/ Battery Charging Systems / Welding Technology / Solar Electronics

Operating Instructions
VR 4000 Yard EN
Spare Parts List
Wire Feeder

42,0426,0013,EN 008-10072015
Dear Reader

Introduction Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new

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machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.

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Safety rules

DANGER!
“DANGER!” indicates an imminently hazardous situation which, if not

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avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.

WARNING!
“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.

CAUTION!
“CAUTION!” indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may also be used to
alert against unsafe practices that may cause property damage.

NOTE! “NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.

Important! “Important!” indicates practical hints and other useful special-information. It is no

signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even closer
attention to the contents of the manual!

General remarks
This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for
- the life and well-being of the operator or of third parties,
- the equipment and other tangible assets belonging to the owner/
operator,
- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must
- be suitably qualified
- know about welding and
- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must
be kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:
- must be kept in a legible condition
- must not be damaged, must not be removed
- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings
are located on the machine, please see the section of your machine’s
instruction manual headed “General remarks”.

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General remarks Any malfunctions which might impair machine safety must be eliminated
(continued) immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

Utilisation for The machine may only be used for jobs as defined by the “Intended purpose”.
intended purpose
only The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall
not be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual
- complete reading and following of all the safety instructions and danger
warnings
- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes
- Charging batteries/accumulators
- Starting engines

The machine is designed to be used in industrial and workshop

environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work
results.

Ambient Operation or storage of the power source outside the stipulated range is
conditions deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)
- when being transported or stored: - 20 °C to + 55 °C (-4 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Obligations of The owner/operator undertakes to ensure that the only persons allowed to
owner/operator work with the machine are persons who
- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine
- have read and understood this operating manual particulary the sections
on “Safety rules”, and have confirmed as much with their signatures
- be trained in such a way that meets with the requirements of the work
results

Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.

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Obligations of Before starting work, all persons to be entrusted with carrying out work with
personnel (or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read this operating manual particulary the sections on “Safety rules”
and to sign to confirm that they have understood these and will comply
with them.

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Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.

Mains connec- High-performance devices can affect the quality of the mains power due to
tion their current-input.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance *)
- criteria with regard to minimum short-circuit power requirement *)

*)
at the interface with the public mains network

see Technical Data

In this case, the plant operator or the person using the device should check
whether or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.

NOTE! Ensure that the mains connection is earthed properly.

Protection for When welding, you are exposed to many different hazards such as:
yourself and - flying sparks and hot metal particles
other persons - arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace-
maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable

protective clothing with the following characteristics:
- flame-retardant
- isolating and dry
- must cover whole body, be undamaged and in good condition
- protective helmet
- trousers with no turn-ups

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Protection for “Protective clothing” also includes:
yourself and - protecting your eyes and face from UV rays, heat and flying sparks with
other persons an appropriate safety shield containing appropriate regulation filter glass
(continued) - wearing a pair of appropriate regulation goggles (with sideguards)
behind the safety shield
- wearing stout footwear that will also insulate even in wet conditions
- protecting your hands by wearing appropriate gloves (electrically insula-
ting, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!

Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must
- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)
- provide them with suitable protective equipment and/or
- erect suitable protective partitions or curtains.

Information on The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
noise emission when idling and in the cooling phase following operation at the maximum
values 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 wel-

ding (or cutting) as this is influenced by both the process and the environ-
ment. 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.

Hazards from The fumes given off during welding contain gases and vapors that are
noxious gases harmful to health.
and vapours
Welding fumes contain substances which may cause birth defects and
cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable
means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an

independent air supply.

If you are not sure whether your fume-extraction system is sufficiently

powerful, compare the measured pollutant emission values with the
permitted threshold limit values.

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

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Hazards from The harmfulness of the welding fumes will depend on e.g. the following
noxious gases components:
and vapours - the metals used in and for the workpiece
(continued) - the electrodes
- coatings
- cleaning and degreasing agents and the like

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For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.

Hazards from Flying sparks can cause fires and explosions!

flying sparks
Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (36 ft. 1.07 in.) away from
the arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that
there is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or
explosion, or in enclosed tanks, barrels or pipes, unless these latter have
been prepared for welding in accordance with the relevant national and
international standards.

Welding must NEVER be performed on containers that have had gases,

fuels, mineral oils etc. stored in them. Even small traces of these
substances left in the containers are a major explosion hazard.

Hazards from An electric shock is potentially life-threatening, and can be fatal.

mains and weld-
ing current Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or

else use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/
frame potential. The base or cover must completely cover the entire area
between your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.

