Fronius VR 1500-M Operating Instructions Manual Download Page 1

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42,0426,0008,EN 001-05022020

VR 1500-M

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Operating Instructions

Wire-feed unit

Summary of Contents for VR 1500-M

Page 1: ...nts on elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0008 EN 001 05022020 VR 1500 M Operating Instructions Wire feed unit EN ...

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Page 3: ...s 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...

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Page 5: ...s 16 Data protection 16 Copyright 16 General 17 Device concept 17 Preconditions for use 17 Applications 17 Scope of delivery 18 Additional requirements 19 Warning notices on the device 20 General 20 Controller 20 Drive plate 21 Options 22 Wire feeder hose 22 Lockable pressure lever for drive plate 22 Wire end plug kit 22 Wire coil intake robot cover for wire coil intake robot 22 Wire end sensors 2...

Page 6: ...re electrode to wire feed unit 33 Feeding in the wire electrode 33 Set the contact pressure 35 Care maintenance and disposal 36 General remarks 36 Every start up 36 Every 6 months 36 Disposal 36 Troubleshooting 37 Wire end error message 37 Wire end special function 37 Troubleshooting 37 Error reset 37 Technical data 38 VR 1500 M 38 ...

Page 7: ...d 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 ...

Page 8: ...ting 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 Co...

Page 9: ...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...

Page 10: ... 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 ...

Page 11: ...ch 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 to...

Page 12: ...ation 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 pos...

Page 13: ...G 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 acc...

Page 14: ...ourless 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 m 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 m...

Page 15: ...mability 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...

Page 16: ...ty 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 dire...

Page 17: ...oller need to be fitted separately the con troller needs to be earthed separately Preconditions for use Power sources TransSynergic 4000 5000 TransPuls Synergic 3200 4000 5000 Welding torches gas cooled robot welding torch Robacta MTG 2500 and Robacta MTG 4000 F Firmware Version of power source Official UST V 2 89 1 Applications Any MIG MAG application in automated operations ...

Page 18: ...t 2 1 x drive cover 3 1 x drive plate with feeder rolls 1 0 mm trapezoid groove 4 1 x drive plate bracket 5 1 x insulation plate 6 1 x Controller 7 4 x hexagonal socket head screw M6 x 16 washer 8 2 x hexagonal socket head screw M6 x 25 washer 9 4 x screws Extrude Tite M5 x 10 ...

Page 19: ...nnecting cable assembly controller article number 4 047 425 length 2 5 m for EA 1400 N article number 4 047 435 length 2 7 m for EA 1900 N 2 2 x strain relief 3 6 x screw Extrude Tite M5 x 16 You additionally require a standard interconnecting cable assembly to connect the system to the power supply ...

Page 20: ...erating the equipment incorrectly as this may result in serious injury and damage Warning label on controller Welding can be dangerous Ensure that the following basic requirements have been fulfilled staff must be qualified for welding task staff must wear protective clothing and mask keep bystanders well away 0 5 22 m min Do not use the described functions until you have familiarized yourself wit...

Page 21: ...ments must be met to en sure the equipment is used properly welders must be sufficiently qualified use appropriate protective equipment all persons not involved in the welding process must be kept at a safe dis tance CAUTION Motor and gearbox become hot under normal operation Only mount insulated ...

Page 22: ...hing a lockable pressure lever Prevents accidental adjustment of the pressure le ver Wire end plug kit For attaching the optional wire end plug power source switch off at wire end Wire coil intake robot cover for wire coil intake robot For attaching a wire coil holder wire coil holder with cover robot side Wire end sensors Wire end sensor VR 1500 with coil cover Wire end sensor VR 1500 for Maratho...

Page 23: ...m components especially the safety guide lines Controller Front View Rear View 1 Gas check key used to set the required gasflow at the pressure reducer Press the key and hold down to allow gas to escape 2 Inching key use to inch the wire electrode into the torch cable assembly with the system in a gasless zero current state 3 Cover unused 4 Connector Robacta robot welding torch 14 pin 5 Cover unus...

Page 24: ...r for attaching welding torch 2 Connector welding potential 3 4 roll drive 4 Wire feed tube 5 Shielding gas connector 6 Controller conntector 17 pin female Amphenol connector Drive plate bottom 7 Connector welding torch CAT lead 5 4 2 1 3 6 7 Detail X X ...

Page 25: ...osition Only carry out work on the machine when it has been disconnected from the mains supply Assembly Over view Assembly Overview 1 Power source e g TPS 5000 2 Interconnecting cable assembly Power source 3 2 x strain relief Assembly position can be chosen to suit application 4 Robot 5 Interconnecting cable assembly Controller 6 Controller with bracket Assembly position dictated by robot 7 Drive ...

