FRO­NIUS VR 4000 User manual

Operating
Instructions
VR 4000
VR 4000-30 TIME
VR 4000-30
42,0426,0012,EN 008-10012024
EN Operating Instructions

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 famili-
arise 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 re-
liable operation. These are essential prerequisites for excellent results.
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.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
This does not indicate a potentially hazardous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care
is required.
3
EN

4

Contents
Dear reader,
Introduction 3
Explanation of safety notices 3
Safety rules 7
General 7
Proper use 7
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 8
Protecting yourself and others 9
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 12
EMC measures 12
EMF measures 12
Specific hazards 13
Factors affecting welding results 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 14
Sicherheitsmaßnahmen am Aufstellort und beim Transport 15
Safety measures in normal operation 15
Commissioning, maintenance and repair 16
Safety inspection 16
Disposal 17
Safety symbols 17
Data protection 17
Copyright 17
General 18
Device concept 18
REQUIREMENTS 18
Application area 19
Warning notices on the device 19
Options 20
"Mode" switch option for VR 4000/VR 4000-30 20
Optional control panels for VR 4000/VR 4000-30 20
Optional installation and conversion kits 20
Controls and indicators 22
General 22
Standard control panel 22
Control panel VR 4000-30 TIME 23
Connections and mechanical components 25
Front of wirefeeder 25
Rear of wire-feed unit 25
Side of wire-feed unit 26
Placing wire-feed unit on power source 28
General 28
General 28
Connecting wire-feed unit to power source 29
General 29
Connecting the wirefeeder to the power source 29
Connecting the welding torch 31
Welding torch connections 31
Safety 31
Connecting MIG/MAG manual welding torch 31
Connecting MIG/MAG robot welding torch 31
Connecting the Tweco welding torch 32
Inserting/replacing feed rollers 33
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EN

General remarks 33
USA wirefeeders 33
inserting/replacing feed rollers 33
Inserting the wirespool, inserting the basket-type spool 35
Safety 35
Inserting the wirespool 35
Inserting the basket-type spool 37
Feeding in the wire electrode 38
Feed in the wire electrode 38
Set the contact pressure 40
Adjust the brake 41
Adjusting the brake 41
Start-up 42
General information 42
Requirements 42
Care, maintenance and disposal 43
General remarks 43
Every start-up 43
Every 6 months 43
Disposal 43
Technical data 44
VR 4000 44
VR 4000-30 44
VR 4000-30 TIME 45
Appendix 47
VR 4000 TIME, VR 4000, VR 4000-30 48
6

Safety rules
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
-injury or death to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the
device must:
-be suitably qualified,
-have sufficient knowledge of welding and
-read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental 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.
For the location of the safety and danger notices on the device, refer to the sec-
tion 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 in-
structions
-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 set-
ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
7
EN

Environmental
conditions
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.
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 sec-
tion "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 pre-
vention
-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 connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
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 mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
8

Protecting your-
self and others
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 us-
ing cardiac pacemakers
-Risk of electrocution from mains current and welding current
-Greater noise pollution
-Harmful welding fumes and gases
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 protect-
ive 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 in-
jury
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 vi-
cinity:
-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 cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that can cause cancer, as stated in Mono-
graph 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 with a ventilation rate of at least 20 m³/
hour.
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
9
EN

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.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation area.
Danger from fly-
ing sparks
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 alternatively 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 accord-
ance 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.
Risks from mains
current and
welding current
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 wire spool, 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 di-
mensioned. 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.
10

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
-never be immersed in liquid for cooling
-never be touched when the welding system is switched on.
Double the open circuit voltage of a welding system can occur between the weld-
ing electrodes of two welding systems. Touching the potentials of both elec-
trodes 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.
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 regula-
tions 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 anyone 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, have a second person switch off the main switch
at the right moment.
Meandering
welding currents
If the following instructions are ignored, meandering welding currents can devel-
op with the following consequences:
-Fire hazard
-Overheating of parts connected to the workpiece
-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 envir-
onments, such as insulation against conductive floor or insulation to conductive
racks.
If power distribution boards, twin-head mounts, etc., are being used, note the fol-
lowing: 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.
11
EN

