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Summary of Contents for Fronius VR 2000
- Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions VR 2000 Spare Parts List Wire Feeder 42,0426,0011,EN 007-08072016...
- 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.
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Page 17: Table Of Contents
USA wirefeeders ............................ 14 Feeding in the welding wire ......................... 15 Safety ..............................15 Feeding in the welding wire ........................15 Setting the contact pressure ........................16 Technical data ............................. 17 Technical data ............................17 Spare parts list Fronius Worldwide... -
Page 18: General Remarks
Software version 2.80.1 (power source) and upwards is needed to run the VR 2000 requirements wirefeeder. The VR 2000 was specially developed for use in shipyards and in the offshore industry. Area of The wirefeed is suited for use with all commercial protective gases. -
Page 19: Warning Notices Affixed To The Machine
Warning notices The wire feeder comes with extra warning labels affixed to the unit. The warning labels affixed to the must NOT be removed or painted over. The symbols warn against incorrect operation. machine Incorrect operation can cause serious personal injury and damage to property. Welding is dangerous. -
Page 20: Options
Optional mode selector switch Optional TR 4000 Optional to the standard control panel the VR 2000 can be equipped with the TR 4000 C C control panel control panel. For detailed information of the control panel please refer to the installation instructions “TR 4000 C control panel“. -
Page 21: Description Of The Control Panel
Description of the control panel General remarks The VR 2000 wirefeeder is equipped with the VR 4000 Ci control panel as standard. Optional the control panel TR 4000 C is available. VR 4000 Ci WARNING! Operating the machine incorrectly can cause serious injury and control panel damage. - Page 22 VR 4000 Ci Item Function control panel Welding power/welding current adjuster (continued) has a different function depending on the process being used: MIG/MAG pulse synergic welding, MIG/MAG standard synergic welding: setting welding power MIG/MAG standard manual welding: setting the wirefeed speed Rod electrode (MMA) welding: setting the welding current Droplet detachment correction/arc force dynamic display...
- Page 23 VR 4000 Ci Item Function control panel (continued) Arc length/hot start adjuster has a different function depending on the process being used: MIG/MAG pulse synergic welding, MIG/MAG standard synergic welding: correcting the arc length shorter arc length neutral arc length longer arc length MIG/MAG standard manual welding: setting the welding voltage...
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Page 24: Controls And Connection Points
Gasflow regulator with flow-rate indicator (in SL / min) SL / min = 1 standard liter per minute Fig.6 VR 2000 - front view Further explanati- By “standard liter”, we mean 1 liter of a gas under standard conditions: ons regarding the temperature = 0 °C (32°F) -
Page 25: Rear Of Wirefeeder
VVR 2000 - rear view Shielding gas connection socket Side of wirefee- Fig.8 VR 2000 - side view Item Function Wirespool holder with braking device for holding standardized 200 mm (7,87 in) welding-wire spools weighing up to 5 kg (11,02 lbs.) -
Page 26: Mode Selector Switch Option
Job mode TIG welding with touch-down ignition Rod-electrode (MMA) welding Important! If the VR 2000 wirefeeder is connected up to a TS 4000 / 5000 power source, the MIG/MAG pulse-synergic welding process is no longer available. (3b) Mode selector for selecting the operating modes... -
Page 27: Connecting Up The Wirefeeder To The Power Source
