Fronius KD 7000 Operating Instructions Manual

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KD 7000

Operating Instructions

EN

Wire-feed unit

42,0426,0028,EN 002-13122016

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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 familiarise 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 reliable operation. These are
essential prerequisites for excellent results.

EN

Explanation of
safety symbols

DANGER! Indicates immediate and real danger. If it is not avoided, death or se-

rious injury will result.

WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.

CAUTION! Indicates a situation where damage or injury could occur. If it is 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.

It does not indicate a potentially damaging or dangerous situation.

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

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Contents

Safety rules ................................................................................................................................................ 7

General ...................................................................................................................................................... 18

Device concept ..................................................................................................................................... 18

Application areas .................................................................................................................................. 18

Warning notices on the device.............................................................................................................. 19

Application ................................................................................................................................................. 20

General ................................................................................................................................................. 20

Configuration 1: unalloyed/high-alloy steels (Push/Internal)................................................................. 20

Configuration 2: unalloyed/high-alloy steels (Push VR 1530/External)................................................. 21

Configuration 3: Aluminium (Pull/Internal) ............................................................................................ 22

Configuration 4: Aluminium (Pull/External) ........................................................................................... 23

Controls, connections and mechanical components.................................................................................. 24

KD 7000 ................................................................................................................................................ 24

TIG-KD connection box......................................................................................................................... 26

Setting wire speed externally ..................................................................................................................... 29

Setting wire speed externally ................................................................................................................ 29

TIG-KD connection box wiring diagram ..................................................................................................... 30

"Minimum start-up requirements" wiring diagram ...................................................................................... 31

Analogue signals................................................................................................................................... 31

Digital signals........................................................................................................................................ 31

KD 7000 wiring diagram............................................................................................................................. 32

Supply voltages.......................................................................................................................................... 33

Supply voltages..................................................................................................................................... 33

Digital input signals (signals from robot) .................................................................................................... 34

Signal level............................................................................................................................................ 34

Ground .................................................................................................................................................. 34

Start KD ................................................................................................................................................ 34

Arc on (Command arc on)..................................................................................................................... 34

Gas on (Command gas on)................................................................................................................... 34

Touch sensing....................................................................................................................................... 35

Wire retract on/off (WR on/off) .............................................................................................................. 35

Job recall (Job mode) ........................................................................................................................... 35

Reserve 4, reserve 5............................................................................................................................. 36

Emergency stop .................................................................................................................................... 36

Wire retract ........................................................................................................................................... 36

Robot wire-pulsing (Wire pulse robot)................................................................................................... 37

Analogue input signals (signals from robot)............................................................................................... 38

General ................................................................................................................................................. 38

Wire speed ("Vd command value" or "VD1") ........................................................................................38

Specifying power source set value for standard welding ...................................................................... 38

Specifying power source set value for pulsed-arc welding ................................................................... 38

Digital output signals (signals to robot) ...................................................................................................... 40

General ................................................................................................................................................. 40

Pulssynch HIGH.................................................................................................................................... 40

Common signal (Signal common)......................................................................................................... 40

Current flow signal (Signal current flow) ............................................................................................... 40

HF on signal (Signal HF on).................................................................................................................. 40

Gas on signal (Signal gas on)............................................................................................................... 40

Alarm signal .......................................................................................................................................... 41

Reserve signal ...................................................................................................................................... 41

Signal KD ready .................................................................................................................................... 41

Main current signal................................................................................................................................ 42

Start-up ...................................................................................................................................................... 43

Safety.................................................................................................................................................... 43

Proper use ............................................................................................................................................ 43

Setup regulations .................................................................................................................................. 43

Mains connection .................................................................................................................................. 43

Connecting the VR 1530 KD wire drive ................................................................................................ 43

Connecting the TIG-KD manual torch................................................................................................... 44

Connecting the wirefeed for TIG robot torches ..................................................................................... 44

EN

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Connecting Robacta Drive KD wire drive.............................................................................................. 44

inserting/replacing feed rollers .............................................................................................................. 44

Inserting the wirespool .......................................................................................................................... 45

Inserting the basket-type spool ............................................................................................................. 46

Feeding in the welding wire .................................................................................................................. 46

Adjusting the brake ............................................................................................................................... 47

Design of the brake............................................................................................................................... 48

Troubleshooting ......................................................................................................................................... 49

Troubleshooting .................................................................................................................................... 49

Care, maintenance and disposal ............................................................................................................... 50

General ................................................................................................................................................. 50

Care and maintenance.......................................................................................................................... 50

Disposal ................................................................................................................................................ 50

Technical data............................................................................................................................................ 51

KD 7000 ................................................................................................................................................ 51

Spare parts list: KD 7000 ........................................................................................................................... 52

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Safety rules

EN

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 environmental 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
section 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
instructions

- 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
setting.

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

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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

Obligations of
personnel

Mains connection

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
section "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.

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

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

- 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.

Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.

This may affect a number of types of device 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
matter with the power supply company.

NOTE! Ensure that the mains connection is earthed properly

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Protecting your­self and others

Persons involved with welding expose 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
using cardiac pacemakers

- risk of electrocution from mains current and welding current

- greater noise pollution

- harmful welding fumes and gases

Anyone working on the workpiece while welding is in progress must wear suit­able protective clothing with 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 protec­tive 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
injury.

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 vicinity,

- 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 current and welding current, etc.),

- provide suitable protective equipment or

- erect suitable safety screens/curtains.

EN

Noise emission
values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per­missible operating point under maximum rated load conditions according to
EN 60974-1.

It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.

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Danger from toxic
gases and va­pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.

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.

Amongst others, the following components are responsible 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
radiation area.

Danger from fly­ing sparks

Risks from mains
current and weld­ing current

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 ac­cordance 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.

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

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

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During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
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
temporary backing or cover for the earth or ground potential. This temporary
backing 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
dimensioned. 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 pre-load.

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

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 electrodes of two power sources. Touching the potentials of both elec­trodes at the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician
to ensure the ground conductor is functioning properly.

The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.

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.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.

After opening the device:

- Discharge all live components

- Ensure that all components in the device are de-energised

If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.

EN

Meandering weld­ing currents

If the following instructions are ignored, meandering welding currents can de­velop with the following consequences:

- Fire hazard

- Overheating of parts connected to the workpiece

- Irreparable damage to ground conductors

- Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be weld­ed.

