Fronius VR 1500-12, VR 1500-22, VR 1500-11, VR 1500-30, VR 1500-KD Operating Instructions Manual

VR 1530 -11 / -12 / - 22 / -30 / -KD

Operating Instructions
Spare Parts List

Wirefeeder

/ Battery Charging Systems / Welding Technology / Solar Electronics

EN

42,0426,0010,EN 005-08112013

ud_fr_st_et_00493 01/2012

EN

Dear Reader

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.

Introduction

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I

EN

Safety rules

DANGER!

WARNING!

CAUTION!

“NOTE!” indicates a situation which implies a risk of impaired welding result

and damage to the equipment.

NOTE!

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”.

General remarks

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.

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

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

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II

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)

Ambient
conditions

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.

Utilisation for
intended purpose
only

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!

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

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

Obligations of
owner/operator

General remarks

(continued)

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III

EN

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.

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

Obligations of
personnel

Protection for
yourself and
other persons

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

Mains connec­tion

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.

- 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

NOTE! Ensure that the mains connection is earthed properly.

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IV

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.

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.

Hazards from
noxious gases
and vapours

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.

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!

Information on
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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V

EN

Hazards from
mains and weld­ing current

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.

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.

Hazards from
flying sparks

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.

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

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.

Hazards from
noxious gases
and vapours

(continued)

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VI

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

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.

Stray welding
currents

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).

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.

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VII

EN

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.

Stray welding
currents

(continued)

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.

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VIII

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.

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.

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 ...).

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.

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.

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

EMI Precautions

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.

Particular danger
spots

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.

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IX

EN

Particular danger
spots

(continued)

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.

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.

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.

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.

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

Factors affecting
welding results

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X

Safety precauti­ons at the instal­lation site and
when being
transported

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.

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.

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.

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.

Danger from
shielding-gas
cylinders

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XI

EN

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.

Safety precau­tions in normal
operation

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.

Safety precauti­ons at the instal­lation site and
when being
transported

(continued)

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XII

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). .

Safety markings

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

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!

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.

Safety inspection

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.

Preventive and
corrective main­tenance

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XIII

EN

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.

Copyright

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

Data security

ud_fr_st_sv_00467 022013

XIV

1

EN

Contents

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

Safety ....................................................................................................................................................... 2

Machine concept ...................................................................................................................................... 2

Overview .................................................................................................................................................. 2

Areas of utilisation ................................................................................................................................... 2

System requirements ............................................................................................................................... 3

Applicational example: VR 1530-22 used as an unreeling-type wirefeeder ............................................ 3

Applicational example: VR 1530-11/-12/-30 used as an unreeling-type wirefeeder ................................ 4

Warning notices affixed to the machine ................................................................................................... 5

Controls and connection points .................................................................................................................... 6

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

VR 1530 -11 / -12 /-22 / - 30 .................................................................................................................... 6

VR 1530-KD20 ......................................................................................................................................... 7

Wire-inching sequence when the welder presses and holds the feeder inching button ......................... 8

Putting the unit into service ........................................................................................................................... 9

Utilisation for intended purpose only ....................................................................................................... 9

Machine set-up regulations ..................................................................................................................... 9

Ready-drilled holes ................................................................................................................................ 10

Space for tilting up the lid of the wirefeeder........................................................................................... 10

Mounting the wirefeed hoses ....................................................................................................................... 11

Safety ...................................................................................................................................................... 11

Mounting the wirefeed hoses .................................................................................................................. 11

Inserting / changing the feed rollers ........................................................................................................... 12

General remarks .................................................................................................................................... 12

USA wirefeeders .................................................................................................................................... 12

Inserting / changing the feed rollers ...................................................................................................... 12

Feeding in the welding wire ........................................................................................................................ 13

Insulated routing of welding wire to wirefeeder ..................................................................................... 13

Safety ..................................................................................................................................................... 13

Preparations........................................................................................................................................... 13

Feeding in the welding wire ................................................................................................................... 13

Feeding in the welding wire ................................................................................................................... 14

Setting contact pressure ........................................................................................................................ 15

Calibrating push-pull unit ............................................................................................................................ 16

