Fronius VR 143-2Z Yard Operating Instruction [EN]

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VR 143-2Z Yard

Operating Instructions
Spare Parts List

EN

Wire Feeder

42,0426,0016,EN 004-08112013

Dear Reader

Introduction

Thank you for choosing Fronius - and congratulations on your new, technically high­grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.

EN

ud_fr_st_et_00493 01/2012

Safety rules

DANGER!

WARNING!

CAUTION!

NOTE!

Important!

“DANGER!” indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices that may cause property damage.

“NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.

“Important!” indicates practical hints and other useful special-information. It is no
signal word for a harmful or dangerous situation.

EN

General remarks

Whenever you see any of the symbols shown above, you must pay even closer
attention to the contents of the manual!

This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for

- the life and well-being of the operator or of third parties,

- the equipment and other tangible assets belonging to the owner/
operator,

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must

- be suitably qualified

- know about welding and

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must
be kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

- must be kept in a legible condition

- must not be damaged, must not be removed

- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings
are located on the machine, please see the section of your machine’s
instruction manual headed “General remarks”.

I

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General remarks

(continued)

Any malfunctions which might impair machine safety must be eliminated
immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

Utilisation for
intended purpose
only

The machine may only be used for jobs as defined by the “Intended purpose”.

The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall
not be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual

- complete reading and following of all the safety instructions and danger
warnings

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

The machine is designed to be used in industrial and workshop
environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work
results.

Ambient
conditions

Obligations of
owner/operator

Operation or storage of the power source outside the stipulated range is
deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

- when being transported or stored: - 20 °C to + 55 °C (-4 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

The owner/operator undertakes to ensure that the only persons allowed to
work with the machine are persons who

- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine

- have read and understood this operating manual particulary the sections
on “Safety rules”, and have confirmed as much with their signatures

- be trained in such a way that meets with the requirements of the work
results

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Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.

II

Obligations of
personnel

Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake

- to observe the basic regulations on workplace safety and accident
prevention

- to read this operating manual particulary the sections on “Safety rules”
and to sign to confirm that they have understood these and will comply
with them.

EN

Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.

Mains connec­tion

Protection for
yourself and
other persons

High-performance devices can affect the quality of the mains power due to
their current-input.
This may affect a number of types of device in terms of:

- connection restrictions

- criteria with regard to maximum permissible mains impedance

- criteria with regard to minimum short-circuit power requirement

*)

at the interface with the public mains network

*)

*)

see Technical Data

In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.

NOTE! Ensure that the mains connection is earthed properly.

When welding, you are exposed to many different hazards such as:

- flying sparks and hot metal particles

- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace­maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable
protective clothing with the following characteristics:

- flame-retardant

- isolating and dry

- must cover whole body, be undamaged and in good condition

- protective helmet

- trousers with no turn-ups

III

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Protection for
yourself and
other persons

(continued)

“Protective clothing” also includes:

- protecting your eyes and face from UV rays, heat and flying sparks with
an appropriate safety shield containing appropriate regulation filter glass

- wearing a pair of appropriate regulation goggles (with sideguards)
behind the safety shield

- wearing stout footwear that will also insulate even in wet conditions

- protecting your hands by wearing appropriate gloves (electrically insula­ting, heat-proof)

- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!

Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must

- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Information on
noise emission
values

Hazards from
noxious gases
and vapours

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.

The fumes given off during welding contain gases and vapors that are
harmful to health.

Welding fumes contain substances which may cause birth defects and
cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable
means.

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Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an
independent air supply.

If you are not sure whether your fume-extraction system is sufficiently
powerful, compare the measured pollutant emission values with the
permitted threshold limit values.

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

IV

Hazards from
noxious gases
and vapours

(continued)

The harmfulness of the welding fumes will depend on e.g. the following
components:

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

Hazards from
flying sparks

For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (36 ft. 1.07 in.) away from
the arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that
there is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or
explosion, or in enclosed tanks, barrels or pipes, unless these latter have
been prepared for welding in accordance with the relevant national and
international standards.

