Related Manuals for Fronius VR 4040
Summary of Contents for Fronius VR 4040
- Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions VR 4040 Spare Parts List Wire Feeder 42,0426,0014,EN 002-30032012...
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Page 3: Table Of Contents
Configuration 2: TIG cold-wire welding ..........7 This brochure is intended to familiarise you with how to operate and maintain your VR 4040 unreeling device. Es liegt in Ihrem Interesse, die Start-up ...................... 8 Bedienungsanleitung aufmerksam zu lesen und die hier angegebenen Accessories ................... -
Page 4: Safety Rules
The owner/operator undertakes to ensure that the only - The VR 4040 unreeling device is designed for indoor use only. It is not persons allowed to work with the VR 4040 unreeling permitted to set it up or operate it outdoors. -
Page 5: Safety Measures For Maintenance, Inspection And Troubleshooting
- Welding must NEVER be performed on containers that have had - For this reason, only operate the VR 4040 unreeling device when the gases, fuels, mineral oils etc. stored in them. Even small traces of cover is closed, the swing-out ramp is folded back up into place, the these substances left in the containers are a major explosion hazard. -
Page 6: General Remarks
The optional end-of-wire watchdog alerts the operator in good time to the fact that the wire spool will soon need changing. This makes it possible The VR 4040 unreeling device is a further member of the modular family to prevent unnecessary disruption of the production process. If the of Fronius wire-feeding equipment. -
Page 7: Practical Examples
KD 7000). / 3000 TIG power source Fig.3 Configuration 2 - VR 4040 combined with the MagicWave 2600 / 2600 CEL or TransTig 2600 CEL / 3000 power source and the KD 7000 cold-wire feeder Legend: ..Power-source robot interface .. -
Page 8: Start-Up
- Feeder set (to fit the type of wirefeeder used) - Spool set (to fit the type of wire spool used) OPENING AND CLOSING THE VR 4040 UNREELING DEVICE Warning! Always latch the ramp securely when it is folded back up... -
Page 9: Dismounting And Re-Mounting The Side Guard Panel
N.B.! The wirefeeder and feeder-set shown here are intended as symbolic, representative examples only. - Insert the wire-guide tube into the wirefeeder unit - Allow 15 mm of the wire-guide tube to project into the housing of the VR 4040 unreeling device 15 mm... -
Page 10: Removing And Inserting The Wire-Spool Carrier
REMOVING AND INSERTING THE WIRE-SPOOL CARRIER ... Removing the wire-spool carrier ... Inserting the wire-spool carrier Warning! Hold the wire-spool carrier firmly! With heavier spools, considerable force may- be required. N.B.! Before inserting the wire-spool carrier into the anchor points , check that the toothed wheels are engaging correctly. -
Page 11: Mounting And Dismounting The Wire-Spool Driver
- Wind adhesive tape around the guiding bushes if these are sitting adapter. too loosely in the wire spool (Fronius has no influence on the fitting accuracy of the wire spool used) - Tighten the clamping lever and set the tensioning position of the... -
Page 12: Inserting The Welding Wire
INSERTING THE WELDING WIRE N.B.! When unwinding the wire from the spool, lift the “lever + drawback Warning! Welding wire that suddenly breaks away and lashes pulley” unit. This releases the wirespool brake, making the wire easy to out can cause very serious injury to the face and eyes. unreel. -
Page 13: 230 V Interior Heating System, Unregulated
230 V INTERIOR HEATING SYSTEM, UNREGULATED General remarks In this way, no “sweating” (the phenomenon by which atmospheric water from warm ambient air condenses on a cold surface) can take place. The interior heating system is designed to operate with a constant heat output. -
Page 14: 24 V Interior Heating System, Regulated
Operating Instructions of the unreeling device! heating system. The safety isolating transformer is located in a separate housing, outside the VR 4040. The pre-set temperature of the interior N.B.! Mount the housing for the safety isolating transformer on the side compartment is kept constant by a digital temperature controller. - Page 15 ... Take off the side guard panel - Mount the heating module - Using a threaded bolt, washer and hexagonal nut, mount the N.B.! The rubber lead-through and supply leads must leave an air-tight temperature sensor in the drilled hole seal.
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Page 16: End-Of-Wire Watchdog
- Pass the temperature-sensor cable and thermostat cable through the lead-through (not illustrated) in the interior compartment - Connect up the litz wires of the temperature-sensor cable and the thermostat cable to the operating panel as shown in the circuit diagram. -
Page 17: Mounting The End-Of-Wire Watchdog
MOUNTING THE END-OF-WIRE WATCHDOG 6-pole Amphenol plug Cable fasteners: Clip the cable binders into the drilled holes Cable fastener Cable fastener Cable fastener Cable-guide tube must pass through the sidewall that the side blanking cover is mounted For more details on mounting the end-of-wire watchdog, please see the illustration on the next page. - Page 18 2 mm...
