Fronius VR 1530-11, VR 1530-12, VR 1530-22, VR 1530-30, VR 1530-KD Operating Instruction [EN]

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

Operating Instructions

EN

Wire-feed unit

[

42,0426,0010,EN 001-07022020

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Dear reader,

Introduction Thank you for the trust you have placed in our company and congratulations on buying this

high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.

Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

EN

Explanation of
safety notices

DANGER!

Indicates immediate danger.

► If not avoided, death or serious injury will result.

WARNING!

Indicates a potentially hazardous situation.

► If not avoided, death or serious injury may result.

CAUTION!

Indicates a situation where damage or injury could occur.

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

NOTE!

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

3

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Contents

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

General ................................................................................................................................................. 7

Proper use ............................................................................................................................................ 7

Environmental conditions...................................................................................................................... 7

Obligations of the operator.................................................................................................................... 8

Obligations of personnel ....................................................................................................................... 8

Mains connection .................................................................................................................................. 8

Protecting yourself and others .............................................................................................................. 8

Danger from toxic gases and vapours .................................................................................................. 9

Danger from flying sparks ..................................................................................................................... 10

Risks from mains current and welding current...................................................................................... 10

Meandering welding currents................................................................................................................ 11

EMC Device Classifications .................................................................................................................. 11

EMC measures ..................................................................................................................................... 11

EMF measures...................................................................................................................................... 12

Specific hazards.................................................................................................................................... 12

Requirement for the shielding gas ........................................................................................................ 13

Danger from shielding gas cylinders..................................................................................................... 13

Danger from escaping shielding gas..................................................................................................... 14

Safety measures at the installation location and during transport ........................................................ 14

Safety measures in normal operation ................................................................................................... 15

Commissioning, maintenance and repair.............................................................................................. 15

Safety inspection................................................................................................................................... 16

Disposal ................................................................................................................................................ 16

Safety symbols...................................................................................................................................... 16

Data protection...................................................................................................................................... 16

Copyright............................................................................................................................................... 16

General ...................................................................................................................................................... 17

Safety.................................................................................................................................................... 17

Machine concept................................................................................................................................... 17

Overview ............................................................................................................................................... 17

Areas of utilisation................................................................................................................................. 17

System requirements ............................................................................................................................ 18

Applicational example: VR 1530-22 used as an unreeling-type wirefeeder.......................................... 18

Applicational example: VR 1530-11/-12/-30 used as an unreeling-type wirefeeder ............................. 19

Warning notices affixed to the machine................................................................................................ 20

Control elements and connections............................................................................................................. 21

Safety.................................................................................................................................................... 21

VR 1530 -11 / -12 / -22 / - 30 ................................................................................................................ 21

VR 1530-KD.......................................................................................................................................... 22

Wire-inching sequence when the welder presses and holds the feeder inching button ....................... 23

Start-up ...................................................................................................................................................... 24

Safety.................................................................................................................................................... 24

Utilisation for intended purpose only..................................................................................................... 24

Machine set-up regulations................................................................................................................... 24

Ready-drilled holes ............................................................................................................................... 25

Space for tilting up the lid of the wirefeeder.......................................................................................... 26

Mounting the wirefeed hoses ..................................................................................................................... 27

Safety.................................................................................................................................................... 27

Mounting the wirefeed hoses ................................................................................................................ 27

Inserting/replacing feed rollers................................................................................................................... 28

General remarks ................................................................................................................................... 28

USA wirefeeders ................................................................................................................................... 28

inserting/replacing feed rollers .............................................................................................................. 28

Feeding in the wire electrode..................................................................................................................... 29

Insulated routing of wire electrode to wire-feed unit ............................................................................. 29

Safety.................................................................................................................................................... 29

Preparations.......................................................................................................................................... 29

Feeding in the welding wire .................................................................................................................. 29

Set the contact pressure ....................................................................................................................... 31

EN

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Calibrating push-pull unit ........................................................................................................................... 32

General remarks ................................................................................................................................... 32

Calibrating the push-pull unit ............................................................................................................... 32

Service codes displayed during calibration of the push-pull unit .......................................................... 32

Care, maintenance and disposal ............................................................................................................... 33

General remarks ................................................................................................................................... 33

Every start-up........................................................................................................................................ 33

