FRONIUS KD 4000 D-11 Bedienungsanleitung

Operating

Instructions

KD 4000 D-11

42,0426,0031,EN 003-10012024

EN Operating Instructions

Contents

Safety rules 5

Explanation of safety notices 5

General 5

Proper use 6

Environmental conditions 6

Obligations of the operator 6

Obligations of personnel 6

Mains connection 7

Protecting yourself and others 7

Noise emission values 8

Danger from toxic gases and vapours 8

Danger from ﬂying sparks 8

Risks from mains current and welding current 9

Meandering welding currents 10

EMC Device Classifications 10

EMC measures 10

EMF measures 11

Specific hazards 11

Requirement for the shielding gas 12

Danger from shielding gas cylinders 12

Danger from escaping shielding gas 13

Sicherheitsmaßnahmen am Aufstellort und beim Transport 13

Safety measures in normal operation 14

Commissioning, maintenance and repair 15

Safety inspection 15

Disposal 15

Safety symbols 15

Data protection 16

General 17

Device concept 17

Application area 17

Warning notices on the device 17

Control elements and connections 18

General 18

Safety 18

Cold wire feeder front 18

Cold wire feeder rear 19

Cold wire feeder right side 19

Cold wire feeder underside 20

Placing the cold wire feeder on the power source 21

General 21

Placing the cold wire feeder on the power source 21

Connect the cold wire feeder to the power source 22

General 22

Connect the cold wire feeder to the power source 22

Fitting the welding torch 23

Fit the welding torch 23

Inserting the wirespool 24

Safety 24

Inserting the wirespool 24

Inserting/replacing feed rollers 26

General remarks 26

USA wirefeeders 26

inserting/replacing feed rollers 26

Inserting the wirespool, inserting the basket-type spool 27

Safety 27

Inserting the wirespool 27

Inserting the basket-type spool 29

Feeding in the wire electrode 30

Set the contact pressure 31

Adjust the brake 32

Adjusting the brake 32

Push-pull unit 33

General 33

Calibrating the push-pull unit 33

Service codes for push-pull calibration 35

Safety 35

Service codes shown when the drive units are disengaged (open-circuit calibration) 35

Service codes shown when the drive units are engaged (engaged calibration) 36

Service codes in conjunction with the cold wire feeder and digital gas control option 38

Service codes displayed in conjunction with the cold wire feeder 38

Service codes displayed in conjunction with the digital gas control option 40

Care, maintenance and disposal 41

General remarks 41

Every start-up 41

Every 6 months 41

Disposal 41

Technical data 42

KD 4000 D-11 42

Safety rules

Explanation of

safety notices DANGER!

Indicates immediate danger.

▶If not avoided, death or serious injury will result.

WARNING!

Indicates a potentially hazardous situation.

▶If not avoided, death or serious injury may result.

CAUTION!

Indicates a situation where damage or injury could occur.

▶If not avoided, minor injury and/or damage to property may result.

NOTE!

Indicates a risk of ﬂawed results and possible damage to the equipment.

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 operating

company,

-inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the

device must:

-be suitably qualified,

-have sufficient knowledge of welding and

-read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being

used. In addition to the operating instructions, attention must also be paid to any

generally applicable and local regulations regarding accident prevention and en-

vironmental protection.

All safety and danger notices on the device

-must be in a legible state,

-must not be damaged,

-must not be removed,

-must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the sec-

tion headed "General" in the operating instructions for the device.

Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating

plate.

Any use above and beyond this purpose is deemed improper. The manufacturer

shall not be held liable for any damage arising from such usage.

Proper use includes:

-carefully reading and following all the instructions given in the operating in-

structions

-studying and obeying all safety and danger notices carefully

-performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

-Thawing out pipes

-Charging batteries

-Starting engines

The device is designed for use in industry and the workshop. The manufacturer

accepts no responsibility for any damage caused through use in a domestic set-

ting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental

conditions

Operation or storage of the device outside the stipulated area will be deemed as

not in accordance with the intended purpose. The manufacturer shall not be held

liable for any damage arising from such usage.

