/
Perfect Welding / Solar Energy / Perfect Charging
/
Perfect Welding / Solar Energy / Perfect Charging
Welding carriage
Flextrack 45
/ MIG-MAG / CMT
/ The compact carriage offers a wide range of application possibilities. Depending on the requirements 3 different rail
types are available. In industries where varying types of surfaces are common (e.g. shipbuilding, tank construction), the
FlexTrack 45 suits perfectly for universal operations.
/ One carriage fOr all applicatiOns
/ fast and easy setup Of rails and carriage
/ HigHest reprOducibility
/ designed fOr rOugH applicatiOn area
/ cOnstant welding speed
/ HigH quality cOmpOnents
/ rObust aluminium HOusing
/ best welding results due tO frOnius welding tecHnOlOgy
/ One system FOr universal
applicatiOns
flextrack 45 – One carriage fOr all applicatiOns
/ The high-quality carriage in combination with Fronius welding technology offers the perfect solution for mechanized
welding applications. Due to precise and constant movement, excellent welding results can be produced. The highly modu-
lar system can be mounted onto any rail configuration. Only the driving angle has to be adjusted – no time consuming
adaption required.
bridges
/ Magnetic bridge with xing lever
/ Vaccum bridge
/ Screw feet bridge
rails
/ 3 dierent types of
rails are available
:
- Flexible
- Straight
- Ring
guiding wHeels
/ Quick adjustable for
easy mounting on dier-
ent rail congurations.
tOrcHes
/ 5 dierent types of
torches are compatible:
- Multilock
- Robacta
- Robacta Drive
- CMT Drive
- Manual torches
limit switcHes
/ For both directions the
carriage has integrated
limit switches for auto-
matic return/stop.
tOrcH HOlders
/ Easy and precise torch
adjusting.
clutcH On/Off
/ Allows manual fast po-
sitioning of the FlexTrack
without unmounting the
carriage.
carrying Handles
/ Two handles for com-
fortable carrying and
mounting.
remOte cOntrOl
/ With magnectic holder,
which allows mounting to
anything that is magnetic.
/ 3 different rail setups are available – the carriage fits any setup perfectly. Only the guiding wheels have to be adjusted cor-
rectly. The mounting/unmounting process is quick and easy.
e-cabinet
/ Remote control and
carriage are connected
to the e-cabinet.
mains VOltage
/ 230 V, 50 - 60 Hz
/ 115 V, 50 - 60 Hz
200 - 6060 mm
(7.9 - 238.6 in)
min. 1500 mm
(59.1 in)
R
min. 1100 mm
(43.4 in)
R
/ ring
/ Flexible
/ straight
OscillatiOn unit (OptiOnal)
/ linear
/ radial
graVity sensOr
/ Determines the angular position of
the carriage during orbital welding.
segment welding
/ Flying start
/ Welding segment length
/ Gap length between segments
/ End crater lling
segment welding Orbital*
/ Segment welding settings for orbital welding.
Own welding parameter can be assigned to
every predened segment.
tOtal welding distance
segment welding settings
arc current cOntrOl
/ Regulation for the dis-
tance of the welding torch.
Osc mOdes
/ 4 modes:
- No weave
- Trapezoid
- Rectangular
- Triangular
welding mOdes
/ 3 modes:
- No arc
- Arc
- Test
cOnnectOr fOr remOte
cOntrOl cable
/ High quality metal socket.
traVel speed
/ Regulation for travel speed.
magnetic HOlder
/ Mounts the remote control
to anything that is magnetic.
traVel directiOn
/ Selection for travel direc-
tion.
Osc Offset
/ Regulation for oscilla-
tion oset.
Osc speed
/ Regulation for oscilla-
tion speed.
directiOn cHange/
stOp
/ Changes direction or
stops when limit switch is
activated.
numeric display (metric/
imperial)
/ Display of parameter values
and error codes.
endcrater filling
/ Allows perfect welding
seam endings.
Osc dwell time
/ Regulation for oscillation
dwell time left/center/right.
Osc amplitude
/ Regulation for oscillation
amplitude.
* Segment welding settings only in combination with CanOpen Interface (optional).
At the moment only available for TPS.
remOte cOntrOl – functiOns
/ The FlexTrack 45 is operated exclusively via remote control for maximum ease of use. The robust aluminium housing
combined with two protection handles can compensate accidentally falls. The magnetic holder allows mounting the remote
control to anything that is magnetic including the carriage itself.
Each parameter can be changed supported by a numeric display – accidentally parameter change is minimized by using
click-wheel-buttons.
/ Radial oscillation for fillet welds.
/ Linear oscillation with arc current control during orbital
welding.
