How it Works
Fronius
Loading...
V
W
Loading...
Loading...
VR 5000 Case, VR 5000 Case D300

Fronius VR 5000 Case, VR 5000 Case D300 Operating Instruction [EN]

Download
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
VR 5000 Case VR 5000 Case D300
Operating Instructions
Wire-feed unit
[
42,0426,0150,EN 026-12052020
2
Dear reader,
Introduction 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. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.
3
4
Contents
Safety rules ................................................................................................................................................ 9
Explanation of safety notices ................................................................................................................ 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 9
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 10
Mains connection.................................................................................................................................. 10
Protecting yourself and others .............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from flying sparks ..................................................................................................................... 12
Risks from mains current and welding current...................................................................................... 12
Meandering welding currents................................................................................................................ 13
EMC Device Classifications .................................................................................................................. 14
EMC measures ..................................................................................................................................... 14
EMF measures...................................................................................................................................... 15
Specific hazards.................................................................................................................................... 15
Requirement for the shielding gas ........................................................................................................ 16
Danger from shielding gas cylinders..................................................................................................... 16
Danger from escaping shielding gas..................................................................................................... 17
Safety measures at the installation location and during transport ........................................................ 17
Safety measures in normal operation ................................................................................................... 17
Commissioning, maintenance and repair.............................................................................................. 18
Safety inspection................................................................................................................................... 18
Disposal ................................................................................................................................................ 19
Safety symbols...................................................................................................................................... 19
Data protection...................................................................................................................................... 19
Copyright............................................................................................................................................... 19
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Requirements........................................................................................................................................ 23
Application area .................................................................................................................................... 23
Options.................................................................................................................................................. 23
Warning notices on the device.............................................................................................................. 23
Description of Warning Notices on the Device...................................................................................... 25
Transporting the VR 5000 Case / VR 5000 Case D300 by crane......................................................... 26
Control elements and connections 29
Description of the control panels................................................................................................................ 31
General information .............................................................................................................................. 31
Safety.................................................................................................................................................... 31
Manual control panel.................................................................................................................................. 32
General ................................................................................................................................................ 32
Manual control panel............................................................................................................................. 32
Adjustment aid for Manual control panel............................................................................................... 33
Keylock ................................................................................................................................................. 34
Service parameters............................................................................................................................... 34
Synergic control panel ............................................................................................................................... 36
General ................................................................................................................................................. 36
Control panel splitting ........................................................................................................................... 36
Synergic A control panel....................................................................................................................... 36
Synergic B control panel overview........................................................................................................ 38
Synergic B control panel....................................................................................................................... 39
Keylock ................................................................................................................................................. 40
Service parameters............................................................................................................................... 40
Connections and mechanical components ................................................................................................ 42
5
Overview of connections for the welding torch ..................................................................................... 42
Front of wire-feed unit........................................................................................................................... 42
Wire-feed unit side ................................................................................................................................ 43
Installation and commissioning 45
Before commissioning................................................................................................................................ 47
Safety.................................................................................................................................................... 47
Intended purpose.................................................................................................................................. 47
Setup regulations.................................................................................................................................. 47
Connecting wire-feed unit to power source................................................................................................ 48
General information .............................................................................................................................. 48
Connecting the wire-feed unit to the power source............................................................................... 48
Connecting the welding torch..................................................................................................................... 50
Safety.................................................................................................................................................... 50
Connecting MIG/MAG manual welding torches.................................................................................... 50
Inserting/replacing feed rollers................................................................................................................... 51
General ................................................................................................................................................. 51
Inserting/replacing feed rollers.............................................................................................................. 51
Inserting the wirespool, inserting the basket-type spool ............................................................................ 52
Safety.................................................................................................................................................... 52
Inserting a wirespool: D200 device....................................................................................................... 52
Inserting a wirespool: D300 device....................................................................................................... 53
Inserting a basket-type spool: D300 device.......................................................................................... 53
Feeding in the wire electrode..................................................................................................................... 54
Feeding in the wire electrode................................................................................................................ 54
Setting the contact pressure ................................................................................................................. 55
Adjust the brake ......................................................................................................................................... 57
General ................................................................................................................................................. 57
Setting the brake: D200 device............................................................................................................. 57
Setting the brake: D300 device............................................................................................................. 58
Brake setup: D200 device..................................................................................................................... 59
Brake setup: D300 device..................................................................................................................... 59
Start-up ...................................................................................................................................................... 60
Safety.................................................................................................................................................... 60
Requirements........................................................................................................................................ 60
Welding 61
MIG/MAG modes ....................................................................................................................................... 63
General information .............................................................................................................................. 63
Symbols and their explanations............................................................................................................ 63
2-step mode.......................................................................................................................................... 64
4-step mode.......................................................................................................................................... 64
Special 4-step mode ............................................................................................................................. 64
Spot welding ......................................................................................................................................... 64
2-step stitch welding ............................................................................................................................. 65
4-step stitch welding ............................................................................................................................. 65
MIG/MAG welding...................................................................................................................................... 66
Safety.................................................................................................................................................... 66
General tasks before MIG/MAG welding .............................................................................................. 66
Overview ............................................................................................................................................... 66
MIG/MAG standard synergic welding ........................................................................................................ 67
General ................................................................................................................................................. 67
MIG/MAG standard synergic welding ................................................................................................... 67
Corrections during welding ................................................................................................................... 68
MIG/MAG standard manual welding .......................................................................................................... 70
General ................................................................................................................................................. 70
Available parameters ............................................................................................................................ 70
MIG/MAG standard manual welding - manual control panel ................................................................ 70
Adjustments while welding - manual control panel ............................................................................... 71
MIG/MAG standard manual welding - Synergic A control panel........................................................... 71
Adjustments while welding - Synergic A control panel.......................................................................... 73
MMA welding ............................................................................................................................................. 74
6
Safety.................................................................................................................................................... 74
Preparations.......................................................................................................................................... 74
MMA welding - manual control panel.................................................................................................... 74
Adjustments while welding - manual control panel ............................................................................... 75
MMA welding - Synergic A control panel .............................................................................................. 75
Corrections during welding ................................................................................................................... 76
HotStart function ................................................................................................................................... 76
Anti-stick function.................................................................................................................................. 76
Saving and retrieving operating points....................................................................................................... 77
General ................................................................................................................................................. 77
Saving operating points ........................................................................................................................ 77
Retrieving operating points ................................................................................................................... 77
Deleting operating points ...................................................................................................................... 77
Retrieving operating points on the up/down welding torch ................................................................... 78
Setup settings 81
Setup menu................................................................................................................................................ 83
General remarks ................................................................................................................................... 83
Setup menu - manual control panel...................................................................................................... 83
Setup menu - Synergic A control panel ................................................................................................ 83
Setup parameters for MIG/MAG standard manual welding .................................................................. 85
Setup parameters for MIG/MAG standard synergic welding................................................................. 87
Setup parameters for MMA welding...................................................................................................... 88
Welding parameters for "Special 4-step mode" in the Mode setup menu............................................. 89
Setup menu - Level 2................................................................................................................................. 90
Level 2 setup menu - manual control panel.......................................................................................... 90
Level 2 setup menu - Synergic control panel........................................................................................ 90
Welding parameters for MIG/MAG welding in the Setup menu level 2................................................. 92
Measuring welding circuit resistance r ....................................................................................................... 94
General ................................................................................................................................................. 94
Measure the welding circuit resistance r............................................................................................... 94
Displaying welding circuit inductivity L ....................................................................................................... 96
General ................................................................................................................................................. 96
Displaying welding circuit inductivity L .................................................................................................. 96
Laying the hosepacks correctly............................................................................................................. 96
Troubleshooting and maintenance 97
Troubleshooting ......................................................................................................................................... 99
General ................................................................................................................................................. 99
Safety.................................................................................................................................................... 99
Fault diagnosis...................................................................................................................................... 99
Displayed service codes ....................................................................................................................... 102
Care, maintenance and disposal ............................................................................................................... 107
General ................................................................................................................................................. 107
Safety.................................................................................................................................................... 107
Every start-up........................................................................................................................................ 107
Every 6 months ..................................................................................................................................... 107
Disposal ................................................................................................................................................ 107
Technical data and settings tables 109
Technical data............................................................................................................................................ 111
VR 5000 Case....................................................................................................................................... 111
VR 5000 Case D300............................................................................................................................. 112
HP 70i ................................................................................................................................................... 112
HP 95i ................................................................................................................................................... 112
Manual control panel settings tables.......................................................................................................... 113
Settings tables ...................................................................................................................................... 113
Appendix 119
Quick reference.......................................................................................................................................... 120
7
8
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 environmental 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 section 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.
