Fronius KD 7000 Operating Instructions Manual
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Fronius KD 7000 Operating Instructions Manual

Fronius KD 7000 Operating Instructions Manual

Wire-feed unit
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/ Perfect Charging /
Perfect Welding
KD 7000
42,0426,0028,EN 002-13122016
/ Solar Energy
Operating Instructions
Wire-feed unit

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Summary of Contents for Fronius KD 7000

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions KD 7000 Wire-feed unit 42,0426,0028,EN 002-13122016...
  • Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.

  • Page 5: Table Of Contents

    Setting wire speed externally ........................ TIG-KD connection box wiring diagram ..................... "Minimum start-up requirements" wiring diagram ..................Analogue signals........................... Digital signals............................KD 7000 wiring diagram..........................Supply voltages............................Supply voltages............................. Digital input signals (signals from robot) ....................Signal level............................Ground ..............................
  • Page 6 Feeding in the welding wire ........................Adjusting the brake ..........................Design of the brake..........................Troubleshooting ............................Troubleshooting ............................ Care, maintenance and disposal ....................... General ..............................Care and maintenance.......................... Disposal ..............................Technical data............................KD 7000 ..............................Spare parts list: KD 7000 ...........................

  • Page 7: Safety Rules

    Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operat- ing company, inefficient operation of the device.
  • Page 8 Environmental Operation or storage of the device outside the stipulated area will be deemed conditions as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. Ambient temperature range: 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) Relative humidity:...
  • Page 9 Protecting your- Persons involved with welding expose themselves to numerous risks, e.g.: self and others 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...
  • Page 10 Danger from toxic The fumes produced during welding contain harmful gases and vapours. gases and va- Welding fumes contain substances that may, under certain circumstances, pours cause birth defects or cancer. Keep your face away from welding fumes and gases. Fumes and hazardous gases must not be breathed in must be extracted from the working area using appropriate methods.
  • Page 11 During MIG/MAG welding and TIG welding, the welding wire, the wirespool, 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 suit- able, insulated wirefeeder holder.
  • Page 12 If the floor is electrically conductive, the device must be set up with sufficient insulating material to insulate it from the floor. If distribution boards, twin-head mounts, etc., are being used, note the follow- ing: The electrode of the welding torch / electrode holder that is not used is also live.
  • Page 13 EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids wearers of pacemakers must seek advice from their doctor before ap- proaching the device or any welding that is in progress for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible do not carry welding cables and hosepacks over the shoulders or wind...
  • Page 14 Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane. Hook chains and/or ropes onto all suspension points provided on the load-carrying equipment. Chains and ropes must be at the smallest angle possible to the vertical. Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
  • Page 15 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 na- tional and international regulations for shielding gas cylinders and accesso- ries. Safety measures A device toppling over could easily kill someone.
  • Page 16 The 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 na- tional and international regulations. The coolant safety data sheet may be ob- tained from your service centre or downloaded from the manufacturer's website.
  • Page 17 (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 rele- vant standards for Canada and the USA.

  • Page 18: General

    In this case, external control of the KD 7000 is via the robot controller. The Robacta Drive KD is recommended as a wire drive for the KD 7000 in the case of al- uminium applications. This is an external drive system that draws the wire during the weld- ing process itself.

  • Page 19: Warning Notices On The Device

    Warning notices The wire-feed unit has safety symbols on the rating plate. The safety symbols must not be on the device removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage. Welding is dangerous.

  • Page 20: Application

    Application General IMPORTANT! The figures below show configuration examples for the KD 7000 with an in- dustrial robot and a Fronius TIG power source. The configuration examples shown apply by analogy to welding machines and cold wire TIG welding applications with laser welding systems.

  • Page 21: Configuration 2: Unalloyed/High-Alloy Steels (Push Vr 1530/External)

    Configuration 2: Recommended for robots unalloyed/high- KD 7000 without wirespool and wire drive alloy steels (Push Wirespool on external wirespool holder on the robot VR 1530/External) Wire pushed by external 4 roller drive (VR 1530 KD) Length of the wirefeed hosepack: up to 3.5 m...

  • Page 22: Configuration 3: Aluminium (Pull/Internal)

    Wire pulled through external 2-roller drive (Robacta Drive KD) during the welding pro- cess itself Length of the Robacta Drive KD hosepack: up to 3.5 m Configuration 3 - Wirespool in the KD 7000, wire pulled by external wire drive KD 7000 with wirespool holder Robacta Drive KD hosepack...

  • Page 23: Configuration 4: Aluminium (Pull/External)

    Configuration 4: Recommended for robots Aluminium (Pull/ KD 7000 without wirespool and wire drive External) Wirespool on external wirespool holder on the robot Wire pulled through external 2-roller drive (Robacta Drive KD) during the welding pro- cess itself Length of the Robacta Drive KD hosepack: up to 3.5 m...

