Fronius VR 4000 Operating Instructions Manual
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Fronius VR 4000 Operating Instructions Manual

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Operating
Instructions
VR 4000
VR 4000-30 TIME
VR 4000-30
EN
Operating Instructions
42,0426,0012,EN
008-10012024

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Summary of Contents for Fronius VR 4000

  • Page 1 Operating Instructions VR 4000 VR 4000-30 TIME VR 4000-30 Operating Instructions 42,0426,0012,EN 008-10012024...

  • Page 3: Dear Reader

    Introduction 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 famili- arise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.

  • Page 5: Table Of Contents

    General Device concept REQUIREMENTS Application area Warning notices on the device Options "Mode" switch option for VR 4000/VR 4000-30 Optional control panels for VR 4000/VR 4000-30 Optional installation and conversion kits Controls and indicators General Standard control panel Control panel VR 4000-30 TIME...
  • Page 6 Set the contact pressure Adjust the brake Adjusting the brake Start-up General information Requirements Care, maintenance and disposal General remarks Every start-up Every 6 months Disposal Technical data VR 4000 VR 4000-30 VR 4000-30 TIME Appendix VR 4000 TIME, VR 4000, VR 4000-30...

  • 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: Environmental Conditions

    Environmental Operation or storage of the device outside the stipulated area will be deemed as conditions not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. 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:...

  • Page 9: Protecting Yourself And Others

    Protecting your- Anyone working with the device exposes themselves to numerous risks, e.g. self and others flying sparks and hot pieces of metal Arc radiation, which can damage eyes and skin Hazardous electromagnetic fields, which can endanger the lives of those us- ing cardiac pacemakers Risk of electrocution from mains current and welding current Greater noise pollution...

  • Page 10: Danger From Flying Sparks

    If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values. The following components are responsible, amongst other things, for the degree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings...

  • Page 11: Meandering Welding Currents

    The electrode (rod electrode, tungsten electrode, welding wire, etc.) must never be immersed in liquid for cooling never be touched when the welding system is switched on. Double the open circuit voltage of a welding system can occur between the weld- ing electrodes of two welding systems.

  • Page 12: Emc Device Classifications

    EMC Device Devices in emission class A: Classifications 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 Wire spools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive com- ponents. Covers and side panels must only be opened/removed while maintenance or re- pair work is being carried out.

  • Page 14: Factors Affecting Welding Results

    The testing interval and scope of testing must comply with applicable national standards and directives as a minimum. 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.

  • Page 15: Sicherheitsmaßnahmen Am Aufstellort Und Beim Transport

    Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply. Close the shielding gas cylinder valve or main gas supply if no welding is tak- ing place.

  • Page 16: Commissioning, Maintenance And Repair

    Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibil- ity, flammability, etc.).

  • Page 17: Disposal

    (e.g. relevant product standards of the EN 60 974 series). 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 Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

  • Page 18: General

    The wirefeeders are also suitable for long hosepacks. Due to their compact size, the wirefeeders can be used in many different ways. The VR 4000-30 TIME wire-feed unit is specially designed for the TIME high-per- formance welding process. All the important TIME process functions can be set directly on the wire-feed unit control panel using the integrated 3-parameter control.

  • Page 19: Application Area

    All variants of the VR 4000 are suitable for all standard shielding gases. NOTE! The VR 4000 - 30 and VR 4000-30 TIME wire-feed units have a water-cooled electric motor with disc-shaped rotor, and may only be operated in conjunction with an appropriate cooling unit.

  • Page 20: Options

    The "Mode selector switch" option cannot be used in conjunction with the VR 4000 digital display control panel. Optional control The VR 4000 and VR 4000-30 wire-feed units can, as an alternative to the stand- panels for VR ard control panel, be fitted with the following control panels:...
  • Page 21 Digital gas control for subsequent installation of the digital gas control Gas economiser valve installation kit for subsequent installation of a gas economiser valve Plastic-to-metal adapter installation kit for subsequent changeover from plastic to metal connection sockets Gas test/wire threading installation kit for retrofitting of a rocker switch for gas test and wire threading Trabant for installing the wire-feed unit on the Trabant trolley...

