FRO­NIUS VR 1500-12 User manual

VR 1530 -11 / -12 / - 22 / -30 / -KD Operating Instructions
Spare Parts List
Wirefeeder
/ Battery Charging Systems / Welding Technology / Solar Electronics
EN
42,0426,0010,EN 005-08112013

ud_fr_st_et_00493 01/2012
EN
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.
Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.
Introduction

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I
EN
Safety rules
DANGER!
WARNING!
CAUTION!
“NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.
NOTE!
This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/
operator,
- efficient working with the equipment.
All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.
The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must
be kept on hand, and of course observed in practice.
All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over
For information about where the safety instructions and danger warnings
are located on the machine, please see the section of your machine’s
instruction manual headed “General remarks”.
General remarks
Important!
“DANGER!” indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.
“CAUTION!” indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices that may cause property damage.
“Important!” indicates practical hints and other useful special-information. It is no
signal word for a harmful or dangerous situation.
Whenever you see any of the symbols shown above, you must pay even closer
attention to the contents of the manual!

ud_fr_st_sv_00467 022013 II
Operation or storage of the power source outside the stipulated range is
deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.
Temperature range of ambient air:
- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 20 °C to + 55 °C (-4 °F to 131 °F)
Relative atmospheric humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Ambient air: Free of dust, acids, corrosive gases or substances etc.
Elevation above sea level: Up to 2000 m (6500 ft)
Ambient
conditions
The machine may only be used for jobs as defined by the “Intended purpose”.
The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall
not be liable for any damage resulting from such improper use.
Utilisation in accordance with the “intended purpose” also comprises
- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.
The appliance must never be used for the following:
- Thawing pipes
- Charging batteries/accumulators
- Starting engines
The machine is designed to be used in industrial and workshop
environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.
ikewise the manufacturer will accept no liability for defective or faulty work
results.
Utilisation for
intended purpose
only
Any malfunctions which might impair machine safety must be eliminated
immediately - meaning before the equipment is next switched on.
It’s your safety that’s at stake!
The owner/operator undertakes to ensure that the only persons allowed to
work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood this operating manual particulary the sections
on “Safety rules”, and have confirmed as much with their signatures
- be trained in such a way that meets with the requirements of the work
results
Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.
Obligations of
owner/operator
General remarks
(continued)

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III
EN
Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read this operating manual particulary the sections on “Safety rules”
and to sign to confirm that they have understood these and will comply
with them.
Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.
Obligations of
personnel
Protection for
yourself and
other persons
When welding, you are exposed to many different hazards such as:
- flying sparks and hot metal particles
- arc radiation which could damage your eyes and skin
- harmful electromagnetic fields which may put the lives of cardiac pace-
maker users at risk
- electrical hazards from mains and welding current
- increased exposure to noise
Mains connec-
tion
High-performance devices can affect the quality of the mains power due to
their current-input.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)
*) at the interface with the public mains network
see Technical Data
In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.
- noxious welding fumes and gases.
Anybody working on the workpiece during welding must wear suitable
protective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups
NOTE! Ensure that the mains connection is earthed properly.

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The fumes given off during welding contain gases and vapors that are
harmful to health.
Welding fumes contain substances which may cause birth defects and
cancers.
Keep your head away from discharges of welding fumes and gases.
Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable
means.
Ensure a sufficient supply of fresh air.
Where insufficient ventilation is available, use a respirator mask with an
independent air supply.
If you are not sure whether your fume-extraction system is sufficiently
powerful, compare the measured pollutant emission values with the
permitted threshold limit values.
Close the shielding gas cylinder valve or central gas supply if no welding is
taking place.
Hazards from
noxious gases
and vapours
Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.
Protection for
yourself and
other persons
(continued)
“Protective clothing” also includes:
- protecting your eyes and face from UV rays, heat and flying sparks with
an appropriate safety shield containing appropriate regulation filter glass
- wearing a pair of appropriate regulation goggles (with sideguards)
behind the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insula-
ting, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!
Information on
noise emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum
permissible operating point under maximum rated load conditions according
to EN 60974-1.
It is not possible to provide a workplace-related emission value during wel-
ding (or cutting) as this is influenced by both the process and the environ-
ment. All manner of different welding parameters come into play, including the
welding process (MIG/MAG, TIG welding), the type of power selected (DC or
AC), the power range, the type of weld metal, the resonance characteristics
of the workpiece, the workplace environment, etc.

