Operating Instructions
Spare Parts List
Wirefeeder
42,0426,0080,EN 022009
GB
VR 5000
ud_fr_st_et_00493 012004
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new
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.
Introduction
ud_fr_st_sv_00467 022009
I
Safety rules
DANGER!
WARNING!
CAUTION!
“NOTE!” indicates a situation which implies a risk of impaired welding result
and damage to the equipment.
NOTE!
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”.
General remarks
Important!
“DANGER!” indicates an imminently hazardous situation which, if not
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!” 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!” 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.
“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!
ud_fr_st_sv_00467 022009
II
Operation or storage of the power source outside the stipulated range is
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: - 25 °C to + 55 °C (-13 °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)
Ambient
conditions
The machine may only be used for jobs as defined by the “Intended
purpose”.
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.
Utilisation for
intended purpose
only
Any malfunctions which might impair machine safety must be eliminated
immediately - meaning before the equipment is next switched on.
It’s your safety that’s at stake!
The owner/operator undertakes to ensure that the only persons allowed to
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 the sections on “safety rules” and the “warnings“ contained in this manual, 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.
Obligations of
owner/operator
General remarks
(continued)
ud_fr_st_sv_00467 022009
III
Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake
- to observe the basic regulations on workplace safety and accident
prevention
- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.
Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.
Obligations of
personnel
Protection for
yourself and
other persons
When welding, you are exposed to many different hazards such as:
- flying sparks and hot metal particles
- arc radiation which could damage your eyes and skin
- harmful electromagnetic fields which may put the lives of cardiac pacemaker users at risk
- electrical hazards from mains and welding current
- increased exposure to noise
Mains connection High-performance devices can affect the quality of the mains power due to
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.
- 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
ud_fr_st_sv_00467 022009
IV
The fumes given off during welding contain gases and vapors that are
harmful to health.
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.
Hazards from
noxious gases
and vapours
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.
Protection for
yourself and
other persons
(continued)
“Protective clothing” also includes:
- protecting your eyes and face from UV rays, heat and flying sparks with
an appropriate safety shield containing appropriate regulation filter glass
- 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 insulating, heat-proof)
- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!
Information on
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
permissible operating point under maximum rated load conditions according to
EN 60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.
ud_fr_st_sv_00467 022009
V
Hazards from
mains and welding current
Flying sparks can cause fires and explosions!
Never perform welding anywhere near combustible materials.
Combustible materials must be at least 11 meters (35 feet) 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
flying sparks
An electric shock is potentially life-threatening, and can be fatal.
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.
The harmfulness of the welding fumes will depend on e.g. the following
components:
- the metals used in and for the workpiece
- the electrodes
- coatings
- cleaning and degreasing agents and the like
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
noxious gases
and vapours
(continued)
ud_fr_st_sv_00467 022009
VI
If the following instructions are ignored, stray welding currents may occur.
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.
Stray welding
currents
Hazards from
mains and welding current
(continued)
Do not loop any cables or other leads around your body or any part of your
body.
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.
ud_fr_st_sv_00467 022009
VII
When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/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
wirespool to the wirefeeder.
Stray welding
currents
(continued)
EMC device
classifications
Devices with emission class A:
- 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.
ud_fr_st_sv_00467 022009
VIII
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.
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.
Risk of scalding from accidental discharge of hot coolant. Before unplugging
the connectors for coolant forward flow and return flow, switch off the cooling
unit.
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).
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.
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.
Electromagnetic fields may cause as yet unknown damage to health.
- Effects on the health of persons in the vicinity, e.g. users of heart pacemakers 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
EMI Precautions
Keep your hands, hair, clothing and tools well away from all moving parts,
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.0
Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.
Particular danger
spots
ud_fr_st_sv_00467 022009
IX
Shielding-gas cylinders contain pressurized gas and may explode if they are
damaged. As shielding-gas cylinders are an integral part of the overall
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).
Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).
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.
Danger from
shielding-gas
cylinders
Particular danger
spots
(continued)
When hoisting the machines by crane, only use suitable manufacturersupplied 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.
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.
ud_fr_st_sv_00467 022009
X
Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:
- 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 features that are not fully functional must be put right before you
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, frostproofing, 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.
Safety precautions in normal
operation
Safety precautions at the installation site and
when being
transported
A machine that topples over can easily kill someone! For this reason, always
place the machine on an even, firm floor in such a way that it stands firmly.
- An angle of inclination of up to 10° is permissible.
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 transportation
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.
ud_fr_st_sv_00467 022009
XI
With parts sourced from other suppliers, there is no certainty that these parts
will have been designed and manufactured to cope with the stressing 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.
Preventive and
corrective maintenance
- 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.
Safety precautions in normal
operation
(continued)
The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.
The manufacturer also recommend the same (12-month) interval for regular
calibration of power sources.
A safety inspection, by a trained and certified electrician, is prescribed:
- after any alterations
- after any modifications or installations of additional components
- following repairs, care and maintenance
- at least every twelve months.
Observe the relevant national and international standards and directives in
connection with the safety inspection.
More detailed information on safety inspections and calibration is available
from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request.
Safety inspection
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!
