Related Manuals for Fronius ArcRover 15
Summary of Contents for Fronius ArcRover 15
- Page 1 / Perfect Welding / Solar Energy / Perfect Charging Translation of original Operating Instructions Operating Instructions ArcRover 15 Welding carriage 42,0426,0298,EN 19112019...
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Page 3: Table Of Contents
Environmental conditions ........................... 9 Warning notices on the carriage ....................... 10 Scope of supply ............................11 Carriage components ............................ 12 ArcRover 15 carriage ..........................12 Accessories and options ..........................13 Accessories .............................. 13 Control and display elements, connections ....................15 Carriage.............................. - Page 4 Charger ..............................46 Rechargeable battery pack ........................46 Disposal of components ........................... 47 Technical Data ............................... 48 ArcRover 15 carriage ..........................48 ArcRover 15 dimensions .......................... 49 Environmental conditions ......................... 49 Spare parts ..............................50 Spare parts, wearing parts and auxiliary materials .................. 50 Details required when placing orders .......................
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Page 5: About This Document
Special care is required if you see any of the symbols shown. Copyright Copyright of these Operating Instructions remains with Fronius International GmbH. The text and illustrations are all technically correct at the time of going to press. We reserve the right to make changes. -
Page 6: General
The control unit is integrated into the carriage. The control panel has an illuminated dis- play allowing simple and user-friendly parameter setting for the carriage. Application area The ArcRover 15 carriage can be used in all situations where a high degree of flexibility is required when executing longitudinal weld seams: Shipyards... -
Page 7: Foreseeable Misuse
Proper use/ Using the spare parts stipulated by Fronius intended purpose Following all the instructions contained in the Operating Instructions (continued) Using this document in combination with the operating instructions for the integrated system components (power source, wirefeeder, etc.) Foreseeable Any use other than for the intended purpose shall be deemed improper use. -
Page 8: Dangers From The Rechargeable Battery Pack
Ignoring this European Directive may be harmful to the environment and your own health! Devices with mechanically undamaged rechargeable batteries may be returned to the relevant Fronius Service Partner for repair or battery replace- ment. As soon as it becomes evident that the rechargeable battery has been me- chanically damaged (e.g. -
Page 9: Use Of Charger And Rechargeable Battery Pack
Use of The charger and the rechargeable battery pack are designed for each other. Therefore charger and you should only ever use the supplied charger to charge the battery pack. rechargeable Recharge the rechargeable battery pack after every discharge. Do not wait until the battery pack rechargeable battery pack is completely discharged before recharging it. -
Page 10: Warning Notices On The Carriage
25,4 VDC 7,1 kg 15 kg 11 kg ArcRover 15 rating plate Do not use the functions until you have fully read the Operating Instruc- tions. Do not dispose of used devices with domestic waste. Dispose of them ac- cording to safety rules. -
Page 11: Scope Of Supply
Scope of supply ArcRover 15 scope of supply Connecting cable to power source ArcRover 15 carriage Universal welding torch holder Guide rails Allen keys: 2 / 2.5 / 3 / 4 Rechargeable battery pack 25.4 V / 3.35 Ah Charger... -
Page 12: Carriage Components
Rechargeable battery pack 25.4 V / 3.35 Ah Handle Universal welding torch Horizontal holder welding torch adjustment unit Lashing point for securing the carriage On-board control unit Guide rails with rollers Chassis with 4-wheel drive ArcRover 15 carriage... -
Page 13: Accessories And Options
(for workpieces with particu- larly rough surfaces). IMPORTANT! Use of the carriage with the "stainless steel drive wheel" accessory is only permitted in the PA welding position. Please seek advice with Fronius service per- sonnel if using pre-heated workpieces. 48,0005,2588... - Page 14 Accessories Article: Item number: Designation: (continued) 4,100,779,IK OPT/i WF external start signal (necessary in combination with TPSi; installed in the WF wirefeeder) 48,0005,2585 Tiltable lateral guide 48,0005,2584 Lateral guide for edge 48,0005,2586 Magnetic lateral guide (1) 48,0005,2587 Guide arm for rail 1850 mm (2 pcs) (2) 48,0005,1894 Flexible guide rail 1850 mm (3) 48,0005,1895 Magnetic guide rail base...