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Hazards from Do not loop any cables or other leads around your body or any part of your
mains and weld- body.
ing current
(continued) Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.

Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and

plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is

sufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the
mains.

Put up a clearly legible and easy-to-understand warning sign to stop

anybody inadvertently plugging the machine back into the mains and
switching it back on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge
- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second

person on hand to immediately switch off the machine at the main switch in
an emergency.

Stray welding If the following instructions are ignored, stray welding currents may occur.
currents These can cause:
- fires
- overheating of components that are connected to the workpiece
- destruction of PE conductors
- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

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

On electrically conductive floors, the machine must be set up in such a way

that it is sufficiently insulated from the floor.

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Stray welding When using current supply distributors, twin head wire feeder fixtures etc.,
currents please note the following: The electrode on the unused welding torch/
(continued) welding tongs is also current carrying. Please ensure that there is sufficient
insulating storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulated

filler wire is routed from the welding wire drum, large wirefeeder spool or

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wirespool to the wirefeeder.

EMC device Devices with emission class A:

classifications - are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.

Devices with emission class B:

- satisfy the emissions criteria for residential and industrial areas. This
also applies to residential areas in which power is supplied from the
public low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures 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.

Examine and evaluate any possible electromagnetic problems that may

occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:
- safety features
- mains, signal and data-transmission leads
- IT and telecoms equipment
- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply
- If electromagnetic interference still occurs, despite the fact that the
mains connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).

b) Welding cables
- Keep these as short as possible
- Arrange them so that they run close together (to prevent EMI problems
as well)
- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity
- Shield the entire welding installation.

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EMI Precautions Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pace-
makers and hearing aids
- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces
- Keep as much space as possible between welding cables and head/
body of welder for safety reasons
- Do not carrywelding cables and hose pack over shoulder and do not
loop around body or or any part of body

Particular danger Keep your hands, hair, clothing and tools well away from all moving parts,
spots e.g.:
- fans
- toothed wheels, rollers, shafts
- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.

Covers and sideguards may only be opened or removed for as long as is

absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...
- ... and that all covers and sideguards are kept closed.

When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...).

For this reason, when feeder-inching etc., always hold the torch so that it is
pointing away from your body (machines with wirefeeder) and wear suitable
protective goggles.

Do not touch the workpiece during and after welding - risk of injury from
burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.

Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion.

Observe all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.

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Particular danger Risk of scalding from accidental discharge of hot coolant. Before unplugging
spots the connectors for coolant forward flow and return flow, switch off the coo-
(continued) ling unit.

Observe the information on the coolant safety data sheet when handling
coolant. The coolant safety data sheet may be obtained from your service

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centre or downloaded from the manufacturer’s website.

When hoisting the machines by crane, only use suitable manufacturer-

supplied lifting devices.
- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.
- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.
- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).

When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that

this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.

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 changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable natio-
nal standards and directives as a minimum.

Danger of colourless and odourless inert gas escaping unnoticed, when

using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.

Factors affecting The following requirements with regard to shielding gas quality must be met
welding results if the welding system is to operate in a correct and safe manner:
- Size of solid matter particles <40µm
- Pressure dew point <-20°C
- Max. oil content <25mg/m³

Filters must be used if necessary.

NOTE! There is an increased risk of soiling if ring mains are being

used

Danger from Shielding-gas cylinders contain pressurized gas and may explode if they are
shielding-gas damaged. As shielding-gas cylinders are an integral part of the overall
cylinders welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive

heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).

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Danger from Keep shielding-gas cylinders well away from welding circuits (and, indeed,
shielding-gas from any other electrical circuits).
cylinders
(continued) Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas

cylinder.

Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories
that are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and

international rules applying to shielding-gas cylinders and accessories.

Safety precauti- A machine that topples over can easily kill someone! For this reason, always
ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly.
lation site and - An angle of inclination of up to 10° is permissible.
when being
transported
Special regulations apply to rooms at risk from fire and/or explosion.
Observe all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportati-
on and carriage.

Before transportation, completely drain any coolant and dismantle the

following components:
- Wire feed
- Wire wound coil
- Gas bottle

Before commissioning and after transportation, a visual check for damage

must be carried out. Any damage must be repaired by trained service
personnel before commissioning.

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Safety precau- Only operate the machine if all of its protective features are fully functional. If
tions in normal any of the protective features are not fully functional, this endangers:
operation - the life and well-being of the operator or other persons
- the equipment and other tangible assets belonging to the owner/operator
- efficient working with the equipment.

