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VR 4000 Case D200
VR 4000 Case D300
Operating Instructions
EN
Wire-feed unit
[
42,0426,0189,EN 011-19052020
2
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
EN
General information 17
General ...................................................................................................................................................... 19
Device concept ..................................................................................................................................... 19
Requirements........................................................................................................................................ 19
Field of application ................................................................................................................................ 19
Options.................................................................................................................................................. 19
Warning notices on the device.............................................................................................................. 20
Crane transport ..................................................................................................................................... 21
Control elements and connections 23
Description of the control panels................................................................................................................ 25
Safety.................................................................................................................................................... 25
General ................................................................................................................................................. 25
Control panel.............................................................................................................................................. 26
General ................................................................................................................................................ 26
Control panel......................................................................................................................................... 26
Connections and mechanical components ................................................................................................ 27
Overview of connections for the welding torch ..................................................................................... 27
VR 4000 Case D200 front..................................................................................................................... 27
VR 4000 Case D300 front..................................................................................................................... 27
VR 4000 Case side ............................................................................................................................... 28
VR 4000 Case rear ............................................................................................................................... 28
Installation and commissioning 31
Before commissioning................................................................................................................................ 33
Safety.................................................................................................................................................... 33
Intended purpose.................................................................................................................................. 33
Setup regulations .................................................................................................................................. 33
Connecting wire-feed unit to power source................................................................................................ 34
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General information .............................................................................................................................. 34
Connecting the wire-feed unit to the power source............................................................................... 34
Connecting the welding torch..................................................................................................................... 35
Safety.................................................................................................................................................... 35
Connecting a MIG/MAG welding torch.................................................................................................. 35
Inserting/replacing feed rollers................................................................................................................... 36
General ................................................................................................................................................. 36
Inserting/replacing feed rollers.............................................................................................................. 36
Inserting the wirespool, inserting the basket-type spool ............................................................................ 37
Safety.................................................................................................................................................... 37
Inserting a wirespool: D200 device ....................................................................................................... 37
Inserting a wirespool: D300 device ....................................................................................................... 37
Inserting a basket-type spool: D300 device.......................................................................................... 38
Feeding in the wire electrode..................................................................................................................... 39
Feeding in the wire electrode................................................................................................................ 39
Setting the contact pressure ................................................................................................................. 40
Adjust the brake ......................................................................................................................................... 42
General ................................................................................................................................................. 42
Setting the brake: D200 device............................................................................................................. 42
Setting the brake: D300 device............................................................................................................. 43
Start-up ...................................................................................................................................................... 44
Safety.................................................................................................................................................... 44
Requirements........................................................................................................................................ 44
Troubleshooting and maintenance 45
Care, maintenance and disposal ............................................................................................................... 47
General ................................................................................................................................................. 47
Safety.................................................................................................................................................... 47
Every start-up........................................................................................................................................ 47
Every 6 months ..................................................................................................................................... 47
Disposal ................................................................................................................................................ 48
Technical data 49
Technical data............................................................................................................................................ 51
VR 4000 Case D200 ............................................................................................................................. 51
VR 4000 Case D300 ............................................................................................................................. 51
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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).
9
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 base or cover for the earth or ground potential. This base 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 pretension.
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
Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing 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.
Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
If distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the
welding torch / electrode holder that is not used is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
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.
12
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 that are to be used 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).
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
Use filters if necessary.
Danger from
shielding gas cylinders
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
13
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 information
General
EN
Device concept
Requirements The VR 4000 Case wire-feed units can be operated with the TransSynergic 4000/5000 and
TransPuls Synergic 3200/4000/5000 power sources.
The VR 4000 Case wire-feed unit is contained in a fully sealed plastic housing. Depending on the model, it is suitable for
wirespools with the following maximum diameters:
- D200: 200 mm (7.87 in.)
- D300: 300 mm (11.81 in.)
The standard 4-roller drive has good wire
feeding properties. The VR 4000 Case
wire-feed unit is also suitable for long hosepacks.
Field of application
Options - VR 4000 Case gas flow meter
The VR 4000 Case wire-feed unit is suitable for all shielding gas welding tasks for steel
applications and can be used with any of the standard shielding gases.