Disposal
ud_fr_st_sv_00467 022009
XII
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.
Copyright
Equipment with CE-markings fulfils the basic requirements of the LowVoltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .
Safety markings
Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.
The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.
Data security
1
Table of contents
General information 5
General .......................................................................................................................................................... 7
Device concept .......................................................................................................................................... 7
Requirements ............................................................................................................................................ 7
Field of application..................................................................................................................................... 7
Warning notices affixed to the device ........................................................................................................ 8
Control elements and connections 9
Description of the control panels ................................................................................................................... 11
General .................................................................................................................................................... 11
Safety .......................................................................................................................................................11
Manual control panel .................................................................................................................................... 12
General ................................................................................................................................................... 12
Manual control panel ............................................................................................................................... 12
Adjustment aid for Manual control panel.................................................................................................. 13
Synergic control panel .................................................................................................................................. 14
General ................................................................................................................................................... 14
Layout of the control panel ...................................................................................................................... 14
Synergic A control panel .......................................................................................................................... 14
Synergic B control panel .......................................................................................................................... 16
Connections and mechanical components ................................................................................................... 17
Wirefeeder front ...................................................................................................................................... 17
Wirefeeder rear ....................................................................................................................................... 17
Wirefeeder side ....................................................................................................................................... 18
Wirefeeder underside .............................................................................................................................. 19
Installation and commissioning 21
Before commissioning .................................................................................................................................. 23
Safety ...................................................................................................................................................... 23
Utilisation in accordance with „intended purpose“ .................................................................................... 23
Setup regulations .................................................................................................................................... 23
Placing wirefeeder on power source ............................................................................................................. 24
General ................................................................................................................................................... 24
Placing wirefeeder on power source ........................................................................................................ 24
Connecting wirefeeder to power source ....................................................................................................... 25
General ................................................................................................................................................... 25
Connecting wirefeeder to power source .................................................................................................. 25
Connecting the welding torch ....................................................................................................................... 26
Safety ...................................................................................................................................................... 26
Connecting MIG/MAG welding torches .................................................................................................... 26
Inserting / replacing feed rollers .................................................................................................................... 27
General ................................................................................................................................................... 27
Inserting / replacing feed rollers............................................................................................................... 27
Inserting the wirespool, inserting the basket-type spool ................................................................................ 28
Safety ...................................................................................................................................................... 28
Inserting the wirespool ............................................................................................................................. 28
Inserting the basket-type spool ................................................................................................................ 28
Feeding in the wire electrode ........................................................................................................................ 29
Feeding in the wire electrode ................................................................................................................... 29
Setting the contact pressure .................................................................................................................... 30
Adjusting the brake ....................................................................................................................................... 31
General ................................................................................................................................................... 31
Adjusting the brake .................................................................................................................................. 31
Design of the brake ................................................................................................................................. 31
2
Commissioning ............................................................................................................................................. 32
General ................................................................................................................................................... 32
Requirements .......................................................................................................................................... 32
Welding 33
MIG/MAG modes.......................................................................................................................................... 35
General ................................................................................................................................................... 35
Symbols .................................................................................................................................................. 35
2-step mode ............................................................................................................................................ 35
4-step mode ............................................................................................................................................ 36
Special 4-step mode ................................................................................................................................ 36
MIG/MAG welding ........................................................................................................................................ 37
Safety ...................................................................................................................................................... 37
General tasks before MIG/MAG welding ................................................................................................. 37
Overview ................................................................................................................................................. 37
MIG/MAG standard synergic welding ........................................................................................................... 38
General ................................................................................................................................................... 38
MIG/MAG standard synergic welding ...................................................................................................... 38
Adjustments while welding - manual control panel................................................................................... 39
MIG/MAG standard manual welding ............................................................................................................. 40
General ................................................................................................................................................... 40
Available parameters ............................................................................................................................... 40
MIG/MAG standard manual welding - manual control panel .................................................................... 40
Adjustments while welding - manual control panel................................................................................... 41
MIG/MAG standard manual welding - Synergic A control panel ............................................................... 42
Corrections during welding - Synergic A control panel ............................................................................. 43
MMA welding ................................................................................................................................................ 44
Safety ...................................................................................................................................................... 44
Preparations ............................................................................................................................................ 44
MMA welding - manual control panel ....................................................................................................... 44
Adjustments while welding - manual control panel................................................................................... 45
MMA welding - Synergic A control panel .................................................................................................. 45
Adjustments while welding - Synergic A control panel.............................................................................. 46
Hotstart function ...................................................................................................................................... 46
Anti-stick function .................................................................................................................................... 47
Saving and retrieving operating points .......................................................................................................... 48
General ................................................................................................................................................... 48
Saving operating points ........................................................................................................................... 48
Retrieving operating points ...................................................................................................................... 48
Setup parameters 49
Process set-up menu ................................................................................................................................... 51
General ................................................................................................................................................... 51
Process set-up menu - manual control panel .......................................................................................... 51
Process set-up menu - Synergic A control panel ..................................................................................... 52
Parameters for MIG/MAG welding in the Process set-up menu .............................................................. 53
Parameters for rod electrode (MMA) welding in the Process set-up menu .............................................. 53
Mode set-up menu ....................................................................................................................................... 54
General ................................................................................................................................................... 54
Mode set-up menu - Synergic A control panel ......................................................................................... 54
Parameters for „Special 4-step mode“ in the mode set-up menu............................................................. 55
Set-up menu - Level 2 .................................................................................................................................. 56
Set-up menu level 2 - manual control panel............................................................................................. 56
Set-up menu Level 2 - Synergic control panel ......................................................................................... 57
Set-up menu Level 2 - Synergic control panel ......................................................................................... 58
Parameters for MIG/MAG welding in the set-up menu level 2 ................................................................. 58
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Troubleshooting and maintenance 59
Troubleshooting ............................................................................................................................................ 61
General ................................................................................................................................................... 61
Displayed service codes .......................................................................................................................... 61
Troubleshooting the wirefeeder ............................................................................................................... 65
Care, maintenance and disposal .................................................................................................................. 67
General ................................................................................................................................................... 67
At every start-up ...................................................................................................................................... 67
Every 6 months ....................................................................................................................................... 67
Disposal .................................................................................................................................................. 67
Annex 69
Technical data .............................................................................................................................................. 71
VR 5000 .................................................................................................................................................. 71
Fronius Worldwide
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General information
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VR 5000 wirefeeder
The VR 5000 series of wirefeeders, in combination with any of the standard protective
gas shields, is suitable for all MIG/MAG welding tasks.
