Fronius VR 4040, Operating Instructions Manual

Page 1: ...nts on elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0014 EN 001 18022020 VR 4040 Operating Instructions Wire f...

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Page 3: ...to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for excellent results Explan...

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Page 5: ...l 19 Configuration 1 MIG MAG welding 19 Configuration 2 TIG cold wire welding 20 Start up 21 Safety 21 Accessories 21 Opening and closing the VR 4040 unreeling device 21 Dismounting and re mounting th...

Page 6: ...orce limitation 41 Care maintenance and inspection 43 Safety 43 General remarks on the wearing parts 43 Fonction test 43 Damper 43 Brake block 44 Brake clearence 45 Overload coupling 46 Wire guide tub...

Page 7: ...General in the operating instructions for the device Before switching on the device rectify any faults that could compromise safety This is for your personal safety Proper use The device is to be use...

Page 8: ...ing instructions especially the Safety rules section and sign to confirm that they have understood them and will follow them Before leaving the workplace ensure that people or property cannot come to...

Page 9: ...anger from toxic gases and va pours The fumes produced during welding contain harmful gases and vapours Welding fumes contain substances that cause cancer as stated in Monograph 118 of the Internation...

Page 10: ...that are in contact with the welding wire are live Always set the wirefeeder up on a sufficiently insulated surface or use a suitable insulated wirefeeder holder Make sure that you and others are prot...

Page 11: ...h the workpiece clamp as close as possible to the area that is to be welded If the floor is electrically conductive the device must be set up with sufficient insulating ma terial to insulate it from t...

Page 12: ...tion EMF measures Electromagnetic fields may pose as yet unknown risks to health effects on the health of others in the vicinity e g wearers of pacemakers and hearing aids wearers of pacemakers must s...

Page 13: ...G MAG and TIG devices If the wire feed unit is attached to a crane holder during welding always use a suitable insulated wirefeeder hoisting attachment MIG MAG and TIG devices If the device has a carr...

Page 14: ...urless and odourless and in the event of a leak can displace the ox ygen in the ambient air Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m hour Observe safety and main...

Page 15: ...ability etc Only use suitable original coolant from the manufacturer Do not mix the manufacturer s original coolant with other coolants Only connect the manufacturer s system components to the cooling...

Page 16: ...y Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area Ignoring this European Directive may hav...

Page 17: ...eering direction and in the direction of travel If one side of the unreeling device housing needs to be placed flush against a wall or an adjacent machine the VR 4040 can also be ordered in a mirror i...

Page 18: ...ugh the unreeling device has been optimally preconfigured for a wide range of differ ent wire spools wirefeed speeds and welding wires before leaving the factory it is possible to fine tune it where n...

Page 19: ...communicates with the robot via the ROB 4000 5000 robot interface 5 Configuration 1 VR 4040 combined with the TS 4000 5000 or TPS 4000 5000 power source and the VR 1500 wirefeeder unit 1 VR 4040 unree...

Page 20: ...the TIG KD connection box 5 robot control is networked with the power source and the KD 7000 Configuration 2 VR 4040 combined with the MagicWave 2600 2600 CEL or TransTig 2600 CEL 3000 power source an...

Page 21: ...following accessories are absolutely essential for running the VR 4040 wire unreeling device Wirefeeder unit Feeder set to fit the type of wirefeeder used Spool set to fit the type of wire spool used...

Page 22: ...22 Dismounting and re mounting the side guard panel 2 to 4 Dismounting the side guard panel 1 A to C Re mounting the side guard panel 1 2 1 Extrude Tite screws 4 3 1 2...

Page 23: ...irefeeder The wirefeeder and feeder set shown here are intended as symbolic representative ex amples only Insert the wire guide tube into the wirefeeder unit Allow 15 mm of the wire guide tube to proj...

Page 24: ...force maybe re quired IMPORTANT Before inserting the wire spool carrier into the anchor points V check that the toothed wheels are engaging correctly Rotate the wire spool slightly if necessary 1 2 R...

Page 25: ...formed work This can result in serious injury and damage to property The driver 1 must not engage into wire spools made of electrically conductive mate rial Only use basket type spools with an insulat...

Page 26: ...ccuracy of the wire spool used Tighten the clamping lever and set the tensioning position of the clamping lever at right angles to the spool axle Inserting in the wire electrode WARNING Danger from el...

Page 27: ...t effective way of preventing condensation on the wire spool is to warm up the spool to approximately the temperature of the heated interior compartment or even slightly above it before inserting it i...

Page 28: ...g system The safety isolating transformer is located in a separate housing outside the VR 4040 The pre set temperature of the interior compartment is kept constant by a digital temperature controller...

Page 29: ...lead through pull through the 24 V supply leads and arrange them in the inside of the housing When piercing the rubber lead through make sure that the resulting opening is not too large The rubber lea...

