Fronius KD 7000, Operating Instructions Manual

Page 1: ...Perfect Charging Perfect Welding Solar Energy 42 0426 0028 EN 002 13122016 KD 7000 Operating Instructions Wire feed unit EN...

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Page 3: ...essential prerequisites for excellent results Explanation of safety symbols If you see any of the symbols depicted in the Safety rules chapter special care is re quired DANGER Indicates immediate and...

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Page 5: ...level 34 Ground 34 Start KD 34 Arc on Command arc on 34 Gas on Command gas on 34 Touch sensing 35 Wire retract on off WR on off 35 Job recall Job mode 35 Reserve 4 reserve 5 36 Emergency stop 36 Wire...

Page 6: ...espool 45 Inserting the basket type spool 46 Feeding in the welding wire 46 Adjusting the brake 47 Design of the brake 48 Troubleshooting 49 Troubleshooting 49 Care maintenance and disposal 50 General...

Page 7: ...t be covered pasted or painted over For the location of the safety and danger notices on the device refer to the section headed General in the operating instructions for the device Before switching on...

Page 8: ...atures are trained to produce the required results Checks must be carried out at regular intervals to ensure that operators are working in a safety conscious manner Before using the device all persons...

Page 9: ...ds with suitable gloves electrically insulated and providing protection against heat wear ear protection to reduce the harmful effects of noise and to prevent injury Keep all persons especially childr...

Page 10: ...s degreasers etc The relevant material safety data sheets and manufacturer s specifications for the listed components should therefore be studied carefully Flammable vapours e g solvent fumes should b...

Page 11: ...elec trodes at the same time may be fatal under certain circumstances Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning prope...

Page 12: ...evice complies with the standard limit values for emissions it may affect the application area for which it was designed e g when there is sensitive equipment at the same location or if the site where...

Page 13: ...the welding torch poses a high risk of injury piercing of the hand injuries to the face and eyes etc Therefore always keep the welding torch away from the body devices with wire feed unit and wear sui...

Page 14: ...r for the shielding gas connection using suitable Tef lon tape The following requirements with regard to shielding gas quality must be met if the welding system is to operate in a correct and safe man...

Page 15: ...mpletely and detach the following components Wire feed unit Wirespool Shielding gas cylinder After transporting the device the device must be visually inspected for dam age before commissioning Any da...

Page 16: ...use original housing screws in the correct number and tightened to the specified torque The manufacturer recommends that a safety inspection of the device is per formed at least once every 12 months T...

Page 17: ...ements of the rele vant standards for Canada and the USA The user is responsible for the safekeeping of any changes made to the fac tory settings The manufacturer accepts no liability for any deleted...

Page 18: ...lications with la ser welding systems In this case external control of the KD 7000 is via the robot controller The Robacta Drive KD is recommended as a wire drive for the KD 7000 in the case of al umi...

Page 19: ...lowing basic requirements must be met to en sure the equipment is used properly Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must be kept...

Page 20: ...ecommended for welding machines Wirespool and 4 roller drive integrated in KD 7000 Wire pushed by integrated 4 roller drive Length of the wirefeed hosepack up to 3 5 m Configuration 1 unalloyed high a...

Page 21: ...epack up to 3 5 m Configuration 2 Wirespool and wire drive external wire pushed 1 KD 7000 2 Wirespool holder and wirespool external 3 4 roller drive external VR 1530 KD 4 Wirefeed hosepack 5 Welding t...

Page 22: ...00 with wirespool holder 2 Robacta Drive KD hosepack 3 Welding torch 4 2 roller drive external Robacta Drive KD 5 Robot control 6 TIG KD connection box 7 Power source robot interface 8 Power source 9...

Page 23: ...2 Robacta Drive KD hosepack 3 Welding torch 4 2 roller drive external Robacta Drive KD 5 Wirespool holder and wirespool external 6 Robot control 7 TIG KD connection box 8 Power source robot interface...

Page 24: ...on the KD 7000 for details of which wire drive is used e g wire drive 0 10 m min Use the table below to determine the actual wire speed e g 719 on the display means 7 19 m min with the 0 10 m min wire...

Page 25: ...et standardised connection socket for the system defaults 10 KD control interface 37 pin plastic CPC socket for external control of the KD 7000 using analogue and digital signals 11 Mains cable 12 Ext...

Page 26: ...TIG KD connection box is not required direct connection between robot controller and the KD 7000 There is also the option of controlling the KD 7000 manually only Inside the TIG KD connection box Wir...

Page 27: ...gnals to X4 X4 To the connection socket for remote control interface for the power source to set the welding parameters on the power source via analogue signals via the robot or machine controller by...

Page 28: ...by the robot or machine controller The wire speed switches between 0 and the entered set value according to the sig nal for pulsing Puls Synch TIG Pulsing of the cold wire is set by the power source...

Page 29: ...e drive used Check the sticker on the KD 7000 for details of which wire drive is used e g wire drive 0 10 m min Use the table below to determine the signal voltage for the relevant wire speed e g 10 V...

Page 30: ...30 TIG KD connection box wiring diagram...