General remarks .................................................................................................................................... 16

Calibrating the push-pull unit ................................................................................................................. 16

Service codes displayed during calibration of the push-pull unit ........................................................... 16

Troubleshooting .......................................................................................................................................... 17

General remarks .................................................................................................................................... 17

VR 1530 error diagnostics ..................................................................................................................... 17

Care, maintenance and disposal ................................................................................................................ 19

General remarks .................................................................................................................................... 19

Every time before starting up ................................................................................................................. 19

Final disposal ......................................................................................................................................... 19

Technical data ............................................................................................................................................. 20

VR 1530-12 ............................................................................................................................................ 20

VR 1530-11 ............................................................................................................................................ 20

VR 1530-22 ............................................................................................................................................ 21

VR 1530-30 ............................................................................................................................................ 21

VR 1530-KD20 ....................................................................................................................................... 22

Spare Parts List

Circuit diagram

Fronius Worldwide

2

The VR 1530‘s good wirefeed properties and compact design give it a very wide and
varied area of utilisation. The VR 1530 was designed specifically for use in automated
and robot applications where steel, aluminium, CrNi and CuSi wires are welded. The
VR 1530 is particularly suitable for applications requiring high-precision wirefeed.

VR 1530 -11 / -12 / -22 / -30:

A matching version of the VR 1530 is available for each version of the main wirefeeder
VR 1500:

- VR 1500-11: VR 1530-11 (11 m/min) (433.07 ipm.)

- VR 1500-12: VR 1530-12 (12 m/min) (472.44 ipm.)

- VR 1500-22: VR 1530-22 (22 m/min) (866.14 ipm.)

- VR 1530-30: VR 1530-30 (30 m/min) (1181.10 ipm.)

VR 1530-KD:

The VR 1530-KD is available in conjunction with the KD 7000 cold-wire feeder.

CAUTION! There is a risk of injury while the lid is open for maintenance or retooling
work to be carried out. Ensure that there is no risk of anybody accidentally starting
up the VR 1530‘s drive components by pressing the feeder inching button(s) on the
control panel, on the VR 1530 itself or on any other system add-ons.

WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Before you start using the VR 1530, you MUST have read and
completely understood the following documents:

- the VR 1530 “Operating Instructions” manual

- the “Operating Instructions” manual for the power source, particularly the
“Safety rules”

With its process-oriented control of the wirefeed system, the VR 1530 unreeling-type
wirefeeder takes the intelligent power-source concept a step further. To facilitate access
to the wirespool for re-loading, this is often located a long distance away from the
welding location. The VR 1530 has been specially designed to meet the requirements
presented by just this situation. In order to achieve extremely constant wirefeed, even
with very long hosepacks, the VR 1530 is used as an additional drive unit between the
unreeling device (bulk wire container) and whichever version of the VR 1500 wirefeeder
you happen to be using. In cases where there are long wirefeed travel distances and/or
where large wirespools are being used, the VR 1530 ensures highly accurate wirefeed
and very exact reproducibility of the welding results.

General remarks

Safety

Machine concept

Areas of utilisati­on

Overview

The VR 1530 -11 / -12 / -22 / -30 unreeling-type wirefeeder can be used with the follo­wing power sources:

Digital power sources:

- Trans (Puls) Synergic 4000

- Trans (Puls) Synergic 5000

- Trans (Puls) Synergic 7200 (with two Trans(Puls) Synergics operated in
parallel)

- Trans (Puls) Synergic 9000 (with two Trans(Puls) Synergics operated in
parallel)

- “TimeTWIN digital” process

The VR 1530-KD has been specifically designed for operation in conjunction with the
KD 7000 unreeling device.

3

EN

System require­ments

The applicational example given below shows an industrial robot being used with a
mounted VR 1500 robot wirefeeder combined with a VR 1530-22 unreeling-type wire­feeder.

