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Summary of Contents for Fronius VR 4040
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions VR 4040 Wire-feed unit 42,0426,0014,EN 001-18022020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Configuration 2: TIG cold-wire welding ....................Start-up ..............................Safety..............................Accessories............................Opening and closing the VR 4040 unreeling device ................Dismounting and re-mounting the side guard panel ................Mounting the wirefeeder ........................Removing and inserting the wire-spool carrier..................Mounting and dismounting the wire-spool driver .................. - Page 6 Damper ..............................Brake block ............................Brake clearence ............................ Overload coupling ..........................Wire-guide tubes........................... Changing the intermediate guide ......................Drawback pulleys..........................Shoe for end-of-wire watchdog ......................Dispsal of used parts and materials...................... Troubleshooting ............................Troubleshooting guide .......................... Technical data............................VR 4040 ..............................
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Page 7: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operating company, inefficient operation of the device. -
Page 8: Obligations Of The Operator
Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity: up to 50% at 40 °C (104 °F) up to 90% at 20 °C (68 °F) The surrounding air must be free from dust, acids, corrosive gases or substances, etc. -
Page 9: Danger From Toxic Gases And Vapours
Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties: Flame-resistant Insulating and dry Covers the whole body, is undamaged and in good condition Safety helmet Trousers with no turn-ups Protective clothing refers to a variety of different items. Operators should: Protect eyes and face from UV rays, heat and sparks using a protective visor and reg- ulation filter Wear regulation protective goggles with side protection behind the protective visor... -
Page 10: Danger From Flying Sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area. Close the shielding gas cylinder valve or main gas supply if no welding is taking place. Danger from fly- Flying sparks may cause fires or explosions. ing sparks Never weld close to flammable materials. -
Page 11: Meandering Welding Currents
Operating the device on a grid without a ground conductor and in a socket without a ground conductor contact will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage. If necessary, provide an adequate earth connection for the workpiece. Switch off unused devices. -
Page 12: Emf Measures
either radio or television receivers). If this is the case, then the operator is obliged to take appropriate action to rectify the situ- ation. Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interfer- ence from the device include: Safety devices Power, signal and data transfer lines... -
Page 13: Requirement For The Shielding Gas
Never touch the workpiece during or after welding - risk of burns. Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected. Welding torches and other parts with a high operating temperature must be allowed to cool down before handling. -
Page 14: Danger From Escaping Shielding Gas
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan- ical impact, slag, naked flames, sparks and arcs. Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over. Keep the shielding gas cylinders well away from any welding or other electrical circuits. Never hang a welding torch on a shielding gas cylinder. -
Page 15: Safety Measures In Normal Operation
Before transporting the device, allow coolant to drain completely and detach the following components: Wirefeeder Wirespool Shielding gas cylinder After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before com- missioning the device. -
Page 16: Safety Inspection
(e.g. relevant product standards of the EN 60 974 se- ries). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com... -
Page 17: General
The VR 4040 unreeling device is specially designed for robot and automated applications. tion and features Both in MIG/MAG welding and in TIG (and laser) cold-wire welding, the VR 4040 unreeling device is a vital component of any precision, high-performance wirefeed system. - Page 18 up at high wirefeed speeds, the wire buffer prevents the spool-mass from accelerating jerk- ily, meaning that the wire is exposed to only moderate tensile forces. During welding start- up, the tensile force of the wire is only increased (as a function of the wirefeed speed) as far as is necessary in order to achieve timely acceleration of the wire spool.
