Table of Contents
Related Manuals for Fronius KD 4000 D-11
Summary of Contents for Fronius KD 4000 D-11
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions KD 4000 D-11 Wire-feed unit 42,0426,0031,EN 001-30012020 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
Contents Safety rules ..............................General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Protecting yourself and others ......................Noise emission values .......................... Danger from toxic gases and vapours ....................Danger from flying sparks ........................Risks from mains current and welding current.................. - 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 remarks ........................... Every start-up............................Every 6 months ............................. Disposal ..............................Technical data............................KD 4000 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 Measures
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. EMC device classification as per the rating plate or technical data. EMC measures In certain cases, even though a device complies with the standard limit values for emis- sions, it may affect the application area for which it was designed (e.g. - Page 13 Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. During operation Ensure that all covers are closed and all side panels are fitted properly. Keep all covers and side panels closed. The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
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Page 14: Requirement For The Shielding Gas
Requirement for Especially with ring lines, contaminated shielding gas can cause damage to equipment and the shielding gas reduce welding quality. Meet the following requirements regarding shielding gas quality: Solid particle size < 40 µm Pressure condensation point < -20 °C Max. -
Page 15: Safety Measures In Normal Operation
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out. Only set up and operate the device in accordance with the degree of protection shown on the rating plate. When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely. -
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
TransTig 4000 / 5000 Job MagicWave 2200 / 2500 / 3000 Job MagicWave 4000 / 5000 Job Cold wire feeder KD 4000 D-11 Application area The KD 4000 D can be used for all types of TIG welding and is especially suited to robot applications and automated tasks. -
Page 19: Control Elements And Connections
Control elements and connections General Owing to software updates, you may find that your machine has certain functions that are not described in these Operating Instructions, or vice-versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way. -
Page 20: Cold Wire Feeder Rear
Cold wire feeder Bushing for control socket rear for connecting a welding torch with a conventional control plug (+) socket with bayonet latch LocalNet connection Interconnecting hosepack Coolant return-flow connection socket (red) Interconnecting hosepack Water flow connection (blue) Interconnecting hosepack Rear Cold wire feeder right side... -
Page 21: Cold Wire Feeder Underside
To facilitate exact positioning of the welding wire, the following sequence is executed when the welder presses and holds the wire threading / wire retract button (3): Hold the button for up to one second Irrespective of what value has been set, the wire speed remains at 1 m/min or 39.37 ipm for the first second. -
Page 22: 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 CAUTION! wire feeder on the... -
Page 23: 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 Danger from incorrect installation This can result in serious injury and damage to property. ►... -
Page 24: Fitting The Welding Torch
Fitting the welding torch Fit the welding Switch the power source mains switch torch to the "Off" position Connect welding torch control plug to the LocalNet port (3) or torch control connection (4) and fasten If present: connect colour-coded exter- nal water connections for water flow (5) and return (6) Plug welding potential bayonet plug... -
Page 25: Inserting The Wirespool
Inserting the wirespool Safety CAUTION! Risk of injury from springiness of spooled welding wire. This can result in serious injury and damage to property. ► When threading in the welding wire, hold the end of it firmly, to prevent any injuries that might be caused by the wire flicking back. - Page 26 CAUTION! Danger of injury and damage from falling wirespool. This can result in serious injury and damage to property. ► Make sure the wirespool sits securely on the wirespool holder ► To ensure that the wirespool is properly in place and that the brake works properly, fit the brake according to the following diagram.
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Page 27: 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 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 wire electrode. When inserting the wirespool/basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. CAUTION! Risk of injury from falling wirespool/basket-type spool. -
Page 30: Feeding In The Wire Electrode
Feeding in the wire electrode Feeding in the CAUTION! wire electrode Danger from elasticity of the spooled wire electrode. This can result in serious injury and damage to property. ► When inserting the wire electrode into the 4-roller drive, hold the end of the wire elec- trode firmly to avoid injuries caused by the wire springing back. -
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... -
Page 33: Design Of The Brake
Design of the brake WARNING! Fitting the equipment incorrectly can cause serious injury and damage. ► Do not dismantle the brake. ► Maintenance and servicing of brakes to be carried out by trained, qualified per- sonnel only. The brake is only available as a complete unit. -
Page 34: 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 35 Press the feeder inching or gas test button The wirefeeder motors are calibrated while not under load; during calibration, the right-hand display will read "run". As soon as calibration - in the unloaded state - is complete, the display will read "St2".
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Page 36: 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 37: Service Codes Shown When The Drive Units Are Engaged (Engaged Calibration)
St1 | E 5 Cause: At maximum wire speed, the cold wire feeder motor does not deliver any ac- tual 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 motor of the push-pull unit does not deliver any actual rotational speed value. - Page 38 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 39: 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 40 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 41: Service Codes Displayed In Conjunction With The Digital Gas Control Option
Err | 056 by pressing the Store button Cause: Excessive motor current on the KD 4000 D-11, e.g. due to wirefeed problems or an inadequately dimensioned wirefeeder for the application Remedy: Check wire feed conditions, rectify errors;... -
Page 42: 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 43: Technical Data
Technical data KD 4000 D-11 Supply voltage 55 V (supply from the power source) 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. - Page 44 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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