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Summary of Contents for Fronius KD 7000 D-11
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions KD 7000 D-11 Wire-feed unit 42,0426,0030,EN 006-14052020 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
Application areas ..........................Warning notices on the device......................Controls, connections and mechanical components.................. General ..............................KD 7000 D-11 ............................Placing the cold wire feeder on the power source ..................General ..............................Placing the cold wire feeder on the power source ................ - Page 6 Service codes displayed in conjunction with the cold wire feeder ............Service codes displayed in conjunction with the digital gas control option ........... Care, maintenance and disposal ....................... General ..............................Every start-up............................Every 6 months ............................. Disposal ..............................Technical data............................KD 7000 D-11 ............................
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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: Noise Emission Values
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
The following components are responsible, amongst other things, for the degree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings Cleaners, degreasers, etc. Welding process used The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully. -
Page 11: Meandering Welding Currents
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must never be immersed in liquid for cooling Never touch the electrode when the power source is switched on. Double the open circuit voltage of a power source can occur between the welding elec- trodes of two power sources. -
Page 12: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage mains. -
Page 13: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive components. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. -
Page 14: Requirement For The Shielding Gas
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape. Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment and the shielding gas reduce welding quality. -
Page 15: Safety Measures In Normal Operation
When transporting the device, observe the relevant national and local guidelines and ac- cident prevention regulations. This applies especially to guidelines regarding the risks aris- ing during transport. Do not lift or transport operational devices. Switch off devices before transport or lifting. Before transporting the device, allow coolant to drain completely and detach the following components: Wirefeeder... -
Page 16: Commissioning, Maintenance And Repair
(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: Copyright
Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the ba- sis for any claims whatsoever on the part of the purchaser. -
Page 18: General
MagicWave 4000 / 5000 Job Application areas The KD 7000 D-11 can be used for all types of TIG welding, and is especially suited to ro- bot applications and automated tasks. The cold wire feeder is suitable for all standard shielding gases. - Page 19 Welding is dangerous. The following basic requirements must be met to en- sure the equipment is used properly: Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must be kept at a safe distance from the wire- feed unit and the welding process Do not use the functions described here until you have fully read and under- stood the following documents:...
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Page 20: Controls, Connections And Mechanical Components
Do not use the functions described until you have thoroughly read and understood the fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules KD 7000 D-11 (10) (11) (13) - Page 21 Item Designation MagicWave: Welding torch / (-) current socket connection in conjunction with a MagicWave power source for connecting: a TIG welding torch the electrode cable for manual metal arc welding in conjunction with a TransTig power source for connecting: a TIG welding torch the electrode cable or grounding cable during MMA welding (depending on the type of electrode used)
- Page 22 IMPORTANT! For more information about the Fdi parameter, refer to the power source operating instructions. If the welder releases the wire threading button (16) before 1 second has elapsed and then presses it again, the sequence starts again from the beginning. This makes it possible to position the wire continuously at the low wire feed speed of 1 m/min or 39.37 ipm when necessary.
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Page 23: Placing The Cold Wire Feeder On The Power Source
Placing the cold wire feeder on the power source General If the TransTig 4000/5000 and MagicWave 4000/5000 power sources have been fixed onto a trolley with cooling unit, the cold wire feeder can be placed on the optional wirefeeder holder on the trolley. Placing the cold wire feeder on the CAUTION! -
Page 24: Connect The Cold Wire Feeder To The Power Source
Connect the cold wire feeder to the power source General The cold wire feeder is connected to the power source using the interconnecting hosepack. Connect the cold WARNING! wire feeder to the power source Fitting the equipment incorrectly can cause serious injury and damage. Do not carry out the steps described here until you have read and completely understood all the operating instructions. -
Page 25: Variant 2: Gas Pipe Separate From Interconnecting Hosepack
If present, plug the colour-coded water flow and return hoses into the screw-type con- nectors (9) and (8) Fit the right side panel of the cold wire feeder: Position side panel Fasten with 5 screws Variant 2: gas (1)(2) (3) (4) pipe separate from intercon- necting hosepack... -
Page 26: Fitting The Welding Torch
Fitting the welding torch Fit the welding Switch the power source mains switch torch to the "Off" position Plug welding torch control plug into Lo- calNet port (4) or torch control connec- tion (3) and lock If present: connect colour-coded exter- nal water connections for water flow (5) and return (6) Plug welding potential bayonet plug... -
Page 27: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers General In order to achieve the best welding wire feed, the feed rollers must be suitable for the di- ameter and alloy of the wire being welded. IMPORTANT! Use only feed rollers that are suitable for the welding wire in question. An overview of the feed rollers available and their potential application areas can be found in the spare parts lists. -
Page 28: 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 welding wire. While inserting the wirespool/basket-type spool, hold the end of the welding wire firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of injury from falling wirespool/basket-type spool. -
Page 30: Feeding In The Welding Wire
Feeding in the welding wire Feeding in the CAUTION! welding wire Risk of injury from springiness of spooled welding wire. While inserting the welding wire into the 4 roller drive, hold the end of the 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 31: Set The Contact Pressure
Set the contact pressure NOTE! Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wire- feeding. Contact pressure stand- Semi-cylindrical Trapeze rolls Plastic rollers ard values rolls Aluminium 3.5 - 4.5 Steel 3 - 4 CrNi... -
Page 32: Adjust The Brake
Adjust the brake Adjusting the NOTE! brake After releasing the torch trigger the wirespool should stop unreeling. Adjust brake if necessary. STOP STOP Design of the CAUTION! brake Risk of injury and damage from falling wirespool. To ensure that the wirespool is properly in place and that the brake works properly, fit the brake according to the following diagram. - Page 33 KLEBER, GLUE, COLLE...