9
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 instructions
- 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 setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental conditions
Obligations of the operator
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.)
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 section "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
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
10
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- 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.
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 matter with the power sup­ply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your­self 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 using 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 protective 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 injury
Danger from toxic gases and va­pours
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 vicinity:
- 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 current and welding current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
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.
11
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 Association website under Health & Safety (https://european-welding.org).
Danger from fly­ing sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials. Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains current and weld­ing current
12
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 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 suitable, insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or cov­er for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimen­sioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding elec­trodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.
Meandering weld­ing currents
Operation of the device on a mains supply without ground conductor and on a socket with­out ground conductor contact is only permitted if all national regulations for protective sep­aration are observed. Otherwise, this is considered gross negligence. 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 any-
one 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, appoint a second person to switch off the main switch at the right moment.
If the following instructions are ignored, meandering welding currents can develop 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.
13
Position the device with sufficient insulation against electrically conductive environments, 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 sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated wire elec­trode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wire­feeder.
EMC Device Clas­sifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
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.
sions, 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.
Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interfer­ence from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
14
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 approaching 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 them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with wire-feed unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant national and international regulations.
Power sources that are to be used in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such are­as.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting cool­ant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The cool­ant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.
15
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).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
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 national standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape.
Requirement for the shielding gas
Danger from shielding gas cyl­inders
Especially with ring lines, contaminated shielding gas can cause damage to equipment and reduce welding quality. Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechan­ical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
16
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylin­ders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder. The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for shielding gas cylinders and accessories.
Danger from es­caping shielding gas
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox­ygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage be­fore every start-up.
Safety measures at the installation location and dur­ing transport
A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and ac­cident prevention regulations. This applies especially to guidelines regarding the risks aris­ing during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
Safety measures in normal opera­tion
After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before com­missioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
17
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due to its prop­erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit. The manufacturer accepts no liability for damage resulting from use of other system com-
ponents or a different coolant. In addition, all warranty claims will be forfeited. Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning, maintenance and repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufac­turer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing parts. Only use original housing screws in the correct number and tightened to the specified torque.
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12­month period.
A safety inspection should be carried out by a qualified electrician
- 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.
18
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 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 either be returned to your dealer or given to one of 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 symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (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 relevant standards for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the ba­sis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.
19
20
General information
General
Device concept
Requirements The VR 5000 wire-feed units can be operated with the TransSteel 3500 / 5000 power
sources.
The VR 5000 Case and VR 5000 Case D300 wire-feed units are contained in a fully sealed plastic housing and are suitable for the following wirespools:
VR 5000 Case max. wirespool diameter 200 mm (7.87 in.)
VR 5000 Case D300 max. wirespool diameter 300 mm (11.81 in.)
The standard 4-roller drive has good wire­feeding properties. The VR 5000 Case D300 and VR 5000 Case wire-feed units are also suitable for long hosepacks.
Application area The VR 5000 Case and VR 5000 Case D300 wire-feed units are suitable for manual shield-
ing gas welding tasks in steel applications in conjunction with all standard shielding gases. The VR 5000 Case /VR 5000 Case D300 is primarily used for the following applications:
- shipbuilding
- in shipyards and in the offshore sector
- mining
Options - VR 5000 Case water cooling
- VR 5000 Case gas flow meter
- VR 5000 Case external start signal
- VR 5000 Case power switch
- VR 5000 Case current socket
Warning notices on the device
The wire-feed units have 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.
23
Warning notices on the device, e.g. on VR 5000 Case D300
40,0006,3035
Caution: Parts may be at welding voltage Attention: Les pièces peuvent être à la tension de soudage
1 - 25 m/min 40 - 980 ipm
360A/100% 450A/60% 500A/40%I
2
2.5 AI
11
U1124 V
U
12
I
12
2.0 A24 V
IEC 60 974-5/-10 Cl.A IP 23
www.fronius.com
Ser.No.:
Part No.:
Do not dispose of used devices with domestic waste. Dispose of them accord­ing to the safety rules.
Welding is dangerous. The following basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment must be used
- All persons not involved in the welding process must be kept at a safe dis-
tance
Do not use the functions described here 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
Keep hands, hair, clothing and tools away from moving parts. For example:
- Cogs
- Feed rollers
- Wirespools and wire electrodes
Do not reach into the rotating cogs of the wire drive or into rotating drive com­ponents.
24
Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
Description of
AB
Warning Notices on the Device
On certain device versions, warning notices are attached to the device.
The arrangement of the symbols may vary.
Warning! Watch Out!
There are possible hazards as shown by the symbols.
A Drive rolls can injure fingers.
B Welding wire and drive parts are at welding voltage during operation
Keep hands and metal objects away.
1. Electric shock can kill.
1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating yourself from work and ground.
1.3 Disconnect input plug or power before working on machine
2. Breathing welding fumes can be hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.
25
3 Welding sparks can cause explosion or fire.
xx,xxxx,xxxx *
3.1 Keep flammables away from welding. Don’t weld near flammables.
3.2 Welding sparks can cause fires.Have a fire extinguisher nearby and have a watch­person ready to use it.
3.3 Do not weld on drums or any closed containers.
4. Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use weld­ing helmet with correct shade of filter. Wear complete body protection.
Transporting the VR 5000 Case / VR 5000 Case D300 by crane
26
5. Become trained and read the instructions before working on the machine or weld­ing.
6. Do not remove or paint over (cover) the label.
* identifying number to order label from manufacturer
The VR 5000 Case and VR 5000 Case D300 wire-feed units can be transported by crane using the handle. The max. load-bearing capacity of the handle is
- 15 kg with the VR 5000 Case,
- 35 kg with the VR 5000 Case D300
CAUTION!
Risk of injury from falling items.
► Use only suitable lifting tackle when transporting devices by crane. ► The lifting tackle must be undamaged and in perfect condition. ► Always attach the lifting tackle to both ends of the handle according to the diagram be-
low.
Note the following when transporting the VR 5000 Case / VR 5000 Case D300 by crane:
- feed out the wire electrode, remove the wirespool
- disconnect the torch hosepack and interconnecting hosepack from the wire-feed unit
- if present, unplug the coolant connections
- use appropriate lifting tackle (e.g. belt with round slings)
- transport the wire-feed unit as close to the centre of the handle as possible
- do not transport any other loads by the handle apart from the wire-feed unit itself
- do not hang from the wire-feed unit as it is being transported
27
28
Control elements and connections
Description of the control panels
General informa­tion
Safety
The functions on the control panels are all arranged in a very logical way. The various weld­ing 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 one parameter is altered, the appropriate changes are automatically made to all the other welding parameters.
NOTE!
As a result of 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 controls on your device. How­ever, these controls function in exactly the same way.
IMPORTANT! Welding parameters that must be entered on a wire-feed unit control panel cannot be changed on the power source. Welding parameters can only be changed on the wire-feed unit.
WARNING!
Operating the equipment incorrectly can cause serious injury and damage.
► Do not use the functions described here until you have read and completely under-
stood these Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions for the system components, in particular the safety rules!
31
Manual control panel
(6)
(5)
(5)
(4)
(3)
(2) (1)
General The control panel allows straightforward manual setting of the welding parameters.