Any safety devices that are not fully functional must be put right before you

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switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by

your doing so.

- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.
- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.
- Owing to its special properties (in terms of electrical conductivity, frost-
proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.
- Only use suitable original coolant of the manufacturer.
- Do not mix original coolant of the manufacturer with other coolants.
- If any damage occurs in cases where other coolants have been used,
the manufacturer shall not be liable for any such damage, and all
warranty claims shall be null and void.
- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.
- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.
- Before starting welding - while the machine is still cool - check the
coolant level.

Preventive and With parts sourced from other suppliers, there is no certainty that these
corrective main- parts will have been designed and manufactured to cope with the stressing
tenance and safety requirements that will be made of them. Use only original spares
and wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine

without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.

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.

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Safety inspection A safety inspection should be carried out by a qualified electrician
(continued) - 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 directives.

Further details on safety inspection and calibration can be obtained from

your service centre. 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 2002/96/EC 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 be returned to our agent, or find out about the approved
collection and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!

Safety markings Equipment with CE-markings fulfils the basic requirements of the Low-
Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .

Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.

Data security The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.

Copyright Copyright to this instruction manual remains the property of the

manufacturer.

The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the
instruction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.

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Contents
General .......................................................................................................................................................... 2
Product concept ........................................................................................................................................ 2
Options ...................................................................................................................................................... 2
Warning notices affixed to the device ........................................................................................................ 3
Control elements and connections ................................................................................................................. 4
General ..................................................................................................................................................... 4
Control elements and connections on front and on left side ..................................................................... 4
Control elements and connections on right side ....................................................................................... 6
Installation ...................................................................................................................................................... 7
Safety ........................................................................................................................................................ 7
Utilisation in accordance with „intended purpose“ ..................................................................................... 7
Fitting the welding torch ............................................................................................................................ 7
Fastening the interconnecting hosepack to the wire-feed unit .................................................................. 8
Connecting the interconnecting hosepack to the wire-feed unit ................................................................ 8
Routing the interconnecting hosepack to the wire-feed unit ...................................................................... 9
Connecting the interconnecting hosepack to the power source ................................................................ 9
Installing the wire infeed tube, wire guide insert and steel capillary tube ..................................................... 10
Safety ...................................................................................................................................................... 10
Wire infeed tube, wire guide insert and capillary tube ............................................................................. 10
Removing the feed roller ......................................................................................................................... 10
Replacing the capillary tube ..................................................................................................................... 11
Replacing the wire guide insert ................................................................................................................ 11
Replacing the wire infeed tube ................................................................................................................ 12
Fitting the feed rollers .............................................................................................................................. 12
Inserting the wirespool, inserting the basket-type spool ............................................................................... 13
Safety ...................................................................................................................................................... 13
Inserting the wirespool ............................................................................................................................ 13
Inserting the basket-type spool ............................................................................................................... 13
Adjusting the brake ...................................................................................................................................... 14
General ................................................................................................................................................... 14
Adjusting the brake ................................................................................................................................. 14
Design of the brake ................................................................................................................................. 15
Inserting/replacing feed rollers ..................................................................................................................... 16
General ................................................................................................................................................... 16
USA wire-feed units ................................................................................................................................. 16
Inserting/replacing feed rollers ................................................................................................................ 16
Feeding in the wire electrode ....................................................................................................................... 17
Feeding in the wire electrode .................................................................................................................. 17
Setting the contact pressure ................................................................................................................... 18
Care, maintenance and disposal .................................................................................................................. 19
General ................................................................................................................................................... 19
Every start-up .......................................................................................................................................... 19
Every 6 months ....................................................................................................................................... 19
Disposal .................................................................................................................................................. 19
Technical data .............................................................................................................................................. 20
VR 4000 Yard wire-feed unit ................................................................................................................... 20
Spare parts list
Fronius Worldwide

1
General

Product concept The VR 4000 Yard wire-feed unit with four-roll drives is designed to be used with wire-
spools with a diameter of up to 300 mm.

The Yard wire-feed unit was specifically developed for use in shipyards and in the
offshore industry. The ergonomic housing is constructed from powder-coated aluminium
sheets. These panels not only weigh very little, but they are also extremely robust and
resistant to corrosion.

The sealed design of the VR 4000 Yard ensures the best possible protection against
dust and other impurities affecting the wirespool.

Further properties of the Yard wire-feed unit are its suitability for use in inspection
openings and the ability to use the unit even when it is lying on its side.