  • Page 22: Controls And Indicators

    Controls and indicators General WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described here until you have fully read and understood the following documents: ▶ These operating instructions ▶ all the operating instructions for the system components, especially the safety rules Setting parameters at control panels is only possible in manual welding mode.

  • Page 23: Control Panel Vr 4000-30 Time

    0 = soft, low-spatter arc 100 = harder and more stable arc Control panel The VR 4000-30 TIME wire-feed unit is part of the TIME high-performance weld- VR 4000-30 ing system. The 3-parameter control allows you to set the starting, main and final TIME currents individually, which is necessary for high-performance welding.
  • Page 24 (4) is set to operating point 3 operating point 3 is running IMPORTANT! If using the VR 4000-30 TIME wire-feed unit, the "Job mode" function is not available. After connecting the wirefeeder, the only welding processes that can be selected...

  • Page 25: Connections And Mechanical Components

    Connections and mechanical components Front of wirefeeder VR 4000-30 TIME - front view VR 4000 - front view Welding torch connection to hold the welding torch Water return connection (red) Water flow connection (blue) Torch control connection for connecting the torch control plug LocalNet connection standardised connection socket for system add-ons (e.g.

  • Page 26: Side Of Wire-Feed Unit

    Side of wire-feed unit VR 4000 - side view Wirespool holder with brake for attaching standardised wirespools up to max.16 kg (35.27 lbs.) and with a maximum diameter of 300 mm (11.81 in.) 4-roller drive "Wire threading/gas test" button To feed the wire electrode into the torch hosepack with no accompanying flow of gas or current.
  • Page 27 "Mode selector switch" option IMPORTANT! If settings have been selected using the "Mode selector switch" option, they cannot be changed using other controls, for example: the control panel on the front of the power source on the front of the wire-feed unit on the remote control...

  • Page 28: Placing Wire-Feed Unit On Power Source

    Placing wire-feed unit on power source General The wire-feed units can be placed on the power source if a swivel pin holder is available, e.g.: "PickUp" swivel pin receptor, for use with the "PickUp" trolley "narrow" swivel pin receptor, for use with an upright console "wide"...

  • Page 29: Connecting Wire-Feed Unit To Power Source

    Connecting wire-feed unit to power source General The wirefeeder is connected to the power source using the interconnecting hosepack. Connecting the WARNING! wirefeeder to the power source An electric shock can be fatal. If the machine is plugged in during installation, there is a high risk of very serious injury and damage.
  • Page 30 IMPORTANT! To prevent signs of wear and tear, the interconnecting hosepack cables/pipes should be "looped inside". A strain-relief device is not provided in the case of 1.2 m (3 ft. 11.24 in.) intercon- necting hosepacks.

  • Page 31: Connecting The Welding Torch

    Fronius F++ tion for Dinse for Tweco VR 4000 VR 4000-30 VR 4000-30 TIME Safety NOTE! When connecting the welding torch, check that ▶ all connections are connected properly ▶ all cables, leads and hosepacks are undamaged and correctly insulated.

  • Page 32: Connecting The Tweco Welding Torch

    Connecting the Switch the power source mains Tweco welding switch to the "0" position torch Open the wirespool cover Insert the welding torch, infeed tube first, into the welding torch connection (5) Inserting the welding torch into the connection for Tweco Fix the welding torch in place using a knurled screw (6) Fixing welding torch in place using a knurled...

