Fronius VR 2000, Operating Instructions Manual

Page 1: ...VR 2000 Operating Instructions Spare Parts List Wire Feeder EN Battery Charging Systems Welding Technology Solar Electronics 42 0426 0011 EN 007 08072016 ...

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Page 3: ...t features of your new Fronius product This really is the best way to get the most out of all the advantages that your machine has to offer Please also take special note of the safety rules and observe them In this way you will help to ensure more safety at your product location And of course if you treat your product carefully this definitely helps to prolong its enduring quality and reliability ...

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Page 5: ...egible condition must not be damaged must not be removed must not be covered pasted or painted over For information about where the safety instructions and danger warnings are located on the machine please see the section of your machine s instruction manual headed General remarks General remarks Important DANGER indicates an imminently hazardous situation which if not avoided will result in death...

Page 6: ... safety instructions and danger warnings performing all stipulated inspection and servicing work The appliance must never be used for the following Thawing pipes Charging batteries accumulators Starting engines The machine is designed to be used in industrial and workshop environments The manufacturer shall not be liable for any damage resulting from use of the machine in residential premises ikew...

Page 7: ...risk electrical hazards from mains and welding current increased exposure to noise Mains connec tion High performance devices can affect the quality of the mains power due to their current input This may affect a number of types of device in terms of connection restrictions criteria with regard to maximum permissible mains impedance criteria with regard to minimum short circuit power requirement a...

Page 8: ...mains or welding current provide them with suitable protective equipment and or erect suitable protective partitions or curtains Protection for yourself and other persons continued Protective clothing also includes protecting your eyes and face from UV rays heat and flying sparks with an appropriate safety shield containing appropriate regulation filter glass wearing a pair of appropriate regulati...

Page 9: ...ouch any live parts either inside or outside the machine In MIG MAG and TIG welding the welding wire the wire spool the drive rollers and all metal parts having contact with the welding wire are also live Always place the wirefeeder on an adequately insulated floor or base or else use a suitable insulating wirefeeder holder Ensure sufficient protection for yourself and for other people by means of...

Page 10: ... the machine supply leads checked regularly by a qualified electrician to ensure that the PE protective earth conductor is functioning correctly Only run the machine on a mains network with a PE conductor and plugged into a power outlet socket with a protective conductor contact If the machine is run on a mains network without a PE conductor and plugged into a power outlet socket without a protect...

Page 11: ...fect the application area for which it was designed e g when there is sensitive equipment at the same location or if the site where the device is installed is close to either radio or television receivers If this is the case then the operator is obliged to take appropriate action to rectify the situation Examine and evaluate any possible electromagnetic problems that may occur on equipment in the ...

Page 12: ...ctive gear and to ensure that other persons are suitably protected when doing post weld finishing on workpieces Electromagnetic fields may cause as yet unknown damage to health Effects on the health of persons in the vicinity e g users of heart pace makers and hearing aids Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces Keep as ...

Page 13: ...r changes caused by other environmental factors The testing interval and scope of testing must comply with applicable natio nal standards and directives as a minimum Risk of scalding from accidental discharge of hot coolant Before unplugging the connectors for coolant forward flow and return flow switch off the coo ling unit Observe the information on the coolant safety data sheet when handling co...

Page 14: ... any coolant and dismantle the following components Wire feed Wire wound coil Gas bottle Before commissioning and after transportation a visual check for damage must be carried out Any damage must be repaired by trained service personnel before commissioning Keep shielding gas cylinders well away from welding circuits and indeed from any other electrical circuits Never hang a welding torch on a sh...

Page 15: ...er shall not be liable for any such damage and all warranty claims shall be null and void Under certain conditions the coolant is flammable Only transport the coolant in closed original containers and keep it away from sources of ignition Used coolant must be disposed of properly in accordance with the relevant national and international regulations A safety data sheet is available from your servi...

Page 16: ...rsonal settings are deleted Data security Do not dispose of this device with normal domestic waste To comply with the European Directive 2002 96 EC on Waste Electrical and Electronic Equipment and its implementation as national law electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility Any device that you no longer requ...

Page 17: ... indicator 8 Rear of wirefeeder 9 Side of wirefeeder 9 Mode selector switch option 10 Connecting up the wirefeeder to the power source 11 General remarks 11 Connecting up the wirefeeder to the power source 11 Mounting the welding torch 12 Torch connections 12 Mounting the welding torch 12 Inserting the wirespool 13 General remarks 13 Inserting the wirespool 13 Inserting changing the feed rollers 1...