Manual control panel
No. Function
(1) "Process" button
*)
for selecting the welding process
MIG/MAG welding STICK manual metal arc welding for selecting welding parameters in the Setup menu
(2) "Mode" button
for selecting the operating mode
2-step mode
4-step mode for selecting welding parameters in the Setup menu
(3) Welding voltage adjuster
for selecting the welding voltage in V The welding voltage is directly related to the arc length.
(4) Wire feed speed adjuster
for selecting the wire feed speed in m/min or ipm. If the welding voltage (3) remains constant, the welding current increases as the
wire feed speed (4) increases
32
(5) "Dynamic" buttons
for influencing the short-circuiting dynamic at the moment of droplet transfer
- ... harder, more stable arc + ... soft, low-spatter arc
(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.
*) In conjunction with the VRD option, the currently selected welding process indica-
tor is simultaneously an additional indicator:
- The indicator is permanently lit: the Voltage Reduction Device (VRD) is active and is limiting the output power to less than 35 V.
- The indicator starts to flash as soon as a welding action starts in which the out­put voltage can exceed 35 V.
Adjustment aid for Manual con­trol panel
For selected material/shielding gas combinations, the wire-feed unit includes adjustment aids in the form of films 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 / shielding gas combination.
(1) Adjustment aid applies with the specified material / shielding gas combina-
tion
e.g.:
- Steel = Material
- Ø 1.0 mm = Wire diameter
- 100 % CO
= Shielding gas
2
33
(2) Scales for sheet thickness
3
1
in mm The two adjusters must be set to the appropriate value for the sheet thickness be-
ing used in order to obtain the basic setting according to the adjustment aid.
(3) Dynamic
Recommended dynamics settings are specified for three ranges of sheet thick­ness.
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the
control panel. As long as the keylock is active
- no settings can be made on the control panel
- only parameter settings can be retrieved
Activate/deactivate the keylock as follows:
Press and hold the "Mode" button
1
Press the "Dynamic" button (right)
2
Release the "Mode" and "Dynamic" buttons
Service parame­ters
Keylock activated: The message "CLO | SEd" appears on the displays.
Keylock deactivated: The message "OP | En" appears on the displays.
Various service parameters can be retrieved by pressing the "Dynamic" buttons at the same time.
Opening the display
Press and hold the "Dynamic-" button
Press the "Dynamic+" button
2
Release the "Dynamic" buttons
3
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Press the "Mode" and "Process" buttons to select the desired set-
1
up parameter
Available parameters
34
Explanation
Example:
1.00 | 4.21
Example: 2 | 491
Example: r 2 | 290
Example: iFd | 0.0
654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins
2nd 2nd menu level for service engineers
Firmware version
Welding program configuration
Number of the currently selected welding program
Motor current for wire drive in A The value changes as soon as the motor is running.
Indicates the actual arc time since using for the first time Note: The arc time indicator is not suitable as a basis for calcu­lating hiring fees, warranty services, etc.
35
Synergic control panel
General The power source uses the Synergic control panel and certain general items of data such
as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best weld­ing parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to be set manually.
Control panel splitting
Synergic A con­trol panel
The Synergic control panel is split.
(9)
(10)
(8)
(1)
(2)
36
(3)
(4)
(7)
(6) (5)
No. Function
(1) "Parameter selection" button (right)
a) for selecting the following welding parameters
Arc length correction
for correcting the arc length
Welding voltage in V
*)
Before the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.
Arc-force dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer
- ... harder, more stable arc 0 ... neutral arc + ... soft, low-spatter arc
Real Energy Input
for displaying the energy applied during the welding operation.
b) for changing parameters in the Setup menu
(2) "Parameter selection" button (left)
a) for selecting the following welding parameters
**)
Sheet thickness
Sheet thickness in mm or in.
Welding current Welding current in A Before the start of welding, the device automatically displays a standard value
based on the programmed parameters. During welding, the actual value is displayed.
Wire feed speed
Wire feed speed in m/min or ipm.
b) for changing parameters in the Setup menu
(3) Adjusting dial (right)
for changing the arc length correction, welding voltage and arc-force dynamic pa­rameters
for changing welding parameters in the Setup menu
(4) Adjusting dial (left)
for changing the sheet thickness, welding current and wire feed speed parameters for selecting welding parameters in the Setup menu
(5) "Process" button
***)
for selecting the welding process
MANUAL - MIG/MAG standard manual welding SYNERGIC - MIG/MAG standard synergic welding
STICK - manual metal arc welding
*)
*)
37
(6) "Mode" button
for selecting the operating mode
2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode
(7) "Save" buttons (Easy Job)
for saving up to 5 operating points
(8) Intermediate arc indicator
Between the dip transfer arc and the spray arc, a spatter-prone "intermediate arc" occurs. The intermediate arc indicator lights up to draw attention to this critical ar­ea.
(9) 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.
(10) SF - spot / stitch welding indicator
lights up if a value has been entered for the spot / stitch welding time Setup param­eter (SPt) (spot or stitch welding operating mode is enabled)
*) If one of these parameters is selected in the MIG/MAG standard synergic welding
process, then the synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically.
**) The Real Energy Input display must be activated in level 2 of the Setup menu –
EnE parameter. The value continuously rises during welding in line with the perma­nently increasing energy yield. The final value at the end of welding remains stored until welding starts again or the power source is switched back on - the "HOLD" indicator lights up.
***) In conjunction with the VRD option, the currently selected welding process indica-
tor is simultaneously an additional indicator:
- The indicator is permanently lit: the Voltage Reduction Device (VRD) is active and is limiting the output power to less than 35 V.
- The indicator starts to flash as soon as a welding action starts in which the out­put voltage can exceed 35 V.
Synergic B con­trol panel over­view
38
Three versions of the Synergic B control panel are available, as explained below:
- Steel
- Yard
- Steel USA
Synergic B con-
(1) (2) (3)
(1) (2) (3)
(1) (2) (3)
trol panel
Synergic B - Steel control panel Synergic B - Yard control panel
Synergic B - Steel USA control panel
No. Function
(1) "Material" button
for selecting the filler metal to be used. Welding parameter SP is reserved for filler metals.
When a material is selected, the LED behind the relevant filler metal lights up.
39
(2) "Wire diameter" button
1
2
1
For selecting the wire diameter to be used. Welding parameter SP is reserved for additional wire diameters.
When a wire diameter is selected, the LED behind the relevant wire diameter lights up.
(3) "Shielding gas" button
For selecting the shielding gas to be used. Welding parameter SP is reserved for additional shielding gases.
When a shielding gas is selected, the LED behind the relevant shielding gas lights up.
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the
control panel. As long as the keylock is active
- no settings can be made on the control panel
- only parameter settings can be retrieved
- any assigned "Save" button can be retrieved provided that an assigned "Save" button was selected when the keylock was enabled
Activate/deactivate the keylock as follows:
Service parame­ters
Press and hold the "Mode" button
Press the "Parameter selection" button (right)
2
Release the "Mode" and "Parameter Selection" buttons
3
Keylock activated: The message "CLO | SEd" appears on the displays.
Keylock deactivated: The message "OP | En" appears on the displays.
Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.
Opening the display
Press and hold the "Parameter selection" button (left)
1
Press the "Parameter selection" button (right)
Release the "Parameter selection" buttons
3
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Select the required setup parameter using the "Mode" and "Pro­cess" buttons or the left-hand adjusting dial
40
Available parameters
Explanation
Example:
1.00 | 4.21
Example: 2 | 491
Example: r 2 | 290
Example: iFd | 0.0
654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins
2nd 2nd menu level for service engineers
Firmware version
Welding program configuration
Number of the currently selected welding program
Motor current for wire drive in A The value changes as soon as the motor is running.
Indicates the actual arc time since using for the first time Note: The arc time indicator is not suitable as a basis for calcu­lating hiring fees, warranty services, etc.
41
Connections and mechanical components
(1)
(2)
(3)
(1)
(2)
(3)
(4)
(5)
Overview of con­nections for the welding torch
Front of wire-feed unit
An overview of the connections available for the welding torch can be found in the spare parts list in the Appendix.