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Page 15: Control And Display Elements, Connections
Do not use the functions described here until you have fully read and understood the following documents: These Operating Instructions All operating instructions for the system components ArcRover 15 carriage No. Function (1) Control panel For the complete operation of the carriage. -
Page 16: Control Panel
Control panel TEST ArcRover 15 control panel No. Function (1) Display For configuring parameters and creating programs using the menu adjusting dial (2). The digital display is illuminated. (2) Adjusting dial menu Used to adjust the Travel Speed of the carriage. The currently set speed is shown on the display. -
Page 17: Display Types
Display types Display Description Display test (after switching on). Carriage programs: 0 - 9 Status of the currently set Travel Speed in cm/min. Speed (Travel Speed): 5 -250 cm/min Path (Total Path): 0 -999 cm Length (Segment Width): 0.0 - 99.9 cm Interval (Segment Gap): 0.0 - 99.9 cm Units: Metric (centimetre) -
Page 18: Parameter Description
Parameter Parameter Function description Program The created parameters (path, length, interval) can be saved under the desired program number. These can be reloaded at any time and corrected as required. Setting range: 0 to 9 Speed (Travel Speed) The speed of the carriage defined in cm/min. Unit: cm/min Range: 5 to 250 cm/min Path (Total Path) -
Page 19: Charger And Rechargeable Battery Pack
Charger and rechargeable battery pack Overview of charging set No. Function (1) Fuse holder with glass-tube fuse (2) LED1 Steady red light ... Mains on. (3) LED2 Steady red light ... Charging process active Steady green light ... Battery finished charging (4) Charging cable with plug (5) Mains connection with integrated glass-tube fuse (6) Mains cable... -
Page 20: Menu Navigation And Parameter Entry
Menu navigation and parameter entry General General rules for entering parameters: Do not enter numbers; values must be entered using the menu adjusting dial Changed parameters become active after the adjusting dial has been pressed, how- ever they will not yet have been saved Turning/pressing Turn the menu adjusting dial: the adjusting dial... -
Page 21: Welding Position And Weld Seam Tracking
Welding position and weld seam tracking Possible welding The 4-wheel drive and built-in permanent magnet ensure that the carriage adheres to the positions workpiece and guarantee the best possible traction. The following welding positions are possible: Horizontal Sloping NOTE! From an angle of 45° upwards, the carriage must be secured by a load securing device with a locking function to prevent it from falling. -
Page 22: Guidance Of The Carriage
Possible NOTE! welding positions When used on the “inside of a contain- (continued) er”, the container must be turned in the opposite direction and at the same speed. Inside of container with minimum diameter of 500 mm IMPORTANT! Use of the carriage in the "PE" overhead position is prohibited. Guidance of the The adjustable guide wheels on the side of the carriage ensure proper tracking of the carriage... - Page 23 Guidance of the carriage (continued) Guidance on angle piece (vertical) or rail Guidance on outside vertical surface Outside of container with minimum diameter of Inside of container with minimum diameter of 5000 mm 5000 mm NOTE! When guided on a horizontal angle piece, the welding torch must only be placed on the upper side.
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Page 24: Optional Lateral Guides
Optional lateral guides Tiltable lateral guide Lateral guide for edge Standard lateral guide / with magnet Lateral guide with guide rail Guide arm for flexible rail (2 pcs.) (1850 mm) Magnetic bases for guide rail Flexible guide rail (1850 mm) IMPORTANT! 10 magnetic bases are required for each rail. -
Page 25: Preparing The Carriage
Preparing the carriage Mounting and setting up the guide rails 1. Use the M6 clamping screw to attach the guide rails to the carriage. 2. Tighten clamping screws by hand first. Make sure that the guide rails are sat in the appropriate recesses on the carriage frame. -
Page 26: Fitting The Carriage Brushes (Option)
Fitting the carriage brushes (option) NOTE! The brush may be fitted to either the front or rear of the carriage. 1. Undo the M6 clamping screw (a). 2. Attach the brush brackets as shown. 3. Screw in the M6 clamping screw (a) and tighten by hand. -
Page 27: Fitting The Lateral Guides (Option)
Fitting the lateral All optional lateral guides for the ArcRover 15 carriage come with the M6 clamping screw guides (option) attached. The lateral guides are attached to the end faces of the carriage. Tiltable lateral guide Lateral guide for edge... -
Page 28: Fitting Lateral Guides With Guide Rails