EN

Hazards from
mains and weld­ing current

Welding must NEVER be performed on containers that have had gases,
fuels, mineral oils etc. stored in them. Even small traces of these
substances left in the containers are a major explosion hazard.

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

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or
else use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/
frame potential. The base or cover must completely cover the entire area
between your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.

V

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Hazards from
mains and weld­ing current

(continued)

Do not loop any cables or other leads around your body or any part of your
body.

Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.

Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).

Stray welding
currents

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the
mains.

Put up a clearly legible and easy-to-understand warning sign to stop
anybody inadvertently plugging the machine back into the mains and
switching it back on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.

If the following instructions are ignored, stray welding currents may occur.
These can cause:

- fires

- overheating of components that are connected to the workpiece

- destruction of PE conductors

- damage to the machine and other electrical equipment

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Ensure that the workpiece clamp is tightly connected to the workpiece.

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

On electrically conductive floors, the machine must be set up in such a way
that it is sufficiently insulated from the floor.

VI

Stray welding
currents

(continued)

When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/
welding tongs is also current carrying. Please ensure that there is sufficient
insulating storage for the unused welding torch/tongs.

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

EN

EMC device
classifications

Devices with emission class A:

- are only designed for use in an industrial setting

- can cause conducted and emitted interference in other areas.

Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas. This

also applies to residential areas in which power is supplied from the
public low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures 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.

Examine and evaluate any possible electromagnetic problems that may
occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:

- safety features

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply

- If electromagnetic interference still occurs, despite the fact that the
mains connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).

b) Welding cables

- Keep these as short as possible

- Arrange them so that they run close together (to prevent EMI problems
as well)

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

VII

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EMI Precautions

Electromagnetic fields may cause as yet unknown damage to health.

- Effects on the health of persons in the vicinity, e.g. users of heart pace­makers and hearing aids

- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces

- Keep as much space as possible between welding cables and head/
body of welder for safety reasons

- Do not carrywelding cables and hose pack over shoulder and do not
loop around body or or any part of body

Particular danger
spots

Keep your hands, hair, clothing and tools well away from all moving parts,
e.g.:

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.

Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...

- ... and that all covers and sideguards are kept closed.

When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...).

For this reason, when feeder-inching etc., always hold the torch so that it is
pointing away from your body (machines with wirefeeder) and wear suitable
protective goggles.

Do not touch the workpiece during and after welding - risk of injury from
burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.

Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.

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VIII

Particular danger
spots

(continued)

Risk of scalding from accidental discharge of hot coolant. Before unplugging
the connectors for coolant forward flow and return flow, switch off the coo­ling unit.

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.

When hoisting the machines by crane, only use suitable manufacturer­supplied lifting devices.

- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.

- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.

- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).

When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that
this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.

EN

Factors affecting
welding results

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.

Danger of colourless and odourless inert gas escaping unnoticed, when
using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.

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 <40µm

- Pressure dew point <-20°C

- Max. oil content <25mg/m³

Filters must be used if necessary.

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

IX

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Danger from
shielding-gas
cylinders

Shielding-gas cylinders contain pressurized gas and may explode if they are
damaged. As shielding-gas cylinders are an integral part of the overall
welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas
cylinder.

Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories
that are in good condition.

Safety precauti­ons at the instal­lation site and
when being
transported

When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and
international rules applying to shielding-gas cylinders and accessories.

A machine that topples over can easily kill someone! For this reason, always
place the machine on an even, firm floor in such a way that it stands firmly.

- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.

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The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m
(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportati­on and carriage.

X

Safety precauti­ons at the instal­lation site and
when being
transported

(continued)

Before transportation, completely drain any coolant and dismantle the
following components:

- Wire feed

- Wire wound coil

- Gas bottle

Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by trained service
personnel before commissioning.

EN

Safety precau­tions in normal
operation

Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety devices that are not fully functional must be put right before you
switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by
your doing so.

- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frost­proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.