VR 5000 Case VR 5000 Case D300
(1) Welding torch connection
for connecting the welding torch
(2) Coolant flow connection (blue) - option
when the optional water connection is installed, otherwise blanking cover
(3) Coolant return connection (red) - option
when the optional water connection is installed, otherwise blanking cover
(4) (+) current socket with bayonet latch - option
when the option for connecting the electrode holder is installed, otherwise blanking cover
(5) LocalNet connection - option
when the option for connecting options (for example remote control) is installed, otherwise blanking cover
42
Wire-feed unit
(1)
(2)
(3) (4) (5) (6)
(7) (8)(9)
(6) (7)(8)
(1)
(2)
(3)
(4)(5)
side
VR 5000 Case
VR 5000 Case D300
(10) (11) (12)(13)
(11) (12)(13)(10)
(1) Enhanced LocalNet connection
for enhanced LocalNet with lines for motor supply and motor control
(2) (+) current connection with bayonet latch
for interconnecting hosepack
(3) Coolant return connection (red) - option
when the optional water connection is installed, otherwise blanking cover
(4) Shielding gas connection
(5) Coolant flow connection (blue) - option
when the optional water connection is installed, otherwise blanking cover
(6) Blanking cover
position for VR 5000 Case gas flow meter option
(7) Blanking cover
position for VR 5000 Case power switch option
43
(8) Blanking cover
position for VR 5000 Case external start signal option
(9) Blanking cover
position for VR 5000 Case current socket option
(10) Wirespool holder with brake
for holding standard wirespools
VR 5000 Case: max. diameter 200 mm (7.87 in.), max. weight 5 kg (11.02 Ibs.)
VR 5000 Case D300: max. diameter 300 mm (11.81 in.), max weight 19 kg (41.89 Ibs.)
(11) Optional "Wire threading / Gas-test" button
Push button downwards: For threading the wire electrode into the torch 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 at the pressure regulator.
- Tap button once: shielding gas flows out
- Tap button again: shielding gas flow stops
If the "Gas-test" button is not tapped again, the shielding gas flow will stop after 30 s.
(12) 4-roller drive
(13) Synergic control panel section B
in conjunction with the Synergic control panel
44
Installation and commissioning
Before commissioning
Safety
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
An electric shock can be fatal.
If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that: ► the power source mains switch is in the "O" position ► the power source is unplugged from the mains
Intended purpose The device is intended exclusively for wire feeding in MIG/MAG welding.
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 held liable for any damages arising from such usage.
WARNING!
WARNING!
Utilisation in accordance with the "intended purpose" also comprises
- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
Setup regulations VR 5000 Case and VR 5000 Case D300 are tested according to protection class IP 23,
which means:
- protection against penetration by solid foreign bodies with diameters exceeding 12.5 mm (0.49 in.)
- protection against direct sprays of water at any angle up to 60° to the vertical
The VR 5000 Case / VR 5000 Case D300 can be set up and operated outdoors in accord­ance with protection class IP 23. Avoid direct wetting (e.g. from rain).
47
Connecting wire-feed unit to power source
1
General informa­tion
Connecting the wire-feed unit to the power source
The wire-feed unit is connected to the power source using the interconnecting hosepack.
WARNING!
Fitting the equipment incorrectly can cause serious injury and damage.
Do not carry out the steps described here until you have read and completely understood all the operating instructions.
NOTE!
When connecting the interconnecting hosepack, check that
► all connections are connected properly ► all cables, leads and hosepacks are undamaged and correctly insulated
VR 5000 Case: VR 5000 Case D300:
1 1
1
48
1 1
2
2
3
1 1
3
IMPORTANT! To prevent wear and tear, leave some slack when connecting the cables.
49
Connecting the welding torch
1
1
Safety
Connecting MIG/ MAG manual welding torches
NOTE!
When connecting the welding torch, check that
► all connections are connected properly ► all cables, leads and hosepacks are undamaged and correctly insulated.
VR 5000 Case VR 5000 Case D300
1 1
* when the optional water connection and the water-cooled welding torch are fitted
50
Inserting/replacing feed rollers
2
4
General In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the
diameter and alloy of the wire being welded.
IMPORTANT! Only use feed rollers that match the wire electrode.
An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.
Inserting/replac­ing feed rollers
CAUTION!
Risk of injury if the feed roller holders fly upwards.
When unlocking the clamping lever, keep fingers away from the area to the left and right of the lever.
1 2
1
CAUTION!
Risk of crushing by exposed feed rollers.
Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roller.
1 2
3
51
Inserting the wirespool, inserting the basket-type spool
Safety
WARNING!
An electric shock can be fatal.
Before starting the work described below: ► turn the power source mains switch to the "O" position ► disconnect the power source from the mains ► ensure that the power source remains disconnected from the mains until all work has
been completed
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 electrode springing back.
CAUTION!
Risk of injury from falling wirespool/basket-type spool.
Ensure that the wirespool/basket-type spool and basket-type spool adapter are always seated securely on the wirespool holder.
Inserting a wire­spool: D200 de­vice
1
1
52
Inserting a wire-
1
1
2
spool: D300 de­vice
1
Inserting a bas­ket-type spool: D300 device
CAUTION!
Risk of injury and material damage 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.
1 2
53
Feeding in the wire electrode
2
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
Feeding in the wire electrode
CAUTION!
Risk of injury from springiness of spooled wire electrode.
When 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
2
1
4
3
CAUTION!
Risk of injury from wire electrode emerging at speed.
When pressing the "Wire threading" button or the torch trigger, keep the welding torch away from your face and body, and wear suitable protective goggles.
IMPORTANT! To facilitate the exact positioning of the wire electrode, the following se­quences are possible when the "Wire threading" button is pressed and held down.
- Hold the button for up to one second ... the wire feed speed stays at 1 m/min or 39.37 ipm for the first second.
- Hold the button for up to 2.5 seconds ... after one second has elapsed, the wire feed speed increases at a uniform rate over the next 1.5 seconds.
- Hold the button for more than 2.5 se- conds ... after 2.5 seconds, the wire is fed at a constant rate equal to the wire feed speed set for the Fdi welding pa­rameter.
54
If you release the "Wire threading" button and press it again before one second has
1
2
4
5
3
1
3
1
1
2
3
4
elapsed, the sequence starts again from the beginning. This makes it possible to continu­ously position the wire at a low wire feed speed of 1 m/min or 39.37 ipm where necessary.
If there is no "Wire threading"/"Gas-test" button, the torch trigger can be used in the same way. Before using the torch trigger for wire threading, proceed as follows:
Press the Mode button to select 2-step mode
Set the "Ito" parameter to "Off" in the Setup menu
2
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.
When pressing the torch trigger: ► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
IMPORTANT! If the torch trigger is pressed instead of the "Wire threading"/"Gas-test" button, the welding wire runs at the feeder creep speed (depending on the welding pro­gram) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.
The welding system detects that the welding process should not start, but that the wire is to be fed in. At the same time, the gas solenoid valve closes, and the welding voltage on the wire electrode is switched off.
If the torch trigger is kept pressed, wire feeding restarts immediately without shielding gas and welding voltage, and the process continues as described above.
1 2
Setting the con-
NOTE!
tact pressure
Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeed.
55
1
1
Contact pressure standard values
U-slot rollers
Steel 4 - 5
CrNi 4 - 5
Tubular cored electrodes 2 -3
56
Adjust the brake
1
4
5
STOP
6
7
3
1
2
2
General
CAUTION!
Risk of injury and material damage from the welding current and accidental ignition of an arc.
Before starting work, disconnect the ground earth connection between the welding system and the workpiece.
CAUTION!
Risk of injury and damage from wire electrode emerging.
While working: ► hold the welding torch with the point directed away from the face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
NOTE!
After releasing the torch trigger the wirespool must stop unreeling.
If it continues unreeling, readjust the brake.