  • Page 24: Controls, Connections And Mechanical Components

    IMPORTANT! The actual wire speed will depend on the wire drive used. Check the sticker on the KD 7000 for details of which wire drive is used (e.g. wire drive "0 - 10 m/min") Use the table below to determine the actual wire speed e.g.:...
  • Page 25 KD 7000 is switched on LocalNet connection socket standardised connection socket for the system defaults (10) KD control interface (37-pin plastic CPC socket) for external control of the KD 7000 using analogue and digital signals (11) Mains cable (12) External welding wire feed...

  • Page 26: Tig-Kd Connection Box

    For robot applications with the TIG cold-wire welding process, the TIG-KD connection box tion box acts as a central node to network the robot controller to the power source and the KD 7000. IMPORTANT! If it is not necessary to control a power source via the robot controller, the TIG KD connection box is not required (direct connection between robot controller and the KD 7000).
  • Page 27 To the KD control interface: controls the KD 7000 using analogue and digital signals via the robot or machine controller and the power source...
  • Page 28 "Puls Synch TIG" and "Start Robot" setting: Dip switch for "Puls Synch TIG" to "on" Dip switch for "Start Robot" to "on" "Puls Robot": The signal for pulsing the cold wire is set by the robot or machine controller. The wire speed switches between 0 and the entered set value, according to the sig- nal for pulsing.

  • Page 29: Setting Wire Speed Externally

    The table below shows the signal voltage to be created for the relevant wire speed. IMPORTANT! The wire speed will depend on the wire drive used. Check the sticker on the KD 7000 for details of which wire drive is used (e.g. wire drive "0 - 10 m/min") Use the table below to determine the signal voltage for the relevant wire speed e.g.:...

  • Page 30: Tig-Kd Connection Box Wiring Diagram

    TIG-KD connection box wiring diagram...

  • Page 31: Minimum Start-Up Requirements" Wiring Diagram

    "Minimum start-up requirements" wiring diagram Analogue signals Analogue input signal for setting wire speed externally X3:14 ... Vd Command Value + X3:15 ... Vd Command Value - Analogue input signal for setting main current externally X3:1 ... Rem.contr. Pin C X3:6 ...

  • Page 32: Kd 7000 Wiring Diagram

    KD 7000 wiring diagram...

  • Page 33: Supply Voltages

    Supply voltages Supply voltages WARNING! An electric shock can be fatal. Never connect the robot controller supply to the power supply for the KD 7000 or the power source. Plug X3/pin 5 ("+ 24 V TIG") 24 V Plug X3/pin 6 ("GND TIG") GND (power supply) Plug X3/pin 7 ("+ 15 V TIG")

  • Page 34: Digital Input Signals (Signals From Robot)

    TIG-KD connection box: Plug X3/pin 16 24 V Plug X3/pin 27 Connection option direct to the KD 7000: Plug X2/pin 17 24 V Plug X2/pin 27 The "Start KD" signal starts wirefeeding at the specified wire speed when "Start Robot" is selected on the "Wire-Mode"...

  • Page 35: Touch Sensing

    TIG-KD connection box: (WR on/off) Plug X3/pin 22 24 V (connection box) Plug X3/pin 27 Connection option direct to the KD 7000: Plug X2/pin 21 24 V Plug X2/pin 27 "Wire retract on" is LOW active 24 V not present: the wire is automatically retracted at the end of welding.

  • Page 36: Reserve 4, Reserve 5

    The "Job memory" option (4,100,189) is a prerequisite for Job mode. Robot torches used for applications with the KD 7000 do not normally have a torch trigger, which is required for programming jobs. The torch trigger simulator (4,100,560) is available if you want to be able to program jobs.

  • Page 37: Robot Wire-Pulsing (Wire Pulse Robot)

    The wire moves backwards at the specified wire speed for as long as the "Wire retract" sig- nal is set. IMPORTANT! It is not possible to send a command to the KD 7000 using the "Start KD" or "Robot wire-pulsing" signals while the "Wire retract" signal is enabled.

  • Page 38: Analogue Input Signals (Signals From Robot)

    Plug X3/pin 14 Analogue in + 0 to + 10 V Plug X3/pin 15 Analogue in - (minus) Connection option direct to the KD 7000: Plug X2/pin 1 Analogue in + 0 to + 10 V Plug X2/pin 2 Analogue in - (minus) A voltage of 0 - 10 V is specified for the "Wire speed set value".
  • Page 39 Pulse frequency (+ 0 to + 10 V) Plug X3/pin 12 Pulse width (+ 0 to + 10 V) Plug X3/pin 6 Connection option direct to the KD 7000: Plug X2/pin 17 24 V Plug X2/pin 27 A voltage of 0 - 10 V is specified for the set values for the listed welding parameters.

  • Page 40: Digital Output Signals (Signals To Robot)

    Digital output signals (signals to robot) General The digital outputs have been implemented as relay outputs. This provides for electrical isolation of the digital output signals. Pulssynch HIGH TIG-KD connection box: Plug X3/pin 18 24 V Plug X3/pin 27 "Pulssynch High" informs the robot control of the moment at which the welding current is in the pulsing current phase.