Applicational
example: VR 1530­22 used as an
unreeling-type
wirefeeder

Fig.1 VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder

(1) TPS 5000 power source, with:

- Software update from the Fronius

databank

- Enhanced motor supply: 55 V / 8 A

(2) Base stand
(3) FK 4000 R cooling unit
(4) Robot interface (e.g. DeviceNet)
(5) Field bus
(6) Robot control
(7) Bulk wire container
(8) Wirefeed hose (to the VR 1530)
(9) VR 1530 -11 / -12 / -22 / -30

System requirements for integrating a VR 1530:
a) Power source with:

- Firmware UST 3.10.22 or higher

- Conversion kit for enhanced motor supply, 55V/8A

b) 1 wirefeed hose (from the unreeling device or bulk wire container to the VR 1530)
c) 1 wirefeed hose (from the VR 1530 to the VR 1500)
d) Suitable model of VR 1500 wirefeeder (main wirefeeder with torch central connec-

tor)

- Firmware SR41 1.70.16 or higher

- Conversion kit for PMR4000 PullMig controller

- Installation kit for VR 1500 ”Abspul-VR” unreeling device

e) Control cable, 6m, for unreeling-type wirefeeders

(10) Wirefeed hose (from the VR 1530 to

the VR 1500)

(11) Unreeling-type wirefeeder control

cable
(12) Standard interconnecting cable
(13) RCU 5000i remote-control panel
(14) VR 1500 robot wirefeeder

- Unreeling-type wirefeeder installa­tion kit

- Conversion kit for PMR4000
PullMig controller

(15) Adapter plate for VR 1500
(16) Robacta torch hosepack
(17) Robacta 280, 300, 500, 700 welding

torch

(14) (16) (17)(15)(10)(9) (12)(11)

(7) (6) (4)

(13)

(2) (1)(3)

(8)

(5)

4

The applicational example given below shows an industrial robot being used with a
mounted VR 1500 robot wirefeeder combined with a VR 1530-11/-12/-30 unreeling-type
wirefeeder.

Applicational
example: VR
1530-11/-12/-30
used as an
unreeling-type
wirefeeder

Fig.2 VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder

(1) TPS 5000 power source, with:

- Software update from the Fronius
databank

- Enhanced motor supply: 55 V / 8 A

(2) Base stand
(3) FK 4000 R cooling unit
(4) Robot interface (e.g. DeviceNet)
(5) Field bus
(6) Robot control
(7) Bulk wire container
(8) Wirefeed hose (to the VR 1530)
(9) VR 1530 -11 / -12 / -22 / -30

(10) Wirefeed hose (from the VR 1530 to

the VR 1500)

(11) Unreeling-type wirefeeder control

cable
(12) Standard interconnecting cable
(13) RCU 5000i remote-control panel
(14) VR 1500 robot wirefeeder

- Unreeling-type wirefeeder installa­tion kit

- Conversion kit for PMR4000
PullMig controller

(15) Adapter plate for VR 1500
(16) Robacta torch hosepack
(17) Robacta 280, 300, 500, 700 welding

torch

(14) (16) (17)(15)(10)(9) (12)(11)

(7) (6) (4)

(13)

(2) (1)(3)

(8)

(5)

5

EN

Warning notices
affixed to the
machine

The wire feeder comes with extra warning labels affixed to the unit. The warning labels
must NOT be removed or painted over. The symbols warn against incorrect operation.
Incorrect operation can cause serious personal injury and damage to property.

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

- these Operation instructions

- all „Operating instructions“ for the system components, especially the
„Safety rules“

Welding is dangerous. The following basic requirements must be fulfilled:

- Suitable qualification for welding

- Suitable protective clothing

- Keep other people well away

Fig.3 Warning notices affixed to the wire feeder

6

Controls and connection points

General remarks

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 the whole of the “Operating Instructions” manuals for
both the wirefeeders and the power source.

VR 1530 -11 / -12 /

-22 / - 30

No. Function

(1) Blanking cap / “Wire-end check” option

(2) Blanking cap

(3) Blanking cap

(4) Wirefeed-hose receptacle

for holding the wirefeed hose from the bulk wire container or bulk pay-off

pack

(5) Wirefeed-hose receptacle

for holding the wirefeed hose that leads to the main wirefeeder (with torch central
connector)

(6) Feeder inching button

for feeding the welding wire into the hosepack with no accompanying flow of gas or
current. Welding-wire is “inched” into the hosepack for as long as you press and
hold the feeder-inching button.

