Fronius VR 4000 Yard Operating Instructions/Spare Parts List

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VR 4000 Yard

42,0426,0013,EN 008-10072015

Operating Instructions

Spare Parts List

Wire Feeder

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Summary of Contents for Fronius VR 4000 Yard

Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions VR 4000 Yard Spare Parts List Wire Feeder 42,0426,0013,EN 008-10072015...
Page 3 Read the manual carefully and you will soon be familiar with all the many great 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.
Page 5 Safety rules DANGER! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.
Page 6 General remarks Any malfunctions which might impair machine safety must be eliminated (continued) immediately - meaning before the equipment is next switched on. It’s your safety that’s at stake! Utilisation for The machine may only be used for jobs as defined by the “Intended purpose”. intended purpose The machine may ONLY be used for the welding processes stated on the only...
Page 7 Obligations of Before starting work, all persons to be entrusted with carrying out work with personnel (or on) the machine shall undertake to observe the basic regulations on workplace safety and accident prevention to read this operating manual particulary the sections on “Safety rules” and to sign to confirm that they have understood these and will comply with them.
Page 8 Protection for “Protective clothing” also includes: yourself and protecting your eyes and face from UV rays, heat and flying sparks with other persons an appropriate safety shield containing appropriate regulation filter glass (continued) wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield wearing stout footwear that will also insulate even in wet conditions protecting your hands by wearing appropriate gloves (electrically insula-...
Page 9 Hazards from The harmfulness of the welding fumes will depend on e.g. the following noxious gases components: and vapours the metals used in and for the workpiece (continued) the electrodes coatings cleaning and degreasing agents and the like For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.
Page 10 Hazards from Do not loop any cables or other leads around your body or any part of your mains and weld- body. ing current (continued) Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.
Page 11 Stray welding When using current supply distributors, twin head wire feeder fixtures etc., currents please note the following: The electrode on the unused welding torch/ (continued) welding tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs. In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
Page 12 EMI Precautions 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 much space as possible between welding cables and head/ body of welder for safety reasons...
Page 13 Particular danger Risk of scalding from accidental discharge of hot coolant. Before unplugging spots the connectors for coolant forward flow and return flow, switch off the coo- (continued) ling unit. Observe the information on the coolant safety data sheet when handling coolant.
Page 14 Danger from Keep shielding-gas cylinders well away from welding circuits (and, indeed, shielding-gas from any other electrical circuits). cylinders (continued) Never hang a welding torch on a shielding-gas cylinder. Never touch a shielding-gas cylinder with a welding electrode. Explosion hazard - never perform welding on a pressurized shielding-gas cylinder.
Page 15 Safety precau- Only operate the machine if all of its protective features are fully functional. If tions in normal any of the protective features are not fully functional, this endangers: operation the life and well-being of the operator or other persons the equipment and other tangible assets belonging to the owner/operator efficient working with the equipment.
Page 16 Safety inspection A safety inspection should be carried out by a qualified electrician (continued) after any changes are made after any additional parts are installed, or after any conversions after repair, care and maintenance has been carried out at least every twelve months. For safety inspections, follow the appropriate national and international standards and directives.
Page 17: Table Of Contents
Setting the contact pressure ........................18 Care, maintenance and disposal ........................19 General ..............................19 Every start-up ............................19 Every 6 months ............................19 Disposal ..............................19 Technical data .............................. 20 VR 4000 Yard wire-feed unit ........................20 Spare parts list Fronius Worldwide...
Page 18: General
General Product concept The VR 4000 Yard wire-feed unit with four-roll drives is designed to be used with wire- spools with a diameter of up to 300 mm. The Yard wire-feed unit was specifically developed for use in shipyards and in the offshore industry.
Page 19: Warning Notices Affixed To The Device
Suitable protective equipment all the operating instructions for the Keep all persons not involved in the system components, especially the welding process at a safe distance safety rules Warning notices on the wire-feed unit VR 4000 Yard...
Page 20: Control Elements And Connections
Do not use the functions described here until you have read and completely understood all the operating instructions. IMPORTANT! Welding parameters that can be adjusted on the VR 4000 Yard wire-feed unit cannot be adjusted on the power source. Parameters can only be changed on the VR 4000 Yard wire-feed unit.
Page 21 VR 4000 Yard No. Function (continued) (7) LocalNet connection (option) standardised connection socket for system extensions (e.g. remote control, Job- Master welding torch, etc.) (8) Braked wirespool holder and adapter for basket-type spool for holding standard welding wire spools up to 18 kg in weight...
Page 22: Control Elements And Connections On Right Side