Every 6 months ..................................................................................................................................... 33

Disposal ................................................................................................................................................ 33

Troubleshooting ......................................................................................................................................... 34

Safety.................................................................................................................................................... 34

General remarks ................................................................................................................................... 34

VR 1530 error diagnostics .................................................................................................................... 34

Technical data............................................................................................................................................ 36

VR 1530-11........................................................................................................................................... 36

VR 1530-12........................................................................................................................................... 36

VR 1530-22........................................................................................................................................... 37

VR 1530-30........................................................................................................................................... 37

VR 1530-KD.......................................................................................................................................... 37

6

Safety rules

General The device is manufactured using state-of-the-art technology and according to recognised

safety standards. If used incorrectly or misused, however, it can cause:

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

- damage to the device and other material assets belonging to the operating company,

- inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device
must:

- be suitably qualified,

- have sufficient knowledge of welding and

- read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applica­ble and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

- must be in a legible state,

- must not be damaged,

- must not be removed,

- must not be covered, pasted or painted over.

EN

For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.

Proper use includes:

- carefully reading and following all the instructions given in the operating instructions

- studying and obeying all safety and danger notices carefully

- performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

- Thawing out pipes

- Charging batteries

- Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.

Environmental
conditions

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

Operation or storage of the device outside the stipulated area will be deemed as not in ac­cordance with the intended purpose. The manufacturer shall not be held liable for any dam­age arising from such usage.

7

Ambient temperature range:

- during operation: -10 °C to + 40 °C (14 °F to 104 °F)

- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)

Relative humidity:

- up to 50% at 40 °C (104 °F)

- up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of the
operator

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

- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device

- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures

- are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.

Obligations of
personnel

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

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

- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.

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

consumption.

Protecting your­self and others

This may affect a number device types in terms of:

- Connection restrictions

- Criteria with regard to the maximum permissible mains impedance

- Criteria with regard to the minimum short-circuit power requirement

*)

at the interface with the public grid

*)

*)

see "Technical data"

In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power sup­ply company.

IMPORTANT! Ensure that the mains connection is earthed properly

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

- flying sparks and hot pieces of metal

- Arc radiation, which can damage eyes and skin

- Hazardous electromagnetic fields, which can endanger the lives of those using cardi­ac pacemakers

- Risk of electrocution from mains current and welding current

- Greater noise pollution

- Harmful welding fumes and gases

8

Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:

- Flame-resistant

- Insulating and dry

- Covers the whole body, is undamaged and in good condition

- Safety helmet

- Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

- Protect eyes and face from UV rays, heat and sparks using a protective visor and reg­ulation filter

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

- Wear stout footwear that provides insulation even in wet conditions

- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)

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

Keep all persons, especially children, out of the working area while any devices are in op­eration or welding is in progress. If, however, there are people in the vicinity:

- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)

- Provide suitable protective equipment

- Alternatively, erect suitable safety screens/curtains.

EN

Danger from toxic
gases and va­pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

- must not be breathed in

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

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:

- Metals used for the workpiece

- Electrodes

- Coatings

- Cleaners, degreasers, etc.

- Welding process used

The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).

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

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

Danger from fly­ing sparks

Risks from mains
current and weld­ing current

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-

ternatively covered with an approved cover.

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

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.

Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.

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

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

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.

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

Make sure that you and others are protected with an adequately insulated, dry temporary
backing or cover for the earth or ground potential. This temporary backing or cover must
extend over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimen­sioned. Replace loose connections and scorched, damaged or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pre-load.

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

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

- never be immersed in liquid for cooling

- Never touch the electrode when the power source is switched on.

Double the open circuit voltage of a power source can occur between the welding elec­trodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.

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

10

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

Operating the device on a grid without a ground conductor and in a socket without a ground
conductor contact will be deemed gross negligence. The manufacturer shall not be held
liable for any damage arising from such usage.

If necessary, provide an adequate earth connection for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-

one from plugging the mains plug back in and switching it on again.

After opening the device:

- Discharge all live components

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

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

EN

Meandering weld­ing currents

EMC Device Clas­sifications

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

- Fire hazard

- Overheating of parts connected to the workpiece

- Irreparable damage to ground conductors

- Damage to device and other electrical equipment

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

Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient insulating ma-

terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-

trode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.

