KD 4000 D-11 Operating Instructions

1. Safety rules

1. Safety rules

• 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.

• be suitably qualified,
• have sufficient knowledge of welding and
• read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

• 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!

1. Safety rules

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.

• 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.

• 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.

1. Safety rules

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.

• 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)

• 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.)

1. Safety rules

• 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.

1. Safety rules

• 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.

1. Safety rules

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

• 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.

IMPORTANT! Ensure that the mains connection is earthed properly

1. Safety rules

• 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

• Flame-resistant
• Insulating and dry
• Covers the whole body, is undamaged and in good condition
• Safety helmet
• Trousers with no turn-ups

• 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 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

• 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.

1. Safety rules

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 permissible 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.

1. Safety rules

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.

• 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.

• 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).

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.

1. Safety rules

Flying sparks may cause fires or explosions.

Never weld close to flammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in 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.

1. Safety rules

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wire spool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.

All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

• never be immersed in liquid for cooling
• never be touched when the welding system is switched on.

Double the open circuit voltage of a welding system can occur between the welding electrodes of two welding systems. 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.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

• Discharge all live components
• Ensure that all components in the device are de-energised.

If work on live parts is required, have a second person switch off the main switch at the right moment.

1. Safety rules

• Fire hazard
• Overheating of parts connected to the workpiece
• Damage to ground conductors
• Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive floor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

1. Safety rules

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• 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.

1. Safety rules

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 rectify the situation.

• Safety devices
• Network, signal and data transfer lines
• IT and telecommunications devices
• Measuring and calibrating devices

1. Mains supply
   • If electromagnetic interference arises despite the correct mains connection, additional measures are necessary (e.g. use of a suitable line filter)
2. Welding power-leads
   • must be kept as short as possible
   • must be laid close together (to avoid EMF problems)
   • must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
   • If necessary, establish an earth connection using suitable capacitors.
5. Shield, if necessary
   • Shield other devices nearby
   • Shield the entire welding installation

1. Safety rules

• Effects on the health of persons in the vicinity, e.g. those with pacemakers and hearing aids
• Individuals with pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
• For safety reasons, maintain as large a distance as possible between the welding power-leads and the head/torso of the welder
• Do not carry welding power-leads and hosepacks over the shoulders or wind them around any part of the body

1. Safety rules

• Fans
• Cogs
• Rollers
• Shafts
• Wire spools 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.

• 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 facing away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.

Welding machines for work in areas with increased electrical risk (e.g. near boilers) must carry the 'Safety' sign. However, the welding machine must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

• Hook chains or ropes onto all suspension points provided on the suitable load-carrying equipment.
• Chains or ropes must be at the smallest angle possible to the vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

Welding with the device during crane transport is only permitted if this is clearly stated in the intended use of the device.

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 tackle (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 Teflon tape.

1. Safety rules

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety rules

Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

1. Safety rules

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

• 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 before every start-up.

1. Safety rules

• The maximum permissible tilt angle is 10°.

• 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 accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off and disconnect devices from the grid before transport or lifting.

• 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 commissioning the device.

1. Safety rules

• 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 properties (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 components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed 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.

1. Safety rules

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 manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

1. Safety rules

The manufacturer recommends that a safety inspection of the device be performed at least once every 12 months.

The manufacturer recommends that the welding system be calibrated during the same 12-month period.

• after any changes are made
• after any additional parts are installed, or after any conversions
• after repair, care and maintenance are carried out
• at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you with any documents you may require, on request.

1. Safety rules

Waste electrical and electronic equipment must be collected separately and recycled in an environmentally responsible manner in accordance with the EU Directive and national law. Used equipment must be returned to the distributor or through a local, authorised collection and disposal system. Correct disposal of the used device promotes sustainable recycling of resources and prevents negative effects on health and the environment.

• Collect separately
• Observe locally valid regulations
• Compress the cardboard box to reduce volume

1. Safety rules

Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety rules

• backing up any changes made to the factory settings
• saving and retaining personal settings

1. Safety rules

Copyright of these operating instructions remains with the manufacturer.

Text and illustrations were accurate at the time of printing, subject to change.
We are grateful for suggestions for improvement and information regarding any discrepancies in the operating instructions.

