Fronius VR 2000 Operating Instructions Manual

/ Battery Charging Systems / Welding Technology / Solar Electronics

VR 2000

Operating Instructions
Spare Parts List

EN

Wire Feeder

42,0426,0011,EN 007-08072016

Dear Reader

Introduction

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

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

EN

ud_fr_st_et_00493 01/2012

Safety rules

DANGER!

WARNING!

CAUTION!

NOTE!

Important!

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

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

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

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

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

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

EN

General remarks

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

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

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

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

- efficient working with the equipment.

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

- be suitably qualified

- know about welding and

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

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

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

- must be kept in a legible condition

- must not be damaged, must not be removed

- must not be covered, pasted or painted over

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

I

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General remarks

(continued)

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

It’s your safety that’s at stake!

Utilisation for
intended purpose
only

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

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

Utilisation in accordance with the “intended purpose” also comprises

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

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

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

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

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

Ambient
conditions

Obligations of
owner/operator

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

Temperature range of ambient air:

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

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

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)

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

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

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

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

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

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

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

II

Obligations of
personnel

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

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

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

EN

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

Mains connec­tion

Protection for
yourself and
other persons

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

- connection restrictions

- criteria with regard to maximum permissible mains impedance

- criteria with regard to minimum short-circuit power requirement

*)

at the interface with the public mains network

*)

*)

see Technical Data

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

NOTE! Ensure that the mains connection is earthed properly.

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

- flying sparks and hot metal particles

- arc radiation which could damage your eyes and skin

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

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

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

- flame-retardant

- isolating and dry

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

- protective helmet

- trousers with no turn-ups

III

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Protection for
yourself and
other persons

(continued)

“Protective clothing” also includes:

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

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

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

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

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

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

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

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Information on
noise emission
values

Hazards from
noxious gases
and vapours

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

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

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

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

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

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

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Ensure a sufficient supply of fresh air.

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

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

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

IV

Hazards from
noxious gases
and vapours

(continued)

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

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

Hazards from
flying sparks

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

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

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

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

Have a suitable, approved fire extinguisher at the ready.

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

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

EN

Hazards from
mains and weld­ing current

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

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

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

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

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

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

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

V

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Hazards from
mains and weld­ing current

(continued)

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

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

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

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

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

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

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

Stray welding
currents

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

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

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

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

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

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

- fires

- overheating of components that are connected to the workpiece

- destruction of PE conductors

- damage to the machine and other electrical equipment

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

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

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

VI

Stray welding
currents

(continued)

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

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

EN

EMC device
classifications

Devices with emission class A:

- are only designed for use in an industrial setting

- can cause conducted and emitted interference in other areas.

Devices with emission class B:

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

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

EMC device classification as per the rating plate or technical specifications

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

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

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

- safety features

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply

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

b) Welding cables

- Keep these as short as possible

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

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

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

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

VII

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EMI Precautions

Electromagnetic fields may cause as yet unknown damage to health.

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

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

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

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

Particular danger
spots

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

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

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

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

While the machine is in use:

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

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

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

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

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

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

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

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

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

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VIII

Particular danger
spots

(continued)

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

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

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

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

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

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

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

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

EN

Factors affecting
welding results

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

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

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

- Size of solid matter particles <40µm

- Pressure dew point <-20°C

- Max. oil content <25mg/m³

Filters must be used if necessary.

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

Danger from
shielding-gas
cylinders

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

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

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

IX

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Danger from
shielding-gas
cylinders

(continued)

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.

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.

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

- Wire feed

- Wire wound coil

- Gas bottle

ud_fr_st_sv_00467 022013

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.

X

Safety precau­tions in normal
operation

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

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

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

- efficient working with the equipment.

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

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

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

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

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

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

- Only use suitable original coolant of the manufacturer.

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

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

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

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

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

EN

Preventive and
corrective main­tenance

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.

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.

XI

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Safety inspection

(continued)

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

Safety markings

Data security

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!

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

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

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

Copyright

ud_fr_st_sv_00467 022013

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.