  • Page 41: Alarm Signal

    Floating connection Plug X3/pin 37 Floating connection Connection option direct to the KD 7000: Plug X2/pin 30 Floating connection Plug X2/pin 37 Floating connection Meaning of the "KD ready" digital output signal: KD 7000 switched on and ready for operation...

  • Page 42: Main Current Signal

    If the "KD ready" signal is not present even though the system has been switched on, the following errors may be present: Motor overcurrent Short circuit/interruption in the actual value pick-up lines Actual value pick-up faulty Earth current watchdog has tripped Reset: Switch the mains switch off and back on again Main current sig- Digital output signal, direct from the power source robot interface to the TIG-KD connection...

  • Page 43: Start-Up

    Proper use The KD 7000 cold wire wire-feed unit should exclusively be used as a wire-feed unit for the cold wire TIG and laser cold wire welding processes.Any use above and beyond this pur- pose is deemed improper.

  • Page 44: Connecting The Tig-Kd Manual Torch

    Connecting the Move the mains switch to the O position TIG-KD manual Check that the welding torch has been completely tooled up. Insert it - infeed tube first torch - into the central connector Tighten the union nut by hand to fix the torch in place Plug the control plug of the welding torch into the torch control connection and latch it in place Connecting the...

  • Page 45: Inserting The Wirespool

    Inserting the wire- spool...

  • Page 46: Inserting The Basket-Type Spool

    Inserting the bas- NOTE! When working with basket-type spools, use only the basket-type spool ket-type spool adapter supplied with the wire-feed unit! USA wire-feed units are supplied without basket-type spool adapters. CAUTION! Risk of injury from falling basket-type spool. Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways.

  • Page 47: Adjusting The Brake

    CAUTION! Risk of injury from emerging welding wire. Keep the welding torch away from your face and body, and wear suitable protective goggles. Adjusting the NOTE! After releasing the torch trigger the wirespool should stop unreeling. Ad- brake just brake if necessary. STOP...

  • Page 48: Design Of The Brake

    STOP Design of the CAUTION! Risk of injury and damage from falling wirespool. To ensure that the brake wirespool is properly in place and that the brake works properly, fit the brake ac- cording to the following diagram. KLEBER, GLUE, COLLE...

  • Page 49: Troubleshooting

    Troubleshooting Troubleshooting WARNING! An electric shock can be fatal. Before opening up the KD 7000, turn the mains switch into the - O - position, unplug the machine from the mains and put up a warning sign to stop anybody inadvertently switching the machine back on again.

  • Page 50: Care, Maintenance And Disposal

    WARNING! An electric shock can be fatal. Before opening up the KD 7000, turn nance the KD 7000 off at the mains switch, unplug the machine from the mains and put up a warning sign to stop anybody inadvertently switching the machine back on again.

  • Page 51: Technical Data

    Technical data KD 7000 Mains voltage 200 - 240 V AC Nominal current 1,2 A Mains fuse protection slow-blow 2 A Types of wirespool all standard Max. permitted wirespool weight 16 kg (35.27 lb.) Wirespool diameter 300 mm (11.81 in.) Wire speed 0,2 - max.

  • Page 52: Spare Parts List: Kd 7000

    Spare parts list: KD 7000...
  • Page 53 Motorplate 42V 4R 42,0400,0123 42,0405,0116 42,0407,0098 42,0404,0264 42,0404,0340 - yellow 42,0409,2106 32,0405,0112 32,0405,0113 42,0405,0117 - PE 42,0200,9352 - CuZn 42,0200,7767 t o r t o r 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...
  • Page 54 VR 1500-M ( 4.045.848.638 VR 1500-PAP ( 4.045.996 4.045.996.800 4.049.001 4.049.001.800 CB RA - M connection 44,0350,2339 42,0200,9872 VR 1500 ( all variants ) TW = Tweco connection Z = Fronius connection 42,0402,0093 42,0100,0499 42,0001,0090 42,0100,0052 44,0001,1277 42,0001,3547 44,0001,0052 42,0401,0952...
  • Page 55 Motorplate 42V 4R Tweco 42,0300,2631 32,0300,2233 12,0405,0118 32,0300,2481 42,0200,9817 42,0001,3259 44,0001,1242 42,0001,3260 42,0407,0077 42,0200,9816 12,0300,2375 15mm/.59in. 17mm/.67in.
  • Page 56 Motorplate 42V 4R Motor IWGTC IWGTD IWGTC 42,0405,0081 42,0405,1085 42,0405,0081 42,0405,1083 4,070,294 - IWGT 4,070,294 - IWGT 43,0011,0029 42,0400,0093 42,0400,0093 42,0407,0312 43,0011,0029 42,0405,1084 43,0004,2846 43,0011,0033 42,0001,1367 - IWGTD 4,070,938 42,0001,1366 32,0405,0080 32,0405,0080 42,0405,1086 42,0405,0082 42,0405,0082 43,0007,0032 42,0001,3671 42,0001,3670 42,0200,5633 IWGTD 42,0405,1085 42,0405,1083 43,0011,0029...
  • Page 60 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...

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