Page 18: ...sPuls Synergic 4000 5000 series of the TransPuls Synergic 2700 Duo series of the TransPuls Synergic 2700 Duo TIG series General remarks Machine concept System requirements Area of utilizationt The VR 2000 is designed to be used with wirespools of diameter 200 mm 7 87 in In conjunction with the 200 mm 7 87 in diameter wirespool a 2 roller drive is used This results in a compact housing and very low...

Page 19: ... injury and damage to property Do not use the functions described here until you have read and understood all of the following documents these Operation instructions all Operating instructions for the system components especially the Safety rules Fig 2 Warning notices affixed to the wire feeder Welding is dangerous The following basic requirements must be fulfilled Suitable qualification for weldi...

Page 20: ...eans that the welder can no longer keep an eye on the power source from where he is working If this is often the case we advise equipping the power source with the optional key lock switch This provides optimum protection against anybody tampering or accidentally interfering with the machi ne while it is being used Fig 4 Optional TR 4000 C control panel Optional to the standard control panel the V...

Page 21: ...panel as standard Optional the control panel TR 4000 C is available 1 7 4 2 3 5 6 8 9 10 Fig 5 VR 4000 Ci control panel Item Function 1 Parameter selection button for selecting and displaying the following parameters on the digital display welding voltage welding current wirefeed speed sheet thickness When changing a parameter the parameter value appears briefly on the digital display so that it c...

Page 22: ...MIG MAG standard synergic welding for influencing the short circuiting dynamic at the instant of droplet transfer harder more stable arc 0 neutral arc soft low spatter arc MIG MAG pulse synergic welding continuous correction facility for the droplet detachment force lower droplet detachment force 0 neutral droplet detachment force increased droplet detachment force MIG MAG standard manual welding ...

Page 23: ...welding setting the welding voltage Rod electrode MMA welding influences the welding current during the ignition phase 0 no influence 10 100 increase in the welding current during the ignition phase 8 Arc length hot start indicator The relevant symbol lights up depending on the process selected hot start frequency welding voltage arc length 9 Hold indicator every time you finish a welding operatio...

Page 24: ...shock can be fatal There is also a risk of injury from welding wire emerging at speed from the torch As soon as the gas flow has been started when you press the torch trigger the welding wire is live Make sure that from this moment on the wire does not touch any persons or electrically conduct ing or grounded earthed parts such as the workpiece etc At the same time the wirefeed is also started whe...

Page 25: ...ide of wirefee der Rear of wirefee der 2 1 3 Item Function 1 socket with bayonet latch for MMA manual electrode welding 2 socket with bayonet latch interconnecting cable 3 LocalNet connection socket interconnecting cable 4 Screw type connection for water return flow red interconnecting cable 5 Screw type connection for water forward flow blue interconnecting cable 6 Shielding gas connection socket...

Page 26: ...al 4 step mode Aluminium welding start up Spot welding 3c Feeder inching gas test button Press the button down to inch the wire electrode into the torch hosepack without any flow of shielding gas or current As long as the button is held down the wirefeeder runs at feeder inching speed Press the button up to set the required gas flow rate on the pressure regulator As long as the button is pressed u...

Page 27: ...swivel nut of the gas hose 5 Screw the water forward flow and return flow hoses of the interconnecting cable to the screw type connectors and red to red and black to black 6 Tighten the swivel nuts of the water forward flow and return flow hoses 7 Plug the LocalNet plug of the interconnecting cable into the LocalNet connection socket 8 Tighten the swivel nut of the LocalNet plug 9 Plug the Welding...

Page 28: ...ighten the swivel nut by hand to fix the torch in place 4 Plug the control plug of the welding torch onto the torch control connec tion socket 2 and turn it to fasten it 5 If available connect external water connections for water flow 3 and water return 4 paying attention to the correct colours A Fig 12 Welding torch connector and torch control connection point on the VR 2000 The VR 2000 wire feed...

Page 29: ...use motor overload CAUTION If the wirespool were to fall off this would be dangerous Make sure that the wirespool is firmly mounted to the wirespool holder Fig 13 Inserting the wirespool Fig 14 View of close up Z Wirespool holder CAUTION Risk of injury from the spring effect of the coiled welding wire When threading in the wire hold the end of the wire firmly to prevent any injuries that might be ...

Page 30: ...ed rollers have to be inserted into the wirefeeder Important Use only feed rollers appropriate to the welding wire Please see the spare parts lists for an overview of the available feed rollers and of their possible areas of use Inserting changing the feed rollers Inserting chan ging the feed rollers NOTE Insert feed rollers in such a way that the toothed rim of the feed roller faces the motor pla...

Page 31: ...er ting the welding wire into the 2 roller drive hold the end of the welding wire firmly to avoid injuries caused by the wire springing back CAUTION Risk of damage to the welding torch from sharp end of welding wire Deburr the end of the welding wire well before feeding in Feeding in the welding wire Safety ...