(7) VR 1500 connection jack

17-pole connection jack for controlling and powering the VR 1530 as shown in
circuit diagram

(8) Blanking cap

(9) Wire-retract button

for reverse-feeding the welding wire out of the hosepack with no accompanying
flow of gas or current. The wire is retracted out of the hosepack for as long as you
press and hold the wire-retract button.

(10) Blanking cap / Optional VR 1530 PD interface

The optional VR 1530 PD interface provides four customer-specific lines via the VR
1500 (e.g. for connecting up a wirespeed sensor).

Fig.4 View of wire inlet section

(4)

(3)

(2)

(1)

Fig.5 View of wire outlet section

(5)

(7)

(8)

(10)

(6)

(9)

7

EN

VR 1530-KD20

Fig.6 View of wire inlet section

No. Function

(1) Blanking cap

(2) Blanking cap

(3) Blanking cap

(4) Blanking cap

(5) KD 7000 connection jack

(CPC 37-pole)

(6) Blanking cap

(7) Wire infeed tube

(8) Blanking cap

(9) Blanking cap

(10) Connection point for wire infeed hosepack

(11) Connection point for wire infeed hosepack

(12) Wire-retract / feeder-inching button

Press the button up ... for reverse-feeding the welding wire out of the hosepack
with no accompanying flow of gas or current. The wire is retracted back into
the hosepack for as long as you press the button UP.

Press the button down ... for feeding the welding wire into the hosepack with no
accompanying flow of gas or current. Welding-wire is “inched” into the hosepack for
as long as you press the button DOWN.

(13) Blanking cap

(14) Blanking cap

(15) Blanking cap

(1)

(3)

(2)

(4)

(5)

(7)

(9)

(10)

(8)

Fig.7 View of wire outlet section

(6)

(11)

(12)

(13)

(14)

(15)

8

To facilitate exact positioning of the welding wire, the following sequence is possible
when the welder presses and holds the feeder inching button:

Important! The sequence described here does not apply to the wire-retract button.

Wire-inching
sequence when
the welder pres­ses and holds
the feeder in­ching button

Fig.8 Time-path of the wirespeed when the feeder

inching button is pressed and held down

Wire diameter (m/min)

t (s)

123452.5

1

Fdi
(e.g. 22)

Press and hold the
feeder inching button

- Hold down the button for up to one
second ... Irrespective of what value
has been set, the inching speed
remains at 1 m/min for the first 1
second.

- Hold down the button for up to 2.5
seconds ... After the end of a 1­second period, the inching speed
increases at a uniform rate over the
next 1.5 seconds.

- Hold down the button for longer than

2.5 seconds ... After a total of 2.5
seconds, the wire starts to be inched
at a constant rate equal to the speed
set for the parameter “Fdi”.

CAUTION! There is a risk of injury while the lid is open for maintenance or
retooling work to be carried out. Ensure that there is no risk of anybody acci­dentally starting up the VR 1530‘s drive components by pressing the feeder
inching button(s) on the control panel, on the VR 1530 itself or on any other
system add-ons.

9

EN

Putting the unit into service

Utilisation for
intended purpose
only

The VR 1530 wirefeeder may ONLY be used in MIG/MAG welding, as part of a suitably
configured installation.
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

- following all the instructions given in this manual

- performing all stipulated inspection and servicing work

Machine set-up
regulations

There are two possible positions in which the VR 1530 wirefeeder can be mounted to
an insulated surface (see “Ready-drilled holes”):

- Position 1: on the baseplate of the VR 1530

- Position 2: on the side of the VR 1530

NOTE! Degree of protection IP 21 is only assured where the VR 1530 is
mounted in the horizontal. However, it is acceptable to mount the VR 1530 in
the vertical in enclosed spaces.

WARNING! Operating the equipment incorrectly can cause serious injury and
damage, as can any work that is not carried out correctly.

- Before putting the unit into service for the first time, read the “Safety rules”

WARNING! An electric shock can be fatal. If you are not using the optional
“Adapter plate for VR 1500”, the wirefeeder must be mounted in such a way
that it is insulated from earth.