Page 31: ...d externally X3 14 Vd Command Value X3 15 Vd Command Value Analogue input signal for setting main current externally X3 1 Rem contr Pin C X3 6 GND TIG Digital signals Digital input signal for arc on X...

Page 32: ...32 KD 7000 wiring diagram...

Page 33: ...d by an internal power supply on the robot con troller For this reason pins 5 to 8 are usually unoccupied WARNING An electric shock can be fatal Never connect the robot controller supply to the power...

Page 34: ...t KD signal wirefeeding starts when the welding current has reached the main current phase The main current phase takes place between the start current and final current phase Arc on Com mand arc on T...

Page 35: ...Digital output signals chapter No welding can take place while the Touch sensing signal is set If the robot control sets the Touch sensing signal during a welding operation welding is stopped Position...

Page 36: ...ages are ap plied to pin C and pin G X3 pin 1 2 V tens X3 pin 9 4 V units It is possible to switch between the individual jobs during welding Reserve 4 re serve 5 TIG KD connection box These pins are...

Page 37: ...gnal sets pulsing of the cold wire by the robot control Puls Robot mode must have been selected on the Wire Mode dip switches The wire speed switches between 0 and the entered set value according to t...

Page 38: ...section Specifying power source set value for standard welding Select simulation of TP mc remote control on the Remote Control dip switches see TIG KD connection box TIG KD connection box A voltage of...

Page 39: ...is specified for the set values for the listed welding parameters 0 V Minimum parameter set value 10 V Maximum parameter set value Plug X3 pin 1 Main current or pulse current 0 to 10 V Plug X3 pin 4 A...

Page 40: ...nal common TIG KD connection box Pin 34 serves as a common root for the Current flow signal HF on Gas on Alarm and Reserve digital output signals see Digital output signals Current flow sig nal Signal...

Page 41: ...ther application op tion Alarm signal TIG KD connection box The Alarm signal is set if the power source is switched off due to overtemperature or mains overvoltage undervoltage The Alarm signal may in...

Page 42: ...IG KD connection box The main current signal is set between the starting current and final current phase If the setting Start TIG has been selected on the Wire Mode dip switches wirefeeding starts wit...

Page 43: ...nter the de vice Mains connection The KD 7000 is designed to run on the mains voltage indicated on the rating plate The mains cable and plug are ready fitted For details of fuse protection of the main...

Page 44: ...hosepack has been completely tooled up Insert it infeed tube first into the central connector Tighten the union nut by hand to fix the torch in place Connecting Ro bacta Drive KD wire drive Move the m...

Page 45: ...45 EN 3 Inserting the wire spool 1 1 2 3 1 2 3 1...

Page 46: ...pe spool Place the basket type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways 1 2 CAUTION Risk of injury from springiness of spooled welding wi...

Page 47: ...Risk of injury from emerging welding wire Keep the welding torch away from your face and body and wear suitable protective goggles 1 2 2 5 NOTE After releasing the torch trigger the wirespool should s...

Page 48: ...OK 3 3 CAUTION Risk of injury and damage from falling wirespool To ensure that the wirespool is properly in place and that the brake works properly fit the brake ac cording to the following diagram 1...

Page 49: ...ts Irregular wire speed The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the welding torch Cause Braking force has been set too high Remedy Loosen the brake Cause Ho...

Page 50: ...inspections at the stipulated intervals see Safety rules Depending on the installation location but in any event at least twice a year remove the side panels and clean the KD 7000 with dry reduced com...

Page 51: ...35 27 lb Wirespool diameter 300 mm 11 81 in Wire speed 0 2 max m min 7 87 max ipm Wire drive 4 roller drive Wire diameter 0 8 1 6 mm 0 03 0 06 in Wirespool diameter max 300 mm max 11 81 in Degree of p...

Page 52: ...52 Spare parts list KD 7000...

Page 53: ...09 2106 32 0405 0113 42 0200 9352 32 0405 0112 44 0001 1203 42 0407 0077 22 0405 0114 42 0405 0119 BF2 0201 1345 42 0406 0034 42 0407 0503 42 0100 0333 42 0001 3481 42 0405 0117 42 0404 0340 42 0400 0...

Page 54: ...001 0090 42 0402 0093 42 0200 9872 42 0001 1508 42 0001 1278 42 0001 1424 42 0001 1682 42 0001 1944 42 0001 3051 44 0001 1197 42 0300 1053 CB RA M connection VR 1500 M VR 1500 PAP VR 1500 all variants...

Page 55: ...55 42 0407 0077 42 0200 9816 42 0001 3260 42 0200 9817 42 0001 3259 44 0001 1242 32 0300 2481 42 0300 2631 12 0405 0118 32 0300 2233 12 0300 2375 Motorplate 42V 4R 15mm 59in 17mm 67in Tweco KD...

Page 56: ...0080 42 0405 0082 42 0200 5633 42 0001 3670 42 0200 8408 41 0001 0592 43 0006 0139 33 0006 0131 43 0006 0105 42 0001 3671 43 0007 0032 BE2 0201 1420 33 0006 0185 43 0006 0113 33 0006 0131 33 0006 0156...

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Page 60: ...1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of...