1. General

Cold wire feeder KD 4000 D-11

The cold wire feeder is designed to be used with wirespools of max. 300 mm (11.81 in) diameter. The standard 4-roller drive has good wirefeeding properties. The cold wire feeder is also suitable for long hosepacks and,
due to its compact size, can be used in many different ways.

The cold wire feeder can be used with the following power sources:

• TransTig 2200 / 2500 / 3000 Job
• TransTig 4000 / 5000 Job
• MagicWave 2200 / 2500 / 3000 Job
• MagicWave 4000 / 5000 Job

1. General

The KD 4000 D can be used for all types of TIG welding and is especially suited to robot applications and automated tasks. The cold wire feeder is suitable for all standard shielding gases.

1. General

The cold wire feeder has safety symbols on the rating plate. These safety symbols must not be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

	Do not use the functions described here until you have fully read and understood the following documents: These Operating Instructions All the Operating Instructions for the system components, especially the safety rules
	Welding is dangerous. The following basic requirements must be met: welders must be sufficiently qualified use appropriate protective equipment all persons not involved in the welding process must be kept at a safe distance

Owing to software updates, you may find that your machine has certain functions that are not described in these Operating Instructions, or vice-versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

1. Control elements and connections

Owing to software updates, you may find that your machine has certain functions that are not described in these Operating Instructions, or vice-versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

1. Control elements and connections

1. Control elements and connections

Front

(1)

Welding torch / (-) current socket connection in conjunction with a MagicWave power source for connecting: a TIG welding torch the electrode cable for manual metal arc welding in conjunction with a TransTig power source for connecting: a TIG welding torch the electrode cable or grounding cable during MMA welding (depending on the type of electrode used)

1. Control elements and connections

Rear

(1)	Bushing for control socket for connecting a welding torch with a conventional control plug
(2)	(+) socket with bayonet latch
(3)	LocalNet connection Interconnecting hosepack
(4)	Coolant return-flow connection socket (red) Interconnecting hosepack
(5)	Water flow connection (blue) Interconnecting hosepack

1. Control elements and connections

Side view

Detailed view of "feeder inching/feeder backward" button

To facilitate exact positioning of the welding wire, the following sequence is executed when the welder presses and holds the wire threading / wire retract button (3):

• Hold the button for up to one second
  Irrespective of what value has been set, the wire speed remains at 1 m/min or 39.37 ipm for the first second.
• Hold the button for up to 2.5 seconds
  After one second has elapsed, the wire speed increases at a uniform rate over the next 1.5 seconds.
• Hold the button for longer than 2.5 seconds
  After 2.5 seconds, the wire is fed at 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 information on the Fdi parameter, please refer to the Operating Instructions for the power source.

If the wire threading button is released (1) before one second has elapsed and then press it again, the sequence starts again from the beginning. This makes it possible to position the wire continuously at the low wire speed of 1 m/min or 39.37 ipm when needed.

1. Control elements and connections

Bottom view

(1)	Receiving socket for receptor pin for placing the cold wire feeder on the wirefeeder receptor pin

If the TransTig 4000/5000 and MagicWave 4000/5000 power sources have been fixed onto a trolley with cooling unit, the cold wire feeder can be placed on the optional wirefeeder holder on the trolley.

1. Placing the cold wire feeder on the power source

If the TransTig 4000/5000 and MagicWave 4000/5000 power sources have been fixed onto a trolley with cooling unit, the cold wire feeder can be placed on the optional wirefeeder holder on the trolley.

1. Placing the cold wire feeder on the power source

Wirefeeder holder (3)

1Position the cold wire feeder over the power source using a suitable lifting device

2Lower cold wire feeder onto the receptor pin (2), so that the socket (1) is sitting firmly on receptor pin (2)

3Check that the cold wire feeder can move and is securely in place

The cold wire feeder is connected to the power source using the interconnecting hosepack.

1. Connect the cold wire feeder to the power source

The cold wire feeder is connected to the power source using the interconnecting hosepack.

