Related Manuals for Fronius VR 1500
Summary of Contents for Fronius VR 1500
- Page 1 Operating Instructions VR 1500 VR 1500 PSA VR 1500 - 11 VR 1500 - 12 VR 1500 - 30 VR 1550 VR 1550 CMT-WS Operating Instructions 42,0426,0006,EN 008-22102024...
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Page 3: Table Of Contents
Controls, connections and mechanical components General remarks Front of wirefeeder Rear of wire-feed unit Notes regarding the operation of the VR 1500 - 11 and VR 1500 - 12 Cooling the wirefeeder motor Welding current above 500 A PMR 4000 push-pull option... - Page 4 General remarks Every start-up Every 6 months Disposal Technical data General remarks VR 1500 VR 1500 - 11 VR 1500 - 12 VR 1500 - 30 VR 1550 (CMT-WS) Circuit diagrams VR 1500 VR 1500 PSA VR 1550 / VR 1550 CMT-WS...
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Page 5: Safety Rules
Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ▶ If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ▶ If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ▶... -
Page 6: Proper Use
Proper use The device is to be used exclusively for its intended purpose. The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating in- structions... -
Page 7: Mains Connection
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connec- Devices with a higher rating may affect the energy quality of the mains due to tion their current consumption. This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement... -
Page 8: Danger From Toxic Gases And Vapours
Danger from tox- The fumes produced during welding contain harmful gases and vapours. ic gases and va- Welding fumes contain substances that cause cancer, as stated in Monograph pours 118 of the International Agency for Research on Cancer. Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device. -
Page 9: Risks From Mains Current And Welding Current
Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard. Risks from mains An electric shock is potentially life threatening and can be fatal. current and Do not touch live parts either inside or outside the device. -
Page 10: Meandering Welding Currents
If work on live parts is required, have a second person switch off the main switch at the right moment. Meandering If the following instructions are ignored, meandering welding currents can devel- welding currents op with the following consequences: Fire hazard Overheating of parts connected to the workpiece Damage to ground conductors Damage to device and other electrical equipment... -
Page 11: Emf Measures
Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite the correct mains connec- tion, additional measures are necessary (e.g. use of a suitable line filter) Welding power-leads must be kept as short as possible must be laid close together (to avoid EMF problems) must be kept well apart from other leads Equipotential bonding Earthing of the workpiece... -
Page 12: Requirement For The Shielding Gas
Welding machines for work in areas with increased electrical risk (e.g. near boil- ers) must carry the 'Safety' sign. However, the welding machine must not be loc- ated in such areas. Risk of scalding from escaping coolant. Switch off cooling unit before discon- necting coolant flow or return lines. -
Page 13: Danger From Escaping Shielding Gas
Never hang a welding torch on a shielding gas cylinder. Never touch a shielding gas cylinder with an electrode. Risk of explosion - never attempt to weld a pressurised shielding gas cylinder. Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). -
Page 14: Safety Measures In Normal Operation
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service techni- cians before commissioning the device. Safety measures Only operate the device when all safety devices are fully functional. If the safety in normal opera- devices are not fully functional, there is a risk of tion... -
Page 15: Safety Inspection
(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 16 Text and illustrations were accurate at the time of printing, subject to change. We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.
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Page 17: General
The VR 1500 - 30 is also used for flat wire applications. In particular, the VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 are also used in conjunction with the high performance TS / TPS 7200 and TPS 9000 power... -
Page 18: Warning Notices On The Device
Warning notices The wire-feed unit has safety symbols on the rating plate. The safety symbols on the device must not be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Do not use the functions described here until you have fully read and understood the following documents: These operating instructions... -
Page 19: Options
Risk of injury from rotating cogs on the wire drive. This can result in serious injury and damage to property. ▶ If you use the wirefeeder without the "VR 1500 cover", you must take other suitable safety precautions. VR 1500 adapter plate... -
Page 20: Optional Installation And Conversion Kits
VR 1530 - PD unreeling wirefeeder with planetary drive Optional install- 900 A VR 1500 installation kit (VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 ation and con- only, each with Fronius central connector F++) -
Page 21: Expansions And Versions
Cover for robot wirespool holder VR 1500 - 22, VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 control unit separate control unit in the event that the motor plate and control unit are... -
Page 22: Controls, Connections And Mechanical Components
(13) (12) (10) Front of VR 1500 / VR 1550 Front of VR 1500 - 11 / 12 / 30 Blanking cover / gas pressure sensor adjusting button (optional) Water return connection (red) Gas test button for setting the required gas flow rate on the pressure regulator. If you press and hold this button, gas will flow. -
Page 23: Rear Of Wire-Feed Unit
(12) (11) (10) (16) (15)(14)(13) (12) (11) (10) (9) Rear of VR 1500 - 11 / 12 / 30 Rear of VR 1500 / VR 1550 LocalNet connection - interconnecting hosepack LocalNet connection standardised connection socket for system extensions (e.g. remote con- trol, etc.) - Page 24 (14) Blanking cover/LocalNet connection (if the optional unreeling wirefeeder installation kit is fitted to the wirefeeder or if the optional VR 1550 CMT installation kit is fitted to the wirefeeder) (15) Blanking cover/AIR IN "torch blow out" connection (high end option, max. 15 bar) (16) Additional filter...