Fitting lateral Lateral guide with guide rail guides with guide rails The flexible lateral rail is secured using magnetic bases. Each rail (1850 mm) requires 10 magnetic bases to guarantee a secure hold. The rail sections can be attached to the magnetic bases in the following ways: Placed end-on Overlapping Attach the rails to the magnet block with the provided M5x16 fixing screws. -
Page 29: Charging The Rechargeable Battery Pack
Charging the IMPORTANT! Recharge the rechargeable rechargeable battery pack after every discharge. Do not battery pack wait until the battery pack is completely discharged before recharging it. 1. Connect the mains cable to the charger. 2. Insert a Schuko plug into a 230 V socket. -
Page 30: Insert Rechargeable Battery Pack Into The Carriage
Charging the 4. Disconnect the Schuko plug. rechargeable battery pack (continued) 5. Remove charging plug from the re- chargeable battery pack. Insert recharge- IMPORTANT! Before inserting the re- able battery chargeable battery pack, check that pack into the the connection contacts are not dirty or carriage shorted. -
Page 31: Connecting The External Power Supply (Option)
Connecting the With the „ArcRover 15 mains operation“ option, the carriage can be operated with an external power external power supply instead of the battery pack. supply (option) External power supply 230V Extension cable Remote control cable 10 m 10 m 10 m max. -
Page 32: Setting Up The Carriage
Setting up the carriage Checking the Before positioning the carriage, check the following: surface of the The surface of the workpiece must be clean (no sand, shavings, etc.) workpiece and The base plate of the carriage must be free of objects which can be attracted by the the carriage to magnet ensure they are... -
Page 33: Attaching Fall Protection (Vertical Operation)
Attaching fall IMPORTANT! In vertical operation, the carriage must be secured by a load securing protection device with a locking function to prevent it from falling. The load securing device must be (vertical opera- designed for the total weight of the carriage. The manufacturer accepts no liability for any tion) damage to persons or property resulting from vertical use of the carriage without a load securing device. -
Page 34: Mounting And Adjusting The Welding Torch
Mounting and 1. Turn the adjusting dial (a) to the left adjusting the and release the torch holder. welding torch 2. Insert the welding torch (b). 3. Turn the adjusting dial (a) to the right and fix the welding torch in position. 4. -
Page 35: Relieving Strain On The Carriage
Relieving strain To attain correct wirefeed, observe the following when laying the hose pack: on the carriage Do not allow the hosepack to become kinked Always lay the hosepack as straight as possible Handling the hosepack 1. Suspend the hosepack (it must not come into contact with the floor), use balancers and hosepack holders (e.g. -
Page 36: Starting Up The Carriage
Starting up the carriage Checking the The following activities and work steps apply to the fully installed system. Before start- connections up, check all the connections between, and connection sockets of, the following system components: Carriage Rechargeable battery pack Power source Cooling unit Gas cylinder Wirefeeder... -
Page 37: Setting The Carriage Parameters
Setting the carriage parameters Setting the unit 1. Press and hold the adjusting dial (a). 2. Press and hold welding toggle switch I/0/TEST in position "TEST". TEST 3. Turn the "Control unit ON/OFF" toggle switch to "ON". Display check is carried out. Currently set unit (e.g. -
Page 38: Creating The Carriage Program
Creating 1. Press the adjusting dial for 5 seconds. the carriage program Press for 5 seconds Menu is opened, "Path" parameter (Total Path) is displayed. 2. Turn the adjusting dial and set the desired distance (e.g. 500 cm). Turn 3. Press the adjusting dial once. Value takes effect; "Length"... -
Page 39: Welding Mode
Welding mode ArcRover Memory 0 Performing Carry out a test run to check that all system components work together correctly. This a test run is performed without an arc and allows the movements during the processes to be checked. 1. Turn welding toggle switch I/0/TEST to "0". TEST ArcRover Memory 0... -
Page 40: Troubleshooting
After-Sales Service team with a detailed description of the error. Error Cause Remedy err1 Save/load error. Possible ► Contact damage of the mobile controller Fronius service technicians. memory. err2 CAN communication systems ► Contact initialization error Fronius service technicians. err3 Communication error ►... - Page 41 Carriage Display does not Rechargeable battery ► Charge up the recharge- (continued) light up pack discharged. able battery pack with the charger. Electronic module - no ► Check the connections power. between the compartment and the electronic module. Electronic module dam- ►...