Setting the brake: D200 device
1 2
1
57
3
2
4
STOP
OK
3
1
1
4
5
STOP
6
7
3
1
2
2
2
4
STOP
OK
3
1
3
Setting the brake: D300 device
1 2
1
3
3
2
1
58
Brake setup: D200 device
WARNING!
Fitting the equipment incorrectly can cause serious injury and damage.
► Do not dismantle the brake. ► Maintenance and servicing of brakes is to be carried out by trained, qualified personnel
only.
The brake is only available as a complete unit. This illustration is for information purposes only.
Brake setup: D300 device
WARNING!
Fitting the equipment incorrectly can cause serious injury and damage.
► Do not dismantle the brake. ► Maintenance and servicing of brakes is
to be carried out by trained, qualified personnel only.
The brake is only available as a complete unit. This illustration is for information purposes only.
59
Start-up
Safety
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
Requirements When commissioning the wire-feed unit, the following requirements must be met:
- Wire-feed unit connected to the power source using the interconnecting hosepack
- Welding torch connected to the wire-feed unit
- Feed rollers inserted into the wire-feed unit
- Wirespool or basket-type spool and adapter inserted in the wire-feed unit
- Wire electrode fed in
- Feed roller contact pressure set
- Brake adjusted
- All covers closed, all side panels in place, all protection devices intact and in their
WARNING!
proper place
60
Welding
MIG/MAG modes
General informa­tion
Symbols and their explanations
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
For details of the meaning, settings, setting range and units of the available welding pa­rameters (e.g. GPr), please refer to the section entitled "Setup parameters".
Press the torch trigger Hold the torch trigger Release the torch trigger
GPr
Gas pre-flow time
I-S
Starting current can be increased or decreased depending on the application
SL
Slope: the starting current is continuously lowered as far as the welding current and the welding current as far as the final current
I
Welding-current phase: uniform thermal input into the base material, whose temperature is raised by the advancing heat
I-E
Final current for filling the end-crater.
GPo
Gas post-flow time
SPt
Spot welding time / stitch welding time
SPb
Stitch pause time
63
2-step mode "2-step mode" is suitable for
I
GPr
GPo
t
I
+
I
GPr
GPo
t
I
+
+
I
GPr
GPo
SPt
t
I
+
- Tacking work
- Short weld seams
4-step mode
Special 4-step mode
+ +
I
I-S I-E
GPr
SL SL
"4-step mode" is suitable for longer weld seams.
Special 4-step mode allows the starting and final current to be configured in addition to the advantages of 4-step mode.
I
t
GPo
Spot welding
64
The "Spot welding" mode is suitable for welded joints on overlapped sheets.
2-step stitch
I
GPr SPt SPtSPb
GPo
t
I
+
+ +
I
GPr SPt SPtSPb
GPo
t
I
welding
The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the base material.
4-step stitch welding
The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the base material.
65
MIG/MAG welding
2
Safety
General tasks be­fore MIG/MAG welding
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
WARNING!
An electric shock can be fatal.
If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that: ► the power source mains switch is in the "O" position ► the power source is unplugged from the mains
Only where cooling units and a water-cooled welding torch are used:
Connect the water hoses of the welding torch to the correct plug-type connectors on
1
the wire-feed unit
Plug in the mains plug
Move the mains switch to the "I" position:
3
- all the indicators on the control panel light up briefly
- where applicable, the cooling unit starts to run
IMPORTANT! Follow the safety rules and note operating conditions in the cooling unit op­erating instructions.
Overview MIG/MAG welding is composed of the following sections:
- MIG/MAG standard synergic welding
- MIG/MAG standard manual welding
- Special functions and options
66
MIG/MAG standard synergic welding
2
4
General The MIG/MAG standard synergic welding process is only available in combination with the
Synergic control panel.
MIG/MAG stand­ard synergic welding
On Synergic B control panel:
Press the Material button to select the filler metal to be used.
1
Assignment of the SP position depends on the welding database used for the power source.
Press the Wire diameter button to select the diameter of the wire electrode to be used.
Assignment of the SP position depends on the welding database used for the power source.
Press the Shielding gas button to select the shielding gas to be used.
3
Assignment of the SP position depends on the welding database used for the power source.
On Synergic A control panel:
Press the Process button to select the desired welding process:
MIG/MAG standard synergic welding
Press the Mode button to select the desired MIG/MAG mode:
5
2-step mode
4-step mode
Special 4-step mode
IMPORTANT! Under certain circumstances, welding parameters that have been set on a control panel of a system component (TR 2000 and TR 3000 remote control units or robot interface) cannot be changed on the control panel of the wire-feed unit.
Press the Parameter selection buttons to select the welding parameters to be used to
6
specify the welding power:
Sheet thickness
Welding current
Wire feed speed
Welding voltage
Use the appropriate adjusting dial to set the relevant welding parameters.
7
The welding parameter values are shown in the digital display located above them.
All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again in the meantime.
67
To display the actual welding current during welding:
2
- Press the Parameter selection button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
Open the gas cylinder valve
8
Set the shielding gas flow rate:
9
If there is a Feeder inching/Gas test button:
- Press the Feeder inching/Gas test button upwards
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Press the Feeder inching/Gas test button upwards again
If there is no Feeder inching/Gas test button:
- Press the Mode button to select 2-step mode
- Set the "Ito" parameter to "Off" in the set-up menu
- Disengage the feed rollers
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
Corrections dur­ing welding
- press and hold the torch trigger
- turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required shielding gas flow rate
- release the torch trigger
- engage the feed rollers
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
Press the torch trigger and start welding
10
To obtain the best possible welding results, the arc length correction and dynamic welding parameters will sometimes need to be adjusted.
Press the "Parameter selection" buttons to select the parameters you wish to correct.
1
Use the adjusting dials to set the selected welding parameters to the required values.
68
Welding parameter values are shown in the indicators located above them.
Arc length correction
for correcting the arc length
- shorter arc length 0 neutral arc length + longer arc length
Dynamic
for influencing the short circuit dynamic at the instant of particle transfer
- harder, more stable arc 0 neutral arc + soft, low-spatter arc
69
MIG/MAG standard manual welding
1
3
6
General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no
synergic function. Changing one parameter does not result in any automatic adjustments to the other param­eters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.
Available parame­ters
MIG/MAG stand­ard manual weld­ing - manual control panel
The following parameters are available in MIG/MAG manual welding:
Wire feed speed
1 m/min (39.37 ipm) - maximum wire feed speed, e.g. 25 m/min (984.25 ipm)
Welding voltage
TSt 3500: 15.5 - 31.5 V TSt 5000: 14.5 - 39 V
Dynamic
... for influencing the short-circuiting dynamic at the moment of particle transfer
Welding current
Only for displaying the actual value
Press the Process button to select the desired welding process:
MIG/MAG welding
Press the Mode button to select the desired MIG/MAG mode:
2
2-step mode
4-step mode
70
IMPORTANT! Under certain circumstances, welding parameters that have been set on a control panel of a system component (TR 2000 and TR 3000 remote control units or robot interface) cannot be changed on the control panel of the wire-feed unit.
Use the wire feed speed adjuster to set the required value for the wire feed speed
Use the welding voltage adjuster to set the required value for the welding voltage
4
Open the gas cylinder valve
5
Set the shielding gas flow rate:
If there is a Feeder inching/Gas test button:
- Press the Feeder inching/Gas test button upwards
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Press the Feeder inching/Gas test button upwards again
If there is no Feeder inching/Gas test button:
- Press the Mode button to select 4-step mode
- Set the "Ito" parameter to "Off" in the set-up menu
- Disengage the feed rollers
CAUTION!
1
3
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
- press the torch trigger briefly
- turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required shielding gas flow rate
- press the torch trigger again briefly
- engage the feed rollers
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
Adjustments while welding ­manual control panel
MIG/MAG stand­ard manual weld­ing - Synergic A control panel
Press the torch trigger and start welding
7
To obtain the best possible welding results, the arc-force dynamic parameter will some­times need to be adjusted.
Set the required arc-force dynamic using the Dynamic buttons.
1
The value of the welding parameter is indicated by the LEDs located between the but­tons.