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If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.

If distribution boards, twin-head mounts, etc., are being used, note the follow­ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.

EMC Device Clas­sifications

EMC measures

Devices in emission class A:

- 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.

EMC device classification as per the rating plate or technical data.

In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rec­tify the situation.

Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:

- Safety devices

- Power, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

1. Mains supply

- If electromagnetic interference arises despite correct mains connec­tion, additional measures are necessary (e.g. use a suitable line fil­ter).

2. Welding power leads

- must be kept as short as possible

- must run close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece

- If necessary, establish an earth connection using suitable capacitors.

5. Shielding, if necessary

- Shield off other nearby devices

- Shield off entire welding installation

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EMF measures

Electromagnetic fields may pose as yet unknown risks to health:

- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids

- wearers of pacemakers must seek advice from their doctor before ap­proaching the device or any welding that is in progress

- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible

- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body

EN

Specific hazards

Keep hands, hair, clothing and tools away from moving parts. For example:

- Fans

- Cogs

- Rollers

- Shafts

- Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive com­ponents.

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.).

Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.

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.

Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before discon­necting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling cool­ant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.

13

Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.

- Hook chains and/or ropes onto all suspension points provided on the
load-carrying equipment.

- Chains and ropes must be at the smallest angle possible to the vertical.

- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).

If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG de­vices).

If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, coun­terbalanced lift truck or other mechanical hoist.

All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
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 device­side thread of the adapter for the shielding gas connection using suitable Tef­lon tape.

Factors affecting
welding results

Danger from
shielding gas cyl­inders

The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:

- Size of solid matter particles < 40 μm

- Pressure dew point < -20 °C

- Max. oil content < 25 mg/m³

Filters must be used if necessary.

NOTE! There is an increased risk of soiling if ring mains are being
used

Shielding gas cylinders contain gas under pressure and can explode if dam­aged. As the shielding gas cylinders are part of the welding equipment, they
must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical 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.

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). Only
use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

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If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.

The manufacturer's instructions must be observed as well as applicable na­tional and international regulations for shielding gas cylinders and accesso­ries.

EN

Safety measures
at the installation
location and dur­ing transport

A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable

- The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.

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 escape unhindered.

When transporting the device, observe the relevant national and local guide­lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.

Before transporting the device, allow coolant to drain completely and detach
the following components:

- Wire-feed unit

- 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 commissioning the device.

Safety measures
in normal opera­tion

Only operate the device if all safety devices are fully functional. If the safety
devices are not fully functional, there is a risk of

- injury or death to the operator or a third party,

- damage to the device and other material assets belonging to the operator,

- inefficient operation of the device.

Any safety devices that are not functioning properly must be repaired before
switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper func­tioning of safety devices.

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 com­patibility, flammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

The manufacturer accepts no liability for damage resulting from use of a dif­ferent coolant. In addition, all warranty claims will be forfeited.

15

The coolant can ignite under certain conditions. Transport the coolant only in
its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant na­tional and international regulations. The coolant safety data sheet may be ob­tained from your service centre or downloaded from the manufacturer's
website.

Check the coolant level before starting to weld and while the system is still
cool.

Commissioning,
maintenance and
repair

Safety inspection

It is impossible to guarantee that bought-in parts are designed and manufac­tured to meet the demands made of them, or that they satisfy safety require­ments.

- Use only original spare and wearing parts (also applies to standard parts).

- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.

- Components that are not in perfect condition must be replaced immedi­ately.

- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the
specified torque.

The manufacturer recommends that a safety inspection of the device is per­formed at least once every 12 months.

The manufacturer recommends that the power source be calibrated during the
same 12-month period.

A safety inspection should be carried out by a qualified electrician

- after any changes are made

- after any additional parts are installed, or after any conversions

- after repair, care and maintenance has been carried out

- at least every twelve months.

For safety inspections, follow the appropriate national and international stand­ards and directives.

Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.

Disposal

16

Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its im­plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa­cility. Any device that you no longer require must either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!

Safety symbols

Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (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.

EN

Data protection

Copyright

The user is responsible for the safekeeping of any changes made to the fac­tory settings. The manufacturer accepts no liability for any deleted personal
settings.

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 basis for any claims whatsoever on the part of the pur­chaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.

17

General

Device concept

The KD 7000 cold-wire wire-feed unit has
been developed specifically for the Ma­gicWave 2600/2600 CEL and TransTig
2600 CEL/3000 power sources.

At the same time, the flexible design of the
KD 7000 with its own mains cable and inte­grated drive control allows for combination
with more or less any TIG power source or
laser welding system.
The wire speed is specified either using the
controls on the KD 7000 itself or by means
of an analogue signal from an external ro­bot or machine controller. The drive control
on the KD 7000 ensures precise adherence
to the specified wire speed.

The TIG-KD manual torch can be used for manual cold wire TIG welding.

For robot applications with the TIG cold-wire welding process, the TIG-KD connection box
acts as a central node to network the robot control to the power source and the KD 7000.
To set the welding parameters for the power source on the robot, the TIG-KD connection
box supports the simulation of various remote controls.

All other communication with the power source takes place via the analogue/digital robot
interface that is required for the MagicWave 2600/2600 CEL and TransTig 2600 CEL/3000
TIG power sources.

The TIG-KD connection box is not intended for cold wire TIG welding applications with la­ser welding systems. In this case, external control of the KD 7000 is via the robot controller.

The Robacta Drive KD is recommended as a wire drive for the KD 7000 in the case of al­uminium applications. This is an external drive system that draws the wire during the weld­ing process itself. The Robacta Drive provides for exceptionally smooth wire travel.

The 4 roller drive integrated in the KD 7000 - that pushes the wire - is designed for use
when working with unalloyed/high-alloy steels. The VR 1530 KD external 4 roller drive is
recommended for robot applications with unalloyed/high-alloy steels.

If it is combined with an external wire drive and an external wirespool holder, the KD 7000
can be used as a flexible control and adjustment unit with unlimited siting options.
Because there is no need for a connection to the hosepack, the KD 7000 can be set up in
virtually any position.

Application areas The KD 7000 cold wire wire-feed unit is ideally suited for automated and robotic welding

tasks, however it can also be used for special applications in manual welding. The KD 7000
can be used for an extremely varied range of applications both for TIG and laser welding.