General
Device concept
The VR 5000 wirefeeders can be operated with the TransSteel 3500 / 5000 power
sources.
Wirefeeders in the VR 5000 series are
equipped with a cover for wirespools with a
maximum diameter of 300 mm (11.81 in.).
The standard 4-roll drive has good wirefeeding properties. The wirefeeders in the
VR 5000 series are also suitable for long
hosepacks.
Due to their compact design, the VR 5000
wirefeeders can be used in many different
ways.
Requirements
Field of application
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Warning notices
affixed to the
device
The wirefeeder is fitted with safety symbols on the rating plate. The safety symbols must
NOT be removed or painted over. The symbols warn against operating the equipment
incorrectly, as this may result in serious injury and damage.
Do not use the functions described until
you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the
system components, especially the
safety rules
Warning notices on the wirefeeder
Welding is dangerous. The following
basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment
- Keep all persons not involved in the
welding process at a safe distance
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Control elements and connections
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Description of the control panels
General The functions on the control panels are all arranged in a very logical way. The various
parameters needed for welding are easy to select, by pressing the appropriate button,
and can easily be
- altered using buttons or the adjusting dial
- displayed on the digital display during welding
Thanks to the synergic function, whenever you alter any one parameter, appropriate
changes will automatically be made to all the other parameters.
NOTE! Owing to software updates, you may find that your device has certain
functions that are not described in these operating instructions, or vice versa.
Certain illustrations may also differ slightly from the actual control elements on
your device. However, these control elements function in exactly the same way.
Important! Parameters that must be entered at a wirefeeder control panel cannot be
changed at the power source. Parameters can only be changed at the wirefeeder.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read
and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the
safety rules
Safety
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No. Function
(1) „Process“ button
for selecting the process
MIG/MAG welding
STICK - MMA welding
to select parameters in the Set-up menu
(2) „Mode“ button
for selecting the mode
2-step mode
4-step mode
to select parameters in the Set-up menu
(3) Welding voltage adjuster
for selecting the welding voltage in V
The welding voltage is directly related to the length of the arc.
(4) Wirefeed speed adjuster
for selecting the wirefeed speed in m/min or ipm.
If the welding voltage remains (3) constant, the welding current increases as the
wirefeed speed (4) increases.
Manual control panel
Manual control
panel
Manual control panel
General The Manual control panel allows welding parameters to be set manually in a very
straightforward process.
(2) (1)
(3)
(4)
(5)
(5)
(6)
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(5) „Dynamic“ buttons
for influencing the short-circuiting dynamic at the instant of droplet transfer
- harder, more stable arc
+ soft, low-spatter arc
to change parameters in the Set-up menu
(6) HOLD indicator
every time you finish a welding operation, the actual values for welding current and
welding voltage are stored, and the „Hold“ indicator lights up.
Manual control
panel
(continued)
Adjustment aid
for Manual control panel
For selected material / protective gas shield combinations, the VR 5000 includes adjustment aids in the form of foils that can be easily attached to and removed from the
Manual control panel. The adjustment aids have additional scales that correspond to the
sheet thickness used. If both the adjusters are set to the current value for the sheet
thickness, this will produce a good basic setting for the respective material / protective
gas shield combination.
Adjustment aid for the Manual control panel, e.g. for steel 1.0 mm, CO2 100 %
No. Function
(1) Adjustment aid applies with the specified material / protective gas shield
combination
e.g.:
- Steel Material
- Ø 1.0 mm Wire diameter
-CO2 100 % Protective gas shield
(2) Scales for sheet thickness
in mm
The two adjusters must be set to the appropriate value for the sheet thickness being
used in order to obtain the basic setting according to the adjustment aid.
(1)
(2)
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