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Page 42: Maintenance
Maintenance Personnel WARNING! Risk of injury and damage from incorrectly performed maintenance work. 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. All maintenance work on the carriage must only be carried out by trained technicians. -
Page 43: Horizontal Welding Torch Adjustment Unit
Horizontal welding torch adjustment unit Item Component Measure Interval Linear guides ► Clean 1/2 Y ► Check oil film ► Eliminate play: tighten pres- sure screws with Allen key Threaded spindle ► Check ► Clean, regrease 1/4 Y... -
Page 44: Vertical Welding Torch Adjustment Unit
Vertical welding torch adjustment unit Item Component Measure Interval Linear guides ► Clean 1/2 Y ► Check oil film ► Eliminate play: tighten pres- sure screws with Allen key Threaded spindle ► Check ► Clean, regrease 1/4 Y... -
Page 45: Carriage Front
Carriage front Item Component Measure Interval Rollers and rails ► Clean 1/4 Y ► Position check Wheels, underbody, ► Clean guide rails Carriage back Item Component Measure Interval Rollers and rails ► Clean 1/4 Y ► Position check Wheels, underbody, ►... -
Page 46: Charger
Charger These devices are largely maintenance-free. To ensure problem-free operation, observe the following instructions: Item Component Measure Interval Ventilation openings ► Keep clean to ensure that (air inlet, air outlet) cooling air is able to circu- late. Danger of short circuit- ing! Make sure that no metal objects, such as metal chips, penetrate the interior of the... -
Page 47: Disposal Of Components
All machine components and electrical parts are separated according to type and disposed of properly Exhausted or defective battery packs are disposed of by the dealer, Fronius Customer Service or at disposal sites approved by the relevant public authority. The rechargea- ble battery packs are then recycled. -
Page 48: Technical Data
Technical Data ArcRover 15 Maximum load capacity (horizontal) 15 kg (33.07 lb) carriage Maximum load capacity (vertical) 15 kg (33.07 lb) Max. tensile load on the torch holder: 50 mm (1.97 in.) 80 mm (3.15 in.) Horizontal: 15 kg (33.07 lb) 12 kg (26.46 lb) -
Page 49: Arcrover 15 Dimensions
4 mm (0.16 in.) (continued) Clearance 4 mm (0.16 in.) Max. preheating temperature of the workpiece 150 °C (302 °F) ArcRover 15 dimensions ArcRover 15 carriage 255 mm 10.0 in 275 mm 10.8 in Min. 198 mm Min 7.8 in Max. 313 mm Max 12.3 in... -
Page 50: Spare Parts
Spare parts, Using spare parts and wearing parts from third-party manufacturers may pose risks. Use wearing parts the prescribed Fronius original 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 51 ArcRover 15 carriage 8,045,645...
- Page 52 ArcRover 15 carriage 8,045,645 Item Designation Item number Rechargeable battery pack 48,0005,2600 Torch body assembly 48,0005,2637 Universal welding torch holder 48,0005,2638 Welding torch adjustment unit (horizontal, vertical) 48,0005,2639 Lashing point for securing the carriage 48,0005,2640 Protective plate for wheels 48,0005,2641...
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Page 53: External Power Supply" Option
„External power supply“ option 10 m 10 m 10 m max. 30 m Item Designation Item number Control box with external power supply 48,0005,0165 Power supply 230V AC - 24V DC/ 5A 48,0005,1818 Extension cable 10 m 38,0100,0476 Remote control cable 10 m 38,0100,0433... -
Page 54: Circuit Diagrams
Circuit Diagrams... - Page 56 619.01.02.10.0 brown BRAKE blue Din0 +24V Din1 +24V MOTOR DRIVER 619.01.02.13.0 MOTOR Enc B ENCODER Enc A Hall H3 Hall H2 Hall H1 MOTOR black 625.01.01.04.0 CAN_H white CANH CAN_L green CANL DRIVE blue 25.2V MODULE...
- Page 57 619.08.06.00.0 619.08.07.00.0 black black BATTERY BATTERY PACK...
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Page 58: Eu Declaration Of Conformity
EU Declaration of Conformity... - Page 61 FRONIUS INTERNATIONAL GMBH TechSupport Automation E-Mail: support.automation@fronius.com www.fronius.com www.fronius.com/addresses...