Page 26: ... CAUTION Danger of injury due to falling parts Work that is carried out incorrectly may re sult in serious injury or damage to property Check the seating of the screw connec tions between the controller bracket and the robot Hold the robot side panel in the requi red position and attach the controller bracket to the robot use the side panel screws for the EA 1400 N robot use 4 hexagonal socekt hea...

Page 27: ...r bracket using 4 Extrude Tite M5 x 10 screws WARNING An electric shock can be fatal Work that is carried out incorrectly may result in serious injury or damage to property Mounting the drive plate to the robot only together with the insulating plate included in the wire feeders scope of delivery Attaching the drive plate IMPORTANT To allow the drive plate to be set up at a later stage do not tigh...

Page 28: ...ose the hose holder 3 Inching in the corrugated hose drive plate side Use a screwdriver to open up the hose holder 4 on the drive plate Insert corrugated hose 5 close hose holder Attach cable assembly components power cable to connector welding po tential 3 control cable gray to the controller connector 1 shielding gas hose to the shielding gas connector 2 Attaching the controller Attach LocalNet ...

Page 29: ... from the welding torch to the CAT line welding torch connector not shown Attaching the controller to the power source Attach the strain relief in the roboter welding cell 2 x choose assembly position to suit application IMPORTANT The distance between the two strain relief brackets should not exceed 550 mm Attach the interconnecting cable assembly for the controller to the robot side strain re lie...

Page 30: ...unction PPU in the second level of the power source menu as described in the power source operating manual The right hand display on the power source shows Press the inching in key The left hand display on the power source shows St1 Decouple the drive plate the wire feeder drive must be unstressed CAUTION Danger of injury due to rotating gears and drive components Operating the equipment incorrect...

Page 31: ...31 EN Press the Store button on the power source twice to quit the Setup menu Engage the drive plate 7 8 ...

Page 32: ... 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 wirefeeders are delivered without feed rollers After inserting the wirespool the feed rollers must be inserted into the wirefeeder inserting replac ing feed rollers 1 2 3 4 4 5 2 1 6 6 1 4 5 3 2 1 2 1 2 3 1 2 ...

Page 33: ... the earthed enclosure of a robot cell chafed wirefeeding hoses exposing the wire electrode Using wirefeeding hoses ensures that the wire electrode remains insulated as it is trans ported towards the wirefeeder To prevent chafing do not route the wirefeeding hoses over sharp edges Use hose holders or hose protectors as necessary Coupling pieces and hoods for welding wire drums also ensure safe tra...

Page 34: ...se injuries Wear suitable protective goggles Keep the tip of the welding torch away from your face and body Do not point the tip of the welding torch at people Make sure that the wire electrode does not touch any conductive or earthed parts e g housing 1 2 2 2 3 3 1 3 4 1 2 3 4 1 2 4 5 3 5 2 3 1 1 6 ...

Page 35: ...ct pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wire feeding 1 1 1 Contact pressure stand ard values Semi cylindrical rolls Trapeze rolls Plastic rollers Aluminium 1 5 3 5 4 5 Steel 3 4 1 5 CrNi 3 4 1 5 ...

Page 36: ...ing instrument check to make sure that electrically charged components e g capacitors have been discharged Every start up Check welding torch interconnecting hosepack and grounding earthing connection for signs of damage Check feed rollers and inner liners for signs of damage Check contact pressure of feed rollers and adjust if necessary Check that all screw connections between the robot wirefeede...

Page 37: ...d thread in the welding wire acknowledge the error on the power source Cause Additional fan filter is contaminated air supply for the additional fan is no longer sufficient to cool the power electronics the power electronics temper ature switch has tripped Remedy Clean filter or replace acknowledge the error on the power source Cause Ambient temperature too high Remedy Reduce ambient temperature i...

Page 38: ...oller IP 21 Protection drive plate IP 20 Dimensions I x w x h Controller Controller mounting bracket 320 x 200 x 65 mm 16 60 x 7 78 x 2 56 in 318 x 210 x 166 mm 12 52 x 8 27 x 6 54 in Gewicht Controller Controller mounting bracket Drive plate incl mounting bracket 1 7 kg 3 75 Ibs 1 8 kg 3 97 lbs 5 0 kg 11 02 lbs Drive 4 roll feeder Maximum shielding gas pressure 7 bar 101 psi ...

Page 39: ...39 EN ...

Page 40: ...NTERNATIONAL GMBH Froniusstraße 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 locations ...

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