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VR 5000 Remote
Operating Instructions
EN
Wire-feed unit
[
42,0426,0292,EN 003-29042020
2
Contents
Safety rules ................................................................................................................................................ 5
Explanation of safety notices ................................................................................................................ 5
General ................................................................................................................................................. 5
Proper use ............................................................................................................................................ 5
Environmental conditions...................................................................................................................... 6
Obligations of the operator.................................................................................................................... 6
Obligations of personnel ....................................................................................................................... 6
Mains connection .................................................................................................................................. 6
Protecting yourself and others .............................................................................................................. 7
Danger from toxic gases and vapours .................................................................................................. 7
Danger from flying sparks ..................................................................................................................... 8
Risks from mains current and welding current...................................................................................... 8
Meandering welding currents................................................................................................................ 9
EMC Device Classifications .................................................................................................................. 10
EMC measures ..................................................................................................................................... 10
EMF measures...................................................................................................................................... 11
Specific hazards.................................................................................................................................... 11
Requirement for the shielding gas ........................................................................................................ 12
Danger from shielding gas cylinders..................................................................................................... 12
Danger from escaping shielding gas..................................................................................................... 12
Safety measures at the installation location and during transport ........................................................ 13
Safety measures in normal operation ................................................................................................... 13
Commissioning, maintenance and repair.............................................................................................. 14
Safety inspection................................................................................................................................... 14
Disposal ................................................................................................................................................ 14
Safety symbols...................................................................................................................................... 15
Data protection...................................................................................................................................... 15
Copyright............................................................................................................................................... 15
General ...................................................................................................................................................... 16
Device concept ..................................................................................................................................... 16
Application areas .................................................................................................................................. 16
Warning notices on the device.............................................................................................................. 17
Description of Warning Notices on the Device...................................................................................... 18
Wirefeeder options................................................................................................................................ 20
Connections, switches and mechanical components ................................................................................ 21
VR 5000 Remote - front of wirefeeder .................................................................................................. 21
Rear of wirefeeder ................................................................................................................................ 21
Side of wirefeeder ................................................................................................................................. 22
Underside of wirefeeder........................................................................................................................ 23
Start-up ...................................................................................................................................................... 24
General ................................................................................................................................................. 24
Placing the wirefeeder on the power source......................................................................................... 24
Fitting the interconnecting hosepack strain-relief device ...................................................................... 24
Connecting a MIG/MAG welding torch.................................................................................................. 25
Inserting/replacing feed rollers.............................................................................................................. 25
Inserting the wirespool .......................................................................................................................... 26
Inserting the basket-type spool............................................................................................................. 27
Feeding in the wire electrode................................................................................................................ 28
Setting the contact pressure ................................................................................................................. 31
Adjusting the brake ............................................................................................................................... 31
Design of the brake............................................................................................................................... 32
Prerequisites for start-up....................................................................................................................... 32
Synergic control panel (option) .................................................................................................................. 33
General ................................................................................................................................................. 33
Control panel splitting ........................................................................................................................... 33
Synergic A control panel ....................................................................................................................... 33
Synergic B control panel ....................................................................................................................... 36
Keylock ................................................................................................................................................. 36
Accessing the Setup menu ................................................................................................................... 37
Setup parameters ................................................................................................................................. 38
EN
3
Service parameters............................................................................................................................... 38
Pulse control panel (option) ....................................................................................................................... 40
General ................................................................................................................................................. 40
Control panel splitting ........................................................................................................................... 40
Pulse A control panel ............................................................................................................................ 40
Setting MIG/MAG pulse synergic welding and spot/stitch welding ....................................................... 43
Pulse B control panel ............................................................................................................................ 44
Keylock ................................................................................................................................................. 44
Accessing the Setup menu ................................................................................................................... 45
Setup parameters ................................................................................................................................. 46
Service parameters............................................................................................................................... 46
Troubleshooting ......................................................................................................................................... 48
General ................................................................................................................................................. 48
Safety.................................................................................................................................................... 48
Fault diagnosis...................................................................................................................................... 48
Care, maintenance and disposal ............................................................................................................... 52
General ................................................................................................................................................. 52
Safety.................................................................................................................................................... 52
At every start-up.................................................................................................................................... 52
Every 6 months ..................................................................................................................................... 52
Disposal ................................................................................................................................................ 52
Technical data............................................................................................................................................ 53
VR 5000 Remote .................................................................................................................................. 53
4
Safety rules
EN
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.