- Do not mix original coolant of the manufacturer with other coolants.

- If any damage occurs in cases where other coolants have been used,
the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.

- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check the
coolant level.

XI

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Preventive and
corrective main­tenance

With parts sourced from other suppliers, there is no certainty that these
parts will have been designed and manufactured to cope with the stressing
and safety requirements that will be made of them. Use only original spares
and wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine
without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.

Safety inspection

Disposal

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.

Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC 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 be returned to our agent, or find out about 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 markings

ud_fr_st_sv_00467 022013

Equipment with CE-markings fulfils the basic requirements of the Low­Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .

Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.

XII

Data security

The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.

Copyright

Copyright to this instruction manual remains the property of the
manufacturer.

The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.

EN

XIII

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XIV

Contents

General remarks ........................................................................................................................................... 2

Appliance concept .................................................................................................................................... 2

Applicational principle .............................................................................................................................. 2

System requirements ............................................................................................................................... 2

Warning labels on the unit........................................................................................................................ 3

Before putting the unit into service ................................................................................................................ 3

Safety ....................................................................................................................................................... 3

Connecting up the VR 143-2Z Yard ............................................................................................................... 4

Safety ....................................................................................................................................................... 4

Connecting up the interconnecting hosepack to the main wirefeeder ...................................................... 4

Connecting up the interconnecting hosepack to the VR 143-2Z Yard ...................................................... 5

Connecting up the welding torch to the VR 143-2Z Yard .......................................................................... 5

Inserting / changing the feed rollers .............................................................................................................. 6

General remarks ...................................................................................................................................... 6

Inserting / changing the feed rollers ......................................................................................................... 6

Feeding in the welding wire ........................................................................................................................... 7

Feeding in the welding wire ...................................................................................................................... 7

Care, maintenance and disposal ................................................................................................................... 8

General remarks ...................................................................................................................................... 8

Every time before starting up ................................................................................................................... 8

Every 6 months ........................................................................................................................................ 8

Final disposal ........................................................................................................................................... 8

EN

Technical data ............................................................................................................................................... 9

General remarks ...................................................................................................................................... 9

VR 143-2Z Yard ........................................................................................................................................ 9

Spare parts list

Fronius Worldwide

1

General remarks

Appliance
concept

The VR 143-2Z Yard is an extra, auxiliary
wirefeed unit (intermediate drive) for use
in situations where the main wirefeeder
(e.g. VR 4000) has to be located a long
distance away from the welding process.

The wirefeeders come as standard with a
4-roller drive, which provides excellent
wirefeed properties. The VR 143-2Z Yard
is also suitable for use with very long
hosepacks of up to 25 m (82 ft.).

The compact design of the VR 143-2Z
Yard suits it for many and varied possible
areas of use.

The VR 143-2Z Yard can be run in

Fig.1 VR 143-2Z Yard wirefeeder

conjunction with any of the following power
sources:

- TransSynergic 4000 / 5000

- TransPuls Synergic 4000 / 5000

The VR 143-2Z Yard can be combined with either of the following wirefeeders:

- VR 4000

- VR 7000

Applicational
principle

System
requirements

The VR 143-2Z Yard can be used for all types of MIG/MAG welding work. The wirefeed
unit is suitable for all customary shielding gases.

“W 10m 70mm²”

VR 4000 / 7000

VR 143-2Z Yard

TS 4000/5000
TPS 4000/5000

Fig.2 Applicational principle

Power source:

- Software version V3.10.1

- Optional “Enhanced motor supply 55 V / 8 A”

Main wirefeeder (e.g.: VR 4000):

- Software version V1.50.38

- Optional “PMR 4000 PullMig TS/TPS 2700-5000”

- Option “Intermediate drive 143-2”

In addition:

- “W 10m 70mm²” interconnecting hosepack, for linking the main wirefeeder to the
VR 143-2Z Yard

2

Warning labels

Warning! Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described here until you have read and
completely understood all of the following documents:

- these “Operating Instructions”

- all the “Operating Instructions” for the system components, especially the
“Safety rules”

Warning! A machine that topples over or falls from its stand can easily kill
someone! Place equipment on an even, firm floor in such a way that it stands
firmly. The VR 143-2Z Yard is not suitable for being hoisted by crane.

on the unit

The wirefeed unit comes with safety symbols on the rating plate. These safety symbols
must NOT be removed or painted over. The symbols warn against incorrect operation,
as this may result in serious injury and damage.