XII

Table of contents

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

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

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

Area of utilizationt ..................................................................................................................................... 2

Warning notices affixed to the machine ................................................................................................... 3

Options .......................................................................................................................................................... 4

Optional mode selector switch ................................................................................................................. 4

Optional TR 4000 C control panel ............................................................................................................ 4

Optional key-lock switch ........................................................................................................................... 4

Description of the control panel ..................................................................................................................... 5

General remarks ...................................................................................................................................... 5

VR 4000 Ci control panel ......................................................................................................................... 5

Controls and connection points ..................................................................................................................... 8

Front of wirefeeder ................................................................................................................................... 8

Further explanations regarding the “Gasflow regulator with flow-rate indicator” ...................................... 8

Rear of wirefeeder ................................................................................................................................... 9

Side of wirefeeder .................................................................................................................................... 9

Mode selector switch option ................................................................................................................... 10

Connecting up the wirefeeder to the power source ......................................................................................11

General remarks .....................................................................................................................................11

Connecting up the wirefeeder to the power source ................................................................................. 11

EN

Mounting the welding torch ......................................................................................................................... 12

Torch connections .................................................................................................................................. 12

Mounting the welding torch .................................................................................................................... 12

Inserting the wirespool ................................................................................................................................ 13

General remarks .................................................................................................................................... 13

Inserting the wirespool ........................................................................................................................... 13

Inserting / changing the feed rollers ............................................................................................................ 14

General remarks .................................................................................................................................... 14

Inserting / changing the feed rollers ....................................................................................................... 14

USA wirefeeders .................................................................................................................................... 14

Feeding in the welding wire ......................................................................................................................... 15

Safety ..................................................................................................................................................... 15

Feeding in the welding wire .................................................................................................................... 15

Setting the contact pressure .................................................................................................................. 16

Technical data ............................................................................................................................................. 17

Technical data ........................................................................................................................................ 17

Spare parts list

Fronius Worldwide

1

General remarks

Machine concept

System
requirements

The VR 2000 is designed to be used with
wirespools of diameter 200 mm (7.87 in).
In conjunction with the 200 mm (7.87 in)
diameter wirespool, a 2-roller drive is
used. This results in a compact housing
and very low weight.
It also runs perfectly even when used with
very long hosepacks.
To facilitate the use of 70 m (229.66 ft.

7.91 in.) hosepacks, the VR 2000 has an
integrated gasflow regulator with a flow­rate indicator.

Fig.1 Shipyard VR 2000 wirefeeder

The VR 2000 wirefeeder can be used in conjunction with all power sources

- of the TransSynergic 4000 / 5000 series,

- of the TransPuls Synergic 4000 / 5000 series,

- of the TransPuls Synergic 2700 Duo series,

- of the TransPuls Synergic 2700 Duo TIG series

Software version 2.80.1 (power source) and upwards is needed to run the VR 2000
wirefeeder.

Area of
utilizationt

The VR 2000 was specially developed for use in shipyards and in the offshore industry.
The wirefeed is suited for use with all commercial protective gases.

2

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.

EN

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

- Suitable qualification for welding

- Suitable protective clothing

- Keep other people well away

Fig.2 Warning notices affixed to the wire feeder

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“

3

Options

Optional mode
selector switch

Optional TR 4000
C control panel

The “Mode selector switch” option allows
the user to select the processes and
operating modes directly from the welding
location, as well as to execute the “gas­test” and feeder-inching functions.

Fig.3 Optional mode selector switch

Optional to the standard control panel the VR 2000 can be equipped with the TR 4000 C
control panel. For detailed information of the control panel please refer to the installation
instructions “TR 4000 C control panel“.

Optional key­lock switch

Fig.4 Optional TR 4000 C control panel

Using the VR 2000 with long hosepacks often means that the welder can no longer
“keep an eye on” the power source from where he is working. If this is often the case, we
advise equipping the power source with the optional “key-lock switch”. This provides
optimum protection against anybody tampering or accidentally interfering with the machi­ne while it is being used.

4

Description of the control panel

General remarks

VR 4000 Ci
control panel

The VR 2000 wirefeeder is equipped with the VR 4000 Ci control panel as standard.
Optional the control panel TR 4000 C is available.

WARNING! Operating the machine 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” manual.

(10)

(9)

(8)

(1)

(2)

(3)

(4)

EN

(7)

(6)

Fig.5 VR 4000 Ci control panel

Item Function

(1) Parameter selection button

for selecting and displaying the following parameters on the digital display:

- welding voltage

- welding current

- wirefeed speed

- sheet thickness

When changing a parameter, the parameter value appears briefly on the digital
display so that it can be verified.

