FRO­NIUS KD 7000 User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0028,EN 002-13122016
KD 7000 Operating Instructions
Wire-feed unit
EN

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EN
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.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is 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.
It does not indicate a potentially damaging or dangerous situation.

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EN
Contents
Safety rules ................................................................................................................................................ 7
General ...................................................................................................................................................... 18
Device concept ..................................................................................................................................... 18
Application areas .................................................................................................................................. 18
Warning notices on the device.............................................................................................................. 19
Application ................................................................................................................................................. 20
General ................................................................................................................................................. 20
Configuration 1: unalloyed/high-alloy steels (Push/Internal)................................................................. 20
Configuration 2: unalloyed/high-alloy steels (Push VR 1530/External)................................................. 21
Configuration 3: Aluminium (Pull/Internal) ............................................................................................ 22
Configuration 4: Aluminium (Pull/External) ........................................................................................... 23
Controls, connections and mechanical components.................................................................................. 24
KD 7000 ................................................................................................................................................ 24
TIG-KD connection box......................................................................................................................... 26
Setting wire speed externally ..................................................................................................................... 29
Setting wire speed externally ................................................................................................................ 29
TIG-KD connection box wiring diagram ..................................................................................................... 30
"Minimum start-up requirements" wiring diagram ...................................................................................... 31
Analogue signals................................................................................................................................... 31
Digital signals........................................................................................................................................ 31
KD 7000 wiring diagram............................................................................................................................. 32
Supply voltages.......................................................................................................................................... 33
Supply voltages..................................................................................................................................... 33
Digital input signals (signals from robot) .................................................................................................... 34
Signal level............................................................................................................................................ 34
Ground .................................................................................................................................................. 34
Start KD ................................................................................................................................................ 34
Arc on (Command arc on)..................................................................................................................... 34
Gas on (Command gas on)................................................................................................................... 34
Touch sensing....................................................................................................................................... 35
Wire retract on/off (WR on/off) .............................................................................................................. 35
Job recall (Job mode) ........................................................................................................................... 35
Reserve 4, reserve 5............................................................................................................................. 36
Emergency stop .................................................................................................................................... 36
Wire retract ........................................................................................................................................... 36
Robot wire-pulsing (Wire pulse robot)................................................................................................... 37
Analogue input signals (signals from robot)............................................................................................... 38
General ................................................................................................................................................. 38
Wire speed ("Vd command value" or "VD1") ........................................................................................38
Specifying power source set value for standard welding ...................................................................... 38
Specifying power source set value for pulsed-arc welding ................................................................... 38
Digital output signals (signals to robot) ...................................................................................................... 40
General ................................................................................................................................................. 40
Pulssynch HIGH.................................................................................................................................... 40
Common signal (Signal common)......................................................................................................... 40
Current flow signal (Signal current flow) ............................................................................................... 40
HF on signal (Signal HF on).................................................................................................................. 40
Gas on signal (Signal gas on)............................................................................................................... 40
Alarm signal .......................................................................................................................................... 41
Reserve signal ...................................................................................................................................... 41
Signal KD ready .................................................................................................................................... 41
Main current signal................................................................................................................................ 42
Start-up ...................................................................................................................................................... 43
Safety.................................................................................................................................................... 43
Proper use ............................................................................................................................................ 43
Setup regulations .................................................................................................................................. 43
Mains connection .................................................................................................................................. 43
Connecting the VR 1530 KD wire drive ................................................................................................ 43
Connecting the TIG-KD manual torch................................................................................................... 44
Connecting the wirefeed for TIG robot torches ..................................................................................... 44

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Connecting Robacta Drive KD wire drive.............................................................................................. 44
inserting/replacing feed rollers .............................................................................................................. 44
Inserting the wirespool .......................................................................................................................... 45
Inserting the basket-type spool ............................................................................................................. 46
Feeding in the welding wire .................................................................................................................. 46
Adjusting the brake ............................................................................................................................... 47
Design of the brake............................................................................................................................... 48
Troubleshooting ......................................................................................................................................... 49
Troubleshooting .................................................................................................................................... 49
Care, maintenance and disposal ............................................................................................................... 50
General ................................................................................................................................................. 50
Care and maintenance.......................................................................................................................... 50
Disposal ................................................................................................................................................ 50
Technical data............................................................................................................................................ 51
KD 7000 ................................................................................................................................................ 51
Spare parts list: KD 7000 ........................................................................................................................... 52

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EN
Safety rules
General
Proper use
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 operat-
ing 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 be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion 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.
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 safe-
ty.
This is for your personal safety!
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 manufac-
turer 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 manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.

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Environmental
conditions
Obligations of the
operator
Obligations of
personnel
Mains connection
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 sub-
stances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
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.
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.
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device 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.
NOTE! Ensure that the mains connection is earthed properly

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EN
Protecting your-
self and others
Noise emission
values
Persons involved with welding expose 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
Anyone working on the workpiece while welding is in progress must wear suit-
able protective clothing with 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 protec-
tive 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 devic-
es 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 or
- erect suitable safety screens/curtains.
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 per-
missible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.

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Danger from toxic
gases and va-
pours
Danger from fly-
ing sparks
Risks from mains
current and weld-
ing current
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances,
cause birth defects or cancer.
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 tak-
ing place.
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.
Amongst others, the following components are responsible 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
radiation area.
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 in-
jury 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 ac-
cordance 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.

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EN
Meandering weld-
ing currents
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 suit-
able, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately
dimensioned. Replace loose connections and scorched, damaged or inade-
quately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pre-load.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the
welding electrodes of two power sources. Touching the potentials of both 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.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent 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, appoint a second person to switch off the main
switch at the right moment.
If the following instructions are ignored, meandering welding currents can de-
velop 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 weld-
ed.