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Page 19: Application Examples
Control (11) (3) (2) Configuration 1 - VR 4040 combined with the TS 4000 / 5000 or TPS 4000 / 5000 power source and the VR 1500 wirefeeder unit VR 4040 unreeling device TS 4000 / 5000 or TPS 4000 / 5000 MIG/MAG power source... -
Page 20: Configuration 2: Tig Cold-Wire Welding
(8) (9) (10) (11) 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 VR 4040 unreeling device MagicWave 2600 / 2600 CEL or TransTig 2600 CEL / 3000 TIG power source... -
Page 21: Start-Up
► In particular, the sub-section “Utilisation for intended purpose only“ must be strictly ob- served Accessories The following accessories are absolutely essential for running the VR 4040 wire unreeling device: Wirefeeder unit Feeder set (to fit the type of wirefeeder used) -
Page 22: Dismounting And Re-Mounting The Side Guard Panel
Dismounting and re-mounting the side guard panel „Extrude-Tite“ screws (2) to (4) Dismounting the side guard panel (1) [A] to [C] Re-mounting the side guard panel (1) -
Page 23: Mounting The Wirefeeder
Mounting the The wirefeeder and feeder-set shown here are intended as symbolic, representative ex- wirefeeder amples only. 15 15 mm Insert the wire-guide tube into the wirefeeder unit Allow 15 mm of the wire-guide tube to project in... -
Page 24: Removing And Inserting The Wire-Spool Carrier
Removing and in- WARNING! serting the wire- spool carrier Danger due to incorrectly performed work. This can result in serious injury and damage to property. ► Hold the wire-spool carrier firmly! With heavier spools, considerable force maybe re- quired. IMPORTANT! Before inserting the wire-spool carrier into the anchor points [V], check that the toothed wheels are engaging correctly. -
Page 25: Fastening The Wire-Spool Carrier To The Spool And Detaching It From The Spool
Driver - claws must point towards the wire spool Hexagon socket screws (width-across = 5) Fastening the WARNING! wire-spool carri- er to the spool Danger due to incorrectly performed work. and detaching it This can result in serious injury and damage to property. from the spool ►... -
Page 26: Inserting In The Wire Electrode
Wind adhesive tape around the guiding bushes (2) if these are sitting 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 clamping lever at right... -
Page 27: 230 V Interior Heating System, Unregulated
Thread the wire through the guide tube Pull approx. 1.5 m of wire out of the guide tube Loop the wire around drawback pulley 1 Loop the wire around drawback pulley 2 Unreel more wire (approx. 1m) and fix it temporarily with the set-screw Thread the wire through the intermediate guide and clamp it in the wirefeeder unit Undo the set-screw and loop the wire around drawback pulley 3 230 V interior... -
Page 28: I24 V Interior Heating System, Regulated
A safety isolating transformer delivers the supply voltage to the interior heating system. heating system, The safety isolating transformer is located in a separate housing, outside the VR 4040. The regulated pre-set temperature of the interior compartment is kept constant by a digital temperature controller. -
Page 29: Mounting The 24 V Inerior Heating System
(1) to ( 3) – The protective film [S] must be located between the safety isolating transformer and the VR 4040. Place the heating module into the housing and connect up the supply leads in accord- ance with the circuit diagram. - Page 30 „Extrude-Tite“ screws Pierce the rubber lead-through [H] in the side of the housing Pull the thermostat cable from the inside of the housing and out through the rubber lead-through [H]. The Molex plug [M] of the thermostat cable remains inside the hous- ing.
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Page 31: Putting The Interior Heating System Into Service
Pass the temperature-sensor cable and thermostat cable through the lead-through [J] (not illustrated) in the interior compartment Connect up the litz wires of the temperature-sensor cable and the thermostat cable to the operating panel [E] as shown in the circuit diagram. Lower the operating panel [E] into place Mount the operating panel [E] - “Extrude-Tide“... - Page 32 Factory pre-settings of parameters Set-point 30 °C Control hysteresis HySt: Alarm 25 °C Digital filter time constant FiLt: 2 Sek. Actual value for offset OFFS: Set-point interlock SPL: Alarm-value setting in the operator control level AEn: EnAb...
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Page 33: End-Of-Wire Watchdog
End-of-wire watchdog 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 to prevent unnecessary disruption of the production process. The end-of-wire watchdog is based on the principle of an inductive sensor that constantly samples the wire spool. - Page 34 2 mm More details on mounting the end-of-wire watchdog...
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Page 35: Functional Principle
Functional principle Idling, Accelerat- (11) (12) Braking-system components inside the housing Braking-system components under the side guard pa- Idling When the unreeling device is idling (i.e. when no wire is being fed), the “lever + drawback pulley” unit (1) is in the bottom position. This position results from the wire spool’s “running on”... -
Page 36: Increase In Tensile Force As A Function Of Wirefeed Speed
Limiting the ten- The VR 4040 unreeling device offers the facility to limit the increased tensile load on the sile load on the wire during acceleration by means of an overload coupling (11). This limitation feature is wire factory-set to a wire load of 15 N. - Page 37 If it is ensured that the “lever + 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 welding wire even at the end of deceleration.
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Page 38: Adjusting The Braking System
Safety measures for maintenance, inspection and troubleshooting Particular danger spots The VR 4040 unreeling device comes with default settings that are ideal for a very wide range of wire spools and welding wires. Only attempt to change any settings if this is really necessary and you have thoroughly un- derstood the contents of the sections headed “Functional principle”... -
Page 39: Adjusting The Braking System Response
If the “lever + drawback pulley” unit (1) reaches the bottom mechanical limit-stop after a break in welding and the wire spool still continues to “run on”, this means that the braking force has been set too low. When very light wire spools are being used, it is helpful to have only a low braking force Take off the side guard panel (see: “Start-up”) Suspend the spring (6) from one of the innermost notches on the braking lever (3) Function test (see: “Care, maintenance and inspection”) -
Page 40: Adjusting The Working Position
Adjusting the The working position automatically adapts to the braking force. The factory setting is ideal working position for nearly all applications If the working position needs to be correc- ted, proceed as follows: Remove the side guard panel – Make sure that the “lever + draw- back pulley”... -
Page 41: Setting The Wire Tensile-Force Limitation
Fit the damper back in Close the VR 4040 Setting the wire The VR 4040 unreeling device offers the facility to limit the increased tensile load on the tensile-force limi- wire during acceleration by means of an overload coupling (11). This limitation feature is tation factory-set to a wire tensile force of 15 N. - Page 42 Setting a lower value for the wire tensile- (11) force limitation Take off the side guard panel (See “Start-up”) Straighten the bent tab of the tab was- (14) vorher her (14) nachher Loosen the shaft nut (12) by turning it anticlockwise with a hook spanner (12) Bend one tab of the tab washer (14).