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Page 34: Fitting Wirefeeding Hose For External Welding Wire
Fitting wirefeeding hose for external welding wire Fitting wirefeed- The wirefeeding hose option serves to protect the external welding wire while it is being ing hose for ex- conveyed to the 4 roller drive of the cold wire feeder. ternal welding The wirefeeding hose is available in two versions: wire for steel (blue) -
Page 35: Push-Pull Unit
0 ..Fronius KD7000/VR1530KD Drive 22 m/min or 866 ipm *) 2 ..Fronius Torch Drive 10 m/min or 394 ipm *) 3 ..Fronius Torch Drive 22 m/min or 866 ipm *) 15 .. - Page 36 As soon as calibration - in the unloaded state - is complete, the display will read "St2". Engage the drive units of both wirefee- der motors (e.g. welding torch and cold wire feeder) once again - the wirefee- der motors must be under load (push- pull calibration - engaged) CAUTION! Risk of injury from welding wire emerging at speed and from rotating cogs and drive...
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Page 37: Service Codes For Push-Pull Calibration
Service codes for push-pull calibration Safety WARNING! An electric shock can be fatal. Before opening the device: ► Move the mains switch to the "O" position ► Unplug the device from the mains ► Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again ►... -
Page 38: Service Codes Shown When The Drive Units Are Engaged (Engaged Calibration)
St1 | E 5 Cause: At maximum wire feed speed, the wire-feed motor does not deliver any actual rotational speed value. Remedy: Repeat the push-pull calibration. If the error message re-appears: Contact Af- ter-Sales Service. St1 | E 6 Cause: At maximum wire feed speed, the wire-feed motor does not deliver any actual rotational speed value. - Page 39 St2 | E 12 Cause: At maximum wire feed speed, the wire-feed motor does not deliver any actual rotational speed value. Remedy: Repeat the push-pull calibration. If the error message re-appears: Contact Af- ter-Sales Service. St2 | E 13 Cause: At maximum wire feed speed, the motor of the push-pull unit does not deliver any actual rotational speed value.
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Page 40: Service Codes In Conjunction With The Cold Wire Feeder And Digital Gas Control Option
Service codes in conjunction with the cold wire feed- er and digital gas control option Service codes EFd | xx.x displayed in con- Cause: Fault in the wire feed system (overcurrent in wire-feed unit drive) junction with the Remedy: Arrange the hosepack in as straight a line as possible; check that there are cold wire feeder no kinks or dirt in the inner liner;... - Page 41 EFd | 15.1 Wire buffer empty Cause: Counter lever on main wire-feed unit open Remedy: Close counter lever on main wire-feed unit Acknowledge service code using Feeder inching button Cause: Main wire-feed unit slipping Remedy: Check wearing parts on wire-feed unit Use suitable feed rollers Decrease wire braking force Increase contact pressure on main wire-feed unit...
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Page 42: Service Codes Displayed In Conjunction With The Digital Gas Control Option
Err | 056 Cause: The "Wire-end check" option has detected the end of the wire electrode Remedy: Insert a new wirespool and feed the wire electrode into the hosepack; acknowledge Err | 056 by pressing the Store button Cause: Additional fan filter of the VR 1500 - 11 / 12 / 30 is contaminated air supply for the additional fan is no longer sufficient to cool the power elec- tronics the power electronics temperature switch has tripped... -
Page 43: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions the cold wire feeder requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the weld- ing system remains in a usable condition for many years. WARNING! An electric shock can be fatal. -
Page 44: Technical Data
Technical data KD 7000 D-11 Supply voltage 55 V Current consumption Wire speed 0.1 - 11 m/min (3.94 - 433.07 ipm) Wire drive 4 roller drive Wire diameter 0.8 - 3.2 mm (0.03 - 0.13 in.) Wirespool diameter max. 300 mm (11.81 in.) Wirespool weight max. - Page 48 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@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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