(2) Parameter display

The relevant symbol lights up when a parameter is selected

welding voltage

welding current

wirefeed speed

sheet thickness

(5)

5

VR 4000 Ci
control panel

(continued)

Item Function

(3) Welding power/welding current adjuster

has a different function depending on the process being used:

MIG/MAG pulse synergic welding, MIG/MAG standard synergic welding:
setting welding power

MIG/MAG standard manual welding:
setting the wirefeed speed

Rod electrode (MMA) welding:
setting the welding current

(4) Droplet detachment correction/arc force dynamic display

The relevant symbol lights up depending on the process selected

arc force dynamic

droplet detachment correction

(5) Droplet detachment correction/dynamic adjuster

has a different function depending on the process being used:

MIG/MAG standard synergic welding:
for influencing the short-circuiting dynamic at the instant of droplet transfer

- harder, more stable arc
0 neutral arc
+ soft, low-spatter arc

MIG/MAG pulse synergic welding:
continuous correction facility for the droplet detachment force

- lower droplet detachment force
0 neutral droplet detachment force
+ increased droplet detachment force

MIG/MAG standard manual welding:
for influencing the short-circuiting dynamic at the instant of droplet transfer

0 harder, more stable arc
10 soft, low-spatter arc

Rod electrode (MMA) welding:
for influencing the short-circuiting amperage at the instant of droplet transfer

0 soft, low-spatter arc
100 harder, more stable arc

(6) Welding power/welding current display

The relevant symbol lights up depending on the process selected

welding current

welding power

wirefeed speed

6

VR 4000 Ci
control panel

(continued)

Item Function

(7) Arc length/hot start adjuster

has a different function depending on the process being used:

MIG/MAG pulse synergic welding, MIG/MAG standard synergic welding:
correcting the arc length

EN

- shorter arc length
0 neutral arc length
+ longer arc length

MIG/MAG standard manual welding:
setting the welding voltage

Rod electrode (MMA) welding
influences the welding current during the ignition phase

0 no influence
10 100% increase in the welding current during the ignition phase

(8) Arc length/hot start indicator

The relevant symbol lights up depending on the process selected

hot start

frequency

welding voltage

arc length

(9) Hold indicator

every time you finish a welding operation, the actual values for welding current
and welding voltage are stored, and the “Hold” indicator lights up.

(10) Digital display

7

Controls and connection points

Front of wirefee­der

Fig.6 VR 2000 - front view

Item Function

(1) Welding torch connector

for connecting up the welding torch

(2) Torch control connection socket

for connecting the torch control plug

(3) LocalNet connection socket ...

standardized connection socket for
system extensions (e.g. remote
control, JobMaster torch, etc.)

(4) Plug-type connection for water

return flow (red)

(5) Plug-type connection for water

forward flow (black)

(6) Gasflow regulator with flow-rate

indicator (in SL / min)

(5)

(6)

(4)(3)(2)(1)

SL / min = 1 standard liter per minute

Further explanati­ons regarding the
“Gasflow regula­tor with flow-rate
indicator”

By “standard liter”, we mean 1 liter of a gas under standard conditions:

- temperature = 0 °C (32°F)

- pressure = 1 bar (14,50 psi.)

NOTE! The indicated shielding-gas flow-rate may deviate slightly from the
actual flow-rate if another type of shielding gas is being used instead of the
specified gas mixture (CO2 / Ar / Corgon 18).

WARNING! If the wirefeeder and the gas hoses are under excessive pressure,
there is a risk of damage to hearing, and of damage to the wirefeeder and the
shielding-gas hoses. Never connect the wirefeeder (i.e. the interconnecting cable)
to the gas cylinder without a pressure regulator. The gasflow regulator is no
substitute for a pressure regulator on the gas cylinder!

For your own safety, and to ensure that the gasflow regulator functions correctly,
proceed as follows:

1. Close the pressure regulator valve on the gas cylinder

2. Open the gasflow regulator to the maximum position

WARNING! An electric shock can be fatal. There is also a risk of injury from
welding wire emerging at speed from the torch. As soon as the gas-flow has been
started when you press the torch trigger, the welding wire is live. Make sure that
from this moment on, the wire does not touch any persons or electrically conduct­ing or grounded (earthed) parts such as the workpiece, etc. At the same time, the
wirefeed is also started when you press the torch trigger:

- Hold the torch so that it points away from your face and body.