Page 32: ...ching inch forward button Feeding in the welding wire continued NOTE Adjust the contact pressure in such a way that the welding wire is not deformed but is nevertheless transported properly Contact pressure reference values Semi cylindrical rolls Trapeze rolls Aluminium 1 5 Steel 3 4 1 5 CrNi 3 4 1 5 Setting the contact pressure ...

Page 33: ...x H 530 x 320 x 215 mm 20 87 x 12 60 x 8 46 in Weight 9 kg 19 84 lb Types of wirespool all standard wirespools Max permitted weight of wirespool 5 kg 11 02 lb Wirespool diameter 200 mm 7 87 in Wire diameter 0 8 1 6 mm 0 03 0 06 in Drive 2 roller drive Max shielding gas pressure 7 bar 101 psi Coolant Original Fronius coolant Max coolant pressure 6 bar 87 psi Technical data ...

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Page 35: ...i di ricambio Lista de repuestos Lista de peças sobresselentes Onderdelenlijst Reservdelsliste Seznam náhradních dílů Ñïèñîê çàïàñíûõ àñòåé Zoznam náhradných dielov Spare Parts List Reservdelslistan Parça Listesi Wykaz czesci zamiennych DE EN FR IT ES PT BR NL NO CS RU SK SV TR PL ...

Page 36: ...zza desiderat indicar o comprimento desejado 42 0405 0305 42 0407 0519 45 0200 1121 32 0405 0248 32 0405 0183 44 0001 1145 42 0405 0187 BLACK 42 0405 0186 RED 42 0405 0189 43 0001 3255 44 0001 1257 44 0001 1256 32 0409 2845 Z 43 0011 0038 43 0009 0045 4 100 360 42 0200 6480 45 0200 1120 42 0001 3106 Z 45 0200 1122 Z BE2 0201 1065 43 0004 1974 43 0003 0485 42 0405 0056 42 0405 0154 42 0404 0024 43 ...

Page 37: ... 0200 8698 42 0407 0137 42 0001 2703 44 0001 1314 44 0001 0442 42 0300 1053 44 0001 0052 42 0100 0052 42 0402 0093 Motorplate 24V 2R 42V 2R 42 0200 9872 44 0001 0276 44 0001 1219 42 0200 9627 12 0405 0118 22 0405 0114 Z Fronius connection 32 0405 0113 42 0001 1278 5x113 42 0001 1424 5x109 42 0001 1682 5x111 42 0001 1944 5x133 42 0001 3051 3 5x113 42 0405 0117 42 0405 0116 42 0407 0098 42 0404 0280...

Page 38: ...Ersatzteilliste Spare parts list Listes de pièces de rechange Lista de repuestos Lista de pecas sobresselentes Lista dei Ricambi Motorplate 24V 2R 42V 2R 2 2 el_fr_st_mp_01221 012015 ...

Page 39: ...7 0048 42 0407 0048 44 0450 0281 G 1 4 42 0001 0942 42 0001 0943 42 0402 0053 42 0405 0239 42 0405 0239 42 0407 0063 42 0407 0063 40 0003 0078 43 0003 0486 43 0003 0485 32 0405 0180 W 1 2m 70mm 4 047 260 W 1 6m 70mm 4 047 324 W 5 0m 70mm 4 047 261 W 10m 70mm 4 047 262 W 15m 70mm 4 047 290 W 20m 70mm 4 047 277 G 1 2m 70mm 4 047 287 G 5 0m 70mm 4 047 288 G 10m 70mm 4 047 289 gewünschte Länge angeben...

Page 40: ...03 0253 42 0407 0048 42 0407 0048 44 0450 0281 G 1 4 42 0407 0063 G 50mm 4m 4 047 411 G 70mm 8m 4 047 412 40 0003 0014 50mm 40 0003 0021 70mm 43 0003 0301 70mm 43 0003 0064 70mm 42 0407 0063 40 0001 0012 32 0405 0226 40 0001 0095 32 0405 0226 42 0407 0482 42 0407 0482 42 0405 0239 42 0405 0239 gewünschte Länge angeben Specify the length required Indiquer la longueur désirée Indicar la longitud des...

Page 41: ... 50mm 5m 4 047 409 G 50mm 10m 4 047 410 40 0003 0014 50mm 42 0407 0063 40 0001 0012 32 0405 0226 40 0001 0095 32 0405 0226 42 0407 0482 42 0407 0482 42 0405 0239 42 0405 0239 32 0405 0232 32 0405 0231 32 0405 0180 42 0407 0048 42 0407 0048 40 0003 0078 43 0003 0486 43 0003 0485 32 0405 0180 gewünschte Länge angeben Specify the length required Indiquer la longueur désirée Indicar la longitud desead...

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