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V
EN
Hazards from
mains and weld-
ing current
Flying sparks can cause fires and explosions!
Never perform welding anywhere near combustible materials.
Combustible materials must be at least 11 meters (36 ft. 1.07 in.) away from
the arc, or else must be covered over with approved coverings.
Have a suitable, approved fire extinguisher at the ready.
Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that
there is no risk of injury or fire.
Do not perform welding in locations that are at risk from fire and/or
explosion, or in enclosed tanks, barrels or pipes, unless these latter have
been prepared for welding in accordance with the relevant national and
international standards.
Welding must NEVER be performed on containers that have had gases,
fuels, mineral oils etc. stored in them. Even small traces of these
substances left in the containers are a major explosion hazard.
Hazards from
flying sparks
An electric shock is potentially life-threatening, and can be fatal.
Do not touch any live parts, either inside or outside the machine.
In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.
Always place the wirefeeder on an adequately insulated floor or base, or
else use a suitable insulating wirefeeder holder.
Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/
frame potential. The base or cover must completely cover the entire area
between your body and the ground/frame potential.
All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.
The harmfulness of the welding fumes will depend on e.g. the following
components:
- the metals used in and for the workpiece
- the electrodes
- coatings
- cleaning and degreasing agents and the like
For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.
Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.
Hazards from
noxious gases
and vapours
(continued)

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If the following instructions are ignored, stray welding currents may occur.
These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment
Ensure that the workpiece clamp is tightly connected to the workpiece.
Attach the workpiece clamp as close as possible to the area to be welded.
On electrically conductive floors, the machine must be set up in such a way
that it is sufficiently insulated from the floor.
Stray welding
currents
Hazards from
mains and weld-
ing current
(continued)
Do not loop any cables or other leads around your body or any part of your
body.
Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.
Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.
Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.
Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.
If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.
Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).
Switch off any appliances that are not in use.
Wear a safety harness if working at height.
Before doing any work on the machine, switch it off and unplug it from the
mains.
Put up a clearly legible and easy-to-understand warning sign to stop
anybody inadvertently plugging the machine back into the mains and
switching it back on again.
After opening up the machine:
- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.
If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.

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VII
EN
When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/
welding tongs is also current carrying. Please ensure that there is sufficient
insulating storage for the unused welding torch/tongs.
In the case of automated MIG/MAG applications, ensure that only insulated
filler wire is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.
Stray welding
currents
(continued)
EMC device
classifications
Devices with emission class A:
- are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.
Devices with emission class B:
- satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.
EMC device classification as per the rating plate or technical specifications
EMC measures In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where
the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to
rectify the situation.
Examine and evaluate any possible electromagnetic problems that may
occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices
Ancillary measures for preventing EMC problems:
a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the
mains connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).
b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.
c) Equipotential bonding
d) Workpiece grounding (earthing)
- where necessary, run the connection to ground (earth) via suitable
capacitors.
e) Shielding, where necessary
- Shield other equipment in the vicinity
- Shield the entire welding installation.

ud_fr_st_sv_00467 022013 VIII
Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.
Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.
Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.
When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...).
While the machine is in use:
- ensure that all the covers are closed and that all the sideguards are
properly mounted ...
- ... and that all covers and sideguards are kept closed.
Do not touch the workpiece during and after welding - risk of injury from
burning!
Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.
Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pace-
makers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/
body of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not
loop around body or or any part of body
EMI Precautions
Keep your hands, hair, clothing and tools well away from all moving parts,
e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires
Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.
Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.
Particular danger
spots
For this reason, when feeder-inching etc., always hold the torch so that it is
pointing away from your body (machines with wirefeeder) and wear suitable
protective goggles.

