11. Wiring diagrams © FRONIUS 2013... - Page 19 © FRONIUS 2013...
- Page 20 © FRONIUS 2013...
-
Page 21: Straight Rails
(without fixing mechanism) with a distance block. Place the rail on ferromagnetic steel with thickness of at least 5 mm and minimum curvature inner/outer radius of 1500/1100 mm. flexible rail R L=1884mm magnetic bridge with distance block M6 screw groove lock © FRONIUS 2013... -
Page 22: Ring Rail
The rail is designed for pipe diameters of 200 to 840 (4 units). The required distance ‘M’ must be read from Table 1. distance ring guide pipe M6 mounting screw hinge catch fixing mechanism © FRONIUS 2013... -
Page 23: Sectional Ring Rail
840–1560 mm (4 units). The required distance ‘M’ must be read from Table 1. Screw feet bridge with or rail segment without distance block magnetic bridge with or without distance block M6 screw catch © FRONIUS 2013... -
Page 24: Sectional Flexible Rails For Pipes
3000 - 3180 mm 3x type III (118.1 - 125.2 in) 3x type II 3180 - 3360 mm 6 x type III (125.2 - 132.3 in) The distance ‘M’ to set on the pitch must be read from Table 1. © FRONIUS 2013... -
Page 25: Magnetic Bridges And Metrical Scale
M12x3 feed screw which will move the nut along the pins to the distance of 0–58 mm. Fasten the mechanism to the magnetic bridge using two M6x20 screws to enable adjustment and clamping onto the pipe. © FRONIUS 2013... -
Page 26: Screw Feet Bridge With Or Without Distance Block
To assemble the screw feet bridge with the fixing mechanism or with the support, or the metrical scale with the support, use two M6x14 screws. The bridge must be assembled only when dismounted from the track. © FRONIUS 2013... -
Page 27: Mounting Of Bridges
Set the distance to the fixing mechanism with two M4x10 screws. Read the recommended number of bridges to be used from Table 1. M6x14 screw M4x10 screw 1.9 Mounting on rail segment M6x14 screw M4x10 screw distance © FRONIUS 2013... -
Page 28: Mounting On Rigid Rail
1.11 Mounting on flexible rail Mount bridge to the flexible rail, using two M6x14 screws. Set the distance with two M4x10 screws. Use 5 bridges for every 1884 mm of flexible track segment. M6x14 screw M4x10 screw distance © FRONIUS 2013... -
Page 29: Assembling An Orbital Track
17. Assembling an orbital track Place two rail segments together on a flat surface. Slightly tighten four M6x20 screws (see picture). M6x20 screw Lock the lower catch. Slightly tighten two M6x16 screws. lower catch M6x16 screw © FRONIUS 2013... - Page 30 Lock the upper catch. upper catch If necessary, align both rail segments together. align Finally, tighten all mentioned M6 screws. © FRONIUS 2013...
-
Page 31: Preparing For Operation On Straight Rail
Plug the cables of the controller, drive system, oscillator, and welding device into the proper sockets. Mount the torch in holder and secure with the knob Put the torch cable into the cable holder, secure with the knobs, and fix the holder in a required position. © FRONIUS 2013... -
Page 32: Preparing For Operation On The Orbital Rail
Plug the cables of the controller, drive system, oscillator, and welding device into the proper sockets. Put the torch in holder and secure with the knob. Put the torch cable into the cable holder, secure with the knobs, and fix the holder in the required position. © FRONIUS 2013... - Page 33 M6 screws pressing roller © FRONIUS 2013...
-
Page 34: Positioning The Orbital Rail Onto Pipe
Toggle the levers of the magnetic bridges to ‘0’. Set the radial position of the magnetic and screw feet bridges, according to the ‘M’ value from Table 1 by rotating the adjusting screw. pitch M12x3 feed screw © FRONIUS 2013... - Page 35 1775-0,5*Dp 3360-3540 3440-3540 3434 3550 1815-0,5*Dp 3780*Vw/Dp 3540-3640 3534 3650 1864-0,5*Dp 3540-3720 3620-3720 3614 3730 1904-0,5*Dp 3960*Vw/Dp 3720-3820 3714 3830 1954-0,5*Dp 3720-3900 3800-3900 3794 3910 1994-0,5*Dp 4140*Vw/Dp 3900-4000 3894 4010 2044-0,5*Dp 3900-4080 3980-4080 3974 4090 2084-0,5*Dp 4320*Vw/Dp © FRONIUS 2013...