18

Depending on the design of the welding machine or the welding robot and the system com­ponents, the flexible design of the KD 7000 means the layout of the wirefeed components
can be customised. The various configuration options are explained in the "Application"
section below.

Warning notices
on the device

The wire-feed unit has safety symbols on the rating plate. The safety symbols must not be
removed or painted over. The symbols warn against operating the equipment incorrectly,
as this may result in serious injury and damage.

Welding is dangerous. The following basic requirements must be met to en­sure the equipment is used properly:

- Welders must be sufficiently qualified

- Suitable protective equipment must be used

- All persons not involved must be kept at a safe distance from the wire­feed unit and the welding process

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

EN

19

Application

General IMPORTANT! The figures below show configuration examples for the KD 7000 with an in-

dustrial robot and a Fronius TIG power source. The configuration examples shown apply
by analogy to welding machines and cold wire TIG welding applications with laser welding
systems.

Figures 1 and 2 apply by analogy to manual TIG welding with cold-wire feed.

Recommended for welding machines

- Wirespool and 4 roller drive integrated in KD 7000

- Wire pushed by integrated 4 roller drive

- Length of the wirefeed hosepack: up to 3.5 m

Configuration 1:
unalloyed/high­alloy steels
(Push/Internal)

(1) (2) (3)

Configuration 1 - Wirespool and wire drive on KD 7000, wire pushed

(1) KD 7000 with wirespool holder and 4 roller drive
(2) Wirefeed hosepack
(3) Welding torch
(4) Wirefeed
(5) Robot control
(6) TIG-KD connection box
(7) Power source robot interface
(8) Power source

Limitation in the case of aluminium:

- Length of hosepack may not exceed 1 m

(4)(5)(6)(7)(8)

20

Configuration 2:
unalloyed/high­alloy steels (Push
VR 1530/External)

Recommended for robots

- KD 7000 without wirespool and wire drive

- Wirespool on external wirespool holder on the robot

- Wire pushed by external 4 roller drive (VR 1530 KD)

- Length of the wirefeed hosepack: up to 3.5 m

EN

(1) (3) (5)

(2) (4)

(11)

Configuration 2 - Wirespool and wire drive external, wire pushed

(1) KD 7000
(2) Wirespool holder and wirespool external
(3) 4 roller drive external VR 1530 KD
(4) Wirefeed hosepack
(5) Welding torch
(6) Wirefeed
(7) Robot control
(8) TIG-KD connection box
(9) Power source robot interface
(10) Power source
(11) Connection cable for external wire drive control (VR 1530 KD)

(6)(7)(8)(9)(10)

Limitation in the case of aluminium:

- Length of hosepack may not exceed 1 m

21

Configuration 3:
Aluminium (Pull/
Internal)

Recommended for welding machines

- KD 7000 with integrated wirespool, without wire drive

- Wire pulled through external 2-roller drive (Robacta Drive KD) during the welding pro­cess itself

- Length of the Robacta Drive KD hosepack: up to 3.5 m

(1) (3)(2)

(9)

(4)(5)(6)(7)(8)

Configuration 3 - Wirespool in the KD 7000, wire pulled by external wire drive

(1) KD 7000 with wirespool holder
(2) Robacta Drive KD hosepack
(3) Welding torch
(4) 2 roller drive external Robacta Drive KD
(5) Robot control
(6) TIG-KD connection box
(7) Power source robot interface
(8) Power source
(9) Connection cable for external wire drive control (Robacta Drive KD)

Limitations in the case of unalloyed/low-alloy steels:

- Length of hosepack may not exceed 2 m

- Wire speed may not exceed 5 m/min

- The braking force of the wirespool brake should be reduced as much as possible so
that the wirespool does not continue unreeling at the end of welding

22

Configuration 4:
Aluminium (Pull/
External)

Recommended for robots

- KD 7000 without wirespool and wire drive

- Wirespool on external wirespool holder on the robot

- Wire pulled through external 2-roller drive (Robacta Drive KD) during the welding pro­cess itself

- Length of the Robacta Drive KD hosepack: up to 3.5 m

(1) (3)(2)

(10)

EN

(5)

Configuration 4 - Wirespool and wire drive external, wire pulled

(4)(6)(7)(8)(9)

(1) KD 7000
(2) Robacta Drive KD hosepack
(3) Welding torch
(4) 2 roller drive external Robacta Drive KD
(5) Wirespool holder and wirespool external
(6) Robot control
(7) TIG-KD connection box
(8) Power source robot interface
(9) Power source
(10) Connection cable for external wire drive control (Robacta Drive KD)

Limitations in the case of unalloyed/low-alloy steels:

- Length of hosepack may not exceed 2 m

- Wire speed may not exceed 5 m/min

- The braking force of the wirespool brake should be reduced as much as possible so
that the wirespool does not continue unreeling at the end of welding

23

Controls, connections and mechanical components

KD 7000

(7)

(1)

(6)

Front view Rear view

(2)
(3)

(4)
(5)

(8)

(9)

(10)

(11)

(12)

(16)(15)(14)(13)

Side view

Item Designation

(1) Indication/wire speed adjustment dial

to display and set the wire speed

IMPORTANT! The actual wire speed will depend on the wire drive used.

Check the sticker on the KD 7000 for details of which wire drive is used (e.g.

1

wire drive "0 - 10 m/min")

Use the table below to determine the actual wire speed

2

e.g.:
"719" on the display means 7.19 m/min with the "0 - 10 m/min" wire drive
Adjustment range: 0.2 m/min up to maximum wire speed

If you want to keep the set wire speed:

3

set the Internal/External (2) selector switch to "Internal"

(2) Internal/External selector switch

to select internal/external wire speed

- on the KD 7000 ("Internal") or

- via a machine or robot controller ("External")

24

Item Designation

(3) Wire retraction length adjuster

to set the length of wire retracted at the end of welding

Scale from 0 to 10:

- 0 .........................1 mm

- 10 .......................50 mm

(4) Connection for external wire drive (14-pin plastic CPC socket)

to control an external wire drive (VR 1530 KD/Robacta Drive KD)

(5) Torch control connection

to connect the control plug for the TIG-KD manual torch

(6) Welding torch central connector (only in combination with internal wirespool

holder or integrated 4 roller drive)
for the wirefeed/Robacta Drive KD/TIG-KD manual torch hosepack