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Page 25: Cooling The Wirefeeder Motor
NOTE! wirefeeder mo- The VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 wirefeeders are equipped with a water-cooled electric motor with shrunk-on-disc rotor and may only be oper- ated in conjunction with an FK 4000 R, FK 4000 R US or FK 9000 R cooling unit. -
Page 26: Operating The Vr 1500 - 12 With An Unreeling Wirefeeder
Operating the NOTE! VR 1500 - 12 To operate the VR 1500 - 12 with an unreeling wirefeeder, the VR 1500 - 12 must with an unreeling wirefeeder be equipped with an increased motor supply installation kit. -
Page 27: Connecting Wire-Feed Unit To Power Source
Turn the power source mains switch to the "O" position Fix the strain-relief device of the interconnecting hosepack to the VR 1500 hosepack holder Connect the gas hose of the interconnecting hosepack to the shielding gas... - Page 28 VR 1500 / VR 1550: connect the interconnecting hosepack to the wirefeeder Interconnecting hosepack; wirefeeder end blue (11) (10) VR 1500 - 11 / 12 / 30: Connecting the interconnecting hosepack to the wirefeeder Interconnecting hosepack; wirefeeder end 2nd power cable (optional) blue...
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Page 29: Fitting The Welding Torch
(X) ... up to a max. of 500 A NOTE! When using a welding current over 500 A, only operate the VR 1500 - 11, VR 1500 - 12 and VR 1500 - 30 wirefeeders with adequately dimensioned Fronius welding torches that have F++ connections. -
Page 30: Fitting The Welding Torch - Tweco Connection
Fitting the weld- turn the power source mains ing torch - Tweco switch to the "O" position connection Check that the welding torch is correctly set up. Insert it - infeed tube first - into the torch connec- tion (1) Inserting the welding torch into the connection for Tweco Fix the welding torch in place using... -
Page 31: 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 32: Feeding In The Wire Electrode
Feeding in the wire electrode Insulated rout- WARNING! ing of wire elec- trode to wire- Risk of serious injury and property damage or an inferior weld as a result of feed unit earth contact or short-circuit of a non-insulated wire electrode. In the case of automated applications, ensure that only an insulated wire elec- trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder (e.g. -
Page 33: Set The Contact Pressure
CAUTION! Risk of injury from wire electrode emerging at speed. This can result in serious injury and damage to property. ▶ When pressing the wire threading button or the torch trigger, keep the weld- ing torch away from your face and body, and wear suitable protective goggles. - Page 34 Contact pressure standard values Feed rollers Semi-cylindrical Trapeze Plastic Aluminium 3.5 - 4.5 Steel 3 - 4 CrNi 3 - 4...
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Page 35: Troubleshooting
Troubleshooting "Wire end" error The "wire end" error message is used for the following errors on VR 1500 series message systems: wire end overheating of power electronics motor current too high "Wire end" spe- Two options can be preset on the power source for the "wire end" error message: cial function complete welding ... -
Page 36: 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! Danger from electrical current. -
Page 37: Technical Data
Technical data General remarks NOTE! The specified degree of protection is only guaranteed if the VR 1500 "cover" in- stallation kit is installed. VR 1500 Supply voltage 55 V DC Nominal current Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. - Page 38 Maximum shielding gas pressure 7 bar 101 psi. Coolant Original Fronius coolant Maximum coolant pressure 6 bar 87 psi. VR 1500 - 12 Supply voltage 55 V DC Nominal current Wire diameter 0.8 - 3.2 mm 0.03 - 0.13 in. Wire feed speed 0.5 - 12 m/min...
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Page 39: Vr 1550 (Cmt-Ws)
Special accessories Additional fan for the power electron- Maximum shielding gas pressure 7 bar 101 psi. Coolant Original Fronius coolant Maximum coolant pressure 6 bar 87 psi. VR 1550 (CMT- Supply voltage 55 V DC Nominal current Wire diameter 0.8 - 1.6 mm... -
Page 40: Circuit Diagrams
Circuit diagrams VR 1500 VR 1500... -
Page 41: Vr 1500 Psa
VR 1500 PSA VR 1500 PSA... -
Page 42: Vr 1550 / Vr 1550 Cmt-Ws
VR 1550 / VR VR 1550 / VR 1550 CMT-WS 1550 CMT-WS...
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