5
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
6
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
EN
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.
7
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
8
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.
EN
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.
9
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
10
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.
EN
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 for work 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.
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).
11
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).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
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.
Danger from escaping shielding
gas
12
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.
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.
EN
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.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
13
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.
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
14
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.
EN
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.
15
General
Device concept
VR 5000 Remote
Application areas The devices are used in workshops and industry for manual applications with classical
steel and galvanised sheets:
- Machine and equipment construction
- Steelwork
- Plant and container construction
- Shipyards and the offshore industry
- Metal and gantry construction
- Rail vehicle construction
- Metalworking trades
The VR 5000 Remote is the standard wirefeeder for the following power sources:
- TSt 3500 / 5000 Syn
- TSt 4000 / 5000 Pulse
The VR 5000 Remote is designed for wirespools with a max. diameter of 300 mm
(11.81 in.).
The standard 4-roller drive offers excellent
wirefeeding properties, even with long hosepacks.
In combination with the TSt 3500 / 5000
Syn and TSt 4000 / 5000 Pulse power
sources, the VR 5000 Remote is suitable
for all shielding gas welding work on steel
and can be used with any of the standard
shielding gases provided for this purpose.
16
Warning notices
on the device
There are warning notices and safety symbols on the wirefeeder. These warning notices
and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and damage.
Model No.
A-4600 Wels
www.fronius.com
Part No.
Ser. No.
EN
IEC 60 974-5/-10 Cl.A
U
11
24 V
12
U
1.0-25 m/min
2
360A/100% 450A/60% 500A/40%I
Warning notices affixed to the wirefeeder
4.0 AI
11
I
12
2.0 A24 V
IP 23
40,0006,3035
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 distance
Do not use the functions described here until you have fully read and understood the following documents:
- These Operating Instructions
- All the Operating Instructions for the system components, especially the safety rules
17
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.
18
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 watch-
person ready to use it.
3.3 Do not weld on drums or any closed containers.
EN
4. Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use weld-
ing helmet with correct shade of filter. Wear complete body protection.
5. Become trained and read the instructions before working on the machine or weld-
ing.
6. Do not remove or paint over (cover) the label.
* identifying number to order label from manufacturer
19
Wirefeeder options
The following options are available for the VR 5000 Remote wirefeeder:
- Synergic control panel
- Pulse control panel
- Wire threading/gas-test button
- I-kit water cooling system
- I-kit remote control socket
- I-kit front current socket
- I-kit crane attachment
- I-kit side-mounted aluminium runner
- I-kit gas flow rate sensor
- I-kit Euro central connector
- I-kit F++ central connector
- I-kit Tweco central connector
20
Connections, switches and mechanical components
(1)
(2)
(3)
(4)
(5)(6)
(1)
(2)
(3)
(4)
(5)
(6)
VR 5000 Remote front of wirefeeder
(4) Dummy panel
for Synergic control panel option
(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
EN
Rear of wirefeeder
(5) Position
for (+) current socket with bayonet latch option
(6) Position
for LocalNet connection socket option
(1) (+) current connection with bayo-
net latch
for interconnecting hosepack
(2) Dummy panel
for remote control connection
option
(3) LocalNet connection
standardised connection socket for
the wirefeeder
(interconnecting hosepack)
(4) Shielding gas connection
(5) Coolant return connection (red) - option
when the optional water connection is installed, otherwise blanking cover
(6) Coolant flow connection (blue) - option
when the optional water connection is installed, otherwise blanking cover
21
Side of wirefeeder
(1) (2) (3) (4)
No. Function
(1) Wirespool holder with brake
for holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a
max. weight of up to 19 kg (41.89 lbs.)
(2) Program selector
(option)
(3) 4-roller drive
(4) 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 wirefeeder runs at
feeder inching speed.
Push button upwards:
For setting the required gas flow rate on 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.
22
Underside of
(1)
wirefeeder
No. Function
(1) Socket for swivel pin
For placing the wirefeeder on the
swivel pin in the swivel pin holder
EN
23
Start-up
1
1
2
3
4
1
2
1
3
4
2
General Commissioning a power source is described by reference to a manual water-cooled MIG/
MAG application.
Placing the wirefeeder on the
power source
CAUTION!
Risk of injury and material damage from falling wirefeeder.
► Make sure that the wirefeeeder is located securely on the swivel pin and that the de-
vices, upright consoles and trolleys are stable.