EN

Do not use the functions described here until you have read and completely
understood all of the following documents:

- these “Operating Instructions”

- all the “Operating Instructions” for the system components, especially
the “Safety rules”

Welding is a dangerous business! Before anyone starts welding, the
following fundamental preconditions must be fulfilled:

- The welder must be sufficiently skilled and qualified ...

- ... and must be using suitable protective gear.

- All persons not involved in welding must be kept well out of the way

Fig.3 Warning labels on the wirefeeder

Before putting the unit into service

Safety

Note! Arrange the interconnecting hosepack in a straight line (without

”looping”). If any damage is done to the interconnecting hosepack, contact
After-Sales Service.

3

Caution! There is a risk of injury from wire emerging at speed from the torch if
the torch trigger or the ”Feeder inching” button are pressed accidentally. Only
carry out any work on the equipment if

- the mains switch of the power source is in the ”O” position, and

- the power source has been disconnected from the mains.

Connecting up the VR 143-2Z Yard

Safety

Connecting up
the interconnect­ing hosepack to
the main wire­feeder

1. Shift the mains switch of the power source into the ”O” position

(1)

Front of the main wirefeeder (e.g. VR

4000):

2. Insert either end of the interconnect­ing hosepack - infeed tube first - into
the welding-torch connector (1)

3. Tighten the swivel nut by hand to fix
the interconnecting hosepack in place

4. Plug the coolant hoses of the inter­connecting hosepack onto the (black)
plug-type connector for coolant

(2)
(3)

forward-flow (2), and onto the red one
for coolant return-flow (3)

5. Plug the (6-pole) control plug of the
interconnecting hosepack onto the
control-plug jack(5)

(4)

Fig.4 Front of the wirefeeder (e.g. VR 4000):

Connecting up the interconnecting
hosepack

Rear of the main wirefeeder (e.g. VR

4000):

6. Plug the (10-pole) LocalNet plug of

(5)

Fig.5 Rear of the wirefeeder (e.g. VR 4000):

Connecting up the interconnecting
hosepack

4

the interconnecting hosepack to the
LocalNet connection jack (4)

Connecting up
the
interconnecting
hosepack to the
VR 143-2Z Yard

1. Shift the mains switch of the power
source into the ”O” position

(1)

On the side of the VR 143-2Z Yard shown

(4) (5) (3) (2)

here (Fig.6):

2. Insert the other end of the
interconnecting hosepack - infeed
tube first - into the welding-torch
connector (1)

3. Tighten the swivel nut by hand to fix
the interconnecting hosepack in place

4. Plug the (10-pole) LocalNet plug of
the interconnecting hosepack to the

(6)

Fig.6 VR 143-2Z Yard: Connecting up the

interconnecting hosepack

LocalNet connection jack (4)

5. Plug the (6-pole) control plug of the interconnecting hosepack onto the control-plug
socket (5)

6. Plug the coolant hoses of the interconnecting hosepack onto the (black) plug-type
connector for coolant forward-flow (2), and onto the red one for coolant return-flow

7. Fix the interconnecting hosepack in place with a hose clamp (6)

EN

Connecting up
the welding torch
to the VR 143-2Z
Yard

(3)

(7)

(2)

(6)

Fig.7 VR 143-2Z Yard: Connecting up the

(standard) welding torch

(1)(3)(2)

1. Shift the mains switch of the power
source into the ”O” position

(1)

On the side of the VR 143-2Z Yard shown
here (Figs. 7 and 8):

2. Check that the torch is correctly and
completely tooled up. Insert it - infeed
tube first - into the welding-torch
connector (1).