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IX
EN
Particular danger
spots
(continued)
When hoisting the machines by crane, only use suitable manufacturer-
supplied lifting devices.
- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).
When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).
If a machine is fitted with a carrying strap or carrying handle, remember that
this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.
Danger of colourless and odourless inert gas escaping unnoticed, when
using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable natio-
nal standards and directives as a minimum.
Risk of scalding from accidental discharge of hot coolant. Before unplugging
the connectors for coolant forward flow and return flow, switch off the coo-
ling unit.
Observe the information on the coolant safety data sheet when handling
coolant. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer’s website.
The following requirements with regard to shielding gas quality must be met
if the welding system is to operate in a correct and safe manner:
- Size of solid matter particles <40µm
- Pressure dew point <-20°C
- Max. oil content <25mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Factors affecting
welding results

ud_fr_st_sv_00467 022013 X
Safety precauti-
ons at the instal-
lation 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 transportati-
on and carriage.
Shielding-gas cylinders contain pressurized gas and may explode if they are
damaged. As shielding-gas cylinders are an integral part of the overall
welding outfit, they also have to be treated with great care.
Protect shielding-gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).
Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).
Never hang a welding torch on a shielding-gas cylinder.
Never touch a shielding-gas cylinder with a welding electrode.
Explosion hazard - never perform welding on a pressurized shielding-gas
cylinder.
Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories
that are in good condition.
When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.
Close the shielding-gas cylinder valve when no welding is being carried out.
When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.
Observe the manufacturer’s instructions and all relevant national and
international rules applying to shielding-gas cylinders and accessories.
Danger from
shielding-gas
cylinders

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EN
Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:
- the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.
Any safety devices that are not fully functional must be put right before you
switch on the machine.
Never evade safety features and never put safety features out of order.
Before switching on the machine, ensure that nobody can be endangered by
your doing so.
- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frost-
proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
- Only use suitable original coolant of the manufacturer.
- Do not mix original coolant of the manufacturer with other coolants.
- If any damage occurs in cases where other coolants have been used,
the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.
- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
- Before starting welding - while the machine is still cool - check the
coolant level.
Safety precau-
tions in normal
operation
Before transportation, completely drain any coolant and dismantle the
following components:
- Wire feed
- Wire wound coil
- Gas bottle
Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by trained service
personnel before commissioning.
Safety precauti-
ons at the instal-
lation site and
when being
transported
(continued)

ud_fr_st_sv_00467 022013 XII
Equipment with CE-markings fulfils the basic requirements of the Low-
Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .
Safety markings
Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility Any device that you no longer
require must be returned to our agent, or find out about the approved
collection and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
Disposal
The manufacturer recommends that a safety inspection of the device is
performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during
the same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international
standards and directives.
Further details on safety inspection and calibration can be obtained from
your service centre. They will provide you on request with any documents
you may require.
Safety inspection
With parts sourced from other suppliers, there is no certainty that these
parts will have been designed and manufactured to cope with the stressing
and safety requirements that will be made of them. Use only original spares
and wearing parts (this also applies to standard parts).
Do not make any alterations, installations or modifications to the machine
without getting permission from the manufacturer first.
Replace immediately any components that are not in perfect condition.
When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.
Preventive and
corrective main-
tenance

ud_fr_st_sv_00467 022013
XIII
EN
Copyright to this instruction manual remains the property of the
manufacturer.
The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.
Copyright
The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.
Data security