Fig.10 Vertical positionFig.9 Horizontal position

10

Ready-drilled
holes

21 mm (.83 in.)160 mm (6.3 in.)

50 mm

1.97 in.

M8
(.32 in.)

Fig.11 Hole-pattern on the baseplate of the VR 1530

50 mm

(1.97 in.)

20.5 mm (.81 in.)

21.5 mm
(.85 in.)

280 mm
(11.03 in.)

21.5 mm
(.85 in.)

M8
(.32 in.)

M8
(.32 in.)

21.5 mm (.85 in.)

M8
(.32 in.)

80.5 mm (3.17 in.)

130 mm
(5.12 in.)

31.5 mm
(1.24 in.)

Fig.12 Hole-pattern on the side of the VR 1530

M8 (.32 in.)

76 mm

2.99 in.

M8

(.32 in.)

M8
(.32 in.)

M8
(.32 in.)

M8
(.32 in.)

M8
(.32 in.)M8(.32 in.)

M8
(.32 in.)

280 mm (11.03 in.)

21 mm (.83 in.)

When deciding where best to mount the
VR 1530, allow the space as shown below
for tilting up the lid of the wirefeeder:

Space for tilting
up the lid of the
wirefeeder

90 °

90 °

213 mm
(8.39 in.)

Fig.13 Space for tilting up the lid of the wirefeeder

11

EN

Fig.14 Inserting and fixing the wirefeed hoses

The following description applies to both wirefeed hoses:

- (1): from the unreeling device or bulk wire container to the VR 1530

- (3): from the VR 1530 to the VR 1500

1. Loosen the knurled thumb-screw (2)

2. Put the knurled thumb-screw (2) in the middle position

Important! The other positions - (A) and (B) - are for custom wirefeed hoses with
specially dimensioned wire-guidance nozzles.

3. Screw in the knurled thumb-screw (2) a short way

4. Position wirefeed hose (1) or (3) in such a way that the knurled thumb-screw (13)
unmistakeably slots into the notch on the brass fitting on the wirefeed hose

5. Fasten the wirefeed hose with the knurled thumb-screw (2)

Mounting the
wirefeed hoses

Mounting the wirefeed hoses

Safety

Warning! Work that is not carried out correctly can cause serious injury and

damage.

- Before putting the unit into service for the first time, read the “Safety rules”

Caution! There is a risk of injury while the lid is open for maintenance or
retooling work to be carried out. Ensure that there is no risk of anybody acci­dentally starting up the VR 1530’s drive components by pressing the feeder
inching button(s) on the control panel, on the VR 1530 itself or on any other
system add-ons.

(3)(2)(1)

(1) / (3)

(2)(A) (B)(2)

12

Inserting / chan­ging the feed
rollers

1

4

4

5

2

1

6

6

3

1

2

3

1

2

2

4

5

3

2

1

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

In the USA, all wirefeeders are delivered without feed rollers. The feed rollers must be
inserted into the wirefeed unit before it is started up for the first time.

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.

Inserting / changing the feed rollers

General remarks

USA wirefeeders

13

EN

1. Fit the wirefeeding hose from the unreeling device or from the welding wire drum to
the VR 1530

2. Fit the wirefeeding hose from the VR 1530 to the VR 1500

Safety

Preparations

Warning! Work that is not carried out correctly can cause serious injury and

damage.

- Before putting the unit into service for the first time, read the “Safety rules”

Caution! There is a risk of injury while the lid is open for maintenance or
retooling work to be carried out. Ensure that there is no risk of anybody acci­dentally starting up the VR 1530‘s drive components by pressing the feeder
inching button(s) on the control panel, on the VR 1530 itself or on any other
system add-ons.

WARNING! Risk of serious injury and material damage or an inferior weld as
the result of earth contact or short-circuit of an uninsulated welding wire. In the
case of automated applications, ensure that only insulated welding wire is
routed from the welding wire drum, large wirefeeder spool or wirespool to the
wirefeeder (e.g. by using a wirefeeding hose).

