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Related Manuals for Fronius VR 1530-11
Summary of Contents for Fronius VR 1530-11
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions VR 1530 -11 / -12 / - 22 / -30 / -KD Wire-feed unit 42,0426,0010,EN 001-07022020 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
Overview ............................... Areas of utilisation..........................System requirements ..........................Applicational example: VR 1530-22 used as an unreeling-type wirefeeder.......... Applicational example: VR 1530-11/-12/-30 used as an unreeling-type wirefeeder ......Warning notices affixed to the machine ....................Control elements and connections......................Safety..............................VR 1530 -11 / -12 / -22 / - 30 ........................ - Page 6 Service codes displayed during calibration of the push-pull unit ............Care, maintenance and disposal ....................... General remarks ........................... Every start-up............................Every 6 months ............................. Disposal ..............................Troubleshooting ............................Safety..............................General remarks ........................... VR 1530 error diagnostics ........................Technical data............................VR 1530-11............................VR 1530-12............................VR 1530-22............................VR 1530-30............................VR 1530-KD............................
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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
General Safety WARNING! Danger from incorrect operation Operating the equipment incorrectly can cause serious injury and damage. Before you start using the VR 1530, you MUST have read and completely understood the following documents: ► the VR 1530 “Operating Instructions” manual ►... -
Page 18: System Requirements
VR 1530-11 / -12 / -22 / -30 A matching version of the VR 1530 is available for each version of the main wirefeeder VR 1500: VR 1500-11: VR 1530-11 (11 m/min) (433.07 ipm.) VR 1500-12: VR 1530-12 (12 m/min) (472.44 ipm.) VR 1500-22: VR 1530-22 (22 m/min) (866.14 ipm.) -
Page 19: Applicational Example: Vr 1530-11/-12/-30 Used As An Unreeling-Type Wirefeeder
Robacta 280, 300, 500, 700 welding torch Applicational ex- The applicational example given below shows an industrial robot being used with a mount- ample: VR 1530- ed VR 1500 robot wirefeeder combined with a VR 1530-11/-12/-30 unreeling-type wire- 11/-12/-30 used as feeder. an unreeling-type... -
Page 20: Warning Notices Affixed To The Machine
(11) Unreeling-type wirefeeder control cable (12) Standard interconnecting cable (13) RCU 5000i remote-control panel (14) VR 1500 robot wirefeeder - Unreeling-type wirefeeder installation kit - Conversion kit for PMR4000 PullMig controller (15) Adapter plate for VR 1500 (16) Robacta torch hosepack (17) Robacta 280, 300, 500, 700 welding torch Warning notices... -
Page 21: Control Elements And Connections
Control elements and connections Safety WARNING! Danger from incorrect operation. Operating the equipment incorrectly can cause serious injury and damage. ► Do not use the functions described here until you have read and completely under- stood the whole of the “Operating Instructions” manuals for both the wirefeeders and the power source. -
Page 22: Vr 1530-Kd
Wire-retract button for reverse-feeding the welding wire out of the hosepack with no accompanying flow of gas or current. The wire is retracted out of the hosepack for as long as you press and hold the wire-retract button. (10) Blanking cap / VR 1530 PD interface option The optional VR 1530 PD interface provides four customer-specific lines via the VR 1500 (e.g. -
Page 23: Wire-Inching Sequence When The Welder Presses And Holds The Feeder Inching Button
(14) Blanking cap (15) Blanking cap Wire-inching se- To facilitate exact positioning of the welding wire, the following sequence is possible when quence when the the welder presses and holds the feeder inching button: welder presses and holds the IMPORTANT! The sequence described here does not apply to the wire-retract button. feeder inching button CAUTION! -
Page 24: Start-Up
