Fronius VR 4000, Operating Instructions/Spare Parts List

Page 1: ...ine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0012 EN 003 16082017 VR 4000 VR 4000 30 VR 4000 30 TIME Operating Instructions S...

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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: ...EMENTS 18 Application area 18 Warning notices on the device 19 Options 20 Mode switch option for VR 4000 VR 4000 30 20 Optional control panels for VR 4000 VR 4000 30 20 Optional installation and conve...

Page 6: ...ressure 35 Adjust the brake 36 Adjusting the brake 36 Design of the brake 36 Start up 37 General information 37 Requirements 37 Care maintenance and disposal 38 General remarks 38 Every start up 38 Ev...

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: ...tection behind the protec tive visor wear stout footwear that provides insulation even in wet conditions protect the hands with suitable gloves electrically insulated and providing protection against...

Page 10: ...t be available and ready for use Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings Take appropriate precautions to prevent any danger of in jury or fire We...

Page 11: ...ssary provide an adequate earth connection for the workpiece Switch off unused devices Wear a safety harness if working at height Before working on the device switch it off and pull out the mains plug...

Page 12: ...susceptible to interference from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avo...

Page 13: ...d Welding torches and other parts with a high operating temperature must be al lowed to cool down before handling Special provisions apply in areas at risk of fire or explosion observe relevant nation...

Page 14: ...ring mains are being used Shielding gas cylinders contain gas under pressure and can explode if dam aged As the shielding gas cylinders are part of the welding equipment they must be handled with the...

Page 15: ...or dam age before commissioning Any damage must be repaired by trained service technicians before commissioning the device Only operate the device if all safety devices are fully functional If the saf...

Page 16: ...ed torque The manufacturer recommends that a safety inspection of the device is per formed at least once every 12 months The manufacturer recommends that the power source be calibrated during the same...

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: ...MAG standard manual welding Job mode LocalNet connection e g operation with remote control or JobMaster welding torch REQUIREMENTS To operate the wirefeeder it must first be configured for use with t...

Page 19: ...units have a water cooled electric motor with disc shaped rotor and may only be operated in con junction with an appropriate cooling unit Do not use the functions described here until you have fully...

Page 20: ...refer to the installation instructions for a detailed description of the optional control panels VR 4000 Ci control panel option VR 4000 digital display option Optional installa tion and conver sion...

Page 21: ...stallation kit for subsequent installation of the optional wire end connector power source switches off at the end of the wire Wire end check installation kit retrofitting of wire end monitoring advan...

Page 22: ...lding parameters that must be entered on a wire feed unit control panel cannot be changed on the power source Welding parameters can only be changed on the wire feed unit Standard control panel 1 Weld...

Page 23: ...elease the torch trigger The set operating points run automatically 4 Selector switch for selecting operating points 1 3 and the operating modes If operating point 1 2 or 3 is selected the following s...

Page 24: ...sition time from operating point 2 to operating point 3 setting range 0 1 9 9 s 10 Operating point 3 indicator illuminates when selector switch 4 is set to operating point 3 operating point 3 is runni...

Page 25: ...connection standardised connection socket for system add ons e g remote control JobMas ter torch etc 6 Blanking cover Rear of wire feed unit VR 4000 rear view 1 Blanking cover 2 current socket with b...

Page 26: ...ush button upwards to set the required gas flow rate at the pressure regulator As long as the button is pressed up gas flows out The wire threading gas test button 5 can also be installed as a separat...

Page 27: ...on the front of the power source on the front of the wire feed unit on the remote control IMPORTANT If settings have been selected using the Mode selector switch option they cannot be changed using ot...

Page 28: ...ivel pin receptor for use with an upright console wide swivel pin receptor for use with two screwed upright consoles and two power sources More detailed information on the swivel pin receptors can be...

Page 29: ...and damage Only carry out work on the device when the power source mains switch is in the O position the device is unplugged from the mains NOTE When connecting the interconnecting hosepack check that...

Page 30: ...sions as a Tuchel plug as a LocalNet plug e g on JobMaster welding torches Connecting MIG MAG robot weld ing torch Fronius F Euro connection for Dinse for Tweco VR 4000 X X X X VR 4000 30 X X VR 4000...

Page 31: ...ch connection 5 Fixing welding torch in place using a knurled screw Fix the welding torch in place using a knurled screw 6 Connecting water connections for water flow and wa ter return Plug the contro...

Page 32: ...use feed rollers that match the wire electrode An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists USA wirefeeders In the USA all wirefeeder...

Page 33: ...g back CAUTION Risk of injury from falling wirespool basket type spool Make sure that the wirespool or basket type spool with adapter is fitted securely to the wirespool holder 1 NOTE When working wit...

Page 34: ...ly to avoid injuries caused by the wire springing back CAUTION Risk of damage to the welding torch from sharp end of wire electrode Deburr the end of the wire electrode well before feeding in 4 4 1 2...

Page 35: ...t the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding Contact pressure stand ard values Semi cylindrical rolls Trapeze rolls Plastic...

Page 36: ...e if necessary 4 3 STOP 6 7 5 1 2 1 2 1 2 2 1 4 STOP OK 3 3 WARNING Fitting the equipment incorrectly can cause serious inju ry and damage Do not dismantle the brake Maintenance and servicing of brake...

Page 37: ...feed unit Feed rollers inserted into the wire feed unit Wirespool or basket type spool and adapter inserted in the wire feed unit Wire electrode fed in Feed roller contact pressure set Brake adjusted...

Page 38: ...f necessary Check brake and adjust if necessary Every 6 months Dismantle device side panels and clean inside of device with dry reduced com pressed air Disposal Dispose of in accordance with the appli...

Page 39: ...Wire drive 4 roller drive Maximum shielding gas pressure 7 bar 101 psi coolant Original Fronius Maximum coolant pressure 6 bar 87 psi LocalNet data rate 57600 Baud Supply voltage supply from the power...

Page 40: ...on IP 23 Dimensions l x w x h 650 x 290 x 410 mm 25 59 x 11 42 x 16 14 in Weight 16 5 kg 36 38 lbs Types of wirespool all standardised wirespools Maximum permitted wirespool weight 16 5 kg 36 38 lbs W...

Page 41: ...Appendix...

Page 42: ...0 TIME VR 4000 VR 4000 30 30 30 65 65 7LPH 95 5 95 5 95 5 95 5 95 5 95 5 95 5 86 95 7LPH 5 95 5 86 95 5 86 95 5 7 86 95 5 95 5 95 5 7 7 5 P PLQ P PLQ P PLQ P PLQ 7LPH VSHFLI OHQJWK 5 8 30 30 65 65 IUR...

Page 43: ...06 32 0405 0113 42 0405 0117 PE 42 0200 9352 CuZn 42 0100 0333 PE 42 0001 3481 Fe 32 0405 0112 44 0001 1203 42 0407 0077 22 0405 0114 42 0405 0119 BF2 0201 1345 42 0406 0034 42 0407 0503 Connector Mot...

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Page 48: ...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...

Page 49: ...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 04...

Page 50: ...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 gew nsc...

Page 51: ...48 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 42 0001 3543 5 8 18UNF W 4m 95mm 4 047 291 W 8m 95mm 4 047 292 W 8m 95mm 4...

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