An earth contact or short circuit can be caused by:

- an uninsulated, exposed length of welding wire coming into contact with an electri­cally conductive object during welding

- missing insulation between the welding wire and the earthed enclosure of a robot
cell

- chafed wirefeeding hoses, exposing the welding wire

Using wirefeeding hoses ensures that the welding wire remains insulated as it is trans­ported towards the wirefeeder. To prevent chafing, do not route the wirefeeding hose
over sharp edges. Use hose holders or hose protectors as necessary.
Coupling pieces and hoods for welding wire drums also ensure safe transport of the
welding wire.

Feeding in the welding wire

Insulated routing
of welding wire
to wirefeeder

Caution! Risk of injury from the spring effect of the coiled welding wire. When

threading in the wire, hold the end of the wire firmly, to prevent any injuries that
might be caused by the wire flicking back and recoiling uncontrollably.

Feeding in the
welding wire

14

1

4

4

1

2

2

1

2

3

2

2

3

3

1

VR 1500
+
VR 1530

Feeding in the
welding wire

(continued)

- Push the filler wire from the unreeling
device or from the welding wire drum
through the wirefeeding hose up to
the feed rollers of the VR 1530
unreeling wire-feed unit

CAUTION! Risk of damage to
wirefeeding hose and welding
torch from sharp end of filler
wire. Thoroughly deburr the end
of the filler wire before feeding in.

- Open the clamping devices and
pressure levers on the VR 1500 and
the VR 1530

- Close the clamping devices and pres
sure levers on the VR 1530

- Press the wire feed button on the VR
1530

Feed the filler wire in the wire feed
hose between VR 1530 and VR 1500

Caution! Risk of injury from filler
wire emerging. Filler wire can
protrude out of the wire feed
hose as result of a wire jam,
especially with thin or soft filler
wire. Keep your face and body
away from the VR 1500 4-roller

- Press the feeder inching button on the VR 1500 until the filler wire reaches the VR­1500 feed rollers.

- Feed the filler wire into the torch hosepack in accordance with the VR 1500 opera­ting instructions

15

EN

NOTE! Adjust the contact pressure in such a way that the welding wire is not
deformed, but is nevertheless transported properly.

Setting contact
pressure

1

1

1

VR 1500
+
VR 1530

Contact pressure HR TR KS
Guideline values

Aluminium 1,5 - 3,5 - 4,5

Steel 3 - 4 1,5 -

CrNi 3 - 4 1,5 -

Feed rollers:

HR = Half-round
TR = Trapeze
KS = Plastic

16

Calibrating push-pull unit

General remarks

Calibrating the
push-pull unit

CAUTION! Risk of injury from rotating parts. During calibration of the push-pull

unit, do not touch the inside of the VR 1530 under any circumstances, and
ensure that body parts, hair and items of clothing are kept well away. Once
calibration of the push-pull unit is complete, close the cover of the VR 1530.

- Calibrate the push-pull unit in accordance with the power source operating instruc­tions.

- Push-pull unit numbers:
VR 1530-11: PPU | 17
VR 1530-12: PPU | 20
VR 1530-22: PPU | 0
VR 1530-30: PPU | 1

Service codes
displayed during
calibration of the
push-pull unit

as described in the power source operating instructions

Important! Calibration of the push-pull unit is not necessary for the VR 1530-KD unree­ling wire-feed unit.

The VR 1530 must be calibrated prior to each initial start-up and after each wire-feed
unit software update. If the VR 1530 is not calibrated, the standard parameters will be
used - which may result in the welding result being unsatisfactory.

17

EN

The following section gives you an overview of the possible causes of errors in
connection with the VR 1530, and of steps you can take to remedy the problem. For
detailed information on the causes of, and remedies for, errors in connection with
wirefeeding in general, please refer to the operating instructions of your power source.