EMC Device
Classifications
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
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 recti-
fy the situation.
Check and evaluate the immunity to interference of nearby devices according to
national and international regulations. Examples of equipment that may be sus-
ceptible to interference from the device include:
-Safety devices
-Network, 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 the correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line filter)
2.Welding power-leads
-must be kept as short as possible
-must be laid 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.Shield, if necessary
-Shield other devices nearby
-Shield the entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
-Effects on the health of persons in the vicinity, e.g. those with pacemakers
and hearing aids
-Individuals with pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
-For safety reasons, maintain as large a distance as possible between the
welding power-leads and the head/torso of the welder
-Do not carry welding power-leads and hosepacks over the shoulders or wind
them around any part of the body
12

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
-Fans
-Cogs
-Rollers
-Shafts
-Wire spools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels must only be opened/removed while maintenance or re-
pair 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.
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
wirefeeder) 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 al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Welding systems for work in areas with increased electrical risk (e.g. near boilers)
must carry the ‘Safety’ sign. However, the welding system must not be located in
such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting 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 down-
loaded from the manufacturer’s website.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
-Hook chains or ropes onto all suspension points provided on the load-carry-
ing equipment.
-Chains and ropes must be at the smallest angle possible to the vertical.
-Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the wirefeeder is attached to a crane holder during welding, always use a suit-
able, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by
hand. The carrying strap is not to be used if transporting with a crane, counter-
balanced lift truck or other mechanical hoist.
All lifting tackle (straps, handles, chains, etc.) used in connection with the device
or its components must be tested regularly (e.g. for mechanical damage, corro-
sion or changes caused by other environmental factors).
13
EN

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.
Factors affect-
ing welding res-
ults
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 < 40 µm
-Pressure dew point < -20 °C
-Max. oil content < 25 mg/m³
Filters must be used if necessary.
IMPORTANT! There is an increased risk of soiling if ring mains are being used
Danger from
shielding gas cyl-
inders
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.
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 international regulations for shielding gas cylinders and accessories.
Danger from es-
caping shielding
gas
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 oxygen in the ambient air.
14

-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 tak-
ing place.
-Check the shielding gas cylinder or main gas supply for uncontrolled gas
leakage before every start-up.
Sicher-
heitsmaßnah-
men am Aufstel-
lort und beim
Transport
Ein umstürzendes Gerät kann Lebensgefahr bedeuten! Das Gerät auf ebenem,
festem Untergrund standsicher aufstellen
-Ein Neigungswinkel von maximal 10° ist zulässig.
In feuer- und explosionsgefährdeten Räumen gelten besondere Vorschriften
-entsprechende nationale und internationale Bestimmungen beachten.
Durch innerbetriebliche Anweisungen und Kontrollen sicherstellen, dass die
Umgebung des Arbeitsplatzes stets sauber und übersichtlich ist.
Das Gerät nur gemäß der am Leistungsschild angegebenen Schutzart aufstellen
und betreiben.
Beim Aufstellen des Gerätes einen Rundumabstand von 0,5 m (1 ft. 7.69 in.)
sicherstellen, damit die Kühlluft ungehindert ein- und austreten kann.
Beim Transport des Gerätes dafür Sorge tragen, dass die gültigen nationalen und
regionalen Richtlinien und Unfallverhütungs-Vorschriften eingehalten werden.
Dies gilt speziell für Richtlinien hinsichtlich Gefährdung bei Transport und
Beförderung.
Keine aktiven Geräte heben oder transportieren. Geräte vor dem Transport oder
dem Heben ausschalten und vom Stromnetz trennen!
Vor jedem Transport eines Schweißsystems (z.B. mit Fahrwagen, Kühlgerät, Sch-
weißgerät und Drahtvorschub) das Kühlmittel vollständig ablassen, sowie fol-
gende Komponenten demontieren:
-Drahtvorschub
-Drahtspule
-Schutzgas-Flasche
Vor der Inbetriebnahme, nach dem Transport, unbedingt eine Sichtprüfung des
Gerätes auf Beschädigungen vornehmen. Allfällige Beschädigungen vor Inbe-
triebnahme von geschultem Servicepersonal instandsetzen lassen.
Safety measures
in normal opera-
tion
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 function-
ing of safety devices.
15
EN