The VR 4000 Case is primarily used for the following applications:
- shipbuilding
- in shipyards and offshore applications
- mining
- VR 5000 Case current socket
- Push-pull unit
- Wire threading button/Gas-test button
- VR 4000 digital display:
19
The wire-feed unit can be fitted with the optional "VR 4000 Case digital display" installation kit as an alternative to the standard
control panel.
A detailed description of the optional control
panel can be found in the relevant installation instructions.
Warning notices
on the device
The device is fitted with safety symbols and a rating plate. The safety symbols and rating
plate must not be removed or painted over. The safety symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
40,0006,3035
VR 4000 Case 4R/G/W/F++
Part No.:
www.fronius.com
IEC 60 974-5/-10 Cl.A IP 23
0.5-22 m/min
Ser.No.:
U
11
12
U
320 A/100% 420 A/60%I
2
55 V
11
I
12
4,049,025
XXXXXXXXXX
4 AI
2 A24 V
20
Do not use the functions described here until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly:
- Anyone performing automated welding must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wirefeed unit and the welding process
Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and wire electrodes
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.
Crane transport The wire-feed unit can be transported by crane using its handle.
The maximum load-bearing capacity of the handle is dependent upon the model:
- D200: 15 kg (33.07 lb.)
- D300: 35 kg (77.16 lb.)
EN
WARNING!
Falling equipment can cause serious or even fatal injury.
► Use only suitable lifting tackle when transporting devices by crane.
► The lifting tackle must be undamaged and in perfect condition.
► Always attach the lifting tackle to both ends of the handle - see diagram below
The following points must be observed when transporting devices by crane:
- feed out the wire electrode, remove the wirespool
- disconnect the torch hosepack and interconnecting hosepack from the wire-feed unit
- if present, unplug the coolant connections
- use appropriate lifting tackle (e.g. belt with round slings)
- do not transport any other loads by the handle apart from the wire-feed unit itself
- do not hang from the wire-feed unit as it is being transported
21
22
Control elements and connections
Description of the control panels
EN
Safety
Danger from incorrect operation.
Possible serious injury and damage to property.
► Do not use the functions described here until you have read and completely under-
► Do not use the functions described here until you have fully read and understood all of
General The functions on the control panel are all arranged in a logical way. The necessary welding
parameters can easily be adjusted using the relevant dials.
As a result of technical revisions, you may find that your device has certain functions that are not described in these operating instructions, or vice versa.
Certain illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
Setting parameters on the control panel is only possible in manual welding mode. In the
automated welding mode or in robot welding, the robot control provides the set values for
welding parameters. Specifying set values via the control panel is not possible in automated welding mode or in robot welding.
WARNING!
stood these Operating Instructions.
the Operating Instructions for the system components, in particular the safety rules!
NOTE!
NOTE!
Welding parameters that must be entered on a wire-feed unit control panel cannot
be changed on the power source.
Welding parameters can only be changed on the wire-feed unit.
25
Control panel
(1)
(2)
General The control panel allows straightforward manual setting of the welding parameters.
Control panel
No. Function
(1) Welding power/wire feed speed
adjuster
has a different function depending
on the welding process being used:
MIG/MAG pulse synergic welding,
MIG/MAG standard synergic welding:
setting the welding power
MIG/MAG standard manual welding:
setting the wire feed speed
No. Function
(2) Arc length/arc-force dynamic adjuster
has a different function depending on the welding process being used:
MIG/MAG pulse synergic welding, MIG/MAG standard synergic welding:
correcting the arc length
- ... shorter arc length
0 ... neutral arc length
+ ... longer arc length
MIG/MAG standard manual welding:
setting the welding voltage
Manual metal arc welding:
influencing the short circuit amperage at the instant of droplet transfer
0 ... soft, low-spatter arc
100 harder, more stable arc
26
Connections and mechanical components
(1)
(3)
(4)
(2)
(2)
(1)
(3)
(4)
(5)
(6)
EN
Overview of connections for the
welding torch
VR 4000 Case
D200 front
An overview of the connections available for the welding torch can be found in the spare
parts list in the Appendix.