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

Devices in emission class A:

- Are only designed for use in industrial settings

- Can cause line-bound and radiated interference in other areas

Devices in emission class B:

- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.

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

EMC measures In certain cases, even though a device complies with the standard limit values for emis-

sions, 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

11

either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situ­ation.

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

- Safety devices

- Power, signal and data transfer lines

- IT and telecommunications devices

- Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

1. Mains supply

- If electromagnetic interference arises despite correct mains connection, addition-

al measures are necessary (e.g. use a suitable line filter).

2. Welding power leads

- must be kept as short as possible

- must run close together (to avoid EMF problems)

- must be kept well apart from other leads

3. Equipotential bonding

4. Earthing of the workpiece

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

5. Shielding, if necessary

- Shield off other nearby devices

- Shield off entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

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

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

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

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

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

- Fans

- Cogs

- Rollers

- Shafts

- Wirespools and welding wires

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

Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.

During operation

- Ensure that all covers are closed and all side panels are fitted properly.

- Keep all covers and side panels closed.

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The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).

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

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.

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

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

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

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

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

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

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

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

EN

Requirement for
the shielding gas

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

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

All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or chang­es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.

Especially with ring lines, contaminated shielding gas can cause damage to equipment and
reduce welding quality.
Meet the following requirements regarding shielding gas quality:

- Solid particle size < 40 µm

- Pressure condensation point < -20 °C

- Max. oil content < 25 mg/m³

Danger from
shielding gas cyl­inders

Use filters if necessary.

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

13

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

Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct
and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylin­ders and accessories that are in good condition.

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

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

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and inter-

national regulations for shielding gas cylinders and accessories.

Danger from es­caping shielding
gas

Safety measures
at the installation
location and dur­ing transport

Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox-

ygen in the ambient air.

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

- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.

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

- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage be­fore every start-up.

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

- The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.

14

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.

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

Do not lift or transport operational devices. Switch off devices before transport or lifting.

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

- Wirefeeder

- Wirespool

- Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before com­missioning the device.

EN

Safety measures
in normal opera­tion

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

- injury or death to the operator or a third party

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

- inefficient operation of the device

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

Never bypass or disable safety devices.

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

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

Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its prop­erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).

Only use suitable original coolant from the manufacturer.

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

Only connect the manufacturer's system components to the cooling circuit.

Commissioning,
maintenance and
repair

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

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer­tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.

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

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

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

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

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

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

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

15

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

Safety inspection 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 12­month period.

A safety inspection should be carried out by a qualified electrician

- after any changes are made

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

- after repair, care and maintenance has been carried out

- at least every twelve months.

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

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

Disposal Do not dispose of this device with normal domestic waste! To comply with the European

Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af­fects on the environment and your health!

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-

tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 se­ries).

Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory settings.

The manufacturer accepts no liability for any deleted personal settings.

Copyright Copyright of these operating instructions remains with the manufacturer.

The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba­sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.

16

General

EN

Safety

Danger from incorrect operation

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 rule

Risk of injury while the lid is open for maintenance or retooling work to be carried
out.

Work that is carried out incorrectly can cause serious injury or damage.
► Ensure that there is no risk of anybody accidentally starting up the VR 1530‘s drive

Machine concept With its process-oriented control of the wirefeed system, the VR 1530 unreeling-type wire-

feeder 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.

WARNING!

CAUTION!

components by pressing the feeder inching button(s) on the control panel, on the VR
1530 itself or on any other system add-ons.

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

power sources:

- Trans Synergic 4000 / 5000

- TransPuls Synergic 3200 / 4000 / 5000

- Trans Synergic 7200 / 9000 (with two Trans(Puls) Synergics operated in parallel)

- TransPuls Synergic 7200 / 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.

Areas of utilisa­tion

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.

17

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.

System require­ments

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

System requirements for integrating a VR 1530:

1. Power source with

- Firmware UST 3.10.22 or higher

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

2. 1 wirefeed hose (from the unreeling device or bulk wire container to the VR 1530)

3. 1 wirefeed hose (from the VR 1530 to the VR 1500)

4. Suitable model of VR 1500 wirefeeder (main wirefeeder with torch central connector)

- Firmware SR41 1.70.16 or higher

- Conversion kit for PMR4000 PullMig controller

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

5. Control cable, 6m, for unreeling-type wirefeeders

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.