In addition to its considerable practicality, the Yard wire-feed unit is also extremely well
suited for use with very long hosepacks.

The Yard wire-feed unit can be used with all standard protective gas shields.

The VR 4000 Yard is available with a Fronius / Dinse / Euro torch connection.

The Yard wire-feed unit is particularly suitable for use with self-shielding flux core wires.
As these are mostly used with gascooled welding torches, VR 4000 Yard has no stan-
dard water connections due to weight considerations.
Gascooled welding torches have also been tried and tested with a basic flux core wire
of 1.2 mm (.047 in.).

Options Mode selector switch

Especially recommended for use with very long hosepacks.
At the point of use
- the welding processes and operating modes can be selected
- the gas test and feeder inching functions can be carried out.

Keylock switch (on the power source)

Recommended for use with long hosepacks when the power source is frequently out of
sight.
Optimum protection against foreign bodies

Steel infeed tube, wire guide insert and capillary tube

Recommended for use with self-shielding flux core wires

2
Warning notices The Yard wire-feed unit has safety symbols on the rating plate. The safety symbols
affixed to the must NOT be removed or painted over. The symbols warn against operating the equip-
device ment incorrectly, as this may result in serious injury and damage.

Welding is dangerous. The following
basic requirements must be met:
- Welders must be sufficiently quali-
fied
- Suitable protective equipment
- Keep all persons not involved in the
welding process at a safe distance
Do not use the functions described until
you have thoroughly read and under-
stood the following documents:
- these operating instructions
- all the operating instructions for the
system components, especially the
safety rules

Warning notices on the wire-feed unit VR 4000 Yard

3
Control elements and connections

General
WARNING! Operating the equipment incorrectly can cause serious injury
and damage. Do not use the functions described here until you have read
and completely understood all the operating instructions.

IMPORTANT! Welding parameters that can be adjusted on the VR 4000 Yard wire-feed
unit cannot be adjusted on the power source. Parameters can only be changed on the
VR 4000 Yard wire-feed unit.

Control elements
and connections (13) (12)
on front and on
left side (11)

(1) (10)
(2)

(3)

(4)(5)(6) (7) (8) (9)

Front view VR 4000 Yard Side view VR 4000 Yard (left)

No. Function
(1) Welding current adjuster
for selecting the welding current
(2) Arc length correction adjuster / dynamic correction
has a different function depending on the process being used

MIG/MAG welding ... for correcting the arc length

- shorter arc length
0 neutral arc length
+ longer arc length

Rod-electrode welding ... for influencing the short-circuiting current at the instant of
droplet transfer
0 soft, low-spatter arc
100 harder, more stable arc
(3) Welding torch connection (for Dinse, Euro)
for connecting the welding torch
(4) Welding torch control line connection (option)
for connecting the Tuchel control plug of the welding torch
(5) Blue water flow connection (option)
(6) Red water return connection (option)

4
VR 4000 Yard No. Function
(continued)
(7) LocalNet connection (option)
standardised connection socket for system extensions (e.g. remote control, Job-
Master welding torch, etc.)
(8) Braked wirespool holder and adapter for basket-type spool
for holding standard welding wire spools up to 18 kg in weight

When using self-shielding flux core wire:

- the spool diameter is 250 mm
- special wirespool adapters are required
(9) 4 roller drive
(10) Mode selection switch (option)
including gas test / feeder inching button

IMPORTANT! Settings made using the optional mode selection switch (10) cannot
be altered on other control units, e.g.:
- the power source control panel
- the front of the wire-feed unit
- the remote control
(11) Feeder inching / gas test button
Push button downwards:
to feed the wire electrode into the hosepack with no accompanying flow of gas or
current. While the button is being held down, the wire-feed unit runs at feeder
inching speed.

Push button upwards:

to set the required gas flow rate on the pressure regulator. Gas flows out for as
long as the button is pushed up.
(12) Mode selection switch
to select the mode:
2-step mode
4-step mode
Aluminium welding start-up
Spot welding
(13) Mode selection switch
to select the welding process:
MIG/MAG pulse synergic welding
MIG/MAG standard synergic welding
Special processes, e.g. standard manual welding
Job mode
TIG welding with touch-down ignition
Rod electrode (MMA) welding

IMPORTANT! If the wire-feed unit is connected to a TS 4000 / 5000 power source,

MIG/MAG pulse synergic welding is not available.