(1) Welding torch connection
for connecting the welding torch
(2) Torch control connection
for connecting the welding torch
control plug
(3) Coolant flow connection (blue)
(4) Coolant return connection (red)
VR 4000 Case
D300 front
(1) Welding torch connection
for connecting the welding torch
(2) Torch control connection
for connecting the welding torch
control plug
(3) Coolant flow connection (blue)
(4) Coolant return connection (red)
(5) (+) - socket with bayonet latch - option
when the optional (+) - socket is installed, otherwise a blanking cover
(6) LocalNet connection - option
when the optional LocalNet connection is installed, otherwise a blanking cover
27
VR 4000 Case
(1) (2) (3)
(7)
(6)
(8)
(10)
(9)
(1)
(2)
(3)
(5)
(4)
side
(1) Wirespool holder with brake
D200:
for holding standard wirespools
with a max. diameter of 200 mm
(7.87 in.) and max. weight of 5 kg
(11.02 lb.)
D300:
for holding standard wirespools
with a max. diameter of 300 mm
(11.81 in.) and max. weight of 19 kg
(41.89 lb.)
(2) Wire threading button/Gas-test button - option
Push button downwards:
to thread the wire into the torch hosepack with no accompanying flow of gas or cur-
rent. While the button is being held down, the wire-feed unit runs at feeder inching
speed.
VR 4000 Case
rear
Push button upwards:
to set the required gas flow rate at the pressure regulator.
- Tap button once: shielding gas flows out
- Tap button again: shielding gas flow stops
If the "Gas-test" button is not tapped again, the shielding gas flow will stop after 30
s.
(3) 4-roller drive
(1) Enhanced LocalNet connection
for interconnecting hosepack
for enhanced LocalNet with lines for
motor supply and motor control
(2) Coolant return connection (red)
(3) Shielding gas connection
(4) Coolant flow connection (blue)
28
(5) (+) current connection with bayonet latch
for interconnecting hosepack
(6) Mounting lug
for securing the interconnecting hosepack
(7) Blanking covers
positions for VR 4000 Case gas flow meter option
(8) Blanking cover
position for VR 4000 Case current socket option
(9) Blanking cover
position for VR 4000 Case external start signal option
(10) Remote control connection
EN
29
30
Installation and commissioning
Before commissioning
EN
Safety
Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described here until you have read and completely under-
► Do not use the functions described here until you have fully read and understood all of
An electric shock can be fatal.
If the power source is connected to the mains electricity supply during installation, there is
a high risk of very serious injury and damage.
► Before carrying out any work on the device make sure that the power source mains
► Before carrying out any work on the device make sure that the power source is un-
Intended purpose The device is intended exclusively for wire feeding in MIG/MAG welding.
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 held liable for any damages arising from such usage.
WARNING!
stood these Operating Instructions.
the Operating Instructions for the system components, in particular the safety rules.
WARNING!
switch is in the "O" position
plugged from the mains
Utilisation in accordance with the "intended purpose" also comprises
- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
Setup regulations The VR 4000 Case is tested to IP23 protection, meaning:
- protection against penetration by solid foreign bodies with diameters exceeding 12.5
mm (0.49 in.)
- protection against direct sprays of water at any angle up to 60° from vertical
The VR 4000 Case can be set up and operated outdoors in accordance with IP23 protection. Avoid direct wetting (e.g. from rain).
33
Connecting wire-feed unit to power source
General information
Connecting the
wire-feed unit to
the power source
The wire-feed unit is connected to the power source using the interconnecting hosepack.
WARNING!
Fitting the equipment incorrectly can cause serious injury and damage.
Do not carry out the steps described here until you have read and completely understood
all the operating instructions.
NOTE!
When connecting the interconnecting
hosepack, check that
► all connections are connected properly
► all cables, leads and hosepacks are un-
damaged and correctly insulated
34
Connecting the welding torch
EN
Safety
Connecting a
MIG/MAG welding
torch
NOTE!
When connecting the welding torch, check that
► all connections are connected properly
► all cables, leads and hosepacks are undamaged and correctly insulated.
* The welding torch control plug comes
in two versions:
- as a conventional torch control
connection
- as a LocalNet plug, e.g. on JobMaster welding torches
35
Inserting/replacing feed rollers
2
4
General 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.
Inserting/replacing feed rollers
CAUTION!
Risk of injury if the feed roller holders fly upwards.
When unlocking the clamping lever, keep fingers away from the area to the left and right
of the lever.