- Never point the welding torch at people, or at objects that you do not intend to
weld

8

Further explanati­ons regarding the
“Gasflow regula­tor with flow-rate
indicator”

(continued)

3. Press the “Process” button to select the “4-step mode”

4. Press the gas-test button on the power source, or the torch trigger

5. Carefully open the pressure regulator on the gas cylinder until the maximum value
of 30 SL/min is shown on the flow-rate indicator

6. Press the gas-test button on the power source, or the torch trigger

7. Close the gasflow regulator

EN

Rear of wirefee­der

Side of wirefee­der

(1)

(2)

(3)

(4)

(5)

(6)

Fig.7 VVR 2000 - rear view

Item Function

(1) (+) socket with bayonet latch

for MMA (manual electrode) welding

(2) (+) socket with bayonet latch

interconnecting cable

(3) LocalNet connection socket

interconnecting cable

(4) Screw-type connection for water

return flow (red)

interconnecting cable

(5) Screw-type connection for water

forward flow (blue)

interconnecting cable

(6) Shielding gas connection socket

(2)(1)

Fig.8 VR 2000 - side view

(3)

Item Function

(1) Wirespool holder with braking device

for holding standardized 200 mm (7,87 in) welding-wire spools weighing up to 5 kg
(11,02 lbs.)

(2) 2-roller drive

(3) Mode selector switch option

9

Mode selector
switch option

(3b)(3a)

Fig.9 Mode selector switches (3): close-up view

(3c)

Item Function

Mode selector switch option

consisting of

(3a) Process selector

for selecting the process

MIG/MAG pulse-synergic welding
MIG/MAG standard-synergic welding
MIG/MAG standard-manual welding
Job mode
TIG welding with touch-down ignition
Rod-electrode (MMA) welding

Important! If the VR 2000 wirefeeder is connected up to a TS 4000 / 5000 power
source, the MIG/MAG pulse-synergic welding process is no longer available.

(3b) Mode selector

for selecting the operating modes

2-step mode
4-step mode
Special-4-step mode (Aluminium welding start-up)
Spot welding

(3c) Feeder-inching / gas-test button

Press the button down
to inch the wire electrode into the torch hosepack without any flow of shielding-gas
or current. As long as the button is held down, the wirefeeder runs at feeder­inching speed.

Press the button up
to set the required gas-flow rate on the pressure regulator. As long as the button is
pressed up, gas flows out.

Important! Settings made with the mode selector switch (3) cannot be altered on other
control elements, e.g.:

- on the control panel of the power source

- on the front of the wirefeeder unit

- on the remote control unit

10

Connecting up the wirefeeder to the power source

General remarks

Connecting up
the wirefeeder to
the power source

The wirefeeder must be connected up to the power source by means of the intercon­necting cable.

EN

NOTE! When using 70 m (229.66 ft. 7.91 in.) hosepacks that you have
prepared yourself or purchased from other manufacturers:

- make sure that the cross-sectional area of the supply cables for the
wirefeeder drive is at least 13 mm² (0.02 sq.in.)

1. Shift the mains switch of the power source into the “0” position

2. Insert the strain-relief device into the opening in the wirefeeder, and fix it in place

NOTE! Where the strain-relief device is subjected to heavy loading, screw it
firmly to the wirefeeder. For 1.2 m (3.9 ft.) long interconnecting cables, no
strain-relief device is provided.

3. Plug the gas hose of the interconnecting cable to the "Shielding-gas" socket

4. Tighten the swivel nut of the gas hose

5. Screw the water forward-flow and return-flow hoses of the interconnecting cable to
the screw-type connectors and, red-to-red and black-to-black

6. Tighten the swivel nuts of the water forward-flow and return-flow hoses

7. Plug the LocalNet plug of the interconnecting cable into the LocalNet connection
socket

8. Tighten the swivel nut of the LocalNet plug

9. Plug the “Welding potential” bayonet plug of the interconnecting cable to socket

10. Twist the “Welding potential” bayonet plug to latch it into place.

Fig.10 Cables and hoses “looped towards the

inside”

“Wirefeeder end” of intercon­necting cable

NOTE! When mounting the
cables and hoses of the
interconnecting cable, these
should be carefully looped
towards the inside, in order to
prevent wear-and-tear

red

blue

Fig.11 Connecting up the interconnecting cable to the wirefeeder

11

Mounting the welding torch

Torch connec­tions

Mounting the
welding torch

The VR 2000-wire feeder is available withe the following welding torch connections:

- Fronius F

- Euro

++

1. Shift the mains switch of the power
source into the “0” position

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

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

4. Plug the control plug of the welding
torch onto the torch control connec­tion socket (2) and turn it to fasten it

5. If available: connect external water
connections for water flow (3) and
water return (4) paying attention to the
correct colours

(D)

(A)

Fig.12 Welding torch connector and torch-control

connection point on the VR 2000

(N)(O)

12

Inserting the wirespool

General remarks

Inserting the
wirespool

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.