1
1
Fitting the interconnecting hosepack strain-relief
device
1
Fitting the strain-relief device to the trolley
2
Fitting the strain-relief device to the wirefeeder
IMPORTANT! To prevent wear and tear, leave some slack when connecting the cables. A
strain-relief device is not provided in the case of 1.2 m (3 ft. 11.24 in.) interconnecting hosepacks.
24
Connecting a
1
2
1
4
4
5
6
3
2
MIG/MAG welding
torch
1
* when the optional water connection and
EN
the water-cooled welding torch are fitted
Inserting/replacing feed rollers
CAUTION!
Danger from feed roller holders flying upwards.
This can result in severe injuries.
► When unlocking the clamping lever, keep fingers away from the area to the left and
right of the lever.
1 2
1
4
5
31
2
3
6
7
CAUTION!
Danger from exposed feed rollers.
This can result in severe injuries.
► Always fit the protective cover of the 4-roller drive after inserting or replacing a feed roll-
er.
25
3 4
3
8
6
7
9
3
1
2
2
5
4
4
4
3
3
2
4
Inserting the wirespool
1
5
5
6
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
► While inserting the wirespool, hold the end of the wire electrode firmly to avoid injuries
caused by the wire springing back.
CAUTION!
Risk of injury from falling wirespool.
► Make sure the wirespool sits securely on the wirespool holder.
CAUTION!
Risk of injury and material damage if the wirespool topples over because the locking
ring has been placed the wrong way around.
► Always position the locking ring as shown in the diagram on the left.
26
1
1
EN
Inserting the basket-type spool
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
► When inserting the basket-type spool, hold the end of the wire electrode firmly to avoid
injuries caused by the wire springing back.
CAUTION!
Risk of injury from falling basket-type spool.
► Make sure that the basket-type spool and basket-type spool adapter are fitted securely
to the wirespool holder.
NOTE!
When working with basket-type spools, only use the basket-type spool adapter included in the scope of supply.
CAUTION!
Risk of injury and material damage if the basket-type spool topples over because the
locking ring has been placed the wrong way round.
► Always position the locking ring as shown in the diagram on the left.
27
CAUTION!
2
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
1
Feeding in the
wire electrode
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
► When inserting the wire electrode into the 4-roller drive, hold the end of the wire elec-
trode 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 threading in.
28
1 2
2
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
2
1
CAUTION!
Risk of injury from emerging wire electrode.
► 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.
EN
IMPORTANT! To facilitate the exact positioning of the wire electrode, the following se-
quences are possible when the wire threading button is pressed and held down.
- Hold the button for up to one second
... the wire 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 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
speed set for the Fdi welding parameter.
If the "Wire threading" button is released and pressed again before one second has
elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire speed of 1 m/min or 39.37 ipm where necessary.
If there is no "Wire threading" 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
1
Set the "Ito" parameter to "Off" in the Setup menu
29
CAUTION!
2
4
5
3
1
4
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 (e.g.
housing)
IMPORTANT! If the torch trigger is pressed instead of the "Wire threading" 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 held down, wirefeeding restarts immediately without shielding gas and
welding voltage, and the process continues as described above.
1 2
3
30
Setting the con-
1
1
4
6
7
1
2
STOP
3
5
2
tact pressure
CAUTION!
Risk from excessive contact pressure.
This can result in severe damage to property and poor weld properties.
► Set the contact pressure in such a way that the wire electrode is not deformed, but is
nevertheless transported properly.
1
Contact pressure standard values for Ugroove rollers:
Steel: 4 - 5
CrNi: 4 - 5
Tubular cored electrodes 2 - 3
EN
Adjusting the
brake
NOTE!
After releasing the "Wire threading" button, the wirespool should stop unreeling.
► If it continues unreeling, readjust the brake.
1 2
1
2
1
31
Design of the
2
4
STOP
OK
1
3
brake
3
3
WARNING!
Danger from incorrect installation.
This can result in severe personal injury
and damage to property.
► Do not dismantle the brake.
► Maintenance and servicing of brakes is
to be carried out by trained, qualified
personnel only.
Prerequisites for
start-up
The brake is only available as a complete
unit.
This illustration is for information purposes
only.
