FRO­NIUS VR 4040 User manual

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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0014,EN 001-18022020
VR 4040
[
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 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.

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EN
Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 7
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 8
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 11
EMC measures ..................................................................................................................................... 11
EMF measures...................................................................................................................................... 12
Specific hazards.................................................................................................................................... 12
Requirement for the shielding gas ........................................................................................................ 13
Danger from shielding gas cylinders..................................................................................................... 13
Danger from escaping shielding gas..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 14
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 15
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 16
Data protection...................................................................................................................................... 16
Copyright............................................................................................................................................... 16
General ...................................................................................................................................................... 17
Machine concept................................................................................................................................... 17
Areas of application and features ......................................................................................................... 17
Application examples ................................................................................................................................. 19
General ................................................................................................................................................. 19
Configuration 1: MIG/MAG-welding ...................................................................................................... 19
Configuration 2: TIG cold-wire welding ................................................................................................. 20
Start-up ...................................................................................................................................................... 21
Safety.................................................................................................................................................... 21
Accessories........................................................................................................................................... 21
Opening and closing the VR 4040 unreeling device............................................................................. 21
Dismounting and re-mounting the side guard panel ............................................................................. 22
Mounting the wirefeeder ....................................................................................................................... 23
Removing and inserting the wire-spool carrier...................................................................................... 24
Mounting and dismounting the wire-spool driver .................................................................................. 24
Fastening the wire-spool carrier to the spool and detaching it from the spool...................................... 25
Inserting in the wire electrode ............................................................................................................... 26
230 V interior heating system, unregulated .......................................................................................... 27
Mounting the interior heating system .................................................................................................... 27
I24 V interior heating system, regulated ............................................................................................... 28
Mounting the 24 V inerior heating system............................................................................................. 29
Putting the interior heating system into service .................................................................................... 31
Technical data: 24 V interior heating system, regulated....................................................................... 31
End-of-wire watchdog ................................................................................................................................ 33
General remarks ................................................................................................................................... 33
Mounting the end-of-wire watchdog...................................................................................................... 33
Functional principle .................................................................................................................................... 35
Idling, Accelerating................................................................................................................................ 35
Increase in tensile force as a function of wirefeed speed ..................................................................... 36
Limiting the tensile load on the wire...................................................................................................... 36
Equilibrium and working position .......................................................................................................... 36
Decelerating.......................................................................................................................................... 36
Adjusting the braking system ..................................................................................................................... 38

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Safety.................................................................................................................................................... 38
Adjusting the braking force ................................................................................................................... 38
Adjusting the braking system response ................................................................................................ 39
Adjusting the working position .............................................................................................................. 40
Measuring the value for the wire tensile-force limitation ....................................................................... 40
Setting the wire tensile-force limitation ................................................................................................. 41
Care, maintenance and inspection ............................................................................................................ 43
Safety.................................................................................................................................................... 43
General remarks on the wearing parts.................................................................................................. 43
Fonction test ......................................................................................................................................... 43
Damper ................................................................................................................................................. 43
Brake block ........................................................................................................................................... 44
Brake clearence .................................................................................................................................... 45
Overload coupling ................................................................................................................................. 46
Wire-guide tubes................................................................................................................................... 49
Changing the intermediate guide.......................................................................................................... 49
Drawback pulleys.................................................................................................................................. 50
Shoe for end-of-wire watchdog ............................................................................................................. 50
Dispsal of used parts and materials...................................................................................................... 51
Troubleshooting ......................................................................................................................................... 52
Troubleshooting guide .......................................................................................................................... 52
Technical data............................................................................................................................................ 54
VR 4040 ................................................................................................................................................ 54

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EN
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 applica-
ble and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as not in ac-
cordance with the intended purpose. The manufacturer shall not be held liable for any dam-
age arising from such usage.