Press the Process button to select the desired welding process:
MIG/MAG standard manual welding
Press the Mode button to select the desired MIG/MAG mode:
2
2-step mode
4-step mode
In MIG/MAG standard manual welding, special 4-step mode corresponds to conventional 4-step mode.
IMPORTANT! Under certain circumstances, welding parameters that have been set on a control panel of a system component (TR 2000, TR 3000, robot interface) cannot be changed on the control panel of the wire-feed unit.
Press the Parameter selection button to select the wirefeed speed parameter
Use the adjusting dial to set the desired value for the wire feed speed
4
71
Press the Parameter selection button to select the welding voltage parameter
5
Use the adjusting dial to set the desired value for the welding voltage
6
The welding parameter values are shown in the digital display located above them.
All welding parameter set values that have been set using the adjusting dial or buttons on the welding torch remain stored until the next time they are changed. This applies even if the power source is switched off and on again in the meantime.
To display the actual welding current during welding:
- Press the Parameter selection button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
Open the gas cylinder valve
7
Set the shielding gas flow rate:
8
If there is a Feeder inching/Gas test button:
- Press the Feeder inching/Gas test button upwards
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Press the Feeder inching/Gas test button upwards again
If there is no Feeder inching/Gas test button:
- Press the Mode button to select 4-step mode
- Set the "Ito" parameter to "Off" in the set-up menu
- Disengage the feed rollers
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
►
- press the torch trigger briefly
- turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required shielding gas flow rate
- press the torch trigger again briefly
- engage the feed rollers
CAUTION!
Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch.
When pressing the torch trigger:
► keep the welding torch away from your face and body ► wear suitable protective goggles ► do not point the welding torch at people ► make sure that the wire electrode does not touch any conductive or earthed parts, such
as the housing, etc.
72
Press the torch trigger and start welding
9
Adjustments while welding ­Synergic A con­trol panel
To obtain the best possible welding results, the arc-force dynamic parameter will some­times need to be adjusted.
Press the "Parameter selection" button to select the arc-force dynamic parameter
1
Use the adjusting dial to set the desired arc-force dynamic value
2
The welding parameter value is shown in the digital display located above it.
73
MMA welding
2
4
7
Safety
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
An electric shock can be fatal.
If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Do not carry out any work on the device unless ► the mains switch is in the "O" position, ► the device is unplugged from the mains.
Preparations Move the mains switch to the - O - position
1
3
WARNING!
WARNING!
Unplug the device from the mains
Remove the MIG/MAG welding torch
MMA welding ­manual control panel
IMPORTANT!
Check the rod electrode packaging to determine whether the rod electrodes are for (+) or (-) welding.
Plug the grounding (earthing) cable into the (-) or (+) current socket (depending upon which type of electrode is to be used) and latch it by turning it clockwise
With the other end of the earthing (grounding) cable, establish a connection to the
5
workpiece
Plug the bayonet current plug of the electrode holder cable into the free current socket
6
with the opposite polarity, according to the type of electrode, and twist it clockwise to latch it in place
Plug in the mains plug
CAUTION!
Risk of injury and damage from electric shock.
As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is LIVE. Make sure that the rod electrode does not touch any persons or electrically con­ducting or earthed parts (e.g. the housing etc.)
Move the mains switch to the "I" position: all the indicators on the control panel light
1
up briefly
74
Press the "Process" button to select the MMA welding process:
411
2
Adjustments while welding ­manual control panel
The welding voltage is connected to the welding socket with a 3-second time lag. If the MMA welding process is selected, any cooling unit present is automatically de-
activated. It is not possible to switch it on.
IMPORTANT! Welding parameters that have been set on a control panel for a system component (TR 2000 and TR 3000) may not be changed on the control panel of the wire-feed unit under certain circumstances.
Use the wire speed adjuster to set the desired amperage.
3
The amperage value in A is shown in the digital display located above it.
Start welding
To obtain the best possible welding results, the arc-force dynamic parameter will some­times need to be adjusted.
Set the required arc-force dynamic using the Dynamic buttons.
The value of the welding parameter is indicated by the LEDs located between the but­tons.
MMA welding ­Synergic A con­trol panel
CAUTION!
Risk of injury and damage from electric shock.
As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is LIVE. Make sure that the rod electrode does not touch any persons or electrically con­ducting or earthed parts (e.g. the housing etc.)
Move the mains switch to the "I" position: all the indicators on the control panel light up briefly
Press the "Process" button to select the MMA welding process:
2
The welding voltage is connected to the welding socket with a 3-second time lag. If the MMA welding process is selected, any cooling unit present is automatically de-
activated. It is not possible to switch it on.
IMPORTANT! Welding parameters that have been set on a control panel for a system component (TR 2000 and TR 3000) may not be changed on the control panel of the wire-feed unit under certain circumstances.
Press the "Parameter selection" button to select the amperage parameter.
3
Use the adjusting dial to set the desired amperage.
4
The amperage value is shown in the left-hand digital display.
All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed. This applies even if the power source is switched on and off again in the meantime.
Start welding
5
75
To display the actual welding current during welding:
2
200
300
I (A)
Hti
HCU > I
H
t (s)
I
H
HCU
0,5 1 1,5
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown in the digital display during welding.
Corrections dur­ing welding
To obtain the best possible welding results, the arc-force dynamic parameter will some­times need to be adjusted.
Press the "Parameter selection" button to select the arc-force dynamic parameter
1
Use the adjusting dial to set the desired arc-force dynamic value
The welding parameter value is shown in the digital display located above it.
HotStart function To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart
function.
Advantages
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base material during the start-up phase, meaning fewer cold-shut defects
- Largely prevents slag inclusions
For details on setting the available welding parameters, please refer to "Setup parame­ters", "Setup menu - level 2".
Legend
Hti: Hot-current time, 0 - 2 s, factory setting: 0.5 s HCU: HotStart-current, 100 - 200 %, factory setting 150 %
: Main current = set welding current
I
H
Anti-stick func­tion
Function
During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (I
).
H
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to "stick". This may also cause "burn-out" of the rod electrode.
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode be­gins to stick, the power source immediately switches the welding current off. After the rod electrode has been detached from the workpiece, the welding operation can be continued without difficulty.
The anti-stick (Ast) function can be activated and deactivated in the Setup parameters in "Setup menu: level 2".
76
Saving and retrieving operating points
2
1
General The "Save" buttons allow up to 5 operating points to be saved. Every operating point
matches the settings on the control panel.
IMPORTANT! Setup parameters are not saved at this time.
Saving operating points
Press and hold one of the "Save" buttons to save the current settings on the control
1
panel, e.g.:
The left indicator displays "Pro".
After a short time, the left indicator switches to the original value, e.g.:
Release the "Save" button
Retrieving operat­ing points
Deleting operat­ing points
To retrieve saved settings press the corresponding "Save" button briefly, e.g.:
The control panel will show the saved settings, e.g.:
Press and hold the relevant "Save" button to delete the memory content of that "Save"
1
button, e.g.:
The left indicator displays "Pro".
77
After a short time, the left indicator switches to the original value, e.g.:
2
4
1
Keep the "Save" button held down
The left display shows "CLr".
3
After a while, both displays show "---"
Release the "Save" button
Retrieving operat­ing points on the up/down welding torch
One of the "Save" buttons on the control panel must be pressed to retrieve the saved set­tings using the up/down welding torch.
Press one of the "Save" buttons on the control panel, e.g.:
The control panel will display the saved settings, e.g.:
The "Save" buttons can now be selected using the buttons on the up/down welding torch. Vacant "Save" buttons are skipped.
In addition to the "Save" button number lighting up, a number is displayed directly on the up/down welding torch:
Number 1
Number 2
Number 3
78
Number 4
Number 5
79
80
Setup settings
Setup menu
6
1
General remarks The Setup menu provides simple access to expert knowledge in the power source and to
additional functions. The Setup menu can be used to make simple adjustments of the pa­rameters to suit the various job settings.
