Fronius KD 4000 D-11 Operating Instructions Manual Download Page 1

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42,0426,0031,EN 001-30012020

KD 4000 D-11

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Operating Instructions

Wire-feed unit

Summary of Contents for KD 4000 D-11

Page 1: ...on elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0031 EN 001 30012020 KD 4000 D 11 Operating Instructions Wire...

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Page 3: ...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 Explan...

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Page 5: ...bols 16 Data protection 16 Copyright 17 General 18 Device concept 18 Application area 18 Warning notices on the device 18 Control elements and connections 19 General 19 Safety 19 Cold wire feeder fron...

Page 6: ...en circuit calibration 36 Service codes shown when the drive units are engaged engaged calibration 37 Service codes in conjunction with the cold wire feeder and digital gas control option 39 Service c...

Page 7: ...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 use...

Page 8: ...ing 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...

Page 9: ...power level of 80 dB A ref 1pW when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN 60974 1 It is not...

Page 10: ...osion 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 o...

Page 11: ...g 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 t...

Page 12: ...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 kep...

Page 13: ...n 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 web...

Page 14: ...ngs 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...

Page 15: ...he 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...

Page 16: ...nal 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 m...

Page 17: ...t 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 a...

Page 18: ...ot applications and automated tasks The cold wire feeder is suitable for all standard shielding gases Warning notices on the device The cold wire feeder has safety symbols on the rating plate These sa...

Page 19: ...and understand all the Operating Instructions for the system components especially the safety rules Cold wire feeder front Front 1 Welding torch current socket connection in conjunction with a MagicWa...

Page 20: ...pack 5 Water flow connection blue Interconnecting hosepack Cold wire feeder right side Side view Detailed view of feeder inching feeder backward but ton 1 Welding torch current socket connection for a...

Page 21: ...t a constant rate equal to the wire speed set for the Fdi welding parameter Time path of the wirespeed when the feeder inching backward button is pressed and held down IMPORTANT For more detailed info...

Page 22: ...er on the power source CAUTION Danger from falling cold wire feeder This can result in serious injury and damage to property Check that the cold wire feeder is securely placed on the receptor pin Wire...

Page 23: ...the 2 screws Swing side panel upwards If the welding torch has a conventional control plug instead of a LocalNet connection socket Remove blanking cover 1 for bushing 3 Feed control socket 4 through b...

Page 24: ...lug to the LocalNet port 3 or torch control connection 4 and fasten If present connect colour coded exter nal water connections for water flow 5 and return 6 Plug welding potential bayonet plug into c...

Page 25: ...el of the wirefeeder Place the wirespool and wirespool holder on the correct side Latch the locking bolt 1 into opening provided on the spool body Adjust braking force with clamping screw 2 Close left...

Page 26: ...serious injury and damage to property Make sure the wirespool sits securely on the wirespool holder To ensure that the wirespool is properly in place and that the brake works properly fit the brake ac...

Page 27: ...y use feed rollers that match the wire electrode An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists USA wirefeeders In the USA all wirefeed...

Page 28: ...e spool Make sure that the wirespool or basket type spool with adapter is fitted securely to the wire spool holder Inserting the wire spool 1 Inserting the bas ket type spool NOTE When working with ba...

Page 29: ...29 EN 1 2 1 2...

Page 30: ...oid injuries caused by the wire springing back CAUTION Danger from sharp end of wire electrode This may result in damage to the welding torch Deburr the end of the wire electrode well before threading...

Page 31: ...ressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wire feeding 1 2 2 5 1 1 1 Contact pressure stand ard values Semi cylindrical rolls Trapeze rolls Plastic...

Page 32: ...32 Adjust the brake Adjusting the brake NOTE After releasing the torch trigger the wirespool should stop unreeling Adjust brake if necessary 1 2 3 4 3 STOP 6 7 5 1 2 1 2 1 2 2 1 4 STOP OK 3 3...

Page 33: ...rrectly can cause serious injury and damage Do not dismantle the brake Maintenance and servicing of brakes to be carried out by trained qualified per sonnel only The brake is only available as a compl...

Page 34: ...following list 0 Fronius KD7000 VR1530KD Drive 22 m min or 866 ipm 2 Fronius Torch Drive 10 m min or 394 ipm 3 Fronius Torch Drive 22 m min or 866 ipm 15 Fronius KD7000 VR1530KD Drive 10 m min or 394...

Page 35: ...d and from rotating cogs and drive parts Keep the welding torch away from your face and body Keep hands away from rotating cogs and the wire drive Press the feeder inching or gas test button The wiref...

Page 36: ...ause Incorrect measurement during push pull calibration Remedy Repeat push pull calibration St1 E 1 Cause At minimum wire speed the cold wire feeder motor does not deliver any ac tual rotational speed...

Page 37: ...speed the motor of the push pull unit does not deliver any actual rotational speed value Remedy Repeat the push pull calibration If the error message re appears Contact Af ter Sales Service St2 E 10...

Page 38: ...the hosepack in as straight a line as possible check the inner liner for kinks or soiling check the contact pressure on the 2 roller or 4 roller drive of the push pull unit Re peat the push pull calib...

Page 39: ...pull unit EFd 8 2 Cause Fault in the wire feed system overcurrent in wire feed unit drive Remedy Arrange the hosepack in as straight a line as possible check that there are no kinks or dirt in the in...

Page 40: ...nter lever on push pull unit Acknowledge service code using Feeder inching button Cause Push pull unit slipping Remedy Check wearing parts for wire feeding Use suitable feed rollers Increase contact p...

Page 41: ...e welding machine at a cooler location acknowledge Err 056 by pressing the Store button Cause Excessive motor current on the KD 4000 D 11 e g due to wirefeed problems or an inadequately dimensioned wi...

Page 42: ...ing a suitable measuring instrument check to make sure that electrically charged components e g capacitors have been discharged Every start up Check welding torch interconnecting hosepack and ground e...

Page 43: ...meter 0 8 3 2 mm 0 03 0 13 in Wirespool diameter max 300 mm max 11 81 in Wirespool weight max 16 kg max 35 27 Ib Wirespool types all standardised wirespools Degree of protection IP 23 Dimensions l x w...

Page 44: ...TERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and...

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