ud_fr_st_sv_00467 022013 XIV

1
EN
Contents
General remarks ........................................................................................................................................... 2
Safety ....................................................................................................................................................... 2
Machine concept ...................................................................................................................................... 2
Overview .................................................................................................................................................. 2
Areas of utilisation ................................................................................................................................... 2
System requirements ............................................................................................................................... 3
Applicational example: VR 1530-22 used as an unreeling-type wirefeeder ............................................ 3
Applicational example: VR 1530-11/-12/-30 used as an unreeling-type wirefeeder ................................ 4
Warning notices affixed to the machine ................................................................................................... 5
Controls and connection points .................................................................................................................... 6
General remarks ...................................................................................................................................... 6
VR 1530 -11 / -12 /-22 / - 30 .................................................................................................................... 6
VR 1530-KD20 ......................................................................................................................................... 7
Wire-inching sequence when the welder presses and holds the feeder inching button ......................... 8
Putting the unit into service ........................................................................................................................... 9
Utilisation for intended purpose only ....................................................................................................... 9
Machine set-up regulations ..................................................................................................................... 9
Ready-drilled holes ................................................................................................................................ 10
Space for tilting up the lid of the wirefeeder ........................................................................................... 10
Mounting the wirefeed hoses .......................................................................................................................11
Safety ...................................................................................................................................................... 11
Mounting the wirefeed hoses .................................................................................................................. 11
Inserting / changing the feed rollers ........................................................................................................... 12
General remarks .................................................................................................................................... 12
USA wirefeeders .................................................................................................................................... 12
Inserting / changing the feed rollers ...................................................................................................... 12
Feeding in the welding wire ........................................................................................................................ 13
Insulated routing of welding wire to wirefeeder ..................................................................................... 13
Safety ..................................................................................................................................................... 13
Preparations........................................................................................................................................... 13
Feeding in the welding wire ................................................................................................................... 13
Feeding in the welding wire ................................................................................................................... 14
Setting contact pressure ........................................................................................................................ 15
Calibrating push-pull unit ............................................................................................................................ 16
General remarks .................................................................................................................................... 16
Calibrating the push-pull unit ................................................................................................................. 16
Service codes displayed during calibration of the push-pull unit ........................................................... 16
Troubleshooting .......................................................................................................................................... 17
General remarks .................................................................................................................................... 17
VR 1530 error diagnostics ..................................................................................................................... 17
Care, maintenance and disposal ................................................................................................................ 19
General remarks .................................................................................................................................... 19
Every time before starting up ................................................................................................................. 19
Final disposal ......................................................................................................................................... 19
Technical data ............................................................................................................................................. 20
VR 1530-12 ............................................................................................................................................ 20
VR 1530-11 ............................................................................................................................................ 20
VR 1530-22 ............................................................................................................................................ 21
VR 1530-30 ............................................................................................................................................ 21
VR 1530-KD20 ....................................................................................................................................... 22
Spare Parts List
Circuit diagram
Fronius Worldwide

2
The VR 1530‘s good wirefeed properties and compact design give it a very wide and
varied area of utilisation. The VR 1530 was designed specifically for use in automated
and robot applications where steel, aluminium, CrNi and CuSi wires are welded. The
VR 1530 is particularly suitable for applications requiring high-precision wirefeed.
VR 1530 -11 / -12 / -22 / -30:
A matching version of the VR 1530 is available for each version of the main wirefeeder
VR 1500:
- VR 1500-11: VR 1530-11 (11 m/min) (433.07 ipm.)
- VR 1500-12: VR 1530-12 (12 m/min) (472.44 ipm.)
- VR 1500-22: VR 1530-22 (22 m/min) (866.14 ipm.)
- VR 1530-30: VR 1530-30 (30 m/min) (1181.10 ipm.)
VR 1530-KD:
The VR 1530-KD is available in conjunction with the KD 7000 cold-wire feeder.
CAUTION! There is a risk of injury while the lid is open for maintenance or retooling
work to be carried out. Ensure that there is no risk of anybody accidentally starting
up the VR 1530‘s drive components by pressing the feeder inching button(s) on the
control panel, on the VR 1530 itself or on any other system add-ons.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Before you start using the VR 1530, you MUST have read and
completely understood the following documents:
- the VR 1530 “Operating Instructions” manual
- the “Operating Instructions” manual for the power source, particularly the
“Safety rules”
With its process-oriented control of the wirefeed system, the VR 1530 unreeling-type
wirefeeder takes the intelligent power-source concept a step further. To facilitate access
to the wirespool for re-loading, this is often located a long distance away from the
welding location. The VR 1530 has been specially designed to meet the requirements
presented by just this situation. In order to achieve extremely constant wirefeed, even
with very long hosepacks, the VR 1530 is used as an additional drive unit between the
unreeling device (bulk wire container) and whichever version of the VR 1500 wirefeeder
you happen to be using. In cases where there are long wirefeed travel distances and/or
where large wirespools are being used, the VR 1530 ensures highly accurate wirefeed
and very exact reproducibility of the welding results.
General remarks
Safety
Machine concept
Areas of utilisati-
on
Overview The VR 1530 -11 / -12 / -22 / -30 unreeling-type wirefeeder can be used with the follo-
wing power sources:
Digital power sources:
- Trans (Puls) Synergic 4000
- Trans (Puls) Synergic 5000
- Trans (Puls) Synergic 7200 (with two Trans(Puls) Synergics operated in
parallel)
- Trans (Puls) Synergic 9000 (with two Trans(Puls) Synergics operated in
parallel)
- “TimeTWIN digital” process
The VR 1530-KD has been specifically designed for operation in conjunction with the
KD 7000 unreeling device.