Setup menu ­manual control panel
Setting the setup parameters is described here with reference to the "MIG/MAG welding" process. The procedure for changing other setup parameters is identical.
Accessing the setup menu
Use the "Process" button to select the "MIG/MAG welding" pro-
1
cess
Press the "Mode" button
2
Press the "Process" button
3
Release the "Mode" and "Process" buttons
4
The control panel is now in the setup menu for the "MIG/MAG welding" process - the last setup parameter that was selected is displayed.
Changing welding parameters
Use the "Mode" and "Process" buttons to select the required set-
5
up parameter Use the "Dynamic" buttons to change the value of the setup pa-
rameter
Setup menu ­Synergic A con­trol panel
Exiting the setup menu
Press and hold the "Mode" button
7
Press the "Process" button
8
Release the "Mode" and "Process" buttons
9
Setting the setup parameters is described here with reference to the "MIG/MAG standard synergic welding" process. The procedure for changing other setup parameters is identi­cal.
Accessing the setup menu
Use the "Process" button to select the "MIG/MAG standard syn­ergic welding" process
Press and hold the "Mode" button
2
83
Press the "Process" button
3
Release the "Mode" and "Process" buttons
4
The control panel is now in the setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.
Changing welding parameters
Use the "Mode" and "Process" buttons or the left-hand adjusting
5
dial to select the required setup parameter
Use the "Parameter selection" buttons or the right-hand adjusting
6
dial to change the value of the setup parameter
Exiting the setup menu
Press and hold the "Mode" button
7
Press the "Process" button
8
Release the "Mode" and "Process" buttons
9
84
Setup parameters for MIG/MAG standard manual welding
"Min." and "max." are used for setting ranges that differ according to power source, wire­feed unit, welding program, etc.
GPr Gas pre-flow time
Unit: s Setting range: 0 - 9.9 Factory setting: 0.5
GPo Gas post-flow time
Unit: s Setting range: 0 - 9.9 Factory setting: 0.5
Fdi Feeder inching (speed)
Unit: m/min (ipm.) Setting range: 1 - max. (39.37 - max.) Factory setting: 10 (393.7)
SL Slope (special 4-step mode only)
Unit: s Setting range: 0 - 9.9 Factory setting: 0.1
I-S I (current) - Starting - Starting current (special 4-step mode only)
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 100
I-E I (current) - End: Final current (special 4-step mode only)
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 50
t-S t (time) - Starting - Starting current duration (special 4-step mode only)
Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF
t-S t (time) - End: Final current duration (special 4-step mode only)
Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF
bbc burn-back time correction
Unit: ms Setting range: 0 - 20 Factory setting: 0
IGC Ignition current
Unit: A Setting range: 100 - 650 Factory setting: 500
Ito Ignition time-out function - Length of wire that is fed before the safety cut-out
is triggered
Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94)
85
Factory setting: Off
NOTE!
The "Ignition time-out" function (ito) is a safety function.
The length of wire that is fed before the safety cut-out trips may differ from the preset wire length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and options" sec­tion.
SPt Spot time - spot / stitch welding time
Unit: s Setting range: OFF, 0.1 - 5 Factory setting: OFF
SPb Spot break - stitch pause time
Unit: s Setting range: OFF, 0.1 - 10 (in 0.1 s increments) Factory setting: OFF
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selec­tion" (Synergic A control panel) button for 2 seconds to restore the factory settings. When "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all the personal settings in the Set­up menu are lost. Operating points that were saved using the "Save" buttons are retained when the power source is reset. The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ignition time-out function pa­rameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
86
Setup parameters for MIG/MAG standard syner­gic welding
"Min." and "max." are used for setting ranges that differ according to power source, wire­feed unit, welding program, etc.
GPr Gas pre-flow time
Unit: s Setting range: 0 - 9.9 Factory setting: 0.1
GPo Gas post-flow time
Unit: s Setting range: 0 - 9.9 Factory setting: 0.1
SL Slope
Unit: s Setting range: 0 - 9.9 Factory setting: 0.1
I-S I (current) - Starting current
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 100
I-E I (current) - End: Final current
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 50
Fdi Feeder inching (speed)
Unit: m/min (ipm.) Setting range: 1 - max. (39.37 - max.) Factory setting: 10 (393.7)
bbc burn back time correction -
Burn back effect due to wire withdrawal at the end of welding
Unit: s Setting range: Aut, 0 - 0.3 Factory setting: Aut
Ito Ignition time-out function - Length of wire that is fed before the safety cut-out
is triggered
Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94) Factory setting: Off
NOTE!
The "Ignition time-out" function (ito) is a safety function.
The length of wire that is fed before the safety cut-out trips may differ from the preset wire length, particularly when the wire is being fed at fast wire feed speeds.
87
The "Ignition time-out" function (ito) is explained in the "Special functions and options" sec­tion.
SPt Spot time - spot / stitch welding time
Unit: s Setting range: OFF, 0.1 - 5 Factory setting: OFF
SPb Spot break - stitch pause time
Unit: s Setting range: OFF, 0.1 - 10 (in 0.1 s increments) Factory setting: OFF
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selec­tion" (Synergic A control panel) button for 2 seconds to restore the factory settings. When "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all the personal settings in the Set­up menu are lost. When the power source is reset, operating points that were saved using the "Save" buttons are not deleted, but are retained in the memory. The functions in the second level of the Setup menu (2nd) are also not deleted. Ex­ception: Ignition time-out function parameter (ito).
Setup parameters for MMA welding
2nd Second level of the Setup menu (see "Setup menu - level 2")
IMPORTANT! If you reset the power source using the FAC factory setup parameter, the
hot-current time (Hti) and HotStart current (HCU) setup parameters are also reset.
HCU HotStart current
Unit: % Setting range: 100 - 200 Factory setting: 150
Hti Hot-current time
Unit: s Setting range: 0 - 2.0 Factory setting: 0.5
Ast Anti-Stick
Unit: ­Setting range: On, Off Factory setting: Off
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selec­tion" (Synergic A control panel) button for 2 seconds to restore the factory settings. When "PrG" is shown on the digital display, the power source has been reset.
88
IMPORTANT! When the power source is reset, all personal settings are lost.
When the power source is reset, operating points that were saved using the "Save" buttons are not deleted, but are retained in the memory. The functions in the sec­ond level of the Setup menu (2nd) are also not deleted. Exception: Ignition time­out function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
Welding parame­ters for "Special 4-step mode" in the Mode setup menu
I-S I (current) - Starting: Starting current
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 100
SL Slope: 0 - 9.9 s
Unit: s Setting range: 0 - 9.9 Factory setting: 0
I-E I (current) - End: Final current
Unit: % of welding current Setting range: 0 - 200 Factory setting: 50
89
Setup menu - Level 2
1
2
5
10
11
Level 2 setup menu - manual control panel
Accessing the setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
3
The control panel is now in the setup menu - the last setup parameter that was selected is displayed.
Selecting the "2nd" parameter
Use the "Mode" and "Process" buttons to select the "2nd" setup
4
parameter
Accessing the Level 2 setup menu
Press and hold the "Mode" button
Press the "Process" button
6
Release the "Mode" and "Process" buttons
7
Changing welding parameters
Use the "Mode" and "Process" buttons to select the required set-
8
up parameter Use the "Dynamic" buttons to change the value of the setup pa-
9
rameter
Exiting the Level 2 setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
12
Exiting the setup menu
Press and hold the "Mode" button
13
Press the "Process" button
14
Release the "Mode" and "Process" buttons
15
Level 2 setup menu - Synergic control panel
90
Accessing the setup menu
Press and hold the "Mode" button
1
Press the "Process" button
9
10
11
15
2
Release the "Mode" and "Process" buttons
3
The control panel is now in the setup menu - the last setup parameter that was selected is displayed.