(7) Mains fuse protection 2 A

(8) Mains switch

lights up when the KD 7000 is switched on

(9) LocalNet connection socket

standardised connection socket for the system defaults

(10) KD control interface (37-pin plastic CPC socket)

for external control of the KD 7000 using analogue and digital signals

(11) Mains cable

(12) External welding wire feed

can be used for external wirefeeding

(13) Wirespool holder with deceleration device

accepts standardised welding wirespools up to max. 16 kg (with internal wirespool
holder)

(14) 4 roller drive (only with internal wire drive)

(15) Wire threading/feeding out button

to thread and feed the wire out of the hosepack

- Wire threading: Push button down and hold

- Feed out: Push button up and hold

EN

The feeder inching speed adjuster is used to set the wire threading and feed-out
speed

(16) Feeder inching speed adjuster

to display and set the wire threading and feed-out speed
(0.2 m/min up to maximum wire speed)

25

Wire drive 0 - 5 m/min 0 - 10 m/min 0 - 22 m/min

Wire speed (m/min) Set value

1 200 100 45

2 400 200 90

3 600 300 136

4 800 400 181

5 1000 500 227

6 - 600 272

7 - 700 318

8 - 800 363

9 - 900 409

10 - 1000 454

11 - - 500

12 - - 545

13 - - 591

14 - - 636

15 - - 682

16 - - 727

17 - - 773

18 - - 818

19 - - 864

20 - - 909

21 - - 955

22 - - 1000

Actual wire speed

TIG-KD connec­tion box

For robot applications with the TIG cold-wire welding process, the TIG-KD connection box
acts as a central node to network the robot controller to the power source and the KD 7000.

IMPORTANT! If it is not necessary to control a power source via the robot controller, the
TIG KD connection box is not required (direct connection between robot controller and the
KD 7000). There is also the option of controlling the KD 7000 manually only.

X1

X4

X2

Remote Control

X3

Inside the TIG-KD connection box

Wire Mode

26

Connections

X1 To the robot interface for the power source:

transmits signals between the robot or machine controller and the power source
using analogue and digital signals

X2 To the KD control interface:

controls the KD 7000

- using analogue and digital signals

- via the robot or machine controller and the power source

X3 To the robot or machine controller:

at X3 the signal lines are bundled for

- analogue and digital signals from and to X1

- analogue and digital signals to X2

- analogue signals to X4

X4 To the "connection socket for remote control" interface for the power

source:

to set the welding parameters on the power source

- via analogue signals

- via the robot or machine controller

- by simulating various power source remote controls

Settings on the "Wire Mode" dip switches

NOTE! Only the settings described below may be set on the "Wire Mode" dip

switches.

EN

IMPORTANT! Before changing a setting, turn all dip switches to "off"

The function of the individual dip switches is described below the various settings.

Remote ControlWire Mode

on

1234

off

on/

Puls Robot

Puls Synch TIG

Start Robot

Start TIG

Settings on the "Wire Mode" and "Remote Control" dip switches

on off

off on

on/

off/

off

on

on/

off/

off

on

off/

off

on

on/

off/

off

on

on off

off on

on

off

TR 55 r

TR 50 mc

TP mc

12345678

off

on on

on

off offoffoffoffoff

on

on on

"Puls Robot" and "Start Robot" setting:

- Dip switch for "Puls Robot" to "on"

- Dip switch for "Start Robot" to "on"

"Puls Synch TIG" and "Start TIG" setting:

- Dip switch for "Puls Synch TIG" to "on"

- Dip switch for "Start TIG" to "on"

"Puls Robot" and "Start TIG" setting:

- Dip switch for "Puls Robot" to "on"

- Dip switch for "Start TIG" to "on"

offoffoffoffoff

offoffoffoffoffoff

27

"Puls Synch TIG" and "Start Robot" setting:

- Dip switch for "Puls Synch TIG" to "on"

- Dip switch for "Start Robot" to "on"

"Puls Robot":

The signal for pulsing the cold wire is set by the robot or machine controller.

- The wire speed switches between 0 and the entered set value, according to the sig­nal for pulsing.

"Puls Synch TIG":

Pulsing of the cold wire is set by the power source.

- The wire speed switches between 0 and the entered set value, synchronous with
pulsing of the welding current.

"Start Robot":

Wirefeeding is initiated by the robot controller.

- Irrespective of the operating status of the power source

"Start TIG":

Wirefeeding begins when the welding current has reached the main current phase.

- The main current phase is between the start current and final current phase

Settings on the "Remote Control" dip switches

NOTE! Only use the dip switch settings appropriate for "Remote Control".

The "Remote Control" dip switches are used to select the power source remote control
whose functionality needs to be simulated for the robot or machine controller. The param­eters for the following remote controls can be simulated:

- TR 55 r

- TR 50 mc

- TP mc

28

Setting wire speed externally

EN

Setting wire
speed externally

If the Internal/External selector switch is set to "External", the wire speed will be specified
by an analogue signal.

The "TIG-KD connection box wiring diagram" section shows connection of the "Vd Com­mand Value+" and "Vd Command Value-" analogue signals.

The table below shows the signal voltage to be created for the relevant wire speed.

IMPORTANT! The wire speed will depend on the wire drive used.

Check the sticker on the KD 7000 for details of which wire drive is used (e.g. wire drive

1

"0 - 10 m/min")

Use the table below to determine the signal voltage for the relevant wire speed

2

e.g.:
10 V for 10 m/min, with "0 - 10 m/min" wire drive

Wire drive 0 - 5 m/min 0 - 10 m/min 0 - 22 m/min

Wire speed (m/min) Set value

1 2.0 V 1.0 V 0.454 V

2 4.0 V 2.0 V 0.909 V

3 6.0 V 3.0 V 1.364 V

4 8.0 V 4.0 V 1.819 V

5 10.0 V 5.0 V 2.274 V

6 - 6.0 V 2.729 V

7 - 7.0 V 3.184 V

8 - 8.0 V 3.639 V

9 - 9.0 V 4.094 V

10 - 10.0 V 4.549 V

11 - - 5.004 V

12 - - 5.459 V

13 - - 5.914 V

14 - - 6.369 V

15 - - 6.824 V

16 - - 7.279 V

17 - - 7.734 V

18 - - 8.189 V

19 - - 8.644 V

20 - - 9.099 V

21 - - 9.554 V

22 - - 10.009 V

29

TIG-KD connection box wiring diagram

30

"Minimum start-up requirements" wiring diagram

Analogue signals Analogue input signal for setting wire speed externally

X3:14 ... Vd Command Value +
X3:15 ... Vd Command Value -

Analogue input signal for setting main current externally

X3:1 ... Rem.contr. Pin C
X3:6 ... GND TIG

EN

Digital signals

Digital input signal for arc on

X3:17 ... Command Arc on
X3:27 ... GND Common

Digital input signal for "Start wirefeeding"

X3:16 ... Start KD
X3:27 ... GND Common

31

KD 7000 wiring diagram

32

Supply voltages

EN

Supply voltages

WARNING! An electric shock can be fatal. Never connect the robot controller

supply to the power supply for the KD 7000 or the power source.