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EMC Device Clas-
sifications
EMC measures
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: 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 wire-feed unit.
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
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 rec-
tify 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 connec-
tion, additional measures are necessary (e.g. use a suitable line fil-
ter).
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

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EN
EMF measures
Specific hazards
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 ap-
proaching 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
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 com-
ponents.
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.
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 al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling cool-
ant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.

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Factors affecting
welding results
Danger from
shielding gas cyl-
inders
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).
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 de-
vices).
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, coun-
terbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the device-
side thread of the adapter for the shielding gas connection using suitable Tef-
lon tape.
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.
NOTE! There is an increased risk of soiling if ring mains are being
used
Shielding gas cylinders contain gas under pressure and can explode if dam-
aged. 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 instruc-
tions 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.

15
EN
Safety measures
at the installation
location and dur-
ing transport
Safety measures
in normal opera-
tion
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 na-
tional and international regulations for shielding gas cylinders and accesso-
ries.
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 protec-
tion shown on the rating plate.
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 escape unhindered.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Before transporting the device, allow coolant to drain completely and detach
the following components:
- Wire-feed unit
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for dam-
age before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Only operate the device if 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 func-
tioning 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 com-
patibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
The manufacturer accepts no liability for damage resulting from use of a dif-
ferent coolant. In addition, all warranty claims will be forfeited.

16
Commissioning,
maintenance and
repair
Safety inspection
Disposal
The 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 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 and while the system is still
cool.
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 immedi-
ately.
- 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
specified torque.
The manufacturer recommends that a safety inspection of the device is per-
formed 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 stand-
ards 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.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive on Waste Electrical and Electronic Equipment and its im-
plementation as national law, electrical equipment that has reached the end of
its life must be collected separately and returned to an approved recycling fa-
cility. 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!

17
EN
Safety symbols
Data protection
Copyright
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 rele-
vant standards for Canada and the USA.
The user is responsible for the safekeeping of any changes made to the fac-
tory settings. The manufacturer accepts no liability for any deleted personal
settings.
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
mistakes that you have found in the instructions, we will be most grateful for
your comments.

18
General
Device concept The KD 7000 cold-wire wire-feed unit has
been developed specifically for the Ma-
gicWave 2600/2600 CEL and TransTig
2600 CEL/3000 power sources.
At the same time, the flexible design of the
KD 7000 with its own mains cable and inte-
grated drive control allows for combination
with more or less any TIG power source or
laser welding system.
The wire speed is specified either using the
controls on the KD 7000 itself or by means
of an analogue signal from an external ro-
bot or machine controller. The drive control
on the KD 7000 ensures precise adherence
to the specified wire speed.
The TIG-KD manual torch can be used for manual cold wire TIG welding.
For robot applications with the TIG cold-wire welding process, the TIG-KD connection box
acts as a central node to network the robot control to the power source and the KD 7000.
To set the welding parameters for the power source on the robot, the TIG-KD connection
box supports the simulation of various remote controls.
All other communication with the power source takes place via the analogue/digital robot
interface that is required for the MagicWave 2600/2600 CEL and TransTig 2600 CEL/3000
TIG power sources.
The TIG-KD connection box is not intended for cold wire TIG welding applications with la-
ser welding systems. In this case, external control of the KD 7000 is via the robot controller.
The Robacta Drive KD is recommended as a wire drive for the KD 7000 in the case of al-
uminium applications. This is an external drive system that draws the wire during the weld-
ing process itself. The Robacta Drive provides for exceptionally smooth wire travel.
The 4 roller drive integrated in the KD 7000 - that pushes the wire - is designed for use
when working with unalloyed/high-alloy steels. The VR 1530 KD external 4 roller drive is
recommended for robot applications with unalloyed/high-alloy steels.
If it is combined with an external wire drive and an external wirespool holder, the KD 7000
can be used as a flexible control and adjustment unit with unlimited siting options.
Because there is no need for a connection to the hosepack, the KD 7000 can be set up in
virtually any position.
Application areas The KD 7000 cold wire wire-feed unit is ideally suited for automated and robotic welding
tasks, however it can also be used for special applications in manual welding. The KD 7000
can be used for an extremely varied range of applications both for TIG and laser welding.
Depending on the design of the welding machine or the welding robot and the system com-
ponents, the flexible design of the KD 7000 means the layout of the wirefeed components
can be customised. The various configuration options are explained in the "Application"
section below.

19
EN
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.
Welding is dangerous. The following basic requirements must be met to en-
sure the equipment is used properly:
- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved must be kept at a safe distance from the wire-
feed unit and the welding process
Do not use the functions described here until you have fully read and under-
stood the following documents:
- These operating instructions
- all the operating instructions for the system components, especially the
safety rules

20
Application
General IMPORTANT! The figures below show configuration examples for the KD 7000 with an in-
dustrial robot and a Fronius TIG power source. The configuration examples shown apply
by analogy to welding machines and cold wire TIG welding applications with laser welding
systems.
Figures 1 and 2 apply by analogy to manual TIG welding with cold-wire feed.
Recommended for welding machines
- Wirespool and 4 roller drive integrated in KD 7000
- Wire pushed by integrated 4 roller drive
- Length of the wirefeed hosepack: up to 3.5 m
Configuration 1:
unalloyed/high-
alloy steels
(Push/Internal)
Configuration 1 - Wirespool and wire drive on KD 7000, wire pushed
(1) KD 7000 with wirespool holder and 4 roller drive
(2) Wirefeed hosepack
(3) Welding torch
(4) Wirefeed
(5) Robot control
(6) TIG-KD connection box
(7) Power source robot interface
(8) Power source
Limitation in the case of aluminium:
- Length of hosepack may not exceed 1 m
(1) (2) (3)
(4)(5)(6)(7)(8)