(8)

(13)

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

18

(7) (6) (4)

VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder

(5)

(2) (1)(3)

(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

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

(7) (6) (4)

(13)

(2) (1)(3)

(8)

(5)

(6) Robot control
(7) Bulk wire container
(8) Wirefeed hose (to the VR 1530)
(9) VR 1530 -11 / -12 /-22 / -30 unreeling-type wirefeeder
(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

EN

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

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.

VR 1500 robot wirefeeder combined with VR 1530-22 unreeling-type wirefeeder

(1) TPS 5000 power source, with:

(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 unreeling-type wirefeeder
(10) Wirefeed hose (from the VR 1530 to the VR 1500)

- Software update from the Fronius databank

- Enhanced motor supply: 55 V / 8 A

19

(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

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.

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

- Suitable qualification for welding

- Suitable protective clothing

- Keep other people well away

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“

20

Control elements and connections

(4)

(3)

(2)

(1)

(5)

(7)

(8)

(10)

(6)

(9)

EN

Safety

VR 1530 -11 / -12 /

-22 / - 30

WARNING!

Danger from incorrect operation.

Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described here until you have read and completely under-

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

View of wire inlet section

(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

View of wire outlet section

21

VR 1530-KD

(1)

(3)

(2)

(4)

(5)

(7)

(6)

(9)

(10)

(8)

(11)

(12)

(13)
(14)

(15)

(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 / VR 1530 PD interface option

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

View of wire inlet section

View of wire outlet section

(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

22

(14) Blanking cap

(m/min)

t (s)

123452,5

1

Fdi

1

2

3

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

(15) Blanking cap

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.

CAUTION!

Risk of injury while the lid is open for maintenance or retooling work to be carried
out.

This may result in serious personal injury.
► 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.

Hold down the button for up to one se-

cond

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 se-

conds

After the end of a 1-second period, the
inching speed increases at a uniform
rate over the next 1.5 seconds.

Hold down the button for longer than

longer than 2 seconds

After a total of 2.5 seconds, the wire
starts to be inched at a constant rate

Time-path of the wirespeed when the feeder inching
button is pressed and held down

equal to the speed set for the parame­ter “Fdi”.

EN

23

Start-up

Safety

Utilisation for in­tended purpose
only

Machine set-up
regulations

WARNING!

Danger from incorrect operation.

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”

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

WARNING!

An electric shock can be fatal.

Incorrect operation or poorly executed work can cause serious injury or damage.
► 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.

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

- Horizontal position: on the baseplate of the VR 1530

- Vertical position: on the side of the VR 1530

IMPORTANT! 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.

Horizontal position Vertical position

24

Ready-drilled

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.)

M8
(.32 in.)

80,5 mm (3.17 in.)

M8 (.32 in.)

holes

EN

Hole-pattern on the baseplate of the VR 1530

21,5 mm (.85 in.)

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

M8
(.32 in.)

M8
(.32 in.)

M8
(.32 in.)

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

31,5 mm
(1.24 in.)

130 mm
(5.12 in.)

21 mm (.83 in.)

Hole-pattern on the side of the VR 1530

280 mm (11.03 in.)

M8
(.32 in.)

M8
(.32 in.)

M8

(.32 in.)

50 mm

1.97 in.

76 mm

2.99 in.

25

Space for tilting

90 °

90 °

213 mm
(8.39 in.)

up the lid of the
wirefeeder

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

26

Mounting the wirefeed hoses

2

3

EN

Safety

Mounting the
wirefeed hoses

WARNING!

Danger from incorrect operation.

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!

Risk of injury while the lid is open for maintenance or retooling work to be carried
out.

Work that is not carried out correctly can cause serious injury and damage.
► 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.

(1) / (3)

(3)(2)(1)

Inserting and fixing the wirefeed hoses

The following description applies to both wirefeed hoses

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

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

Loosen the knurled thumb-screw (2)

1

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.

Screw in the knurled thumb-screw (2) a short way
Position wirefeed hose (1) or (3) in such a way that the knurled thumb-screw (13) un-

4

mistakeably slots into the notch on the brass fitting on the wirefeed hose

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

5

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

27

Inserting/replacing feed rollers

4

4

5

2

1

6

6

2

1

2

3

1

2

General remarks In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the

diameter and alloy of the wire being welded.