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Page 19: Functional Principle
(Fig.12). Limiting the tensile load on the wire The VR 4040 unreeling device offers the facility to limit the increased ACCELERATING tensile load on the wire during acceleration by means of an overload coupling (Fig.11). -
Page 20: Equilibrium, And Working Position
EQUILIBRIUM, AND WORKING POSITION In equilibrium, the wire being fed by the wirefeeder and the wire at the periphery of the wire spool both have the same speed. After briefly swinging back and forward before reaching the working position, the “lever + drawback pulley” unit no longer moves, and stays in the working position (Fig.12). -
Page 21: Adjusting The Braking System
By “response”, we mean the speed at which the braking force is built up. - Particular danger spots N.B.! The VR 4040 unreeling device comes with default settings that are ideal for a very wide range of wire spools and welding wires. -
Page 22: Adjusting The Working Position
upward (Fig.13) N.B.! Make sure that the “lever + drawback pulley” unit is resting - Push the clamping ring against the bottom mechanical limit-stop (Fig.12). N.B.! The further up the clamping ring sits, the sooner the full braking - To do this, turn the wire spool in the direction of unreeling effect starts to occur. -
Page 23: Setting The Wire Tensile-Force Limitation
- Fit the damper back in - Close the VR 4040 SETTING THE WIRE TENSILE-FORCE LIMITATION The VR 4040 unreeling device offers the facility to limit the increased tensile load on the wire during acceleration by means of an overload coupling . -
Page 24: Troubleshooting Guide
TROUBLESHOOTING GUIDE Fault Cause Remedy - Wire jumps out of the guide grooves of Braking force has been set too low Set a higher braking force (See “Adjusting the the drawback pulleys braking force”) - Wire is not sufficiently tensioned when Spring not suspended from braking lever Suspend spring from braking lever the unreeling device is idling... -
Page 25: Care, Maintenance And Inspection
- At least once a week, inspect the VR 4040 unreeling device for any then the VR 4040 unreeling device is working correctly (Fig.12). damage that can be seen from the outside, and to check that the... -
Page 26: Damper
DAMPER Inspection interval - Every 60,000 weld seams - At least once a month N.B.! The piston rod of the damper must be pointing downwards. Inspection procedure - Wipe a light-coloured cleaning cloth across the piston rod of the damper and the bottom rod-end - If there is oil on the cloth, change the damper... -
Page 27: Brake Block
BRAKE BLOCK BRAKE CLEARANCE Inspection interval General remarks Every 500,000 weld seams, at least once every 6 months The gap between the brake wheel and the brake lining is known as the brake clearance (Fig.19). Inspection procedure N.B.! The brake clearance is checked indirectly, with reference to the gap between the limitation eccentric and the bottom of the braking - Take off the side guard panel... -
Page 28: Overload Coupling
The overload coupling serves to limit the increased tensile load on the - Open up the VR 4040 wire during acceleration of the wire spool (Fig.20). - Take off the side guard panel... - Page 29 Fig.21 Changing the braking lever, complete with friction linings...
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Page 30: Wire-Guide Tubes
- Do a sight-check on wire-guide tubes (Fig.22) VR 4040 unreeling device (cut off excess length, chamfer the end on - If more than 5 mm of wear can be seen on the ends of wire-guide tubes the inside) (Fig.22) , (e.g. -
Page 31: Drawback Pulleys
DRAWBACK PULLEYS Inspection interval Drawback pulley Every 5th time the wire spool is changed Hexagonal nut, width-across 17 Drawback pulley Hexagon socket screw, width-across 8 Inspection procedure - Do a sight-check on drawback pulleys - If there are definite signs of wear on the wireguide grooves (wire has cut its way around 1 mm into the metal): - replace the drawback pulley in question with a new pulley Drawback pulley... -
Page 32: Shoe For End-Of-Wire Watchdog
SHOE FOR END-OF-WIRE WATCHDOG N.B.! When unscrewing the sensor, take care that the cable does not get twisted. Inspection interval - Unscrew the shoe from the sensor - in such a way that the gap between the slide-face of the shoe Every 5th time the wire spool is changed and the surface of the sensor is 2 mm... -
Page 33: Disposal Of Used Parts And Materials
DISPOSAL OF USED PARTS AND TECHNICAL DATA MATERIALS Wire tensile force when the unreeling device is in equilibrium Dispose of used parts and waste materials in line with the principle of Max. wire tensile force when the device is accelerating 15 N waste separation. -
Page 35: Spare Parts List
Ersatzteilliste Schaltplan Spare Parts List Circuit Diagram Liste de pièces de rechange Schéma de connexions Lista parti di ricambio Schema Lista de repuestos Esquema de cableado Lista de peças sobresselentes Esquema de conexões Onderdelenlijst Bedradingsschema Reservdelsliste Koblingsplan Seznam náhradních dílù Schéma zapojení... - Page 36 42,0401,0842 42,0405,0269 AM2,0200,9938 44,0450,1104 42,0001,3355 42,0406,0319 44,0001,1246 42,0401,0884 45,0200,1111 44,0001,1245 42,0407,0500 VR 4040 4,045,864 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_dv_00362 012001...
- Page 37 43,0001,1092 4,055,345 41,0007,0014 43,0001,1157 42,0300,2552 42,0300,2551 42,0300,2553 42,0300,2550 43,0002,0351 HEATING 24V VR 4040 4,100,348 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_so_00439 012001...
- Page 38 43,0002,0384 42,0100,0475 41,0009,0060 42,0407,0341 WIRE-END CONTROL VR 4040 44,0450,1109 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_so_00438 012001...
- Page 41 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...
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