5
Control elements
and connections
on right side (1)

(2)

(3)

(4)

(5)

Right side view VR 4000 Yard

No. Function
(1) Shielding gas connection
(2) (+) current connection with bayonet latch
Interconnecting hosepack
(3) LocalNet connection socket
Interconnecting hosepack
(4) Red water return connection - option
(5) Blue water flow connection - option

6
Installation

Safety
WARNING! Operating the equipment incorrectly can cause serious injury
and damage. The following activities must only be carried out by trained
and qualified personnel! Observe the safety rules in the power source
operating instructions.

Utilisation in The Yard wire-feed unit is only to be used for MIG/MAG welding with a TS 4000 / 5000
accordance with or TPS 3200 / 4000 / 5000 power source.
„intended purpo-
se“ Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
accordance with the intended purpose“. The manufacturer shall not be liable for any
damage resulting from such improper use.

Refer to the „Before switching on the power source“ section in the „Installation“ chapter
of the power source operating instructions. Also refer to „Setup regulations“ and „Mains
connection“.

Fitting the wel- NOTE! Applies when using 70 m hosepacks, either made up in-house or
ding torch purchased from another manufacturer:
- Ensure that the cross section of the wire drive supply line is at least 13
mm² (0.02 sq.in.).

Only welding torches with a connection for Dinse / Euro can be used.

If the VR 4000 Yard is equipped with optional water connections, then only a welding
torch with external water connections may be used.

1. Turn the power source mains switch

to the - O - position
2. Check that the welding torch is
correctly set up. Insert it - infeed tube
first - into the torch connection (1)

3. Fix welding torch in place:

Manually tighten the torch union nut
on the torch connection (1)

(1)

Plugging in the welding torch

7
Fitting the wel- 4. If present, plug-in and lock the wel-
ding torch ding torch control plug to the torch
(continued) control lead connection (3) (option)
5. If present, connect the water flow and
return connectors for the welding
torch to connections (4) and (5) of the
wire-feed unit

(3)(4)(5)
Welding torch activation and water connections
(option)

Fastening the 1. Turn the power source mains switch

interconnecting to the - O - position
hosepack to the 2. If present, allow the wire-feed unit to
wire-feed unit engage with the swivel pin on the
swivel pin holder
3. Remove cover on the right side of the
wire-feed unit
(1) (2) (3) 4. Attach the metal piece (2) on the
interconnecting hosepack (3) strain
relief device (1) to the anchoring (4)
on the wire-feed unit

(4)
Fastening the strain relief device to the wire-feed
unit

Connecting the NOTE! To prevent wear and tear,

interconnecting form a loop towards the inside
hosepack to the when connecting the cables and
wire-feed unit hoses of the interconnecting
(1)
hosepack.
(2)
1. Plug the interconnecting hosepack
(3) gas hose into the shielding gas
(4) connection socket (1) and tighten
(5) union nut
2. Plug the welding potential cable of
the interconnecting hosepack into the
(+) current connection (2) and twist to
secure

3. Plug the LocalNet plug on the inter-

Connecting the interconnecting hosepack to the connecting hosepack into the Local-
wire-feed unit Net connection (3) and secure with a
union nut

8
Connecting the 4. If present: Connect the colour-coded
interconnecting interconnecting hosepack water flow
hosepack to the and return hoses to connection
wire-feed unit sockets (4) and (5) - option - and
(continued) tighten the union nut

Routing the NOTE! When routing the interconnecting hosepack (2), ensure that it
interconnecting - runs through the bushing (1)
hosepack to the - is not kinked when the cover is in place
wire-feed unit
1. Routing the interconnecting hosepack
(2) through the bushing (1)
2. Refit the cover on the right side of the
VR 4000 Yard wire-feed unit

(1) (2)

Routing the interconnecting hosepack

Connecting the The interconnecting hosepack is connected to the power source as described in the
interconnecting power source operating instructions.
hosepack to the
power source

9
Installing the wire infeed tube, wire guide insert and
steel capillary tube

Safety
WARNING! Operating the equipment incorrectly can cause serious injury
and damage. The following activities must only be carried out by trained
and qualified personnel! Observe the safety rules in the power source
operating instructions.

Wire infeed tube, Standard

The figure shows:
wire guide insert (1) the wire infeed tube
and capillary (2) the wire guide insert
tube (3) the capillary tube

as a standard as well as a steel version

(option).
(1) (2) (3)
NOTE! The steel version (option)
Steel
is recommended primarily for use
with self-shielding flux core
wires.