1 2
1
CAUTION!
36
Risk of crushing by exposed feed rollers.
Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roller.
1 2
3
Inserting the wirespool, inserting the basket-type
spool
Safety
Inserting a wirespool: D200 device
EN
CAUTION!
Risk of injury from springiness of spooled wire electrode.
While inserting the wirespool, hold the end of the wire electrode firmly to avoid injuries
caused by the wire springing back.
CAUTION!
Risk of injury from falling wirespool.
Make sure the wirespool sits securely on the wirespool holder.
1
1
Inserting a wirespool: D300 device
1
1
37
Inserting a bas-
1
2
ket-type spool:
D300 device
CAUTION!
Risk of injury and material damage from falling basket-type spool.
Place the basket-type spool on the adapter provided in such a way that the bars on the
spool are inside the adapter guideways.
1 2
38
Feeding in the wire electrode
2
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
EN
Feeding in the
wire electrode
CAUTION!
Risk of injury from springiness of spooled wire electrode.
When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode
firmly to avoid injuries caused by the wire springing back.
CAUTION!
Risk of damage to the welding torch from sharp end of wire electrode.
Deburr the end of the wire electrode well before feeding in.
1 2
1
2
1
4
3
CAUTION!
Risk of injury from wire electrode emerging at speed.
When pressing the "Wire threading" button or the torch trigger, keep the welding torch
away from your face and body, and wear suitable protective goggles.
IMPORTANT! To facilitate the exact positioning of the wire electrode, the following sequences are possible when the "Wire threading" button is pressed and held down.
- Hold the button for up to one second
... the wire feed speed stays at 1 m/min
or 39.37 ipm for the first second.
- Hold the button for up to 2.5 seconds
... after one second has elapsed, the
wire feed speed increases at a uniform
rate over the next 1.5 seconds.
- Hold the button for more than 2.5 se-
conds ... after 2.5 seconds, the wire is
fed at a constant rate equal to the wire
feed speed set for the Fdi welding parameter.
39
If you release the "Wire threading" button and press it again before one second has
1
2
4
5
3
1
3
1
1
2
3
4
elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire feed speed of 1 m/min or 39.37 ipm where necessary.
If there is no "Wire threading"/"Gas-test" button, the torch trigger can be used in the same
way. Before using the torch trigger for wire threading, proceed as follows:
Press the Mode button to select 2-step mode
Set the "Ito" parameter to "Off" in the Setup menu
2
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging
from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body
► wear suitable protective goggles
► do not point the welding torch at people
► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
IMPORTANT! If the torch trigger is pressed instead of the "Wire threading"/"Gas-test"
button, the welding wire runs at the feeder creep speed (depending on the welding program) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.
The welding system detects that the welding process should not start, but that the wire is
to be fed in. At the same time, the gas solenoid valve closes, and the welding voltage on
the wire electrode is switched off.
If the torch trigger is kept pressed, wire feeding restarts immediately without shielding gas
and welding voltage, and the process continues as described above.
1 2
Setting the con-
NOTE!
tact pressure
Set the contact pressure in such a way that the wire electrode is not deformed but
nevertheless ensures proper wirefeed.
40
1
1
Contact pressure
U-slot rollers
standard values
Steel 4 - 5
EN
CrNi 4 - 5
Tubular cored electrodes 2 -3
41
Adjust the brake
1
4
5
STOP
6
7
3
1
2
2
General
CAUTION!
Risk of injury and material damage from the welding current and accidental ignition
of an arc.
Before starting work, disconnect the ground earth connection between the welding system
and the workpiece.
CAUTION!
Risk of injury and damage from wire electrode emerging.
While working:
► hold the welding torch with the point directed away from the face and body
► wear suitable protective goggles
► do not point the welding torch at people
► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
NOTE!
After releasing the torch trigger the wirespool must stop unreeling.
If it continues unreeling, readjust the brake.
Setting the brake:
D200 device
1 2
1
42
3
2
4
STOP
OK
3
1
1
4
5
STOP
6
7
3
1
2
2
2
4
STOP
OK
3
1
3
EN
Setting the brake:
D300 device
1 2
1
3
3
2
1
43
Start-up
Safety
Operating the equipment incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the following documents:
► these operating instructions
► all the operating instructions for the system components, especially the safety rules
The wire-feed unit is started by pressing the torch trigger (for manual applications) or by
means of a welding start-up signal (for automatic applications).