3. Tighten the swivel nut by hand to fix
the interconnecting hosepack in place

4. Plug the coolant hoses of the
interconnecting hosepack onto the
(black) plug-type connector for
coolant forward-flow (2), and onto the
red one for coolant return-flow

5a. Standard welding torch (Fig.7): Plug

the welding torch to the torch
connection jack (7)

5b. Up/Down or JobMaster welding torch

(Fig.8): Plug the LocalNet plug of the
welding torch onto the LocalNet
connection jack (4)

6. Fix the interconnecting hosepack in
place with a hose clamp (6)

(6)

(4)

Fig.8 VR 143-2Z Yard: Connecting up the

(JobMaster, Up/Down) welding torch

5

Inserting / changing the feed rollers

General remarks

Inserting /
changing the
feed rollers

In order to achieve optimum wire travel, the feed rollers must be suitable for the
diameter and alloy of the wire to be welded.

The VR 143-2Z Yard is supplied without feed rollers.

Important! Use only feed rollers that are suitable for the welding wire!

Please see the spare-parts lists for an overview of the available feed rollers and of their
possible areas of use.

1. Shift the mains switch of the power source into the ”O” position

2. Open the wirefeeder cover on the VR 143-2Z Yard

3. Pivot clamping devices (8) and (9) forward

4. Pull pressure levers (10) and (11) upward

(8) (21) (22)(9)(10) (11)

(17) (18)

5. Remove the protective cover (12) (if
there is one):

- Gently push the protective cover

(12) downward

- Pull out the protective cover (12)

towards the front

6. Detach axles (13) - (16)

7. Only where the feed rollers are being
changed: Remove feed rollers (17) to
(20)

8. Insert the new feed rollers

(19) (20)

(13) (16)

Fig.9 Changing the feed rollers

9. Push axles (13) - (16) back in again - the anti-twist lock of each axle must latch into
place

10. Mount the protective cover (12), if there is one:

- Position the recess of the protective cover over the plastic guide - the fixing nibs

- Press down on the protective cover until this clicks into place

11. Push pressure levers (10) and (11) downward

12. Pivot clamping devices (8) and (9) into the vertical position

13. Set the contact pressure by means of clamping nuts (21) and (22)

14. Close the wirefeeder cover on the VR 143-2Z Yard

(14) (15)(12)

must be facing upwards

Note! Insert feed rollers in such a
way that the toothed rim of the feed
roller faces the motor plate.

Feeding in the welding wire

Feeding in the
welding wire

1. Open the wirefeeder cover on the VR 143-2Z Yard

(8) (21) (22)(9)(10) (11)

(23)

Fig.10 Feeding in the welding wire

7. Set the contact pressure by means of clamping nuts (21) and (22)

Note! Set a contact pressure that is high enough to ensure smooth wire travel,
but not so high that the welding wire is deformed.

8. Arrange the torch hosepack in as straight a line as possible

9. Detach the gas nozzle from the torch

10. Unscrew the contact tube

2. Pivot clamping devices (8) and (9)
forward

3. Pull pressure levers (10) and (11)
upward

4. Feed the welding wire into the main
wirefeeder (e.g. VR 4000):

- until the wire has emerged around

5 cm (2 in.) from the VR 143-2Z
Yard and into the wire-guidance
nozzle (23) of the welding torch

5. Push pressure levers (10) and (11)
downward

6. Pivot clamping devices (8) and (9)
into the vertical position

Caution! Risk of injury from welding wire emerging at speed from the torch. Hold
the torch so that it points away from your face and body.

11. Press the “Feeder inching” button on the control panel of the power source and hold
it until the wire emerges from the torch.

12. To end the feeder-inching operation, release the ”Feeder inching” button

Note! The wirespool of the main wirefeed unit must not continue to unreel after
you release the torch trigger. Re-adjust the brake if necessary.