Plug X3/pin 5 ("+ 24 V TIG") 24 V

Plug X3/pin 6 ("GND TIG") GND (power supply)

Plug X3/pin 7 ("+ 15 V TIG") 15 V

Plug X3/pin 8 ("- 15 V TIG") - 15 V

IMPORTANT! The voltages listed above may only be used to supply a robot control output
card. The output cards are usually supplied by an internal power supply on the robot con­troller. For this reason, pins 5 to 8 are usually unoccupied.

33

Digital input signals (signals from robot)

Signal level - LOW 0 - 2.5 V

- HIGH 18 - 30 V

Ground When connecting to the TIG-KD connection box:

GND Common = X3/pin 27

When connecting directly to the KD7000:
GND Common = X2/pin 27

All digital inputs are electrically isolated using optical couplers.

Start KD TIG-KD connection box:

Plug X3/pin 16 24 V

Plug X3/pin 27 GND

Arc on (Com­mand arc on)

Connection option direct to the KD 7000:

Plug X2/pin 17 24 V

Plug X2/pin 27 GND

The "Start KD" signal starts wirefeeding at the specified wire speed when "Start Robot" is
selected on the "Wire-Mode" dip switches

IMPORTANT! If "Start TIG" mode has been selected on the "Wire-Mode" dip switches,

- it is not possible to start wirefeeding using the "Start KD" signal,

- wirefeeding starts when the welding current has reached the main current phase.
The main current phase takes place between the start current and final current phase

TIG-KD connection box:

Plug X3/pin 17 24 V

Plug X3/pin 27 GND

The "Arc on" signal starts the power source. The gas flow is controlled from the power
source. Therefore, the "Gas on" signal does not need to be additionally set.

Gas on (Com­mand gas on)

34

TIG-KD connection box:

Plug X3/pin 19 24 V

Plug X3/pin 27 GND

The "Gas on" signal starts the "Gas test" function on the power source. The required gas
flow can be set on the pressure regulator on the gas cylinder.

The "Gas on" signal can be used to create an additional gas pre-flow during positioning.

IMPORTANT! Throughout the welding process, the gas pre-flow and post-flow time is con­trolled by the power source. Therefore, the "Gas test" signal does not need to be set during
the welding process.

Touch sensing TIG-KD connection box:

Plug X3/pin 21 24 V

Plug X3/pin 27 GND

IMPORTANT! If a remote control is directly connected to the power source, the "Touch
sensing" function will be disabled.

The "Touch sensing" signal can be used to indicate that the tungsten electrode has made
contact with the workpiece (short-circuit between workpiece and electrode).

If the "Touch sensing" signal is set, the power source switches to "TouchSensing" mode.
There will be a low voltage on the tungsten electrode (current limited to a low value).

The fact that a short-circuit has occurred is transmitted to the robot control via the current
flow signal (see the "Digital output signals" chapter).

No welding can take place while the “Touch sensing” signal is set. If the robot control sets
the "Touch sensing" signal during a welding operation, welding is stopped. Position detec­tion can be carried out.

EN

Wire retract on/off
(WR on/off)

Job recall (Job
mode)

TIG-KD connection box:

Plug X3/pin 22 24 V (connection box)

Plug X3/pin 27 GND

Connection option direct to the KD 7000:

Plug X2/pin 21 24 V

Plug X2/pin 27 GND

"Wire retract on" is LOW active

- 24 V not present: the wire is automatically retracted at the end of welding.

"Wire retract off" is HIGH active

- 24V is required for wire retraction to be automatically disabled.

"Wire retract on/off" is different to the "Wire retract" signal, which instantly enables wire re­traction irrespective of the end of welding.

TIG-KD connection box:

Plug X3/pin 23 24 V

Plug X3/pin 27 GND

If the "Job recall" signal is set, the power source switches to "Job mode" providing the "Job
memory" option has been installed.

35

The "Job memory" option (4,100,189) is a prerequisite for Job mode.
Robot torches used for applications with the KD 7000 do not normally have a torch trigger,
which is required for programming jobs.
The torch trigger simulator (4,100,560) is available if you want to be able to program jobs.

The "Job recall" signal must be set to recall saved jobs via the robot control. Two analogue
channels are required to select jobs to recall.
These are linked to the TIG-KD connection box using plug X3 as follows:

- X3/pin 1........................GND

- X3/pin 1........................ Recall the tens

- X3/pin 9........................ Recall the units

Jobs are recalled in 1 V steps. For example, to recall job 24 the following voltages are ap­plied to pin C and pin G:

- X3/pin 1........................ 2 V (tens)

- X3/pin 9........................ 4 V (units)

It is possible to switch between the individual jobs during welding.

Reserve 4, re­serve 5

Emergency stop TIG-KD connection box:

TIG-KD connection box:

Plug X3/pin 24/26 24 V

Plug X3/pin 27 GND

These pins are not assigned and therefore do not have any function.

Plug X3/pin 25 24 V

Plug X3/pin 27 GND

"Emergency stop" is LOW active

- 24 V missing: "Emergency stop" is set

The "Emergency Stop" signal stops the welding process immediately.

Alternative: emergency stop via Setup menu

If "E-S" is set to "on" in the power source setup menu, the emergency stop can be enabled
on the socket for the torch trigger.