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
When commissioning the wirefeeder, the following requirements must be met:
- Wirefeeder connected to the power source using the interconnecting hosepack
- Welding torch connected to the wirefeeder
- Feed rollers inserted into the wirefeeder
- Wirespool or basket-type spool and adapter inserted in the wirefeeder
- Wire electrode fed in
- Feed roller contact pressure is set
- Brake adjusted
- All covers closed, all side panels in place, all protection devices intact and in their
proper place
32
The wirefeeder is started by pressing the torch trigger (for manual applications) or by
means of a welding start-up signal (for automatic applications).
Synergic control panel (option)
General IMPORTANT! The Synergic control panel can only be operated in conjunction with the fol-
lowing power sources:
- TransSteel 4000 Syn
- TransSteel 5000 Syn
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 expert knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to
be set manually.
EN
Control panel
splitting
Synergic A control panel
The Synergic control panel is split.
(9)
(10)
(8)
(1)
(2)
(7)
(3)
(4)
(6) (5)
33
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. The actual value is displayed during welding.
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. The actual value is displayed during welding.
Wire speed
*)
Wire 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
welding parameters
For changing welding parameters in the Setup menu
34
(4) Adjusting dial (left)
For changing the sheet thickness, welding current and wire speed welding 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 (MMA) welding
(6) "Mode" button
For selecting the operating mode
2 T - 2-step mode
4 T - 4-step mode
EN
***)
S 4 T - Special 4-step mode
(7) "Save" buttons (Easy Job)
For saving up to 5 operating points
(8) "Intermediate arc" indicator
A spatter-prone intermediate arc occurs between the dip transfer arc and the spray
arc. The intermediate arc indicator lights up to draw attention to this critical area.
(9) HOLD indicator
At the end of each welding operation, the actual values for welding current and
welding voltage are stored - 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 voltage 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.
35
Synergic B con-
(1) (2) (3)
1
2
+
3
trol panel
(1) "Material" button
For selecting the filler metal to be
used. The SP parameter is reserved for additional filler metals.
When a material is selected, the
LED behind the relevant filler metal
lights up.
(2) "Wire diameter" button
For selecting the wire diameter to be used. The SP parameter 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. The SP parameter 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:
Press and hold the "Mode" button
Press the "Parameter selection" button
(right)
Release the "Mode" and "Parameter
selection" buttons
Keylock activated:
The message "CLO | SEd" appears on the displays.
Keylock deactivated:
The message "OP | En" appears on the displays.
36
Accessing the
1
2
3
4
5
6
7
8
9
10
Setup menu
Accessing the Setup menu
EN
Use the "Process" button to select the
required welding process
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
The control panel is now in the Setup menu of the chosen welding process - the last Setup
parameter that was selected is displayed.
Accessing the Level 2 Setup menu
Use the "Mode" and "Process" buttons
or the left-hand adjusting dial to select
the "2nd" Setup parameter
Changing welding parameters
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Use the "Mode" and "Process" buttons
or the left-hand adjusting 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
37
Exiting the Level 2 Setup menu
11
12
13
14
15
16
1
2
3
1
Exiting the Setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Setup parameters See TransSteel 3500-5000 Syn instruction manual (42,0426,0258,XX)
Service parameters
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)
Press the "Parameter selection" button
(right)
Release the "Parameter selection" buttons
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Use the "Mode" and "Process" buttons
or the left-hand adjusting dial to select
the required Setup parameter
38
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 Second menu level for service technicians
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.
EN
39
Pulse control panel (option)
Pulse B
Pulse A
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(11)
(8)
(10)
(9)
(12)
General IMPORTANT! The Pulse control panel can only be operated in conjunction with the follow-
ing power sources:
- TransSteel 4000 Pulse
- TransSteel 5000 Pulse
The power source uses the Pulse 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 expert knowledge is available at all times. All the parameters can be adjusted manually. The Pulse control panel also allows parameters to be set
manually.
Control panel
splitting
Pulse A control
panel
The Pulse control panel is split.
40
No. Function
(1) HOLD indicator
At the end of each welding operation, the actual values for welding current and
welding voltage are stored - the "HOLD" indicator lights up.
(2) Real Energy Input
For displaying the energy applied during the welding operation.
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.
(3) "Intermediate arc" indicator
A spatter-prone intermediate arc occurs between the dip transfer arc and the spray
arc. The intermediate arc indicator lights up to draw attention to this critical area.
(4) "Parameter selection" button (right)
a) for selecting the following welding parameters
Arc length correction
For correcting the arc length
EN
Welding voltage in V *)
Before the start of welding, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during welding.