Start-up Safety WARNING! Danger from incorrect operation. Operating the equipment incorrectly can cause serious injury and damage, as can any work that is not carried out correctly. ► Before putting the unit into service for the first time, read the “Safety rules” Utilisation for in- The VR 1530 wirefeeder may ONLY be used in MIG/MAG welding, as part of a suitably tended purpose... -
Page 25: Ready-Drilled Holes
Ready-drilled holes (.32 in.) (.32 in.) 21,5 mm 280 mm 21,5 mm (.32 in.) (.85 in.) (11.03 in.) (.85 in.) Hole-pattern on the baseplate of the VR 1530 21,5 mm (.85 in.) 280 mm (11.03 in.) (.32 in.) (.32 in.) (.32 in.) (.32 in.) (.32 in.) -
Page 26: Space For Tilting Up The Lid Of The Wirefeeder
Space for tilting When deciding where best to mount the VR up the lid of the 1530, allow the space as shown below for wirefeeder tilting up the lid of the wirefeeder. 213 mm (8.39 in.) 90 ° 90 °... -
Page 27: Mounting The Wirefeed Hoses
Mounting the wirefeed hoses Safety WARNING! Danger from incorrect operation. Work that is not carried out correctly can cause serious injury and damage. ► Before putting the unit into service for the first time, read the “Safety rules” CAUTION! Risk of injury while the lid is open for maintenance or retooling work to be carried out. -
Page 28: Inserting/Replacing Feed Rollers
Inserting/replacing feed rollers General remarks In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded. IMPORTANT! Only use 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 29: Feeding In The Wire Electrode
Feeding in the wire electrode Insulated routing WARNING! of wire electrode to wire-feed unit Risk of serious injury and property damage or an inferior weld as a result of earth contact or short-circuit of a non-insulated wire electrode. In the case of automated applications, ensure that only an insulated wire electrode is rout- ed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder (e.g. - Page 30 Open the clamping devices and pres- sure levers on the VR 1500 and the VR 1530 VR 1500 VR 1530 CAUTION! Risk of damage to wirefeeding hose and welding torch from sharp end of filler wire. This can result in serious damage to property. ►...
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Page 31: Set The Contact Pressure
Close the clamping devices and pres sure levers on the VR 1530 Press the wire feed button on the VR 1530. Feed the filler wire in the wire feed hose between VR 1530 and VR 1500 Press the feeder inching button on the VR 1500 until the filler wire reaches the VR-1500 feed rollers. -
Page 32: Calibrating Push-Pull Unit
Once calibration of the push-pull unit is complete, close the cover of the VR 1530. Calibrate the push-pull unit in accordance with the power source operating instruc- tions. Push-pull unit numbers: VR 1530-11: PPU | 17 VR 1530-12: PPU | 20 VR 1530-22: PPU | 0 VR 1530-30: PPU | 1 Service codes... -
Page 33: Care, Maintenance And Disposal
Care, maintenance and disposal General remarks Under normal operating conditions, the wire-feed unit requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years. WARNING! An electric shock can be fatal. -
Page 34: Troubleshooting
Troubleshooting 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 35 Welding wire is deformed or snaps Cause: The contact pressure on the 4-roller drive is set too high Remedy: Set the correct contact pressure on the 4-roller drive Cause: VR 1530 is turning too fast or too slowly Remedy: For push-pull alignment, select the right number (e.g. ”PPU | 17”) for the VR 1530 (see the section headed ”Configuration table”) EFd | 8.1 Cause:...
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Page 36: Technical Data
Technical data VR 1530-11 Supply voltage (from the power source) 55 V DC Rated current Wire diameter 0,8 - 3,2 mm 0.03 - 0.13 in. Wirefeed speed 0,5 - 11 m/min 19.69 - 433.07 ipm. Torque 11 Nm Degree of protection... - Page 37 5 kg 11 Ibs. Type of drive 4-roller drive Max. shielding-gas pressure 7 bar 101 psi. Coolant Original Fronius coolant (40,0009,0046) Max. coolant pressure 6 bar 87 psi. VR 1530-30 Supply voltage (from the power source) 55 V DC Rated current...
- Page 38 345 x 160 x 220 mm 13.59 x 6.3 x 8.67 in. Weight - without optional extras 5 kg 11 Ibs. Type of drive 4-roller drive Max. shielding-gas pressure 7 bar 101 psi. Coolant Original Fronius coolant (40,0009,0046) Max. coolant pressure 6 bar 87 psi.
- Page 40 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...