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Page 43: Care, Maintenance And Inspection
To keep the VR 4040 unreeling device operational, observe the following points: At least once a week, inspect the VR 4040 unreeling device for any damage that can be seen from the outside, and to check that the safety features are all fully functional´... -
Page 44: Brake Block
Inspection procedure Wipe a light-coloured cleaning cloth across the piston rod (38) of the damper and the bottom rod-end (39) If there is oil on the cloth, change the damper (38) (39) Brake block 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 the... -
Page 45: Brake Clearence
< 1 mm (22) (23) (30) (13) (24) (25) (29) (5) (29) (25) > 0,5 mm Replacing the brake block Checking the wear on the brake block, checking and setting the brake clearance Changing the brake bloc Take off the side guard panel Use a screwdriver to bend the positioning lugs (24) down to the same level as the brake block (25) Lift the brake and push the brake block (25) sideways out of the body of the brake (4) -
Page 46: Overload Coupling
< 1 mm (22) (23) (30) (13) (24) (25) (29) (5) (25) (29) > 0,5 mm Replacing the brake block Checking the wear on the brake block, checking and setting the brake clearance Inspection procedure Take off the side guard panel Using a feeler gauge, measure the gap between the limitation eccentric (13) and the bottom of the braking lever (22) If the gap is greater than 1 mm, set the brake clearance (see: “Setting the brake clear-... - Page 47 Before placing the new braking lever (3) in position, push the damper all the way in (see: “Damper”) Place the new braking lever (3) in position Position the friction disc (33) with the polished surface facing towards the VR 4040 Replace the cup springs (32) as shown in the diagram –...
- Page 48 Set the wire tensile-force limitation (see: “Setting the wire tensileforce limitation”) Set the braking force (See “Adjusting the braking force”) Carry out a function test (see: “Care, maintenance and inspection”) Re-mount the side guard panel Close the VR 4040 (38) (40) (37)
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Page 49: Wire-Guide Tubes
Changing the wire-guide tube (intermediate guide) Allow 15 mm of the wire-guide tube to project into the housing of the VR 4040 unreel- ing device (cut off excess length, chamfer the end on the inside) Close the VR 4040... -
Page 50: Drawback Pulleys
Drawback pulleys Inspection interval every 5th time the wire spool is changed Inspection procedure Do a sight-check on drawback pulleys [U], [V], [W] 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 –... -
Page 51: Dispsal Of Used Parts And Materials
Adjusting the shoe If it is no longer possible to adjust the shoe to the extent described below, change the shoe (see “Changing the shoe”). Undo the hexagonal nut (51) Detach the shoe (50), complete with the sensor (49), from the carrier arm (48) Unscrew the shoe from the sensor in such a way that the gap between the slide-face of the shoe and the surface of the sensor is 2 mm When unscrewing the sensor, take care that the cable does not get twisted. -
Page 52: Troubleshooting
Troubleshooting Troubleshooting Wire jumps out of the guide grooves of the drawback pulleys guide Wire is not sufficiently tensioned when the unreeling device is idling. “Lever + drawback pulley” unit is touching the bottom mechanical limitstop Cause: Braking force has been set too low Remedy: Set a higher braking force (See “Adjusting the braking force”) Cause:... - Page 53 No significant acceleration of the wire spool while the “lever + drawback pulley” is moving upwards “Lever + drawback pulley” unit is touching the top mechanical limit-stop Cause: The wire tensile-force limitation value is set too low Remedy: Set a higher value for the wire tensile-force limitation (see: “Setting the wire tensile-force limitation”) Cause: Damper is faulty...
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Page 54: Technical Data
Technical data VR 4040 Wire tensile force when the unreeling device is in equilib- rium Max. wire tensile force when the device is accelerating 15 N Wire diameter 0,8 - 1,6 mm 0.03 - 0.06 in. Wirefeed speed up to 22 m/min up to 866.14 ipm. - Page 56 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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