(1) (2) (3)

Wire infeed tube, wire guide insert and capillary

tube, standard and steel

Removing the
feed roller 1
1
4
2

4
6

10
Replacing the 1. Disconnect the brass capillary tube
capillary tube (1) in the vicinity of the 4 roller drive
by pressing down with a screwdriver
(Fig.10)
2. Remove the capillary tube (1) from
(1) the welding torch connection

3. Insert the steel capillary tube (1) into

the torch connection and, using
(1) pliers, push it in as far as it will go

Replacing the capillary tube

Replacing the 1. Remove plastic wire guide (1) with

wire guide insert pliers

(1)

Removing the wire guide

NOTE! When inserting the steel

wire guide insert (1), position the
screwdriver as shown so that the
plastic parts of the 4 roller drive
are not damaged.

2. Insert steel wire guide insert (1) using

a screwdriver

(1)

Inserting the wire guide

11
Replacing the 1. Remove plastic wire infeed tube (1)
wire infeed tube with pliers
2. Push in the infeed tube (1) as far as it
will go

(1)

Inserting the wire infeed tube

Fitting the feed

rollers 2 3

1
2
5
2
4
3
3

12
Inserting the wirespool, inserting the basket-type
spool

Safety
CAUTION! Risk of injury from springiness of spooled wire electrode. When
inserting the wirespool/basket-type spool, hold the end of the wire electrode
firmly to avoid injuries caused by the wire springing back.

CAUTION! Risk of injury from falling wire spool / basket-type spool. Make
sure that the wirespool or basket-type spool with adapter is fitted securely to
the wirespool holder.

Inserting the
wirespool

Inserting the NOTE! When working with basket-type spools, use only the basket-type spool
basket-type adapter supplied with the wire-feed unit! USA wire-feed units are supplied
spool without basket-type spool adapters.

CAUTION! Risk of injury from falling spool. Place basket-type spool on the
adapter provided in such a way that the bars on the spool are inside the
adapter guideways.

13
Adjusting the brake

General IMPORTANT! After releasing the torch trigger the wirespool should stop unreeling.
Adjust brake if necessary.

Adjusting the
brake

14
Design of the
CAUTION! Risk of injury and damage from falling wirespool. To ensure that
brake
the wirespool is properly in place and that the brake works properly, fit the
brake according to the following diagram.

15
Inserting/replacing feed rollers

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

IMPORTANT! Use only 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 wire-feed In the USA, all wire-feed units are delivered without feed rolls. After inserting the wire-
units spool the feed rollers must be inserted in the wire-feed unit.

Inserting/repla-
cing feed rollers 1 2
1
4
2

1
4
6

6 5
2
4

1
2

16
Feeding in the wire electrode

Feeding in the
CAUTION! Risk of injury from springiness of spooled wire electrode. When
wire electrode
inserting the wire electrode into the 4 roller drive, hold the end of the wire
electrode firmly to avoid injuries caused by the wire springing back.

CAUTION! Risk of damage to the welding torch from sharp end of wire
electrode. Deburr the end of the wire electrode well before feeding in.

1 2
1 4

4
2

3 2

17
Feeding in the
CAUTION! Risk of injury from the emerging wire electrode. Keep the welding
wire electrode
torch away from face and body when pressing the feeder inching button.
(continued)

Setting the NOTE! Adjust contact pressure in such a way that the wire electrode is not
contact pressure deformed, but is nevertheless transported properly.

1 1

Contact pressure guideline values

Semi-cylindrical rolls Trapeze rolls Plastic rolls
Aluminium 1.5 - 3.5 - 4.5
Steel 3-4 1.5 -
CrNi 3-4 1.5 -

18
Care, maintenance and disposal

General Under normal operating conditions the wire-feed units require only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the
welding system remains in a usable condition for many years.

WARNING! An electric shock can be fatal. Before opening the device

- Turn the mains switch to the „O“ position
- Unplug the device from the mains
- Put up an easy-to-understand warning sign to stop anybody inadver-
tently switching it back on again
- Using a suitable measuring instrument, check to make sure that electri-
cally charged components (e.g. capacitors) have discharged

Every start-up - Check welding torch, interconnecting hosepack and grounding (earthing) connec-
tion for signs of damage
- Perform a visual check on the feed rollers and inner liners for signs of damage
- Check contact pressure of wire-feed rollers and adjust if necessary
- Check brake and adjust if necessary

Every 6 months - Dismantle device side panels and clean inside of device with dry reduced com-
pressed air

NOTE! Risk of damage to electronic components. Do not bring air nozzle too
close to electronic components.