Connecting up the wirefeeder to the power source General remarks The wirefeeder must be connected up to the power source by means of the intercon- necting cable. NOTE! When using 70 m (229.66 ft. 7.91 in.) hosepacks that you have prepared yourself or purchased from other manufacturers: make sure that the cross-sectional area of the supply cables for the wirefeeder drive is at least 13 mm²... -
Page 28: Mounting The Welding Torch
Mounting the welding torch Torch connec- The VR 2000-wire feeder is available withe the following welding torch connections: tions Fronius F Euro Mounting the Shift the mains switch of the power welding torch source into the “0” position Check that the torch is correctly and completely tooled up. -
Page 29: Inserting The Wirespool
Fig.14 View of close-up Z: Wirespool holder Shift the mains switch of the power source into the “0” position Open the left side panel of the VR 2000 Mount the wirespool onto the wirespool holder - the right way round... -
Page 30: Inserting / Changing The Feed Rollers
Inserting / changing the feed rollers General remarks In order to achieve satisfactory wire travel, the feed rollers must be suitable for the diameter and alloy of the wire to be welded. USA wirefeeders In the USA all wirefeeders are delivered without feed rollers. After inserting the wirespool the feed rollers have to be inserted into the wirefeeder. -
Page 31: Feeding In The Welding Wire
Feeding in the welding wire Safety CAUTION! Risk of injury from springiness of spooled welding wire. While inser- 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. -
Page 32: Setting The Contact Pressure
Feeding in the CAUTION! Danger from welding wire emerging at speed. Keep the welding welding wire torch away from face and body when pressing the feeder inching / inch forward (continued) button. Setting the NOTE! Adjust the contact pressure in such a way that the welding wire is not contact pressure deformed, but is nevertheless transported properly. -
Page 33: Technical Data
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.) -
Page 35: 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 36 VR 2000 2R/W/F++ 4,045,875,000 * gewünschte Länge angeben * Specify the length required VR 2000 2R/G/W/E 4,045,875,001 * Indiquer la longueur désirée VR 2000 2R/G/E 4,045,876,001 * Indicar la longitud deseada * Indicare la lunghezza desiderat * indicar o comprimento desejado...
- Page 37 Motorplate 24V 2R / 42V 2R Z = Fronius connection 42,0405,0116 42,0407,0098 42,0404,0280 32,0405,0132 BE2,0200,8292 42,0409,2106 42,0401,0847 32,0405,0112 44,0001,1024 42,0407,0429 E = Euro connection 42,0405,0119 44,0001,1039 42,0405,0117 42,0407,0137 42,0001,2703 42,0200,8698 42,0001,2700 (2x) 42,0399,0015 42,0400,0100 22,0405,0122 42,0200,5678 44,0001,1219 BF2,0201,1512 42,0200,9627 D = Dinse connection 44,0001,1314 42,0300,2162 - 120mm/4.72in.
- Page 38 Motorplate 24V 2R / 42V 2R Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_mp_01221 012015...
- Page 39 W 1,2m 70mm² 4,047,260 W 1,6m 70mm² 4,047,324 W 5,0m 70mm² 4,047,261 W 10m 70mm² 4,047,262 W 15m 70mm² 4,047,290 W 20m 70mm² 4,047,277 G 1,2m 70mm² 4,047,287 32,0405,0226 G 5,0m 70mm² 4,047,288 42,0407,0482 G 10m 70mm² 4,047,289 40,0001,0095 - * 42,0405,0239 42,0407,0482 42,0407,0063...
- Page 40 G 50mm² 4m 4,047,411 G 70mm² 8m 4,047,412 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 32,0405,0226 44,0450,0281 - G 1/4" 42,0407,0063 43,0003,0251 40,0001,0012 - * 43,0003,0253 42,0405,0239 42,0407,0048 40,0003,0447 - * 42,0407,0063 44,0450,0281 - G 1/4" 43,0003,0063 - 50mm² 43,0003,0064 - 70mm² 40,0003,0014 - * - 50mm²...
- Page 41 G 50mm² 1,2m 4,047,408 G 50mm² 5m 4,047,409 G 50mm² 10m 4,047,410 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 44,0450,0281 - G 1/4" 32,0405,0226 42,0407,0063 43,0003,0485 40,0001,0012 - * 32,0405,0232 42,0405,0239 32,0405,0180 42,0407,0048 40,0003,0078 - * 42,0407,0063 44,0450,0281 - G 1/4" 43,0003,0063 - 50mm²...
- Page 42 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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