Pin 7 ............................... 24 V

Pin 9 ...............................GND

Wire retract TIG-KD connection box:

Plug X3/pin 35 24 V

Plug X3/pin 27 GND

Connection option direct to the KD 7000:

Plug X2/pin 22 24 V

Plug X2/pin 27 GND

36

The wire moves backwards at the specified wire speed for as long as the "Wire retract" sig­nal is set.

Robot wire-puls­ing (Wire pulse
robot)

IMPORTANT! It is not possible to send a command to the KD 7000 using the "Start KD" or

"Robot wire-pulsing" signals while the "Wire retract" signal is enabled.

"Wire retract" is different to the "Wire retract on/off" signal, which disables automatic wire
retraction at the end of welding.

TIG-KD connection box:

Plug X3/pin 36 24 V

Plug X3/pin 27 GND

Connection option direct to the KD 7000:

Plug X2/pin 24 24 V

Plug X2/pin 27 GND

The "Wire pulse robot" signal sets pulsing of the cold wire by the robot control.

- "Puls Robot" mode must have been selected on the "Wire-Mode" dip switches.

- The wire speed switches between 0 and the entered set value, according to the signal
for pulsing.

- 24 V set ==> wirefeeding stops

- 24 V missing ==> wirefeeding at set wire speed value

EN

IMPORTANT! If "Puls Synch Tig" mode has been selected on the "Wire-Mode" dip switch-

es,

- it is not possible to send a command to the KD 7000 via the "Wire pulse robot" signal,

- pulsing of the cold wire is set by the power source.
The wire speed switches between 0 and the entered set value, synchronous with puls­ing of the welding current.

37

Analogue input signals (signals from robot)

General

Wire speed ("Vd
command value"
or "VD1")

WARNING! An electric shock can be fatal. Never connect the GND for the robot

control analogue output signal to the GND Common for the digital input and out­put signals.

Ground: GND = X3/pin 6

The analogue input on the robot interface has its own negative or GND potential.

IMPORTANT! Connect the GND for the analogue robot control output signal to the nega­tive potential of the "Wire speed set value" analogue input signal ("Vd command value -"
or "VD1 -").

The "Wire speed set value" analogue input signal described below is active at voltages of
0-10 V.

TIG-KD connection box:

Plug X3/pin 14 Analogue in + 0 to + 10 V

Plug X3/pin 15 Analogue in - (minus)

Connection option direct to the KD 7000:

Specifying power
source set value
for standard
welding

Plug X2/pin 1 Analogue in + 0 to + 10 V

Plug X2/pin 2 Analogue in - (minus)

A voltage of 0 - 10 V is specified for the "Wire speed set value".

0 V ........ Minimum wire speed (0.2 m/min)

10 V...... Maximum wire speed (10 m/min)

IMPORTANT! The table for determining the required signal voltage for the wire speed you
want can be found in the "Setting wire speed externally" section.

Select simulation of TP mc remote control on the "Remote Control" dip switches (see "TIG­KD connection box").

TIG-KD connection box:

Plug X3/pin 1 Main current (+ 0 to + 10 V)

Plug X3/pin 6 GND

A voltage of 0 - 10 V is specified for the "Welding current set value".

0 V ........ Minimum welding current

10 V ...... Maximum welding current

Specifying power
source set value
for pulsed-arc
welding

38

If the robot controller has at least 5 analogue line voltages (0 - 10 V), all welding parame­ters required for pulsed-arc welding can be specified via the robot control.
TransTig power source ... 5 analogue line voltages
MagicWave power source ... 6 analogue line voltages

Select simulation of TR 55 r remote control on the "Remote Control" dip switches (see
"TIG-KD connection box").

TIG-KD connection box:

Plug X3/pin 1 Main current or pulse current (+ 0 to + 10 V)

Plug X3/pin 4 AC balance (MagicWave only) (+ 0 to + 10 V)

Plug X3/pin 9 Base current (+ 0 to + 10 V)

Plug X3/pin 10 frequency range switchover (+ 0 to +10 V)

IMPORTANT! Frequency range switchover takes place in 0.8 V steps.

Plug X3/pin11 Pulse frequency (+ 0 to + 10 V)

Plug X3/pin 12 Pulse width (+ 0 to + 10 V)

Plug X3/pin 6 GND

Connection option direct to the KD 7000:

Plug X2/pin 17 24 V

Plug X2/pin 27 GND

A voltage of 0 - 10 V is specified for the set values for the listed welding parameters.

0 V ........ Minimum parameter set value

10 V ...... Maximum parameter set value

EN

39

Digital output signals (signals to robot)

General The digital outputs have been implemented as relay outputs. This provides for electrical

isolation of the digital output signals.

Pulssynch HIGH TIG-KD connection box:

Plug X3/pin 18 24 V

Plug X3/pin 27 GND

"Pulssynch High" informs the robot control of the moment at which the welding current is
in the pulsing current phase.

The digital output for the "Pulssynch High" signal is "open collector". For this reason, a "10
kOhm pull-up resistor" must be connected to the 24 V of the robot control for the
"Pulssynch High" signal on the digital output.

Common signal
(Signal common)

Current flow sig­nal (Signal cur­rent flow)

HF on signal (Sig­nal HF on)

TIG-KD connection box:

Plug X3/pin 34 24 V

Pin 34 serves as a common root for the "Current flow signal", "HF on", "Gas on", "Alarm"
and "Reserve" digital output signals (see "Digital output signals").

TIG-KD connection box:

Plug X3/pin 28 24 V

Plug X3/pin 27 GND

The current flow signal is set as soon as a stable arc is present.

TIG-KD connection box:

Plug X3/pin 29 24 V

Plug X3/pin 27 GND

Gas on signal
(Signal gas on)

40

The "HF on" signal is active for as long as the high frequency start arc current is enabled,
before ignition of the arc itself.

The "HF on" signal can be used to send commands to an external high frequency genera­tor, for example.

TIG-KD connection box:

Plug X3/pin 31 24 V

Plug X3/pin 27 GND

If the robot control sets the "Arc on" ("Command arc on") digital input signal, the welding
process starts with the gas pre-flow.

The power source sets the "Gas on" signal from the start of the gas pre-flow to the end of
the gas post-flow.

The "Gas on" signal can be used to ensure the best possible gas shield by allowing ade­quate dwell time for the robot at the start and end of the weld seam.

Furthermore, the "Gas on" signal can be used to send commands to the external gas so­lenoid valve (this is useful if a long torch hosepack is used).