Requirements When commissioning the wire-feed unit, the following requirements must be met:
- Wire-feed unit connected to the power source using the interconnecting hosepack
- Welding torch connected to the wire-feed unit
- Feed rollers inserted into the wire-feed unit
- Wirespool or basket-type spool and adapter inserted in the wire-feed unit
- Wire electrode fed in
- Feed roller contact pressure set
- Brake adjusted
- All covers closed, all side panels in place, all protection devices intact and in their
WARNING!
proper place
44
Troubleshooting and maintenance
Care, maintenance and disposal
General Under normal operating conditions, the welding system requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
EN
Safety
WARNING!
Incorrect operation or shoddy workmanship can cause serious injury or damage.
All functions described in this document may only be carried out by trained and qualified
personnel after they have fully read and understood the following documents:
► this document
► all documents relating to the system components, especially the safety rules
WARNING!
An electric shock can be fatal.
Before starting work:
► turn the power source mains switch to the "O" position
► disconnect the power source from the mains
► ensure that the power source remains disconnected from the mains until all work has
been completed
After opening the device, use a suitable measuring instrument to check that electrically
charged components (e.g. capacitors) have been discharged.
CAUTION!
Risk of injury from hot system components.
Before starting work, allow all hot system components to cool down to room temperature
(+25 °C, +77 °F). For example:
► coolant
► water-cooled system components
► wire-feed unit drive motor
Every start-up - Check all hosepacks and the ground earth connection for damage. Replace any dam-
aged components.
- Check feed rollers and inner liners for signs of damage. Replace any damaged com-
ponents.
- Check contact pressure of feed rollers and adjust if necessary.
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.
47
Disposal Dispose of in accordance with the applicable national and local regulations.
48
Technical data
Technical data
EN
VR 4000 Case
D200
Supply voltage
(supply from the power source)
Nominal current 2 A / 4 A
Welding current at 10 min/40 °C (104 °F) 60 % D.C.* 100 %
Maximum shielding gas pressure 7 bar
Coolant Original Fronius
Maximum coolant pressure 5 bar
Wire feed speed 0.5 - 22 m/min
Wire drive 4-roller drive
Wirespool types all standardised wirespools
Maximum permitted wirespool weight 5 kg
Wire diameter 0.8 - 1.6 mm
Wirespool diameter max. 200 mm
Degree of protection IP 23
Mark of conformity S, CE, CSA
Dimensions l x w x h 507 x 200 x 320 mm
Weight 9.5 kg
LocalNet data rate 57600 Baud
*) D.C. = Duty cycle
24 V DC / 55 V DC
D.C.*
420 A 320 A
101.53 psi
72.49 psi
19.69 - 866.14 ipm
max. 11.02 lb.
.03 - .06 in.
max. 7.87 in
19.96 x 7.87 x 12.6 in.
20.94 Ib.
VR 4000 Case
D300
Supply voltage
(supply from the power source)
Nominal current 2 A / 4 A
Welding current at 10 min/40 °C (104 °F) 60 % D.C.* 100 %
Maximum shielding gas pressure 7 bar
Coolant Original Fronius
Maximum coolant pressure 5 bar
Wire feed speed 0.5 - 22 m/min
Wire drive 4-roller drive
24 V DC / 55 V DC
D.C.*
420 A 320 A
101.53 psi
72.49 psi
19.69 - 866.14 ipm
51
Wirespool types all standardised wirespools
Maximum permitted wirespool weight 19 kg
max. 41.89 lb.
Wire diameter 0.8 - 1.6 mm
.03 - .06 in.
Wirespool diameter max. 300 mm
max. 11.81 in
Degree of protection IP 23
Mark of conformity S, CE, CSA
Dimensions l x w x h 613 x 244 x 437 mm
24.13 x 9.61 x 17.2 in.
Weight 14.8 kg
32.63 Ib.
LocalNet data rate 57600 Baud
*) D.C. = Duty cycle
52
EN
53
54
EN
55
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1
A-4643 Pettenbach
AUSTRIA
contact@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations.
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