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Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
operator
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the section "safety
rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are working in a
safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
consumption.
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance *)
- Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power sup-
ply company.
IMPORTANT! Ensure that the mains connection is earthed properly
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 using cardi-
ac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases

9
EN
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 reg-
ulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Keep all persons, especially children, out of the working area while any devices are in op-
eration or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
Danger from toxic
gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).

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Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Danger from 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 al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains
current and weld-
ing 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 wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry 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 dimen-
sioned. 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 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 elec-
trodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
The device must only be operated on a mains supply with a ground conductor and a socket
with a ground conductor contact.

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EN
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 any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
Meandering weld-
ing currents
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient insulating ma-
terial to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following: The elec-
trode 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 elec-
trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wire-
feed unit.
EMC Device Clas-
sifications
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
sions, it may affect the application area for which it was designed (e.g. when there is sen-
sitive equipment at the same location, or if the site where the device is installed is close to

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either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situ-
ation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interfer-
ence from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing
aids
- wearers of pacemakers must seek advice from their doctor before approaching the de-
vice or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/
torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around
any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
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.

13
EN
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources 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 disconnecting cool-
ant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The cool-
ant safety data sheet may be obtained from your service centre or downloaded from the
manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
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, counterbalanced 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 chang-
es caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Requirement for
the shielding gas
Especially with ring lines, contaminated shielding gas can cause damage to equipment and
reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Danger from
shielding gas 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.

14
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan-
ical 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 cylin-
ders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.
The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Danger from 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 ox-
ygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage be-
fore every start-up.
Safety measures
at the installation
location and dur-
ing transport
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and ac-
cident prevention regulations. This applies especially to guidelines regarding the risks aris-
ing during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.

15
EN
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before com-
missioning the device.
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 functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its prop-
erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system com-
ponents 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 cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac-
turer'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.

16
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 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 di-
rectives.
Further details on safety inspection and calibration can be obtained from your service cen-
tre. They will provide you on request with any documents you may require.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 se-
ries).
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 ba-
sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for
improvement, or can point out any mistakes that you have found in the instructions, we will
be most grateful for your comments.

17
EN
General
Machine concept
VR 4040 unreeling device
The VR 4040 unreeling device is a further
member of the modular family of Fronius
wire-feeding equipment.
Suitable adapters are available for moun-
ting whatever wirefeeder unit is used. There
are also suitable adapter sets for fitting a
wide range of different types of wire spool.
In designing the unreeling device, Fronius
paid particular attention to ergonomic issu-
es. Special emphasis was placed here on
making it easier to change the wire spools,
which can often be very heavy. A remova-
ble wire-spool carrier facilitates spool
changeover. If a second wire-spool carrier
is mounted, this can save even more down-
time by making it easy to prepare a second
spool ready for insertion.
The swing-out ramp and the guide-rails make it possible to change the wire spool easily,
quickly and with a minimum of physical effort. The large viewing panel allows users to
check constantly on the operational status, and on how much wire there is left on the spool
(N.B. this latter point can also be monitored by the optional end-of-wire watchdog).
In order to provide greater flexibility at the welding location, the unreeling device comes
with an integral trolley consisting of two fixed castors and two swivel castors. The swivel
castors can be locked, both in the steering direction and in the direction of travel. If one
side of the unreeling-device housing needs to be placed flush against a wall or an adjacent
machine, the VR 4040 can also be ordered in a “mirror-image” version.
The optional end-of-wire watchdog alerts the operator in good time to the fact that the wire
spool will soon need changing. This makes it possible to prevent unnecessary disruption
of the production process. If the unreeling device is used in locations with strong tempera-
ture fluctuations and high atmospheric humidity, we advise ordering the optional interior
heating system. The interior heating system practically rules out any risk of condensation
inside the unit, and so prevents any quality-impairing oxidation from taking place on the
welding wire.
Areas of applica-
tion and features
The VR 4040 unreeling device is specially designed for robot and automated applications.
Both in MIG/MAG welding and in TIG (and laser) cold-wire welding, the VR 4040 unreeling
device is a vital component of any precision, high-performance wirefeed system.
The unreeling device is ideal for wire spools with a mass of up to 80 kg, a diameter of up
to 500 mm and a width of up 250 mm. Increases in the permissible spool mass are possible
on request.
The high-dynamism concept underlying the VR 4040 unreeling device makes possible
both high wirefeed speeds and high wire-spool weights, at the same time as ensuring that
the welding wire is only exposed to a minimum of tensile strain. Even when welding starts