IMPORTANT! Only use feed rollers that match the wire electrode.

An overview of the feed rollers available and their possible areas of use can be found in
the spare parts lists.

USA wirefeeders In the USA, all wirefeeders are delivered without feed rollers. After inserting the wirespool,

the feed rollers must be inserted into the wirefeeder.

inserting/replac­ing feed rollers

1 2

1

3

3

1

2

5

4

3

28

Feeding in the wire electrode

1

EN

Insulated routing
of wire electrode
to wire-feed unit

Safety

WARNING!

Risk of serious injury and property damage or an inferior weld as a result of earth
contact or short-circuit of a non-insulated wire electrode.

In the case of automated applications, ensure that only an insulated wire electrode 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 wire electrode coming into contact with an electri-

cally conductive object during welding

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

- chafed wirefeeding hoses, exposing the wire electrode

Using wirefeeding hoses ensures that the wire electrode remains insulated as it is trans­ported towards the wirefeeder. To prevent chafing, do not route the wirefeeding hoses 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 wire electrode.

WARNING!

Danger from incorrect operation.

Operating the equipment incorrectly can cause serious injury and damage.
► Before putting the unit into service for the first time, read the "Safety rules"

CAUTION!

Risk of injury while the lid is open for maintenance or retooling work to be carried
out.

Work that is carried out incorrectly can cause serious injury or damage.
► 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.

Preparations Fit the wirefeeding hose from the unreeling device or from the welding wire drum to

the VR 1530

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

2

Feeding in the
welding wire

Risk of injury from the spring effect of the coiled welding wire.

This can result in serious injury and damage to property.
► When threading in the wire, hold the end of the wire firmly, to prevent any injuries that

CAUTION!

might be caused by the wire flicking back and recoiling uncontrollably.

29

Open the clamping devices and pres-

4

4

1

2

VR 1500
+
VR 1530

1

1

2

2

sure levers on the VR 1500 and the VR
1530

CAUTION!

Risk of damage to wirefeeding hose and welding torch from sharp end of filler wire.

This can result in serious damage to property.
► Thoroughly deburr the end of the filler wire before feeding in.

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 injury from filler wire emerging.

This can result in serious damage to property. 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

30

Close the clamping devices and pres

1

2

3

4

5

6

1

1

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

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

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

EN

Set the contact
pressure

1

1

NOTE!

Set the contact pressure in such a way
that the wire electrode is not deformed
but nevertheless ensures proper wire­feeding.

Contact pressure stand­ard values

Semi-cylindrical

rolls

Trapeze rolls Plastic rollers

Aluminium 1.5 - 3.5 - 4.5
Steel 3 - 4 1.5 ­CrNi 3 - 4 1.5 -

31

Calibrating push-pull unit

General remarks IMPORTANT! Calibration of the push-pull unit is not necessary for the VR 1530-KD unreel-

ing 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.

Calibrating the
push-pull unit

Service codes
displayed during
calibration of the
push-pull unit

CAUTION!

Risk of injury from rotating parts.

This can result in serious personal injury
► 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 instruc-

1

tions.

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

as described in the power source operating instructions

32

Care, maintenance and disposal

General remarks Under normal operating conditions, the wire-feed unit requires only a minimum of care and

maintenance. However, some important points must be noted to ensure that the welding
system remains in a usable condition for many years.

WARNING!

An electric shock can be fatal.

Before opening the device:
► Move the mains switch to the O position
► Unplug the device 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

Every start-up - Check welding torch, interconnecting hosepack and grounding (earthing) connection

for signs of damage

- Check feed rollers and inner liners for signs of damage

- Check contact pressure of feed rollers and adjust if necessary

- Check that all screw connections between the robot, wirefeeder mount and wire-feed
unit are secure

EN

Every 6 months - Dismantle device side panels and clean inside of device with dry, reduced com-

pressed air

NOTE!

Risk of damage to electronic components.

Do not bring the air nozzle too close to electronic components.

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

33

Troubleshooting

Safety

An electric shock can be fatal.