Detail Z

Fig.13 Inserting the wirespool Fig.14 View of close-up Z: Wirespool holder

1. Shift the mains switch of the power source into the “0” position

2. Open the left side panel of the VR 2000

3. Mount the wirespool onto the wirespool holder - the right way round

4. Latch the locking bolt (2) into the opening provided on the body of the spool

5. Adjust the braking force with the clamping screw (1)

6. Close the left side panel of the VR 2000

EN

(1)

(2)

NOTE! Always adjust the brake so that the wirespool does not continue
unreeling after the end of welding - but without overtightening the clamping
screw, as this might cause motor overload.

CAUTION! If the wirespool were to fall off, this would be dangerous! Make sure
that the wirespool is firmly mounted to the wirespool holder.

CAUTION! Danger of wire spool falling down. Assemble the brake as shown in
the figure below to ensure a tight fit of the wire spool and an optimum efficiency of
the brake.

Fig.15 Ensure correct assembly after completion of service work

13

Inserting / changing the feed rollers

General remarks

USA wirefeeders

Inserting / chan­ging the feed
rollers

In order to achieve satisfactory 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. After inserting the wirespool
the feed rollers have to be inserted into the wirefeeder.

Important! Use only feed rollers appropriate to the welding wire!

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

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

14

Feeding in the welding wire

Safety

Feeding in the
welding wire

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

ting the welding wire into the 2-roller drive, hold the end of the welding wire firmly
to avoid injuries caused by the wire springing back.

CAUTION! Risk of damage to the welding torch from sharp end of welding wire.
Deburr the end of the welding wire well before feeding in.

EN

15

Feeding in the
welding wire

(continued)

CAUTION! Danger from welding wire emerging at speed. Keep the welding
torch away from face and body when pressing the feeder inching / inch forward
button.

Setting the
contact pressure

NOTE! Adjust the contact pressure in such a way that the welding wire is not

deformed, but is nevertheless transported properly.

Contact pressure reference values Semi-cylindrical rolls Trapeze rolls

Aluminium 1,5 -

Steel 3 - 4 1,5

CrNi 3 - 4 1,5

16

Technical data

Technical data

Supply voltage (from the power source) 55 V DC

Rated current 4 A

Wirefeed speed 0,5 - 22 m/min (19.69 - 866.14 ipm.)

Degree of protection IP 23

Dimensions (L x W x H) 530 x 320 x 215 mm (20.87 x 12.60 x 8.46 in.)

Weight 9 kg (19.84 lb.)

Types of wirespool all standard wirespools

Max. permitted weight of wirespool 5 kg (11.02 lb.)

Wirespool diameter 200 mm (7.87 in.)

Wire diameter 0,8 - 1,6 mm (0.03 - 0.06 in.)

Drive 2-roller drive

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

Coolant Original Fronius coolant

Max. coolant pressure 6 bar (87 psi.)

EN

17

18

Ersatzteilliste

DEENFRITESPT-BRNLNOCSRUSKSVTR

Spare Parts List

Liste de pièces de rechange

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílů

Список запасных частей

Zoznam náhradných dielov

Reservdelslistan

ud_fr_st_tb_00150 012014

Parça Listesi

Wykaz czesci zamiennych

PL

VR 2000 2R/W/F++ 4,045,875,000
VR 2000 2R/G/W/E 4,045,875,001
VR 2000 2R/G/E 4,045,876,001

42,0407,0519

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

42,0300,2527

45,0200,1120

42,0300,2525

42,0405,0305

45,0200,1121

42,0200,6480

43,0001,3255

32,0409,2845,Z
43,0011,0038

32,0405,0248

32,0405,0183
44,0001,1145

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

42,0405,0189

4,100,360

44,0001,1256
44,0001,1257
43,0009,0045

43,0002,0331
42,0406,0242

BE2,0201,1065

43,0003,0485
42,0405,0056
42,0405,0154
42,0404,0024

45,0200,1122,Z

43,0004,1974

42,0001,3106,Z

SR41A

BE2,0201,1071

43,0003,0031

43,0003,0146

43,0004,2072

42,0001,0133

42,0001,2666

43,0013,0015

42,0407,0063

*40,0001,0012*

4,070,677,Z

42,0300,2526

VR 2000

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

el_fr_st_dv_00456 012016

1/1

Motorplate 24V 2R / 42V 2R

42,0405,0117

1

42,0405,0116

42,0407,0098

42,0404,0280

42,0409,2106

32,0405,0112

42,0407,0429

42,0405,0119

22,0405,0122

42,0200,5678

BE2,0200,8292

Z = Fronius connection

E = Euro connection

44,0001,1039

42,0407,0137

42,0001,2703

32,0405,0132

42,0401,0847

44,0001,1024

42,0200,8698

42,0001,2700

42,0399,0015

42,0400,0100

(2x)

42,0405,0120,U

32,0405,0113

12,0405,0118

BF2,0201,1512

1

42,0300,2162 - 120mm/4.72in.
42,0300,2199 - 200mm/7.87in.