- Page 36 Number of Number of of rail rail rail Dp[mm] L=1884 L=1695,6 L=1130,4 1560-1740 1740-1920 1920-2100 2100-2280 2280-2460 2460-2640 2640-2820 2820-3000 3000-3180 3180-3360 3360-3540 3540-3720 3720-3900 3900-4080 4080-4260- 4260-4440 4440-4620 4620-4800 4800-4980 4980-5160 5160-5340 5340-5520 5520-5700 5700-5880 5880-6060 © FRONIUS 2013...
-
Page 37: Adjusting Pressing Force Of Rollers
IMPORTANT! Minimum clearance of 0,6 mm (maximum force) is achieved by tightening the M8 screw maximally and then loosening by half rotation. carrying handle disk springs M8 set screw M8 hex nut engaging lever rotational roller unit lever fixed roller unit lever © FRONIUS 2013... -
Page 38: Mounting Rail Onto The Pipe
OFF and two M6 set screws loosened) onto the pipe in a way to contact the faces of both rail guides. Then, mount the catch, tighten two M6 screws, and toggle the magnetic bridge levers to ON. d) Assemble consecutive segments in the same way. © FRONIUS 2013... -
Page 39: Mounting Flexible Rail Onto Pipe (Two Persons Required)
Manually or mechanically rotate the carriage by one full turn to check whether the torch is in a constant distance from the pipe that will enable proper operation. If the distance is not constant, correct the value of ‘M’ on appropriate bridges. © FRONIUS 2013... -
Page 40: Usage
A notice “memX” will appear on the display. “X” means the number of the program to save the current parameters to. Rotate the travel speed knob B to change the number and press the knob to apply the choice. © FRONIUS 2013... -
Page 41: Loading A Program
B for 2 seconds. If an error occurs, the display will show “ErrX” message, where X is the number of the error. Once the operation is finished, turn off the power and unplug the carriage from the power supply. © FRONIUS 2013... -
Page 42: Changing The Measurement System
Switch on the main switch on control box (position I). The actual measurement (inch or cm) is shown on display (M). Choose the required measurement by turning button B. Press button B, to accept and save your change. © FRONIUS 2013... -
Page 43: Alarm Codes
Replace communication wires if control and oscillation damaged. Communication error between the remote err4 control and control box. Save/load error. Possible damage of the Contact your FRONIUS service err5 remote control memory. technician. Operating temperature level exceeded. Operate in lower ambient err6 Ambient temperature is too high. -
Page 44: Maintenance
1.20 Lubricating drive system gear Dismount the wheels cover by unscrewing four M5 screws, clean the gear using brush, and lubricate the gear with EP2 grease. IMPORTANT! Perform lubrication once a month. lubricate wheels cover M5 screw © FRONIUS 2013... -
Page 45: Lubricating Oscillator Gear Rack
Remove the guide cover from the oscillator by unscrewing three M5 screws. Use a lubricator with head diameter of 12 mm to introduce 2 g of EP2 grease into the grease nipple. IMPORTANT! Perform lubrication every six months. © FRONIUS 2013... - Page 46 Spare parts recommendation, FCP 600 - II Mechanical spare parts...
- Page 47 FRONIUS INTERNATIONAL GMBH TechSupport Automation )URQLXVSODW] $ :HOV $XVWULD 7HO )D[ (0DLO VDOHV#IURQLXVFRP www.fronius.com www.fronius.com/addresses 8QGHU KWWS ZZZIURQLXVFRPDGGUHVVHV \RX ZLOO I QG DOO DGGUHVVHV RI RXU 6DOHV VHUYLFH SDUWQHUV DQG /RFDWLRQV...
Need help?
Do you have a question about the FlexTrack 45 and is the answer not in the manual?
Questions and answers