FRONIUS VR 4000 User manual

Operating

Instructions

VR 4000

VR 4000-30 TIME

VR 4000-30

42,0426,0012,EN 008-10012024

EN Operating Instructions

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.

Please also note the safety rules to ensure greater safety when using the

product. Careful handling of the product will repay you with years of safe and re-

liable operation. These are essential prerequisites for excellent results.

Explanation of

safety notices DANGER!

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.

▶If not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of ﬂawed results and possible damage to the equipment.

IMPORTANT!

Indicates tips for correct operation and other particularly useful information.

This does not indicate a potentially hazardous situation.

If you see any of the symbols depicted in the "Safety rules" chapter, special care

is required.

Contents

Dear reader,

Introduction 3

Explanation of safety notices 3

Safety rules 7

General 7

Proper use 7

Environmental conditions 8

Obligations of the operator 8

Obligations of personnel 8

Mains connection 8

Protecting yourself and others 9

Danger from toxic gases and vapours 9

Danger from ﬂying sparks 10

Risks from mains current and welding current 10

Meandering welding currents 11

EMC Device Classifications 12

EMC measures 12

EMF measures 12

Specific hazards 13

Factors affecting welding results 14

Danger from shielding gas cylinders 14

Danger from escaping shielding gas 14

Sicherheitsmaßnahmen am Aufstellort und beim Transport 15

Safety measures in normal operation 15

Commissioning, maintenance and repair 16

Safety inspection 16

Disposal 17

Safety symbols 17

Data protection 17

General 18

Device concept 18

REQUIREMENTS 18

Application area 19

Warning notices on the device 19

Options 20

"Mode" switch option for VR 4000/VR 4000-30 20

Optional control panels for VR 4000/VR 4000-30 20

Optional installation and conversion kits 20

Controls and indicators 22

General 22

Standard control panel 22

Control panel VR 4000-30 TIME 23

Connections and mechanical components 25

Front of wirefeeder 25

Rear of wire-feed unit 25

Side of wire-feed unit 26

Placing wire-feed unit on power source 28

General 28

Connecting wire-feed unit to power source 29

General 29

Connecting the wirefeeder to the power source 29

Connecting the welding torch 31

Welding torch connections 31

Safety 31

Connecting MIG/MAG manual welding torch 31

Connecting MIG/MAG robot welding torch 31

Connecting the Tweco welding torch 32

Inserting/replacing feed rollers 33

General remarks 33

USA wirefeeders 33

inserting/replacing feed rollers 33

Inserting the wirespool, inserting the basket-type spool 35

Safety 35

Inserting the wirespool 35

Inserting the basket-type spool 37

Feeding in the wire electrode 38

Feed in the wire electrode 38

Set the contact pressure 40

Adjust the brake 41

Adjusting the brake 41

Start-up 42

General information 42

Requirements 42

Care, maintenance and disposal 43

General remarks 43

Every start-up 43

Every 6 months 43

Disposal 43

Technical data 44

VR 4000 44

VR 4000-30 44

VR 4000-30 TIME 45

Appendix 47

VR 4000 TIME, VR 4000, VR 4000-30 48

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.

All persons involved in commissioning, operating, maintaining and servicing the

device must:

-be suitably qualified,

-have sufficient knowledge of welding and

-read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being

used. In addition to the operating instructions, attention must also be paid to any

generally applicable and local regulations regarding accident prevention and en-

vironmental protection.

All safety and danger notices on the device

-must be in a legible state,

-must not be damaged,

-must not be removed,

-must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the sec-

tion headed "General" in the operating instructions for the device.

Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

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

-studying and obeying all safety and danger notices carefully

-performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

-Thawing out pipes

-Charging batteries

-Starting engines

The device is designed for use in industry and the workshop. The manufacturer

accepts no responsibility for any damage caused through use in a domestic set-

ting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental

conditions

Operation or storage of the device outside the stipulated area will be deemed as

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:

-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.

Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of

the operator

The operator must only allow persons to work with the device who:

-are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device

-have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures

-are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are

working in a safety-conscious manner.

Obligations of

personnel

Before using the device, all persons instructed to do so undertake:

-to observe the basic instructions regarding safety at work and accident pre-

vention

-to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any

harm in your absence.

Mains connec-

tion

Devices with a higher rating may affect the energy quality of the mains due to

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 *)

*) at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check

whether the device may be connected, where appropriate by discussing the mat-

ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting your-

self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

-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

-Harmful welding fumes and gases

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 regulation filter

-Wear regulation protective goggles with side protection behind the protect-

ive visor

-Wear stout footwear that provides insulation even in wet conditions

-Protect the hands with suitable gloves (electrically insulated and providing

protection against heat)

-Wear ear protection to reduce the harmful effects of noise and to prevent in-

jury

Keep all persons, especially children, out of the working area while any devices

are in operation or welding is in progress. If, however, there are people in the vi-

cinity:

-Make them aware of all the dangers (risk of dazzling by the arc, injury from

ﬂying sparks, harmful welding fumes, noise, possible risks from mains cur-

rent and welding current, etc.)

-Provide suitable protective equipment

-Alternatively, erect suitable safety screens/curtains.

Danger from tox-

ic gases and va-

pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that can cause cancer, as stated in Mono-

graph 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.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

-must not be breathed in

-must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/

hour.

Otherwise, a protective mask with an air supply must be worn.

Close the shielding gas cylinder valve or main gas supply if no welding is taking

place.

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

-Cleaners, degreasers, etc.

The relevant material safety data sheets and manufacturer's specifications for

the listed components should therefore be studied carefully.

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-

ation area.

Danger from ﬂy-

ing sparks

Flying sparks may cause fires or explosions.

Never weld close to ﬂammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the

arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small

gaps or openings. Take appropriate precautions to prevent any danger of injury or

fire.

Welding must not be performed in areas that are subject to fire or explosion or

near sealed tanks, vessels or pipes unless these have been prepared in accord-

ance with the relevant national and international standards.

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

current and

welding current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the

feed rollers and all pieces of metal that are in contact with the welding wire are

live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable,

insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry

base or cover for the earth or ground potential. This base or cover must extend

over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately di-

mensioned. Replace loose connections and scorched, damaged, or inadequately

dimensioned cables and leads immediately.

Use the handle to ensure the power connections are tight before every use.

In the case of power cables with a bayonet connector, rotate the power cable

around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

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