Use of the "Gas on" signal as a "Process active" signal represents a further application op­tion.

Alarm signal TIG-KD connection box:

Plug X3/pin 32 24 V

Plug X3/pin 27 GND

EN

The "Alarm" signal is set if the power source is switched off due to overtemperature or
mains overvoltage/undervoltage. The "Alarm" signal may initiate an emergency stop of the
robot or the output of an error message.

Reserve signal TIG-KD connection box:

Plug X3/pin 33 24 V

Plug X3/pin 27 GND

This pin is not assigned and therefore does not have any function.

Signal KD ready TIG-KD connection box:

Plug X3/pin 30 Floating connection

Plug X3/pin 37 Floating connection

Connection option direct to the KD 7000:

Plug X2/pin 30 Floating connection

Plug X2/pin 37 Floating connection

Meaning of the "KD ready" digital output signal:
KD 7000 switched on and ready for operation

41

If the "KD ready" signal is not present even though the system has been switched on, the
following errors may be present:

- Motor overcurrent

- Short circuit/interruption in the actual value pick-up lines

- Actual value pick-up faulty

- Earth current watchdog has tripped

Reset: Switch the mains switch off and back on again

Main current sig­nal

Digital output signal, direct from the power source robot interface to the TIG-KD connection
box.

The main current signal is set between the starting current and final current phase. If the
setting "Start TIG" has been selected on the "Wire Mode" dip switches, wirefeeding starts
with the main current signal.

NOTE! Select "Start TIG" on the "Wire Mode" dip switch. If the setting "Start KD"
is selected instead, it is not possible to start wirefeeding with the main current sig­nal.

(1)

I

(3) (4) (5) (6) (7) (8) (9)

(2)

t

Digital output signals "Gas on" (1) and "Main current signal" (2)

(1) Gas on
(2) Main current signal
(3) Gas pre-flow time
(4) Starting current

(6) welding current
(7) Slope
(8) Final current
(9) Gas post-flow time

(5) Slope

42

Start-up

EN

Safety

Proper use The KD 7000 cold wire wire-feed unit should exclusively be used as a wire-feed unit for the

cold wire TIG and laser cold wire welding processes.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 also includes:

- Complying with all the instructions in the operating instructions

- performing all stipulated inspection and maintenance work

WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All work described in this document must only be carried out by
trained and qualified personnel. All functions described in this document must
only be used by trained and qualified personnel. Do not carry out any of the work
or use any of the functions described until you have fully read and understood the
following documents:

- this document

- all the operating instructions for the system components, especially the safe­ty rules

Setup regulations

The KD 7000 is tested to IP23, meaning:

- protection against penetration by solid foreign bodies greater than 12 mm in diameter

- protection against spraywater at any angle up to 60° to the vertical

The KD 7000 can be set up and operated outdoors in accordance with protection class
IP23.
However, the built-in electrical components must be protected against direct wetting.

The cooling is a very important safety feature. When choosing the installation site, ensure
that the cooling air can enter and exit unhindered through the relevant air openings. Elec­troconductive metallic dust (e.g. from grinding work) must not be allowed to enter the de­vice.

Mains connection The KD 7000 is designed to run on the mains voltage indicated on the rating plate.

The mains cable and plug are ready-fitted. For details of fuse protection of the mains lead,
please see the technical data.

WARNING! A wire-feed unit that topples over could easily kill someone!
The KD 7000 must be installed or mounted on a suitable fixture or on a solid, level
surface so that it remains stable.

Connecting the
VR 1530 KD wire
drive

Plug the connecting cable control plug into the connection socket for the external wire

1

drive of the KD 7000

Tighten the union nut by hand to fix the torch in place

2

Plug the connecting cable control plug into the VR 1500 KD control connection and

3

twist it to fasten it

Tighten the union nut by hand to fix the torch in place

4

43

Connecting the
TIG-KD manual
torch

Move the mains switch to the O position

1

Check that the welding torch has been completely tooled up. Insert it - infeed tube first

2

- into the central connector

Tighten the union nut by hand to fix the torch in place

3

Plug the control plug of the welding torch into the torch control connection and latch it

4

in place

Connecting the
wirefeed for TIG
robot torches

Connecting Ro­bacta Drive KD
wire drive

inserting/replac­ing feed rollers

Move the mains switch to the O position

1

Check that the wirefeed hosepack has been completely tooled up. Insert it - infeed

2

tube first - into the central connector

Tighten the union nut by hand to fix the torch in place

3

Move the mains switch to the O position

1

Insert the Robacta Drive KD hosepack - infeed tube first - into the central connector

2

and secure to the external wire-feed unit holder

Tighten the union nut by hand to fix the torch in place

3

Plug the Robacta Drive KD control plug into the connection socket for the external wire

4

drive

Tighten the union nut by hand to fix the torch in place

5

1 2

1

1

2

4

2

1

4

6

5

6

2

5

4

3

44

3

3

EN

1

2

Inserting the wire­spool

1

1

2

3

1

45

Inserting the bas­ket-type spool

NOTE! 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
basket-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.

1 2

1

2

Feeding in the
welding wire

CAUTION! Risk of injury from springiness of spooled welding wire. While insert-

ing the welding wire into the 4 roller drive, hold the end of the wire firmly to avoid
injuries caused by the wire springing back.

CAUTION! Risk of damage to the welding torch from sharp end of welding wire.
Thoroughly deburr the end of the welding wire before threading.

1 2

1

1

4

2

4

2

1

2

46

3 4

3

2

3

4

1

EN

2

3

1

2

3

4

5

CAUTION! Risk of injury from emerging welding wire. Keep the welding torch
away from your face and body, and wear suitable protective goggles.

1

5

1

Adjusting the
brake

2

2

NOTE! After releasing the torch trigger the wirespool should stop unreeling. Ad­just brake if necessary.

1 2

1

2

1

3

STOP

5

4

6

2

2

1

7

47

3

3

1

2

STOP

Design of the
brake

3

OK

4

CAUTION! Risk of injury and damage from falling wirespool. To ensure that the
wirespool is properly in place and that the brake works properly, fit the brake ac­cording to the following diagram.