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:

-up to 50% at 40 °C (104 °F)

-up to 90% at 20 °C (68 °F)

The surrounding air must be free from dust, acids, corrosive gases or substances,

etc.

Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

Obligations of

the operator

The operator must only allow persons to work with the device who:

-are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device

-have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures

-are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are

working in a safety-conscious manner.

Obligations of

personnel

Before using the device, all persons instructed to do so undertake:

-to observe the basic instructions regarding safety at work and accident pre-

vention

-to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any

harm in your absence.

Mains connec-

tion

Devices with a higher rating may affect the energy quality of the mains due to

their current consumption.

This may affect a number device types in terms of:

-Connection restrictions

-Criteria with regard to the maximum permissible mains impedance *)

-Criteria with regard to the minimum short-circuit power requirement *)

*) at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check

whether the device may be connected, where appropriate by discussing the mat-

ter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Protecting your-

self and others

Anyone working with the device exposes themselves to numerous risks, e.g.

-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 us-

ing cardiac pacemakers

-Risk of electrocution from mains current and welding current

-Greater noise pollution

-Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The

protective clothing must have the following properties:

-Flame-resistant

-Insulating and dry

-Covers the whole body, is undamaged and in good condition

-Safety helmet

-Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

-Protect eyes and face from UV rays, heat and sparks using a protective visor

and regulation filter

-Wear regulation protective goggles with side protection behind the protect-

ive visor

-Wear stout footwear that provides insulation even in wet conditions

-Protect the hands with suitable gloves (electrically insulated and providing

protection against heat)

-Wear ear protection to reduce the harmful effects of noise and to prevent in-

jury

Keep all persons, especially children, out of the working area while any devices

are in operation or welding is in progress. If, however, there are people in the vi-

cinity:

-Make them aware of all the dangers (risk of dazzling by the arc, injury from

ﬂying sparks, harmful welding fumes, noise, possible risks from mains cur-

rent and welding current, etc.)

-Provide suitable protective equipment

-Alternatively, erect suitable safety screens/curtains.

Noise emission

values

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 per-

missible 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 work-

piece, the workplace environment, etc.

Danger from tox-

ic gases and va-

pours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph

118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system.

If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

-must not be breathed in

-must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of

at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the

measured toxic emission values should be compared with the permissible limit

values.

The following components are responsible, amongst other things, for the degree

of toxicity of welding fumes:

-Metals used for the workpiece

-Electrodes

-Coatings

-Cleaners, degreasers, etc.

-Welding process used

The relevant material safety data sheets and manufacturer's specifications for

the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for

identifying working conditions can be found on the European Welding Associ-

ation website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-

ation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking

place.

Danger from ﬂy-

ing sparks

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 accord-

ance 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.

Risks from mains

current and

welding current

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 di-

mensioned. 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.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

-never be immersed in liquid for cooling

-never be touched when the welding system is switched on.

Double the open circuit voltage of a welding system can occur between the weld-

ing electrodes of two welding systems. Touching the potentials of both elec-

trodes 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 regula-

tions for protective separation are observed.

Otherwise, this is considered gross negligence. The manufacturer shall not be

held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

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

Attach a clearly legible and easy-to-understand warning sign to the device to

prevent anyone from plugging the mains plug back in and switching it on again.

After opening the device:

-Discharge all live components

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

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

at the right moment.

Meandering

welding currents

If the following instructions are ignored, meandering welding currents can devel-

op with the following consequences:

-Fire hazard

-Overheating of parts connected to the workpiece

-Irreparable damage to ground conductors

-Damage to device and other electrical equipment

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

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

Position the device with sufficient insulation against electrically conductive envir-

onments, e.g. Insulation against conductive ﬂoor or insulation to conductive

racks.

If 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 suffi-

ciently 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

Classifications

Devices in emission class A:

-Are only designed for use in industrial settings

-Can cause line-bound and radiated interference in other areas

Devices in emission class B:

-Satisfy the emissions criteria for residential and industrial areas. This is also

true for residential areas in which the energy is supplied from the public low-

voltage mains.

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

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).

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