Page 30: ...nut mount the temperature sensor in the drilled hole D Roll up the temperature sensor cable in a spiral and fasten it to fixing point Q togeth er with the thermostat cable Risk of the temperature sen...

Page 31: ...mains plug Set the desired temperature For a description of the operating panel for the interior heating system please see the en closed Operating Instructions for the thermostat Technical data 24 V...

Page 32: ...arameters Set point SP 30 C Control hysteresis HySt 0 8 Alarm AL 25 C Digital filter time constant FiLt 2 Sek Actual value for offset OFFS 0 Set point interlock SPL OFF Alarm value setting in the oper...

Page 33: ...that constantly samples the wire spool Before the final layer has been completely unreeled the system ceases to detect any more wire and the inductivity of the sensor changes This property can be exp...

Page 34: ...34 More details on mounting the end of wire watchdog 2 mm...

Page 35: ...l limit stop this ensures that there is sufficient tensile load on the wire even when the unreeling device is idling Accelerating Right at the very beginning of the welding operation the wirefeeder un...

Page 36: ...r this reason the tensile load on the wire is half of the effective weight of the lever drawback pulley unit In all three conditions of the unreeling device equilibrium idling and decelerating the ten...

Page 37: ...drawback pulley unit 1 remains sufficiently far away ap prox 2 cm from the bottom mechanical limitstop when the wire spool is full then the nec essary tensile force will still be applied to the weldin...

Page 38: ...er drawback pulley unit assumes a slightly higher working position This allows for the longer deceleration time that is needed for heavy wire spools In such a case then do not attempt to correct the w...

Page 39: ...wback pul ley unit moves downwards Rapid response The braking force takes effect abruptly Where very heavy wire spools 80 kg are being used with very high wirefeed speeds 22 m min it may be necessary...

Page 40: ...mandrel 19 by tightening the counter nut 18 Perform a function test see Care maintenance and inspection Mount the side guard panel Measuring the value for the wire tensile force limi tation There are...

Page 41: ...e cut off end of wire downward until the overload coupling 11 begins to slip The lever drawback pulley unit 1 moves upward Read off the value shown on the spring gauge The value indicated must corresp...

Page 42: ...in the shaft nut 12 Function test see Care maintenance and inspection Re mount the side guard panel Setting a higher value for the wire tensile force limitation Take off the side guard panel See Star...

Page 43: ...feed speed and the weight of the wire spool used For every seam that is welded there is both an acceleration phase and a braking phase The service life of the damper the brake block and the friction l...

Page 44: ...ock Inspection interval every 500 000 weld seams at least once every 6 months Inspection procedure Take off the side guard panel Using a feeler gauge measure the clearance between the wear markers and...

Page 45: ...e brake 4 Use a screwdriver to bend the positioning lugs 24 upwards so that the brake block 25 cannot accidentally be pushed out to one side Set the correct brake clearance see Setting the brake clear...

Page 46: ...centric 13 until it is possible to pull the 0 3 mm feeler gauge through between the limitation eccentric 13 and the bottom of the braking lever 22 Tighten the screw 23 on the limitation eccentric 13 C...

Page 47: ...of the tab washer 14 Loosen the shaft nut 12 by turning it with a hook spanner Detach the tab washer 14 Detach the spacer ring 31 Detach the six cup springs 32 Detach the friction disc 33 Detach the b...

Page 48: ...correct brake clearance see Setting the brake clearance Set the wire tensile force limitation see Setting the wire tensileforce limitation Set the braking force See Adjusting the braking force Carry...

Page 49: ...6 Chamfer the inside of the wire guide tube at the wire inlet end Gently tighten the swivel nut 45 of the clamping device 46 To prevent damage to the wire guide tube T only tighten the swivel nut 459...

Page 50: ...with a new pulley Shoe for end of wire watchdog Inspection interval every 5th time the wire spool is changed Inspection procedure Tilt up the carrier arm 48 of the induc tive sensor 49 Use a sliding...

Page 51: ...e shoe 50 complete with the sensor 49 from the carrier arm 48 Unscrew the shoe 50 from the sensor 49 When unscrewing the sensor take care that the cable does not get twisted Screw the new shoe onto th...

Page 52: ...ge Remedy Correct the brake clearance see Care maintenance and inspection Brake clearance Cause Excessive wear on brake lining Remedy Change the brake block see Care maintenance and inspection Brake b...

Page 53: ...damper see Care maintenance and inspection Damper Lever drawback pulley unit badly overshoots oscillating back and forward over the working position before finally reaching this position Cause The wi...

Page 54: ...when the unreeling device is in equilib rium1 6 N Max wire tensile force when the device is accelerating 1 15 N Wire diameter 0 8 1 6 mm 0 03 0 06 in Wirefeed speed 2 up to 22 m min up to 866 14 ipm W...

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