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

19
Technical data

VR 4000 Yard Supply voltage 24 V DC / 55 V DC

wire-feed unit
Nominal current 2A/4A
Wire diameter 0.8 – 1.6 mm
(0.03 - 0.06 in.)
Wire feed speed 0.5 - 22 m/min
(19.69 - 866.14 ipm)
Protection IP 23
Dimensions (l/w/h) 610 x 210 x 400 mm
(24.03 / 8.27 / 15.76 in.)
Weight (version for gascooled welding torch without wirespool) 11.2 kg
(24.64 lb.)
Drive 4 roller drive
Maximum protective gas shield pressure 7 bar
(101 psi.)
Coolant Original Fronius coolant
Maximum coolant pressure 4.2 bar
(61 psi.)

20
 Ersatzteilliste

DE
Spare Parts List

EN
Liste de pièces de rechange

FR
Lista parti di ricambio

IT
ES
Lista de repuestos

PT-BR
Lista de peças sobresselentes

NL
NO Onderdelenlijst

Reservdelsliste
CS

Seznam náhradních dílů

RU

Ñïèñîê çàïàñíûõ ÷àñòåé

SK

Zoznam náhradných dielov

SV

Reservdelslistan
TR

Parça Listesi

Wykaz czesci zamiennych

PL

ud_fr_st_tb_00150 012014
 3

2 2

9, 15
8, 15
17
18
20

16
1 12 4 10, 11 13

14

6 7

19 19 19

POS. BENENNUNG ARTICLE DENOMINATION

VR 4000 4R/G/E YARD VR 4000 4R/G/E YARD VR 4000 4R/G/E YARD 4,045,895,001
VR 4000 4R/G/D YARD VR 4000 4R/G/D YARD VR 4000 4R/G/D YARD 4,045,895,002

1 BREMSVORRICHTUNG D=110x117 KST BRAKE MECHANISM. D=110x117 KST MECANISME DE FREIN D=110x117 KST 42,0001,3045,Z
2 GRIFFHALTER HANDLE HOLDER SUPPORT DE POIGNEE 42,0300,0985
3 GRIFFROHR VR4000 YARD HANDLE TUBE TUBE DE POIGNEE 42,0201,1241
4 STROMSTECKER EB 50-70 600 CURRENT PLUG EB 50-70 600 PRISE COURANT EB 50-70 600 43,0003,0146
5 GEHÄUSE ROT VR4000 YARD CASE RED VR4000 YARD CHASSIS VR4000 YARD AM4,0450,1217
6 DRUCK SEITENT. L. VR4000 YARD SIDE PANEL L. VR4000 YARD PANNEAU LATERAL L. VR4000 YARD 45,0200,1143
7 DRUCK SEITENT. R. VR4000 YARD SIDE PANEL R. VR4000 YARD PANNEAU LATERAL R. VR4000 YARD 45,0200,1144
8 DREHKNOPF D=23 RT SW RT KNOB D=23 RT SW RT BOUTON D=23 RT SW RT 42,0406,0073
9 DREHKNOPF D=31 RT SW RT KNOB D=31 RT SW RT BOUTON D=31 RT SW RT 42,0406,0218
10 STECKEREINSATZ 18 10 PLUG INSERT 18 10 CONNECTEUR 18 10 43,0003,0252
11 STECKDOSENGEHÄUSE EB 18 PLUG SOCKET HOUSING EB 18 BOITIER DE PRISE EB 18 43,0003,0255
12 MAGNETVENTIL-KL.24= 0-12 G1/8" GAS SOLENOID VALVE VANNE MAGNETIQUE GAZ 43,0013,0015
13 PRINT SR 41 PC-BOARD SR 41 CIRCUIT ELECTRONIQUE SR 41 4,070,677,Z
14 BEFEST.FLANSCH ABGEDR. BIN-ZA FASTENER FLANGE TURNED OFF COUVERCLE DE CONNEXION 42,0300,1053
15 WIDPOT 22K 10 ABW1 POTENTIOMETER 22 K / 10 POTENTIOMETRE 22 K / 10 41,0001,0001
16 ABDECKKAPPE 12.7/4.3/10.3/3.2 COVER DISK 12.7/4.3/10.3/3.2 COUVERCLE 12.7/4.3/10.3/3.2 42,0300,1734
17 ABDECKKAPPE 30.0/33.8/11.5/3.2 COVER DISK 30.0/33.8/11.5/3.2 COUVERCLE 30.0/33.8/11.5/3.2 42,0300,1677
18 ABDECKKAPPE F. TUCHELSTECKER COVER DISK F. TORCH SOCKET COUVERCLE P. PRISE TORCHE 42,0200,4080
19 SCHNAPPVERSCHLUSS SNAP (FASTENER) VERROU ENCLIQUETABLE 42,0405,0357
20 SCHARNIER HINGE PART CHARNIERE 42,0407,0511