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up at high wirefeed speeds, the wire buffer prevents the spool-mass from accelerating jerk-
ily, meaning that the wire is exposed to only moderate tensile forces. During welding start-
up, the tensile force of the wire is only increased (as a function of the wirefeed speed) as
far as is necessary in order to achieve timely acceleration of the wire spool.
Although the unreeling device has been optimally preconfigured for a wide range of differ-
ent wire spools, wirefeed speeds and welding wires before leaving the factory, it is possible
to “fine-tune” it where needed.
The following key parameters can be adjusted:
- braking force of the wire-spool brake
- braking system response
- working position
- limitation of wire tensile force in the acceleration phase
For a detailed explanation of how the braking system works, and of how to adjust it, please
see the sections headed “Functional principle” and “Adjusting the braking system”.

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EN
Application examples
General The examples given below also apply, analogously, to applications using automatic weld-
ing equipment.
Configuration 1:
MIG/MAG-weld-
ing
In the configuration example the VR 4040 unreeling device (1) is combined with an indus-
trial robot (8), the VR 1500 MIG/MAG wirefeeder unit (4) and a TS 4000 / 5000 or TPS 4000
/ 5000 digital MIG/MAG power source (2).
In this example, the power source communicates with the robot via the ROB 4000 / 5000
robot interface (5).
Configuration 1 - VR 4040 combined with the TS 4000 / 5000 or TPS 4000 / 5000 power source and the VR 1500
wirefeeder unit
(1) VR 4040 unreeling device
(2) TS 4000 / 5000 or TPS 4000 / 5000 MIG/MAG power source
(3) FK 4000 / FK 4000 R cooling unit
(4) VR 1500 MIG/MAG wirefeeder unit
(5) ROB 4000 / 5000 robot interface
(6) Robot control
(7) Robot control cubicle
(8) Robot
(9) Welding torch
(10) Interconnecting cable
(11) LocalNet connection cable
(12) “LocalNet passive” splitter
(13) Wirefeeder mounting adapter
in out
Control
Roboter-
interface
(9)
(5)
(11)
(10) (8)(4)
(13)
(3) (2) (6) (7) (1)
(12)

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Configuration 2:
TIG cold-wire
welding
In the configuration example the VR 4040 unreeling device (1) is combined with an indus-
trial robot (7), the KD 7000 TIG coldwire feeder (3) and a MagicWave 2600 / 2600 CEL or
TransTig 2600 CEL / 3000 TIG power source (2).
The power source communicates with the robot via the robot interface (6) (for MagicWave
2600 / 2600 CEL and TransTig 2600 CEL / 3000) and the TIG-KD connection box (5) (robot
control is networked with the power source and the KD 7000).
Configuration 2 - VR 4040 combined with the MagicWave 2600 / 2600 CEL or TransTig 2600 CEL / 3000 power
source and the KD 7000 cold-wire feeder
(1) VR 4040 unreeling device
(2) MagicWave 2600 / 2600 CEL or TransTig 2600 CEL / 3000 TIG power source
(3) KD 7000 cold-wire feeder
(4) Robot control
(5) TIG-KD connection box
(6) Power-source robot interface
(7) Robot
(8) Welding torch
(9) Wire infeed
(10) Interconnecting cable for addressing KD 7000 cold-wire feeder
(11) KD 7000 mounting adapter
(10)
(3)
(2)
(5)(6)
(7) (8) (9)
(11)
(1)
(4)