  • Page 33: Inserting/Replacing Feed Rollers

    Inserting/replacing feed rollers General remarks In order to achieve optimum wire electrode feed, the feed rollers must be suit- able 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 35: 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 elec- trode firmly to avoid injuries caused by the wire electrode springing back. CAUTION! Risk of injury from falling wirespool/basket-type spool.
  • Page 36 WARNING! Danger from falling wirespool/basket-type spool. This can result in serious personal injury and damage to property. ▶ Ensure that the wirespool/basket-type spool including basket-type spool ad- apter is always firmly seated on the wirespool holder.

  • Page 37: Inserting The Basket-Type Spool

    Inserting the NOTE! basket-type spool When working with basket-type spools, use only the basket-type spool adapter supplied with the wire-feed unit! USA wire-feed units are supplied without bas- ket-type spool adapters. CAUTION! Risk of injury from falling basket-type spool. Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways.

  • Page 38: Feeding In The Wire Electrode

    Feeding in the wire electrode Feed in the wire CAUTION! electrode Risk of injury from springiness of spooled wire electrode. When inserting the wire electrode into the 4 roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of damage to the welding torch from sharp end of wire electrode.
  • Page 39 CAUTION! Risk of injury from wire electrode emerging at speed. When pressing the wire threading button or the torch trigger, keep the welding torch away from your face and body, and wear suitable protective goggles.

  • Page 40: Set The Contact Pressure

    Set the contact NOTE! pressure Set the contact pressure in such a way that the wire electrode is not de- formed but nevertheless ensures proper wirefeeding. Contact pressure Semi-cylindric- Trapeze rolls Plastic rollers standard values al rolls Aluminium 3.5 - 4.5 Steel 3 - 4 CrNi...

  • Page 41: 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 42: Start-Up

    Start-up General informa- WARNING! tion Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and under- stood the following documents: ▶ these operating instructions ▶ all the operating instructions for the system components, especially the safety rules The wire-feed unit is commissioned by pressing the torch trigger (for manual ap- plications) or by means of a welding start-up signal (for automatic applications).

  • Page 43: 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 en- sure that the welding system remains in a usable condition for many years. WARNING! An electric shock can be fatal.

  • Page 44: Technical Data

    Technical data VR 4000 Supply voltage 55 V DC (supply from the power source) Nominal current Wire speed 0.5 - 22 m/min 19.69 - 866.14 ipm Degree of protection IP 23 Dimensions l x w x h 650 x 290 x 410 mm 25.59 x 11.42 x 16.14 in.

  • Page 45: Vr 4000-30 Time

    101 psi coolant Original Fronius Maximum coolant pressure 6 bar 87 psi LocalNet data rate 57600 Baud VR 4000-30 Supply voltage 55 V DC TIME (supply from the power source) Nominal current Wire speed 0.5 - 30 m/min 19.69 - 1181.10 ipm...

  • Page 47: Appendix

    Appendix...

  • Page 48: Vr 4000 Time, Vr 4000, Vr 4000-30

    Spare parts list: VR 4000 TIME, VR 4000, VR 4000-30 VR 4000 2R/G/W/Z 4,045,830 VR 4000-30 Time 4R/G/W/F++ 4,045,831,630 VR 4000 2R/G/W/F++ 4,045,830,000 VR 4000 4R/G/W/F++ 4,045,831,800 US VR 4000 2R/G/W/E 4,045,830,001 VR 4000 4R/G/W/E 4,045,831,801 US VR 4000 4R/G/W/Z...
  • Page 54 Connection hose pack 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...
  • Page 55 Connection hose pack 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...
  • Page 56 Connection hose pack 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"...
  • Page 57 Connection hose pack W 4m 95mm² 4,047,291 W 8m 95mm² 4,047,292 W 8m 95mm² 4,047,292,800 ** W 10m 95mm² 4,047,396 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 42,0407,0063 32,0405,0226 42,0402,0053 40,0001,0012 - * 42,0001,0942 42,0001,0943 42,0405,0239 44,0450,0281 - G 1/4" 43,0003,0251 43,0003,0253 42,0407,0048...

This manual is also suitable for:

Vr 4000-30 timeVr 4000-30

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