Troubleshooting

General remarks

No number (“PPU”) is available for selecting the unit for push-pull alignment

Cause: The “PMR4000 PullMig installation kit” has not been installed
Remedy: Install the installation kit

The number of the VR 1530 (e.g. ”PPU | 17”) cannot be selected for push-pull
alignment

Cause: The “FS Drive” software has not been installed on the power source
Remedy: Equip the power source with the ”FS Drive” software

The feed rollers of the VR 1530 do not rotate

Cause The control plug of the VR 1530 is not plugged in

Remedy: Connect up the control plug of the VR 1530 to the torch-control

connection point on the wirefeeder or on the TPS 2700 power source

Cause The connecting cable on the VR 1530 is defective
Remedy: Check the connecting cable and have it changed if necessary

Irregular Wire diameter

Cause: The wirefeed rollers are unsuitable for the wire being used
Remedy: Use suitable feed rollers

Cause: The feed rollers of the VR 1530 are not applying sufficient pressure to the

wire

Remedy: Optimise the contact pressure of the feed rollers

Welding wire is deformed or snaps

Cause: The contact pressure on the 4-roller drive is set too high
Remedy: Set the correct contact pressure on the 4-roller drive

Cause: VR 1530 is turning too fast or too slowly
Remedy: For push-pull alignment, select the right number (e.g. ”PPU | 17”) for the

VR 1530 (see the section headed ”Configuration table”)

EFd | 8.1

Cause: Wirefeeder motor is stuck or defective
Remedy: Check / change the wirefeeder motor

EFd | 8.2

Cause: Fault in the wirefeed system (overcurrent in drive of push-pull unit)
Remedy: Arrange the torch hosepack in as straight a line as possible; check the

inner liner for kinks or soiling; check the contact pressure on the VR 1530

VR 1530 error
diagnostics

18

EFd | 9.1

Cause: External supply voltage: The supply voltage has dropped below the

tolerance range

Remedy: Check the external supply voltage

EFd | 9.2

Cause: External supply voltage: The supply voltage has risen above the tolerance

range

Remedy: Check the external supply voltage

EFd | 12.1

Cause: No actual rotational speed value from the wirefeeder motor
Remedy: Check the actual-value pick-up and the cable connections to & from it,

and replace if necessary

EFd | 12.2

Cause: No actual rotational speed value from the push-pull unit
Remedy: Check the actual-value pick-up and the cable connections to & from it,

and replace if necessary

VR 1530 error
diagnostics

(continued)

19

EN

Care, maintenance and disposal

Under normal operating conditions, the VR 1530 needs only a minimum of care and
maintenance. However, to ensure continued trouble-free operation of your unreeling­type wirefeeder for years to come, there are a few basic points that you should observe.

Inspect the VR 1530, interconnecting cable and earth connection for any signs of
damage.

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

General remarks

Every time before
starting up

Final disposal

20

VR 1530-12

Supply voltage (from the power source) 55 V DC

Rated current 6 A

Wire diameter 0,8 - 3,2 mm (.03 - .13 in.)

Wirefeed speed 0.5 - 12 m/min (19.69 - 472.44 ipm.)

Torque 21.6 Nm

Degree of protection IP 21

Dimensions L x W x H 345 / 205 / 220 mm (13.59 / 8.08 / 8.67 in.)

Weight - without optional extras 8 kg (17.6 lb.)

Drive 4-roller drive, water-cooled electric motor with shrunk-on-disc rotor

Option Extra fan for the power electronics

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

Technical data

VR 1530-11

Supply voltage (from the power source) 55 V DC

Rated current 4 A

Wire diameter 0,8 - 3,2 mm (.03 - .13 in.)

Wire diameter 0.5 - 11 m/min (19.69 - 433.07 ipm.)

Torque 11 Nm

Degree of protection IP 21

Dimensions L x W x H 345 / 205 / 220 mm (13.59 / 8.08 / 8.67 in.)

Weight - without optional extras 8 kg (17.6 lb.)

Drive 4-roller drive, water-cooled electric motor with shrunk-on-disc rotor

Option Extra fan for the power electronics

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

21

EN

VR 1530-22

Supply voltage (from the power source) 55 V DC

Rated current 4 A

Wire diameter 0,8 - 1,6 mm (.03 - .06 in.)

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

Torque 4 Nm

Degree of protection IP 21

Dimensions L x W x H 345 / 160 / 220 mm (13.59 / 6.3 / 8.67 in.)