Selecting the "2nd" parameter
Use the "Mode" and "Process" buttons or the left-hand adjusting
4
dial to select the "2nd" setup parameter
Accessing the Level 2 setup menu
Press and hold the "Mode" button
5
Press the "Process" button
6
Release the "Mode" and "Process" buttons
7
Changing welding parameters
Use the "Mode" and "Process" buttons or the left-hand adjusting
8
dial to select the required setup parameter
Use the "Parameter selection" buttons or the right-hand adjusting dial to change the value of the setup parameter
Exiting the Level 2 setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
12
Exiting the setup menu
Press and hold the "Mode" button
13
Press the "Process" button
14
Release the "Mode" and "Process" buttons
91
Welding parame­ters for MIG/MAG welding in the Setup menu level 2
C-C Cooling unit control
Unit: ­Setting range: Aut, On, Off Factory setting: Aut
Aut: The cooling unit cuts out after a 2-minute welding off-time.
IMPORTANT! If the coolant temperature and flow monitoring options have been installed in the cooling unit, the cooling unit cuts out as soon as the return-flow temperature drops below 50°C, but at the earliest after a 2-minute welding off­time.
On: The cooling unit is permanently ON Off: The cooling unit is permanently OFF
IMPORTANT! If the FAC welding parameter is used, the C-C parameter is not restored to the factory setting. If the MMA welding process is selected, the cool­ing unit is always switched off, even if the switch is in the "On" position.
C-t Cooling time - time from when flow monitoring is triggered until the "no | H2O"
service code is output. For example, if there are air bubbles in the cooling sys­tem, the cooling unit will not cut out until the end of this pre-set time.
Unit: s Setting range: 5 - 25 Factory setting: 10
IMPORTANT! Every time the power source is switched on, the cooling unit car­ries out a test run for 180 seconds.
SEt Setting - country-specific setting (Standard/USA) ... Std / US
Unit: ­Setting range: Std, US (Standard/USA) Factory setting: Standard version: Std (measurements: cm/mm) USA version: US (measurements: inches)
r r (resistance) - welding circuit resistance (in mOhm)
see "Measuring welding circuit resistance r"
L L (inductivity) - welding circuit inductivity (in microhenry)
see "Displaying welding circuit inductivity L"
EnE Real Energy Input – electrical energy of the arc relative to the welding speed
Unit: kJ Setting range: ON / OFF Factory setting: OFF
Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three­digit display, the following display format has been selected:
Value in kJ / indication on display: 1 to 999 / 1 to 999 1000 to 9999 / 1.00 to 9.99 (without "ones" digit, e.g. 5270 kJ -> 5.27) 10000 to 99999 / 10.0 to 99.9 (without "ones" and "tens" digits, e.g. 23580 kJ -> 23.6)
92
PFS Permanent Feeder Speed - wire feed speed is permanently displayed
Unit: mm (in.) Setting range: ON / OFF Factory setting: OFF
If the setting is "ON", the wire feed speed (m/min) is permanently displayed on the manual control panel instead of the welding current (A). In this case the hold value for the welding current (A) is deactivated.
ALC Arc Length Correction - correction of the arc length via the welding voltage
Setting range: ON / OFF Factory setting: OFF
The arc length depends on the welding voltage. The welding voltage can be ad­justed to suit individual needs in Synergic operation.
If the ALC parameter is set to "OFF", the welding voltage cannot be adjusted. The welding voltage is automatically determined by the selected welding current or wire speed. If the arc length correction is adjusted, the voltage changes, but the welding current and wire speed remain the same. When setting the arc length correction using the adjusting dial, the left display is used for the correction value of the arc length. The welding voltage value on the right display changes simul­taneously. Afterwards the left display shows the original value, e.g. welding cur­rent.
93
Measuring welding circuit resistance r
2
5
6
General Measuring the welding circuit resistance r makes it possible to have a constant welding re-
sult at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. The use of arc length correction is no longer required.
The calculated welding circuit resistance is shown on the display.
r = welding circuit resistance in milliohm (mOhm)
If the welding circuit resistance r has been measured correctly, the set welding voltage will correspond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.
NOTE!
The welding circuit resistance r depends on the hosepack used:
► If the length or cross-sectional area of the hosepack has changed, measure the weld-
ing circuit resistance r again
► Measure the welding circuit resistance for every welding process separately with the
appropriate welding power-leads
Measure the welding circuit re­sistance r
NOTE!
In order to obtain good welding results, it is essential to measure the welding circuit resistance correctly.
Make sure that the contact between the earthing clamp and the workpiece is on a cleaned workpiece surface.
Establish a grounding (earthing) connection to the workpiece
1
Accessing the Level 2 (2nd) Setup menu
Select parameter "r"
3
Remove the gas nozzle from the welding torch
4
Screw on the contact tip
NOTE!
Make sure that the contact between the contact tip and the workpiece is on a cleaned workpiece surface.
Place the contact tip flush against the workpiece surface
Press the torch trigger briefly
7
- The welding circuit resistance is calculated. "run" is shown on the display during
the measurement
The measurement is finished when the welding circuit resistance is shown on the display in mOhm ( for example, 11.4).
94
Fit the gas nozzle back onto the welding torch
8
95
Displaying welding circuit inductivity L
2
General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore
affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result.
Displaying weld­ing circuit induc­tivity L
Laying the hose­packs correctly
The setup parameter "L" is used to display the most recently calculated welding circuit in­ductivity. The welding circuit inductivity is calibrated at the same time as the welding circuit resistance r is calculated. Detailed information can be found in the "Measuring welding cir­cuit resistance r" section.
Access the setup menu level 2 (2nd)
1
Select parameter “L”
The most recently calculated welding circuit inductivity L is shown on the right-hand digital display.
L ... Welding circuit inductivity (in microhenry)
96
Troubleshooting and maintenance
Troubleshooting
General The devices are equipped with an intelligent safety system. This means that to a large ex-
tent it has been possible to dispense with melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again.
Safety
WARNING!
Work that is carried out incorrectly can cause serious injury or damage.
The following activities must only be carried out by trained and qualified personnel. Read the safety rules in the wire-feed unit operating instructions.
WARNING!
An electric shock can be fatal.
Before opening the unit ► 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 inadvertently switching it
back on again
► Using a suitable measuring device, check to make sure that electrically charged com-
ponents (e.g. capacitors) have discharged
CAUTION!
Inadequate PE conductor connections can cause serious injury and damage.
The housing screws provide a suitable PE conductor connection for earthing (grounding) the housing and must NOT be replaced by any other screws which do not provide a reliable PE conductor connection.
Fault diagnosis Make a note of the serial number and configuration of the device and contact our After-
Sales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
Power source has no function
Mains switch is on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty
Remedy: Replace faulty parts
Cause: Mains fuse protection
Remedy: Change the mains fuse protection
99
Nothing happens when the torch trigger is pressed
Power source mains switch is ON and indicators are lit up
Cause: Only for welding torches with an external control plug: The control plug is not
plugged in
Remedy: Plug in the control plug
Cause: Welding torch or welding torch control line is faulty
Remedy: Replace welding torch
Nothing happens when the torch trigger is pressed
Power source mains switch is on, power source ON indication is lit up on the power source, indications on wire-feed unit are not lit up
Cause: The interconnecting hosepack is faulty or not connected properly
Remedy: Check interconnecting hosepack
No welding current
Mains switch is on, one of the overtemperature service codes "to" is displayed. Detailed information on the service codes "to0" to "to6" can be found in the section "Displayed ser­vice codes".
Cause: Overload
Remedy: Take the duty cycle into account
Cause: Thermostatic safety cut-out has tripped
Remedy: Wait until the power source automatically comes back on after the end of the
cooling phase
Cause: Limited supply of cooling air
Remedy: Remove air filter on the rear of the housing from the side and clean. Ensure
that the cooling air ducts are accessible.
Cause: The fan in the power source is faulty
Remedy: Contact After-Sales Service
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is incorrect
Remedy: Check the grounding (earthing) connection for correct polarity
Cause: There is a break in the power cable in the welding torch
Remedy: Replace the welding torch
100
Loading...
Buy Points How it Works FAQ Contact Us Questions and Suggestions Privacy Policy Cookie Policy Terms of Use