2

1

3

PVC

4

1

KLEBER,
GLUE,
COLLE

PVC

48

Troubleshooting

EN

Troubleshooting

WARNING! An electric shock can be fatal. Before opening up the KD 7000, turn

the mains switch into the - O - position, unplug the machine from the mains and
put up a warning sign to stop anybody inadvertently switching the machine back
on again.

Make a note of the serial number and configuration of the device and contact our After­Sales Service team with a detailed description of the error, if

- errors occur that are not listed below

- the troubleshooting measures listed are unsuccessful

KD 7000 is not functioning

Mains switch switched on

Cause: There is a break in the mains lead; the mains plug is not plugged in

Remedy: Check the mains lead, ensure that the mains plug is plugged in

Cause: Mains fuse is faulty

Remedy: Change the mains fuse

Cause: Mains outlet socket or plug is faulty

Remedy: Remedy: Change faulty components

Irregular wire speed

The welding wire forms a loop between the feed rollers and the wire inlet nozzle of the
welding torch

Cause: Braking force has been set too high

Remedy: Loosen the brake

Cause: Hole in the wire centring case is too narrow

Remedy: Use suitable wire centring case

Cause: Inner liner in the welding torch is faulty

Remedy: Check the inner liner for kinks, dirt, etc.

Cause: The feed rollers are unsuitable for the welding wire being used

Remedy: Use suitable feed rollers

Cause: The feed rollers have the wrong contact pressure

Remedy: Optimise the contact pressure

49

Care, maintenance and disposal

General Under normal operating conditions, the device requires only a minimum of care and main-

tenance. However, it is vital to observe some important points to ensure the welding sys­tem remains in a usable condition for many years.

Care and mainte­nance

Observe the following points to ensure the KD 7000 gives you years of troublefree opera­tion:

- Carry out safety inspections at the stipulated intervals (see "Safety rules")

- Depending on the installation location, but in any event at least twice a year, remove

Disposal Dispose of in accordance with the applicable national and local regulations.

WARNING! An electric shock can be fatal. Before opening up the KD 7000, turn

the KD 7000 off at the mains switch, unplug the machine from the mains and put
up a warning sign to stop anybody inadvertently switching the machine back on
again.

the side panels and clean the KD 7000 with dry, reduced compressed air. Do not bring
the air nozzle too close to electronic components.

50

Technical data

EN

KD 7000

Mains voltage 200 - 240 V AC

Nominal current 1,2 A

Mains fuse protection slow-blow 2 A

Types of wirespool all standard

Max. permitted wirespool weight 16 kg (35.27 lb.)

Wirespool diameter 300 mm (11.81 in.)

Wire speed 0,2 - max. m/min

7.87 - max. ipm

Wire drive 4-roller drive

Wire diameter 0,8 - 1,6 mm

0.03 - .0.06 in.

Wirespool diameter max. 300 mm

max. 11.81 in.

Degree of protection IP 23

Dimensions l x w x h 640 / 260 / 430 mm

25.2 / 10.2 / 16.9 in.

Weight 17 kg

37.4 Ib.

EMC device class (in accordance with EN/IEC 60974-10) A

Mains connection Restrictions possible

51

Spare parts list: KD 7000

52

Motorplate 42V 4R

42,0400,0123

42,0405,0116

42,0407,0098

Motor

1

42,0404,0264
42,0404,0340

42,0409,2106

32,0405,0112

32,0405,0113

42,0405,0117
42,0200,9352

42,0200,7767

- yellow

- PE

- CuZn

Connector

42,0407,0503

42,0406,0034

44,0001,1203

42,0407,0077

42,0100,0333
42,0001,3481

22,0405,0114

42,0405,0119

BF2,0201,1345

53

- PE

- Fe

Connerctors

VR 1500-M ( )
VR 1500-PAP ( , , , )

4.045.848.638

4.045.996 4.045.996.800 4.049.001 4.049.001.800

CB RA - M connection

44,0350,2339

42,0200,9872

VR 1500 ( all variants )

Z = Fronius connection

42,0402,0093

42,0100,0052

44,0001,1277

44,0001,0052

42,0200,9872

TW = Tweco connection

42,0100,0499

42,0001,0090

42,0201,1518

42,0001,3547

42,0401,0952

E = Euro connection

42,0001,1278
42,0001,1424
42,0001,1682
42,0001,1944
42,0001,3051

- 5x113 - 5x109 - 5x111 - 5x133 - 3,5x113

D = Dinse connection

42,0300,1053

44,0001,1197

44,0001,0069

42,0001,1642

42,0200,4128

42,0400,0141

Cnomo connection

44,0001,1348

42,0001,1508

42,0200,9872

54

Motorplate 42V 4R

42,0300,2631

Tweco

32,0300,2233

12,0300,2375

12,0405,0118

32,0300,2481

42,0001,3260

42,0407,0077

KD

42,0200,9817

42,0001,3259

44,0001,1242

42,0200,9816

15mm/.59in.

55

17mm/.67in.

Motorplate 42V 4R Motor

42,0405,1085

42,0405,1083

43,0011,0029

42,0405,1084

4,070,938

42,0405,1086

42,0001,3671

- IWGTD

IWGTD

43,0004,2846

42,0405,0081

4,070,294

42,0400,0093

42,0407,0312

43,0011,0033

32,0405,0080

42,0405,0082

43,0007,0032

42,0001,3670

- IWGT

IWGTC

42,0405,0081

4,070,294

42,0400,0093

43,0011,0029

42,0001,1367

42,0001,1366

32,0405,0080

42,0405,0082

42,0200,5633

IWGTD

42,0405,1085

IWGTC

- IWGT

BE2,0201,1420

33,0006,0185

41,0001,0592

42,0200,8408

- 12m/min

43,0006,0139

33,0006,0131 43,0006,0105

33,0006,0131
33,0006,0156

- 30 m/min

- 11 m/min

43,0006,0113

42,0405,1083

43,0011,0029

42,0405,1084

43,0004,2846

4,070,938

42,0300,7120

- IWGTD

42,0405,1086

56

43,0006,0105

43,0006,0124

- 24,5:1

- 49:1

575859

FRONIUS INTERNATIONAL GMBH

Froniusplatz 1, A-4600 Wels, Austria

Tel: [phone], Fax: [phone]

E-Mail: [e-mail]

www.fronius.com

www.fronius.com/addresses

Under http://www.fronius.com/addresses you will find all addresses

of our Sales & service partners and Locations