VR 4000 Yard 4R / E / Dinse

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/1

el_fr_st_dv_00472 012003
 13

16 17 1 17
14

8 3 7
10 10 9
9

2
5 6

11 15 4 15 11

POS . B E NE NNUNG AR TICL E DE NOMINATION

1 SCHLAUCH Synthetik 42 WS HOSE Synth. 42 WS TUYAU Synth. 42 WS * 40,0001,0411
2 SCHWEISSKABEL H01N2-D 95MM2 * WELD. CABLE H01N2-D 95MM2 * CABLE DE SOUDAGE H01N2-D 95MM2 * 40,0003,0015
3 KABEL PUR 6x2 + 4x0,5 * CABLE PUR 6x2 + 4x0,5 * CABLE PUR 6x2 + 4x0,5 * 40,0003,0447
4 SCHLAUCH PVC MG 5x3 SW * HOSE PVC THREADED D=5X3 BLACK * TUYAU PVC FILETE NOIR * 40,0001,0012
5 KABELSTECKER -95 800 CABLE-PLUG -95 800 CABLE-PRISE -95 800 43,0003,0301
6 KABELKUPPLUNG -95 800 CABLE-COUPLING -95 800 RACCORD DE CABLE -95 800 43,0003,0385
7 STECKDOSENEINSATZ 18 10 PLUG-SOCKET-INSERT 18 10 SUPPORT PRISE I NTERNE1810 43,0003,0251
8 STECKEREINSATZ 18 10 PLUG-INSERT 18 10 PRISE INTERNE 18 10 43,0003,0252
9 STECKERGEHÄUSE 18 CONNECTION (PLUG) 18 CONNECTION PRISE 18 43,0003,0253
10 ZUGENTLASTUNG GEHÄUSE 18 STRESS RELIEF HOUSING 18 DECHARGE DE TRACTION 18 42,0407,0048
11 ANSCHLUSS GASARMATUR 1/4” CONNECTION GAS ARMATURE 1/4" RACCORD GAZ 1/4" 44,0450,0281
13 ANSCHLUSS ZUGENTLASTUNG TRACTION RELEASE CONNECTION ECROU FREIN CONNECTION 42,0001,3484
14 GEWINDESTÜCK FÜR ZUGENTL WINDINGBOLD ENROULEMENT DE TUYAU 42,0405,0239
15 KLEMME 1OHR M. EINLAGE 12,8-706R CLAMP 1 EAR W.INSERT 12,8-706R COLLIER DE SERRAGE 12,8-706R 42,0407,0063
16 ZUGENTLASTUNG TA 500 ST RESS RELIEF TA 500 DECHARGE DE TRACTION TA 500 44,0750,0009
17 SCHLAUCHKLEMME 32, 0-50,0 CLAMP 32, 0-50,0 COLLIER DE SERRAGE 32, 0-50, 0 42,0407,0072

* BITTE LÄNGE ANGEBEN PLEASE INDICATE LENGTH INDIQUE Z LA LONGUE UR ,S VP *

Verb. Schlauchpaket G 10m 70mm² - 4,047,352

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/1

el_fr_st_vp_00473 012010
Motorplate 42V 4R

42,0400,0123

42,0405,0116

42,0407,0098

42,0404,0264
BF2,0404,0340 - yellow

42,0409,2106

32,0405,0112

32,0405,0113

42,0405,0117 - PE
42,0200,9352 - CuZn

42,0200,7767

to r
ec
nn
Mo Co
tor

42,0405,0120

42,0300,2162
44,0001,1203
42,0407,0077
42,0407,0503
42,0406,0034 42,0100,0333 - PE
42,0001,3481 - Fe
22,0405,0114
42,0405,0119
BF2,0201,1345

Motorplate 42V 4R
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/4

el_fr_st_mp_01220 012012
Motorplate 42V 4R
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/4

el_fr_st_mp_01220 012012
Motorplate 42V 4R
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 3/4

el_fr_st_mp_01220 012012
Motorplate 42V 4R
Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 4/4

el_fr_st_mp_01220 012012
 FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com

www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.

ud_fr_st_so_00082 012011