1. Connect the cold wire feeder to the power source

1. Fitting the welding torch

Welding torch and torch control connections

1Switch the power source mains switch to the "Off" position

2Connect welding torch control plug to the LocalNet port (3) or torch control connection (4) and fasten

3If present: connect colour-coded external water connections for water flow (5) and return (6)

4Plug welding potential bayonet plug into current socket (1) and turn to fasten it

5Insert the wire feeder, infeed tube first, into the wirefeeder connection (2)

6Tighten the union nut by hand to fix in place

1. Inserting the wirespool

1. Inserting the wirespool

Insert the wirespool

1Switch the power source mains switch to the "Off" position

2Open left side panel of the wirefeeder:

3Place the wirespool and wirespool holder on the correct side

4

5

6Close left side panel of the cold wire feeder again

Always adjust the brake so that the wirespool does not continue unreeling after the end of welding - but without overtightening the clamping screw, as this might cause motor overload.

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

IMPORTANT! Only 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.

1. Inserting/replacing feed rollers

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

IMPORTANT! Only 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.

1. Inserting/replacing feed rollers

In the USA, all wirefeeders are delivered without feed rollers. After inserting the wirespool, the feed rollers must be inserted into the wirefeeder.

1. Inserting/replacing feed rollers

1

2

3

1. Inserting the wirespool, inserting the basket-type spool

1. Inserting the wirespool, inserting the basket-type spool

1

2

3

1. Inserting the wirespool, inserting the basket-type spool

1

2

1. Feeding in the wire electrode

1

2

3

4

5

1. Feeding in the wire electrode

1

NOTE!

Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.

1. Adjust the brake

1

2

3

The push-pull unit must be calibrated prior to each initial start-up and each time the cold wire feeder software is updated. If the push-pull unit is not calibrated, the default parameters will be used - which may result in unsatisfactory welding results.

1. Push-pull unit

The push-pull unit must be calibrated prior to each initial start-up and each time the cold wire feeder software is updated. If the push-pull unit is not calibrated, the default parameters will be used - which may result in unsatisfactory welding results.

1. Push-pull unit

1In the power source setup menu, select the "PPU" function - level 2: TIG setup parameters (see power source operating instructions)

For an overview of the error messages that may occur during calibration of the push-pull unit, please refer to "Service codes for push-pull calibration".

2On the power source adjusting dial, select the appropriate push-pull unit from the 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 ipm
18 .... Fronius Torch Drive 5 m/min or 197 ipm
19 .... Fronius KD4010 10 m/min or 394 ipm
21 .... Binzel Torch Drive IWG 8 m/min or 315 ipm **)
25 .... Fronius KD4000/KD7000 Drive 11 m/min or 433 ipm *)

3Press the feeder inching or gas test button

4Disengage the drive units of both wirefeeder motors (e.g. welding torch and cold wire feeder) - the wirefeeder motors must not be under load (push-pull calibration - open circuit)

5Press the feeder inching or gas test button

The wirefeeder motors are calibrated while not under load;
during calibration, the right-hand display will read "run".

As soon as calibration - in the unloaded state - is complete, the display will read "St2".

6Engage the drive units of both wirefeeder motors (e.g. welding torch and cold wire feeder) once again - the wirefeeder motors must be under load (push-pull calibration - engaged)

7Press the feeder inching or gas test button

The wirefeeder motors are calibrated while under load; during calibration, the right-hand display will read "run".

If the push-pull unit does not need to be calibrated while under load (St2), the previously set values (e.g. "PPU" and "2") will appear in the display when you press the feeder inching or gas test button.

Calibration of the push-pull unit is complete when the previously set values - e.g. "PPU" and "2" - reappear on the display.

8Press the Store button twice to exit from the Setup menu

1. Service codes for push-pull calibration

1. Service codes for push-pull calibration

1. Service codes for push-pull calibration

1. Service codes in conjunction with the cold wire feeder and digital gas control option

1. Service codes in conjunction with the cold wire feeder and digital gas control option

Under normal operating conditions, the wire-feed unit requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years.

1. Care, maintenance and disposal

Under normal operating conditions, the wire-feed unit requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years.

1. Care, maintenance and disposal

• Check welding torch, interconnecting hosepack and ground earth connection for signs of damage
• Perform a visual check on the feed rollers and inner liners for signs of damage
• Check contact pressure of feed rollers and adjust if necessary
• Check brake and adjust if necessary

1. Care, maintenance and disposal

• Dismantle device side panels and clean inside of device with dry, reduced compressed air

1. Care, maintenance and disposal

Dispose of in accordance with the applicable national and local regulations.

1. Technical data