OscillatiOn unit
OscillatiOn unit linear
Oscillation speed 5 - 400 cm/min (1.97 - 157.48 in/min)
Amplitude 2 - 30 mm (0.079 - 1.18 in)
Oset 0 - 50 mm (0 - 1.97 in)
Dwell time 0 - 3 seconds
Net weight (without torch holder) 2 kg (4.4 lb)
IEC Ingress Protection rating IP 23
OscillatiOn unit radial
Travel speed (radius: 150 mm (5.91 in)) 20 - 120 cm/min (7.87 - 47.24 in/min)
Travel distance (radius: 150 mm (5.91 in)) 1 - 30 mm (0.039 - 1.18 in)
Oset 0 - 50 mm (0 - 1.97 in)
Dwell time 0 - 3 seconds
Net weight (without torch holder) 3,6 kg (7.94 lb)
IEC Ingress Protection rating IP 23
no weave
trapezoid
rectangular
triangular
no weave
trapezoid
rectangular
triangular
/ The radial oscillation unit is especially used
for fillet welds.
OscillatiOn mOdes OscillatiOn mOdes
/ Available are 2 types of oscillation units, which can be used in 4 different modes. The linear- and the radial oscillation are,
depending on the application, operated as a right or left variant.
Due to the modular design of the Flex Track 45, it is possible to add or change the appropriate oscillation unit just in a few
steps.
radiallinear
Vacuum pump
Pumping speed 40 m³/h
Ultimate pressure 120 mbar
Mains voltage 50 - 60 Hz 3x200-240/346-420 V
Power consumption 900 W
IEC Ingress Protection rating IP 23
A (height) 406 mm (15.98 in)
B (length) 547 mm (21.54 in)
C (width) 307 mm (12.09 in)
Net weight 38 kg (83.80 lb)
standard equipment
/ Dry-sealed, oil-free, rotary vane vacuum pump
/ Portable base frame
/ Non reversing starter
/ Inlet filter with paper cartridge
/ Pressure manometer
/ Mains cable with plug 5m (196.85 in)
arc current cOntrOlarc current cOntrOlarc current cOntrOl
Vacuum pump
/ In working cases of using non-magnetic materials, where you have to fix the rails via vacuum bridges, a corresponding
vacuum pump is needed. Integrated in a robust steel frame, it provides a suction performance, which ensures a best-possi-
ble fastening of up to 13 vacuum bridges on the object. The suction strength can be adjusted by shut-off valves.
arc current cOntrOl (acc)
features
/ Compact protected design
/ Quick and easy assembly
/ Spatter protection
/ The ACC module is used for automatic distance control of the torch to the work piece.
The main advantage is, that on possibly uneven surfaces or at not exactly centrically mounted guide rails, best welding
results can be realised.
arc current cOntrOl
Control voltage 24 VDC B (height) 308 mm (12.13 in)
Power consumption 8 W C 203 mm (7.99 in )
IEC Ingress Protection rating IP 23 D 54 mm (2.13 in)
Working distance 5 - 100 mm (0.2 - 3.94 in) E (width) 111 mm (4.37 in)
Travel speed (automatic mode) 30 cm/min (11.81 in) F 50 mm (1.97 in)
Travel speed (manual mode) 100 cm/min (39.37 in) G 50 mm (1.97 in)
Sensibility 1 - 9 Max. load capacity 15 kg (33.07 lb)
Dwell time 1 - 60 seconds Net weight 2,45 kg (5.40 lb)
A (length) 124 mm (4.88 in)
/ vacuum bridge
/ magnetic bridge
/ screW Feet bridge
rails and bridges
/ The high quality spring steel rails can be used on flat, curved or round objects. There are 3 different bridges for fixing the
rails to the objects. Rails and bridges can be configured for various diameters. The FlexTrack fits any rail configuration
perfectly.
/ Can be mounted on curved or at surfaces – min. inside
radius 1500 mm (59.1 in) / min. outside radius 1100 mm
(43.3 in).
/ Straight rigid rail with aluminium prole for vertical
and horizontal applications.
/ Can be also mounted on tubes as ring rails for in-
side* and outside welding. Dierent segment lengths
(1130/1695/1884 mm 44.5/66.7/74.2 in) provide a wide
diameter range.
/ Ring rails with rigid aluminium proles. The rails are
connected with hinge and catch for fast and easy setup.
/ For work pieces that are magnetic.
Heat resistant up to 180 °C (356 °F).
Adjustable magnetic force.
* Inside diameter on request!
/ Mostly used for non-magnetic work
pieces with smooth surfaces like alu-
minium or stainless steel. Temperature
range 0 to 120 °C (248 °F). Optional -30
to 250 °C (-22 to 482 °F).
/ Recommended for rigid ring rails
up to 840 mm (33.1 in) diameter.
All bridges contain adjustment units with a metrical scale and a distance block.