Pulse-/dynamic correction
For continuous correction of the droplet detachment energy in MIG/MAG pulse
synergic welding
- ... lower droplet detachment force
0 ... neutral droplet detachment force
+ ... higher droplet detachment force
For influencing the short-circuiting dynamic at the instant of droplet transfer in MIG/
MAG standard synergic welding and in MIG/MAG standard manual welding
- ... harder, more stable arc
0 ... neutral arc
+ ... soft, low-spatter arc
b) for changing parameters in the Setup menu
(5) Pulse indicator
Lights up when the MIG/MAG pulse synergic welding process is set
(6) Adjusting dial (right)
For changing the arc length correction, welding voltage and arc-force dynamic
welding parameters
For changing welding parameters in the Setup menu
41
(7) "Process" button
***)
For selecting the welding process
MIG/MAG standard manual welding
MIG/MAG standard synergic welding / MIG/MAG pulse synergic welding
MMA welding
(8) "Mode" button
For selecting the operating mode
2-step mode
4-step mode
Spot welding / Stitch welding / Special 4-step mode
(9) "Save" buttons (Easy Job)
For saving up to 5 operating points
(10) Adjusting dial (left)
For changing the sheet thickness, welding current and wire speed welding parameters
For selecting welding parameters in the Setup menu
(11) "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. The actual value is displayed during welding.
Wire speed
*)
Wire speed in m/min or ipm.
b) for changing parameters in the Setup menu
(12) SF - spot / stitch / SynchroPulse welding indicator
- Lights up if a value has been entered for the spot/stitch welding time Setup pa-
rameter (SPt) when spot or stitch welding mode is enabled.
- Lights up if a value has been entered for the frequency (F) Setup parameter when
the MIG/MAG synergic process is enabled.
42
*) The synergic function means that if one of these parameters is selected during
2
1
2
MIG/MAG standard synergic welding or MIG/MAG pulse synergic welding, then all
other parameters including the welding voltage parameter are automatically set as
well.
**) 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 voltage 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.
EN
Setting MIG/MAG
pulse synergic
welding and spot/
stitch welding
Setting MIG/MAG pulse synergic welding:
Press the "Process" button (7) until the LED lights up on:
1
The display shows Stn | drd for 1 second; the MIG/MAG standard synergic welding process
is set.
Press the "Process" button (7) again
The LED lights up unchanged. The display shows PUL | SE for 1 second, the Pulse indicator (5) lights up.
The MIG/MAG pulse synergic welding process is set.
Setting spot welding/stitch welding mode:
Press the "Mode" button (8) until the LED lights up on:
The display shows S4t for 1 second, and special 4-step mode is set.
Press the "Mode" button (8) again
The LED lights up unchanged. The display shows SPt* or Int* for 1 second, the SF indicator
(12) lights up.
Spot/stitch welding mode is set.
* Depending on the setting of the SPb and SPt Setup parameters
43
Pulse B control
(1) (2) (3)
1
2
3
panel
(1) "Material" button
For selecting the filler metal to be
used. The SP parameter is reserved for additional filler metals.
When a material is selected, the
LED behind the relevant filler metal
lights up.
(2) "Wire diameter" button
For selecting the wire diameter to be used. The SP parameter 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. The SP parameter 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:
Press and hold the "Mode" button
Press the "Parameter selection" button
(right)
44
Release the "Mode" and "Parameter
selection" buttons
Keylock activated:
The message "CLO | SEd" appears on the displays.
Keylock deactivated:
The message "OP | En" appears on the displays.
Accessing the
1
2
3
4
5
6
7
8
9
10
Setup menu
Accessing the Setup menu
EN
Use the "Process" button to select the
required welding process
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
The control panel is now in the Setup menu of the chosen welding process - the last Setup
parameter that was selected is displayed.
Accessing the Level 2 Setup menu
Use the "Mode" and "Process" buttons
or the left-hand adjusting dial to select
the "2nd" Setup parameter
Changing welding parameters
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Use the "Mode" and "Process" buttons
or the left-hand adjusting 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
45
Exiting the Level 2 Setup menu
11
12
13
14
15
16
1
2
3
1
Exiting the Setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process"
buttons
Setup parameters See TransSteel 4000 / 5000 Pulse Operating Instructions (42,0426,0353,XX)
Service parameters
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)
Press the "Parameter selection" button
(right)
Release the "Parameter selection" buttons
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Use the "Mode" and "Process" buttons
or the left-hand adjusting dial to select
the required Setup parameter
46
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 Second menu level for service technicians
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.