Control elements and connections on right side Right side view VR 4000 Yard No. Function (1) Shielding gas connection (2) (+) current connection with bayonet latch Interconnecting hosepack (3) LocalNet connection socket Interconnecting hosepack (4) Red water return connection - option...
Page 23: Installation
(0.02 sq.in.). Only welding torches with a connection for Dinse / Euro can be used. If the VR 4000 Yard is equipped with optional water connections, then only a welding torch with external water connections may be used. Turn the power source mains switch...
Page 24: Fastening The Interconnecting Hosepack To The Wire-Feed Unit
Fitting the wel- If present, plug-in and lock the wel- ding torch ding torch control plug to the torch (continued) control lead connection (3) (option) If present, connect the water flow and return connectors for the welding torch to connections (4) and (5) of the wire-feed unit (3)(4)(5) Welding torch activation and water connections...
Page 25: Routing The Interconnecting Hosepack To The Wire-Feed Unit
Routing the interconnecting hosepack (2) through the bushing (1) Refit the cover on the right side of the VR 4000 Yard wire-feed unit Routing the interconnecting hosepack Connecting the The interconnecting hosepack is connected to the power source as described in the interconnecting power source operating instructions.
Page 26: Installing The Wire Infeed Tube, Wire Guide Insert And Steel Capillary Tube
Installing the wire infeed tube, wire guide insert and steel capillary tube Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel! Observe the safety rules in the power source operating instructions.
Page 27: Replacing The Capillary Tube
Replacing the Disconnect the brass capillary tube capillary tube (1) in the vicinity of the 4 roller drive by pressing down with a screwdriver (Fig.10) Remove the capillary tube (1) from the welding torch connection Insert the steel capillary tube (1) into the torch connection and, using pliers, push it in as far as it will go Replacing the capillary tube...
Page 28: Replacing The Wire Infeed Tube
Replacing the Remove plastic wire infeed tube (1) wire infeed tube with pliers Push in the infeed tube (1) as far as it will go Inserting the wire infeed tube Fitting the feed rollers...
Page 29: Inserting The Wirespool, Inserting The Basket-Type Spool
Inserting the wirespool, inserting the basket-type spool Safety CAUTION! Risk of injury from springiness of spooled wire electrode. When inserting the wirespool/basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of injury from falling wire spool / basket-type spool.
Page 30: Adjusting The Brake
Adjusting the brake General IMPORTANT! After releasing the torch trigger the wirespool should stop unreeling. Adjust brake if necessary. Adjusting the brake...
Page 31: Design Of The Brake
Design of the CAUTION! Risk of injury and damage from falling wirespool. To ensure that brake the wirespool is properly in place and that the brake works properly, fit the brake according to the following diagram.
Page 32: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers General In order to achieve satisfactory wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded. IMPORTANT! Use only 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.
Page 33: Feeding In The Wire Electrode
Feeding in the wire electrode Feeding in the CAUTION! Risk of injury from springiness of spooled wire electrode. When wire electrode inserting the wire electrode into the 4 roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of damage to the welding torch from sharp end of wire electrode.
Page 34: Setting The Contact Pressure
Feeding in the CAUTION! Risk of injury from the emerging wire electrode. Keep the welding wire electrode torch away from face and body when pressing the feeder inching button. (continued) Setting the NOTE! Adjust contact pressure in such a way that the wire electrode is not contact pressure deformed, but is nevertheless transported properly.
Page 35: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions the wire-feed units require only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. WARNING! An electric shock can be fatal.
Page 36: Technical Data
Technical data VR 4000 Yard Supply voltage 24 V DC / 55 V DC wire-feed unit Nominal current 2 A / 4 A Wire diameter 0.8 – 1.6 mm (0.03 - 0.06 in.) Wire feed speed 0.5 - 22 m/min (19.69 - 866.14 ipm)
Page 37: Spare Parts List
Ersatzteilliste Spare Parts List Liste de pièces de rechange Lista parti di ricambio Lista de repuestos Lista de peças sobresselentes Onderdelenlijst Reservdelsliste Seznam náhradních dílů Ñïèñîê çàïàñíûõ ÷àñòåé Zoznam náhradných dielov Reservdelslistan Parça Listesi Wykaz czesci zamiennych ud_fr_st_tb_00150 012014...
Page 38 42,0405,0357 SCHARNIER HINGE PART CHARNIERE 42,0407,0511 VR 4000 Yard 4R / E / Dinse Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_dv_00472 012003...
Page 39 SCHLAUCH Synthetik 42 WS HOSE Synth. 42 WS TUYAU Synth. 42 WS * 40,0001,0411 SCHWEISSKABEL H01N2-D 95MM2 * WELD. CABLE H01N2-D 95MM2 * CABLE DE SOUDAGE H01N2-D 95MM2 * 40,0003,0015 KABEL PUR 6x2 + 4x0,5 * CABLE PUR 6x2 + 4x0,5 * CABLE PUR 6x2 + 4x0,5 * 40,0003,0447 SCHLAUCH PVC MG 5x3 SW *...
Page 40 Motorplate 42V 4R 42,0400,0123 42,0405,0116 42,0407,0098 42,0404,0264 BF2,0404,0340 - yellow 42,0409,2106 32,0405,0112 32,0405,0113 42,0405,0117 - PE 42,0200,9352 - CuZn 42,0200,7767 t o r t o r 42,0405,0120 42,0300,2162 44,0001,1203 42,0407,0077 42,0407,0503 42,0100,0333 - PE 42,0406,0034 42,0001,3481 - Fe 22,0405,0114 42,0405,0119 BF2,0201,1345 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi...
Page 41 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
Page 42 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
Page 43 Motorplate 42V 4R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01220 012012...
Page 44 FRONIUS INTERNATIONAL GMBH Froniusplatz 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 our Sales & service partners and Locations. ud_fr_st_so_00082 012011...