Before opening the device:
► Move the mains switch to the "O" position
► Unplug the device from the mains
► Put up an easy-to-understand warning sign to stop anybody inadvertently switching it

► Using a suitable measuring device, check that electrically charged parts (e.g. capaci-

Inadequate PE conductor connections can cause serious injury and damage.

The housing screws provide a suitable PE conductor connection for earthing (grounding)
the housing and must NOT be replaced by any other screws which do not provide a reliable
PE conductor connection.

General remarks 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.

WARNING!

back on again

tors) have been discharged

CAUTION!

VR 1530 error di­agnostics

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

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

34

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: Fault in the wire feed system (overcurrent in wire-feed unit drive)

Remedy: Arrange the hosepack in as straight a line as possible; check that there are

no kinks or dirt in the inner liner; check the contact pressure on the 2-roller (or
4-roller) drive

Cause: Wire-feed unit motor is sticking or defective

Remedy: Check or replace the wire-feed unit motor

EFd | 8.2

Cause: Fault in the wire feed system (overcurrent in wire-feed unit drive)

Remedy: Arrange the hosepack in as straight a line as possible; check that there are

no kinks or dirt in the inner liner; check the contact pressure on the 2-roller (or
4-roller) drive

EN

EFd | 9.1

Cause: The external supply voltage has dropped below the tolerance range

Remedy: Check the external supply voltage

Cause: Wire-feed unit motor is sticking or defective

Remedy: Check or replace the wire-feed unit motor

EFd | 9.2

Cause: The external supply voltage has exceeded the upper limit of the tolerance

range

Remedy: Check the external supply voltage

EFd | 12.1

Cause: No actual rotational speed value from the wire-feed unit motor

Remedy: Check the actual-value pick-up and the cable connections to and from it, and

replace if necessary

EFd | 12.2

Cause: No actual value rotational speed from the push-pull unit motor

Remedy: Check the actual-value pick-up and the cable connections to and from it, and

replace if necessary

35

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

0.03 - 0.13 in.

Wirefeed speed 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 x 205 x 220 mm

13.59 x 8.08 x 8.67 in.

Weight - without optional extras 8 kg

17.6 Ibs.

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

(40,0009,0046)

Max. coolant pressure 6 bar

87 psi.

VR 1530-12

Supply voltage (from the power source) 55 V DC

Rated current 4 A

Wire diameter 0,8 - 3,2 mm

0.03 - 0.13 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 x 205 x 220 mm

13.59 x 8.08 x 8.67 in.

Weight - without optional extras 8 kg

17.6 Ibs.

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

(40,0009,0046)

Max. coolant pressure 6 bar

87 psi.

36

VR 1530-22

Supply voltage (from the power source) 55 V DC

Rated current 4 A

Wire diameter 0,8 - 1,6 mm

0.03 - 0.06 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 x 205 x 220 mm

13.59 x 8.08 x 8.67 in.

Weight - without optional extras 5 kg

11 Ibs.

Type of drive 4-roller drive

Max. shielding-gas pressure 7 bar

101 psi.

Coolant Original Fronius coolant

(40,0009,0046)

Max. coolant pressure 6 bar

87 psi.

EN

VR 1530-30

Supply voltage (from the power source) 55 V DC

Rated current 6 A

Wire diameter 0,8 - 1,6 mm

0.03 - 0.06 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 x 205 x 220 mm

13.59 x 8.08 x 8.67 in.

Weight - without optional extras 6 kg

13.2 Ibs.

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

(40,0009,0046)

Max. coolant pressure 6 bar

87 psi.

VR 1530-KD

Supply voltage (from the KD 7000) 55 V DC

Rated current 4 A

37

Wire diameter 0,8 - 1,6 mm

0.03 - 0.06 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 x 160 x 220 mm

13.59 x 6.3 x 8.67 in.

Weight - without optional extras 5 kg

11 Ibs.

Type of drive 4-roller drive

Max. shielding-gas pressure 7 bar

101 psi.

Coolant Original Fronius coolant

(40,0009,0046)

Max. coolant pressure 6 bar

87 psi.

38

EN

39

FRONIUS INTERNATIONAL GMBH

Froniusstraße 1, A-4643 Pettenbach, Austria

E-Mail: [e-mail]

www.fronius.com

Under www.fronius.com/contact you will find the addresses

of all Fronius Sales & Service Partners and locations