/ Flexible rails
/ rigid rails
diameter segments bridges
1560 - 1740 mm
(61.4 - 68.5 in)
3x type I
1x type II
18
1740 - 1920 mm
(68.5 - 75.6 in)
3x type III
1x type I
18
1920 - 2100 mm
(75.6 - 82.7 in)
3x type III
1x type II
20
2100 - 2280 mm
(82.7 - 89.8 in)
3x type III
2x type I
21
2280 - 2460 mm
(89.8 - 95.9 in)
5x type II 25
2460 - 2640 mm
(95.9 - 103.9 in)
3x type III
2x type II
25
2640 - 2820 mm
(103.9 - 111 in)
5x type II
1x type I
25
2820 - 3000 mm
(111 - 118.1 in)
6x type II 28
3000 - 3180 mm
(118.1 - 125.2 in)
3x type III
3x type II
30
3180 - 3360 mm
(125.2 - 132.3 in)
6 x type III 30
3360 - 6060 mm
(132.3 - 238.6 in)
on request
segment
type
lengtH
I 1130 mm (44.5 in)
II 1695 mm (66.7 in)
III 1884 mm (74.2 in)
diameter segments bridges
200 - 300 mm
(7.9 - 11.8 in)
2 3
300 - 480 mm
(11.8 - 18.9 in)
2 4
480 - 660 mm
(18.9 - 26 in)
2 6
660 - 840 mm
(26 - 33.1 in)
2 8
840 - 1020 mm
(33.1 - 40.2 in)
3 9
1020 - 1200 mm
(40.2 - 47.2 in)
3 12
1200 - 1380 mm
(47.2 - 54.3 in)
3 15
1380 - 1560 mm
(54.3 - 61.4 in)
4 16
/ Perfect Welding / Solar Energy / Perfect Charging
v05 May 2015 EN
Text and images correspond to the current state of technology at the time of printing. Subject to modifications.
All information is without guarantee in spite of careful editing - liability excluded. Copyright © 2011 Fronius™. All rights reserved.
Further information about all Fronius products and our global sales partners and representatives can be found at www.fronius.com
WE HAVE THREE DIVISIONS AND ONE PASSION: SHIFTING THE LIMITS OF POSSIBILITY.
/ Whether welding technology, photovoltaics or battery charging technology − our goal is clearly defined: to be the innovation leader. With around
3,300 employees worldwide, we shift the limits of what’s possible - our record of over 900 granted patents is testimony to this. While others progress
step by step, we innovate in leaps and bounds. Just as we’ve always done. The responsible use of our resources forms the basis of our corporate policy.
v02 2015
aw20
Fronius International GmbH
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4600 Wels
Austria
Telephone +43 7242 241-0
Fax +43 7242 241-953940
www.fronius.com
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Maidstone Road, Kingston
Milton Keynes, MK10 0BD
United Kingdom
Telephone +44 1908 512 300
Fax +44 1908 512 329
www.fronius.co.uk
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6797 Fronius Drive
Portage, IN 46368
USA
Telephone +1 877 FRONIUS
www.fronius-usa.com
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2875 Argentia Road, Units 4,5 & 6
Mississauga, ON L5N 8G6
Canada
Telephone +1 905 288-2100
Fax +1 905 288-2101
www.fronius.ca
/ Watch the video on
our YouTube channel.
tecHnical data
flextrack 45
carriage
Welding position PA, PB, PC, PF, PG
Material thickness min. 4 mm (0.16 in)
Horizontal travel speed 5 - 300 cm/min (1.97 - 118.11 in/min)
Vertical travel speed 5 - 250 cm/min (1.97 - 98.43 in/min)
Endcrater ll time 0 - 5 seconds
Max. load capacity horizontally/vertically 45/30 kg (99.2/66.1 lb)
Weight (without torch holder) 12,5 kg (27.6 lb)
IEC Ingress Protection rating IP 23
e-cabinet
Mains voltage 50 - 60 Hz 115/230 V
Power supply 24 V DC
Weight (without cables) 5,3 kg (11.7 lb)
IEC Ingress Protection rating IP 23
remOte cOntrOl
Cable length 10 m (393.7 in)
Weight (without cable) 1,5 kg (3.3 lb)
IEC Ingress Protection rating IP 23
dimensiOns
A (with linear OSC)
(without linear OSC)
543 - 623 mm (21.4 - 24.5 in)
480 - 560 mm (18.9 - 22 in)
B (with linear OSC)
(without linear OSC)
97 - 201 mm (3.8 - 7.9 in)
119 - 223 mm (4.7 - 8.8 in)
C (with linear OSC)
(without linear OSC)
352 mm (13.9 in)
334 mm (13.1 in)
D 304 mm (12 in)
E 230 mm (9.1 in)
F (overall height rigid straight rail setup) 318 mm (12.5 in)
G (overall height with magnetic bridge) 317 - 415 mm (12.4 - 16.3 in)
H (overall height with screw feet bridge) 317 - 415 mm (12.4 - 16.3 in)
I (with radial OSC)
(without radial OSC)
507 - 628 mm (20 in - 24.7 in)
480 - 560 mm (18.9 - 22 in)
J (with radial OSC)
(without radial OSC)
204 - 280 mm (8 in - 11 in)
119 - 223 mm (4.7 - 8.8 in)
K 333 mm (13.1 in)
L (height) 382 mm (15 in)
/ Custom fitting metal transport box including a toolkit for
the entire system (rails separately).
I
J
K
L
A
F
G
H
B
E
D
C
