KD 4000 D-11

The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.

The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.

The warnings and safety instructions in these instructions are intended to protect people from possible injury and the product from damage.

The warnings and safety instructions are an integral part of these instructions and must always be observed to ensure the safe and proper use of the product.

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.

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.

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 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.

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose.

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.)

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

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

^*) 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

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.

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.

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 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.

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.

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.

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.

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.

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

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.

EMC device classification as per the rating plate or technical data.

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

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.

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.

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.

Use filters if necessary.

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.

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.

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.

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.

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.

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.

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.

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

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

The manufacturer recommends that the welding machines be calibrated at the same 12-monthly interval.

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

Further details on the safety inspection and calibration can be obtained from your Fronius branch or your Fronius partner. They will provide you with any documents you may require, on request.

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.

The full text of the EU Declaration of Conformity can be found at
https://www.fronius.com .

Devices with the CSA mark satisfy the requirements of the relevant standards in Canada and the USA.

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.

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.

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.

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.

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):

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.

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.

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.

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

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

Insert the wirespool; e.g.: Basket-type spool with basket-type adapter (3)

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.

After servicing, take care to assemble correctly

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.

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.

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

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.

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.

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

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.

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.

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