EN
47
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 may result in serious injury or damage to property.
► The activities described below must only be carried out by trained and qualified per-
sonnel.
► Observe the safety rules in the power source 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
WARNING!
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the housing.
► The housing screws must NOT be replaced by any other screws that do not provide a
reliable ground 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
48
Power source does not 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
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
EN
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
49
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
No protective gas shield
All other functions are OK
Cause: Gas cylinder is empty
Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty
Remedy: Replace the gas pressure regulator
Cause: Gas hose is not fitted or is damaged
Remedy: Fit or change the gas hose
Cause: Welding torch is faulty
Remedy: Change the welding torch
Cause: Gas solenoid valve is faulty
Remedy: Contact After-Sales Service
Irregular wire feed speed
Cause: Braking force has been set too high
Remedy: Loosen the brake
Cause: Hole in the contact tip is too narrow
Remedy: Use a suitable contact tip
Cause: Faulty inner liner in welding torch
Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary
Cause: The feed rollers are not suitable for the wire electrode being used
Remedy: Use suitable feed rollers
Cause: Feed rollers have the wrong contact pressure
Remedy: Optimise the contact pressure
Wirefeed problems
when using applications with long welding torch hosepacks
50
Cause: Incorrect arrangement of welding torch hosepack
Remedy: Arrange the welding torch hosepack in as straight a line as possible, avoiding
bends
Welding torch becomes very hot
Cause: The specification of the welding torch is inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled systems: Inadequate coolant flow
Remedy: Check coolant level, coolant flow, for coolant contamination, etc. For further
information refer to the cooling unit operating instructions.
Poor weld properties
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor ground earth connection
Remedy: Ensure good contact to workpiece
Cause: Inadequate or no protective gas shield
Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.
Cause: Welding torch is leaking
Remedy: Change the welding torch
EN
Cause: Wrong contact tip, or contact tip is worn out
Remedy: Replace the contact tip
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the wire electrode that has been inserted
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check weldability of the base material
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
51
Care, maintenance and disposal
General Under normal operating conditions, the welding system requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
Safety
An electric shock can be fatal.
Before opening the device
► Turn the mains switch to the "O" position
► Unplug the device from the mains
► Ensure the device cannot be switched back on
► Using a suitable measuring instrument, check to make sure that electrically charged
Work that is carried out incorrectly can cause serious injury and damage.
► The following activities must only be carried out by trained and qualified personnel.
► All instructions in the section headed "Safety rules" must be observed.
At every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and ground
- Check that the device has an all-round clearance of 0.5 m (1 ft. 8 in.) to ensure that
WARNING!
components (e.g. capacitors) have been discharged
WARNING!
earth connection for damage
cooling air can flow in and out freely
NOTE!
The air inlets and outlets must never be covered, not even partially.
Every 6 months - Dismantle device side panels and clean inside of device with dry, reduced com-
pressed air
CAUTION!
Danger of damage to electronic components.
► Do not bring the air nozzle too close to electronic components.
Disposal Dispose of in accordance with the applicable national and local regulations.
52
Technical data
EN
VR 5000 Remote
Supply voltage 24 V
Current consumption of control
Current consumption of motor
Welding current at 10 min/40 °C (104 °F) 40% D.C.* 500 A
60% D.C.* 450 A
100% D.C.* 360 A
Maximum shielding gas pressure 5 bar / 72.49 psi
Coolant Original Fronius
Maximum coolant pressure 5 bar / 72.49 psi
Gear ratio 16 : 1
Wire speed 1 - 25 m/min / 39.37 - 984.25 ipm
Wire drive 4-roller drive
Wire diameter 0.8 - 1.6 mm / 0.03 - 0.06 in.
Wirespool diameter max. 300 mm / max. 11.81 in.
Wirespool weight max. 19 kg / max. 41.89 Ib.
Degree of protection IP 23
Dimensions l x w x h 640 x 270 x 365 mm
25.20 x 10.63 x 14.37 in.
Weight 12.5 kg / 27.56 Ib.
2 A
2.5 A
* D.C. = Duty cycle
53
54
EN
55
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1, A-4643 Pettenbach, Austria
E-Mail: sales@fronius.com
www.fronius.com
Under www.fronius.com/contact you will find the addresses
of all Fronius Sales & Service Partners and locations
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