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 compatibil-
ity, 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.
The manufacturer accepts no liability for damage resulting from use of other sys-
tem 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 con-
tainers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na-
tional and international regulations. The coolant safety data sheet may be ob-
tained 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.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
-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.
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 spe-
cified torque.
Safety inspec-
tion
The manufacturer recommends that a safety inspection of the device be per-
formed at least once every 12 months.
The manufacturer recommends that the welding system 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 are carried out
-at least every twelve months.
For safety inspections, follow the appropriate national and international stand-
ards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you with any documents you may require, on re-
quest.
16

Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally responsible manner in accordance with the EU Dir-
ective and national law. Used equipment must be returned to the distributor or
through a local, authorised collection and disposal system. Proper disposal of the
old device promotes sustainable recycling of material resources. Ignoring this
may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume
of the box.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic 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 pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
17
EN

General
Device concept
VR 4000/VR 4000-30 wire-feed unit VR 4000-30 TIME wire-feed unit
The wire-feed units are designed to be used with wirespools of max. 300 mm
(11.81 in) diameter. The standard 4-roller drive has good wirefeeding properties.
The wirefeeders are also suitable for long hosepacks. Due to their compact size,
the wirefeeders can be used in many different ways.
The VR 4000-30 TIME wire-feed unit is specially designed for the TIME high-per-
formance welding process. All the important TIME process functions can be set
directly on the wire-feed unit control panel using the integrated 3-parameter
control. The following functions are not available:
-MIG/MAG standard manual welding
-Job mode
-LocalNet connection (e.g. operation with remote control or JobMaster weld-
ing torch)
REQUIRE-
MENTS
To operate the wirefeeder, it must first be configured for use with the corres-
ponding power source:
VR
4000
VR
4000-30
VR 4000-30
TIME
TransSynergic 4000/5000 X X -
TransSynergic 7200/9000 X X -
TransPuls Synergic
3200/4000/5000
X X -
TransPuls Synergic 7200/9000 X X -
TIME 5000 Digital - X X
TransPuls Synergic 2700 Duo X - -
TransPuls Synergic 2700 Duo TIG X - -
18

Application area -VR 4000: for all types of MIG/MAG welding
-VR 4000-30: primarily used with TS/TPS 7200 and TS/TPS 9000 high-per-
formance power sources. In conjunction with the TR 2100 remote control,
and also with the TIME 5000 Digital power source
-VR 4000-30 TIME: in conjunction with the TIME 5000 Digital high-perform-
ance power source, for all types of MIG/MAG high-performance welding
All variants of the VR 4000 are suitable for all standard shielding gases.
NOTE!
The VR 4000 - 30 and VR 4000-30 TIME wire-feed units have a water-cooled
electric motor with disc-shaped rotor, and may only be operated in conjunction
with an appropriate cooling unit.
Warning notices
on the device
The wire-feed unit has safety symbols on the rating plate. The safety symbols
must not be removed or painted over. The symbols warn against operating the
equipment incorrectly, as this may result in serious injury and damage.
Do not use the functions described here until you have fully read and
understood the following documents:
-These operating instructions
-all the operating instructions for the system components, espe-
cially the safety rules
Welding is dangerous. The following basic requirements must be met:
-welders must be sufficiently qualified
-use appropriate protective equipment
-all persons not involved in the welding process must be kept at a
safe distance
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EN

Options
"Mode" switch
option for VR
4000/VR
4000-30
Detailed view of "Mode" switch option
The "mode" switch enables the pro-
cesses and modes to be selected on
site; the "gas test" and "wire threading"
functions can also be carried out on
site.
NOTE!
The "Mode selector switch" option cannot be used in conjunction with the VR
4000 digital display control panel.
Optional control
panels for VR
4000/VR
4000-30
The VR 4000 and VR 4000-30 wire-feed units can, as an alternative to the stand-
ard control panel, be fitted with the following control panels:
-VR 4000 Ci control panel
-VR 4000 digital display
Please refer to the installation instructions for a detailed description of the op-
tional control panels
VR 4000 Ci control panel option VR 4000 digital display option
Optional install-
ation and con-
version kits
Robacta Drive installation kit
for retrofitting a connection socket for the Robacta Drive robot welding torch
Push-pull unit installation kit
for subsequent installation of a push-pull unit
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