Weight - without optional extras 5 kg (11 lb.)

Drive 4-roller drive

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

VR 1530-30

Supply voltage (from the power source) 55 V DC

Rated current 6 A

Wire diameter 0,8 - 1,6 mm (.03 - .06 in.)

Wirefeed speed 0.5 - 30 m/min (19.69 - 1181.10 ipm.)

Torque 3.7 Nm

Degree of protection IP 21

Dimensions L x W x H 345 / 205 / 220 mm (13.59 / 8.08 / 8.67 in.)

Weight - without optional extras 6 kg (13.2 lb.)

Type of drive 4-roller drive, water-cooled electric motor with shrunk-on-disc rotor

Option Extra fan for the power electronics

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

22

VR 1530-KD20

Supply voltage (from the KD 7000) 55 V DC

Rated current 4 A

Wire diameter 0,8 - 1,6 mm (.03 - .06 in.)

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

Torque 4 Nm

Degree of protection IP 21

Dimensions L x W x H 345 / 160 / 220 mm (13.59 / 6.3 / 8.67 in.)

Weight - without optional extras 5 kg (11 lb.)

Type of drive 4-roller drive

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

ud_fr_st_tb_00149 012012

DEENFRITESPT-BRNLNOCSRUSKSVTR

PL

Liste de pièces de rechange
Schéma de connexions

Ersatzteilliste
Schaltplan

Spare Parts List
Circuit Diagram

Lista parti di ricambio
Schema

Lista de repuestos
Esquema de cableado

Lista de peças sobresselentes
Esquema de conexões

Onderdelenlijst
Bedradingsschema

Reservdelsliste
Koblingsplan

Seznam náhradních dílù
Schéma zapojení

Список запасных частей
Электрическая схема

Zoznam náhradných dielov
Schéma zapojenia

Reservdelslistan
Kopplingsschema

Parça Listesi
Baðlantý þemasý

Czyszczenie palnika
Schemat po³¹czeñ

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

VR 1530

1/2

el_fr_st_dv_00691 012007

BE2,0200,9699

BE2,0200,9691

4,100,257,U

42,0407,0501

42,0407,0500

42,0405,0269

BE2,0200,9906

43,0002,0079

43,0003,0256

43,0003,0584

VR 1530-22 4R 4,045,921
VR 1530-KD 4R Z 4,045,867

BE2,0201,1567

42,0400,0183

BE2,0200,9693 - KD
42,0409,3015

BE2,0200,9905 - KD
BE2,0201,1568

44,0001,1255 - Z,10m/min,KD
44,0001,1260 - 22m/min

43,0002,0217

42,0406,0224

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

VR 1530

2/2

el_fr_st_dv_00691 012007

42,0405,0189

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

44,0001,1145

44,0001,1269 - 30m/min
44,0001,1271 - 12m/min
44,0001,1312 - 11m/min

BE2,0200,9906

40,0001,0012 - *

42,0409,3030

VR 1530-11 4R 4,045,919
VR 1530-12 4R 4,045,920
VR 1530-30 4R 4,045,922

BE2,0201,1374

BE2,0201,1376

42,0407,0063

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

Motorplate 42V 4R

1/4

el_fr_st_mp_01220 012012

42,0200,7767

42,0405,0116

42,0407,0098

BF2,0404,0340 - yellow

42,0409,2106

32,0405,0113

42,0405,0117 - PE
42,0200,9352 - CuZn

42,0100,0333 - PE
42,0001,3481 - Fe

32,0405,0112

44,0001,1203

42,0407,0077

22,0405,0114

42,0405,0119

BF2,0201,1345

42,0406,0034

42,0407,0503

Connector

Motor

42,0400,0123

42,0404,0264

42,0405,0120

42,0300,2162

Motorplate 42V 4R

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

Motorplate 42V 4R

2/4

el_fr_st_mp_01220 012012

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

Motorplate 42V 4R

3/4

el_fr_st_mp_01220 012012

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

Motorplate 42V 4R

4/4

el_fr_st_mp_01220 012012

VR 1530

VR 1530-KD

ud_fr_st_so_00082 012011

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.