D = Dinse connection

Z = Fronius connection

E = Euro connection

42,0001,1278 - 5x113
42,0001,1424 - 5x109
42,0001,1682 - 5x111
42,0001,1944 - 5x133
42,0001,3051 - 3,5x113

44,0001,1219

42,0200,9627

44,0001,1314

42,0100,0052

42,0402,0093

44,0001,0052

42,0200,9872

44,0001,0442

42,0100,0333

22,0405,0114

BF2,0201,1345

Motorplate 24V 2R / 42V 2R

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

42,0300,1053

44,0001,0276

1/2

el_fr_st_mp_01221 012015

Motorplate 24V 2R / 42V 2R

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

el_fr_st_mp_01221 012015

2/2

W 1,2m 70mm² 4,047,260
W 1,6m 70mm² 4,047,324
W 5,0m 70mm² 4,047,261
W 10m 70mm² 4,047,262
W 15m 70mm² 4,047,290
W 20m 70mm² 4,047,277
G 1,2m 70mm² 4,047,287
G 5,0m 70mm² 4,047,288
G 10m 70mm² 4,047,289

32,0405,0226

42,0407,0482

40,0001,0095 - *

42,0405,0239

32,0405,0226

42,0001,1506

44,0450,0281 - G 1/4"

42,0407,0482

42,0405,0239

42,0407,0063

42,0402,0053

40,0001,0012 - *

42,0001,0942

42,0001,0943

44,0450,0281 - G 1/4"

43,0003,0485

32,0405,0232

32,0405,0180

42,0407,0048

40,0003,0078 - *

42,0407,0063

32,0405,0231

43,0003,0486

43,0003,0064

40,0003,0021 - *

42,0407,0048

32,0405,0180

43,0003,0019

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

Connection hose pack

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1/1

el_fr_st_vp_00105 012003

G 50mm² 4m 4,047,411
G 70mm² 8m 4,047,412

42,0407,0482

32,0405,0226

40,0001,0095 - *

42,0407,0482

42,0407,0063

32,0405,0226

42,0405,0239

44,0450,0281 - G 1/4"

42,0407,0063

44,0450,0281 - G 1/4"

43,0003,0252

42,0405,0239

42,0407,0048

43,0003,0253

40,0001,0012 - *

40,0003,0447 - *

43,0003,0019 - 50mm²
43,0003,0301 - 70mm²

40,0003,0014 - * - 50mm²
40,0003,0021 - * - 70mm²

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

XYHGWHSRåDGRYDQRXGpONX

43,0003,0251

43,0003,0253

42,0407,0048

43,0003,0063 - 50mm²
43,0003,0064 - 70mm²

Connection hose pack

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

el_fr_st_vp_00773 012010

1/1

G 50mm² 1,2m 4,047,408
G 50mm² 5m 4,047,409
G 50mm² 10m 4,047,410

32,0405,0226

42,0407,0482

40,0001,0095 - *

42,0405,0239

32,0405,0226

42,0407,0063

44,0450,0281 - G 1/4"

42,0407,0482

42,0405,0239

42,0407,0048

40,0001,0012 - *

40,0003,0078 - *

42,0407,0063

44,0450,0281 - G 1/4"

43,0003,0485

32,0405,0232

32,0405,0180

42,0407,0048

43,0003,0063 - 50mm²

32,0405,0231

43,0003,0486

32,0405,0180

43,0003,0019 - 50mm²

40,0003,0014 - * - 50mm²

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

Connection hose pack

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1/1

el_fr_st_vp_00774 012003

FRONIUS INTERNATIONAL GMBH

Froniusplatz 1, A-4600 Wels, Austria

Tel: [phone], Fax: [phone]

E-Mail: [e-mail]

www.fronius.com

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

www.fronius.com/addresses

of our Sales & service partners and Locations.

ud_fr_st_so_00082 012011