13. Shift the mains switch of the power source into the “O” position

14. Screw the contact tube back in

15. Replace the gas nozzle

16. Close the wirefeeder cover on the VR 143-2Z Yard

Care, maintenance and disposal

Warning! An electric shock can be fatal. Before opening up the machine

- Shift the mains switch into the ”O” position

- Unplug the machine from the mains

- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again

- Using a suitable measuring instrument, check to make sure that
electrically charged components (e.g. capacitors) have been discharged

General remarks Under normal operating conditions, the VR 143-2Z Yard needs only a minimum of care

and maintenance. However, to ensure continued trouble-free operation of your
equipment for years to come, there are a few basic points that you should observe.

Every time before
starting up

Every 6 months

Final disposal

- Inspect the torch, interconnecting hosepack and earth connection for any signs of
damage

- Do a sight check of the wirefeed rollers and inner liners for any signs of damage

- Check the contact pressure of the wirefeed rollers and adjust this if necessary

- Remove the side panels and blow clean the inside of the unit with dry, reduced-blow
compressed air

Note! Risk of damage to electronic components. Do not aim air-jets at
electronic components from too close a range.

At the end of its useful life, only dispose of equipment in accordance with all applicable
national and local regulations.

8

Technical data

General remarks

VR 143-2Z Yard

Note! Inadequately dimensioned electrical installations can lead to serious

damage to (or loss of) property. The mains supply lead, and its fuse protection,
must be dimensioned accordingly. The technical data shown on the rating plate
shall apply.

Supply voltage (from the power source) 42 V DC

Rated current 3.9 A

Wirefeed speed 0.5 - 22 m/min (19.69 - 866.14 ipm.)

Degree of protection IP 23

Dimensions (L x W x H) 560 x 180 x 230 mm (22.06 x 7.09 x 9.06 in.)

Weight 10 kg (22 lb.)

Wire diameter 0.8 - 1.6 mm (0.03 - 0.06 in.)

Drive 4-roller drive

Max. shielding-gas pressure 7 bar (101 psi.)

Coolant Standard Fronius coolant (40,0009,0046)

Max. coolant pressure 4.2 bar (61 psi.)

EN

9

10

Ersatzteilliste

DEENFRITESPT-BRNLNOCSRUSKSVTR

Spare Parts List

Liste de pièces de rechange

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílù

Список запасных частей

Zoznam náhradných dielov

Reservdelslistan

ud_fr_st_tb_00150 012012

Parça Listesi

Czyszczenie palnika

PL

VR 143-2Z 4R/F++ Yard 4,045,646,630
VR 143-2Z 4R/Z/E Yard 4,045,646,631

BE2,0201,1670

* gewünschte Länge angeben
* Specify the length required
* Indiquer la longueur désirée
* Indicar la longitud deseada
* Indicare la lunghezza desiderat
* indicar o comprimento desejado

44,0001,1230 - Z 22/min
44,0001,1231 - E 22/min

40,0001,0012 - *

42,0300,0480

42,0300,0482

44,0450,1270

42,0300,0642

42,0407,0063

42,0001,2666

42,0001,0133

44,0001,1277

42,0100,0052

43,0003,0252

43,0003,0246

42,0407,0063

42,0405,0189

42,0405,0186 - RED
42,0405,0187 - BLACK

44,0001,1145

42,0404,0024

42,0405,0154

43,0003,0255

43,0003,0251

BE2,200,2678

42,0401,0004

BE2,0201,1672

42,0405,0056
43,0003,0485

43,0003,0255

BE4,0450,1269

BE2,0200,9699

BE2,0201,1668

42,0400,0183

42,0200,6853

42,0401,0004

BE4,0450,0828

VR 143 - 2 Z

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

el_fr_st_dv_00804 012003

1/1

FRONIUS INTERNATIONAL GMBH

Froniusplatz 1, A-4600 Wels, Austria

Tel: [phone], Fax: [phone]

E-Mail: [e-mail]

www.fronius.com

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

www.fronius.com/addresses

of our Sales & service partners and Locations.

ud_fr_st_so_00082 012011