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VR 5000rob
Operating Instructions
EN
Wire-feed unit
[
42,0426,0085,EN 019-15052020
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.
EN
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4
Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety notices ................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 9
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 12
EMC measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 13
Specific hazards.................................................................................................................................... 13
Requirement for the shielding gas ........................................................................................................ 14
Danger from shielding gas cylinders..................................................................................................... 14
Danger from escaping shielding gas..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 16
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 17
Data protection...................................................................................................................................... 17
Copyright............................................................................................................................................... 17
General information ................................................................................................................................... 18
Device concept ..................................................................................................................................... 18
PAP overview........................................................................................................................................ 18
Standard overview ................................................................................................................................ 19
Intended purpose.................................................................................................................................. 20
Field of application ................................................................................................................................ 20
Warning notices affixed to the device ................................................................................................... 20
Options.................................................................................................................................................. 21
Controls, connections and mechanical components.................................................................................. 22
Safety.................................................................................................................................................... 22
Mechanical components ....................................................................................................................... 22
VR 5000rob PAP connections .............................................................................................................. 23
VR 5000rob Standard connections....................................................................................................... 23
Fitting the wire-feed unit............................................................................................................................. 25
Safety.................................................................................................................................................... 25
Fitting the VR 5000rob conventional..................................................................................................... 25
Mounting the VR 5000rob PAP............................................................................................................. 25
Inserting/replacing feed rollers................................................................................................................... 27
General ................................................................................................................................................. 27
USA wire-feed units .............................................................................................................................. 27
Inserting/replacing feed rollers.............................................................................................................. 27
Feeding in the wire electrode..................................................................................................................... 29
Insulated routing of wire electrode to wire-feed unit ............................................................................. 29
Feeding in the wire electrode................................................................................................................ 29
Setting the contact pressure ................................................................................................................. 30
Care, maintenance and disposal ............................................................................................................... 32
General ................................................................................................................................................. 32
Safety.................................................................................................................................................... 32
Every start-up........................................................................................................................................ 32
Every 6 months ..................................................................................................................................... 32
Preparing the VR 5000rob for replacing the inner liners on the welding torch...................................... 32
Disposal ................................................................................................................................................ 33
EN
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Troubleshooting ......................................................................................................................................... 34
General ................................................................................................................................................. 34
Safety.................................................................................................................................................... 34
Fault diagnosis...................................................................................................................................... 34
Technical data............................................................................................................................................ 38
VR 5000rob........................................................................................................................................... 38
6
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.
7
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
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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.
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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
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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.
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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
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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).
13
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
14
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.
15
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
16
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.
17
General information
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
(10)
Device concept The VR 5000rob robot wire-feed unit is designed specifically to be fitted to a robot. The VR
5000rob is available in two versions:
- PAP for torch hosepack built into the robot arm
- Standard with external torch hosepack
The robot wire-feed unit is controlled via the power source or robot control.
The device has a "Power limitation" safety feature. This means that the power source can
be operated at the power limit without compromising process safety. Details can be found
in the "Welding mode" section of the operating instructions for the TransSteel 3500 Rob
and TransSteel 5000 Rob power sources.
PAP overview
18
No. Function
(1) Cooling unit
e.g. FK 5000 with optional flow watchdog
(2) Power source
e.g. TransSteel 3500
(3) Interconnecting hosepack
Power source - robot interface
(4) Wire-feed unit mount
(5) VR 5000rob wire-feed unit
(6) Robacta W/CB-PAP or G/CB hosepack
(2)
(1)
(3)
(6)
(7)
(8)
(9)
(4)
(5)
(10)
Standard overview
(7) Robacta PAP CrashBox
(8) Robacta robot welding torch
(9) Robot
(10) Wirespool holder
EN
No. Function
(1) Cooling unit
e.g. FK 5000 with optional flow watchdog
(2) Power source
e.g. TransSteel 3500
(3) Interconnecting hosepack
Power source - robot interface
(4) Wire-feed unit mount
(5) VR 5000rob wire-feed unit
(6) Robacta W/CB-PAP or G/CB hosepack
(7) Robacta PAP CrashBox
(8) Robacta robot welding torch
19
(9) Robot
(10) Wirespool holder
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 liable for any damage resulting from such
improper use.
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
Utilisation not in accordance with the intended purpose comprises:
- wire feeding for applications other than MIG/MAG welding
- feeding in wires that are unsuitable for the feed rollers in use
- using unsuitable feed rollers
- feeding in wire using wirespool holders or wire containers that are unsuitable or have
insufficient electrical insulation
Field of application
Warning notices
affixed to the device
All indoor and automated MIG/MAG applications.
Safety symbols and warning notices affixed to the device must not be removed or painted
over. The symbols warn against operating the equipment incorrectly, as this may result in
serious injury and damage.
20
EN
Options - VR 5000rob gas pressure sensor
Monitors the gas pressure
- High End blow-off
VR 5000rob torch blow-off
For cleaning the welding torch using compressed air, max. 16 bar (231.98 psi.)
- Basic blow-off
VR 5000rob torch blow-off
For cleaning the welding torch using compressed air, max. 7 bar (101.49 psi.)
- Wirefeeding hose
For protected transport of the wire from the wirespool to the VR 5000rob; available in
different lengths. The wirefeeding hose also ensures a constant wire feed.
- QuickConnect
For easily connecting a wirefeeding hose to the VR 5000rob and to a welding wire
drum
- Robot wirespool holder
Wirespool holder fitted to the robot
- External CAT signal
Safety cut-out in the event of a welding torch collision
21
Controls, connections and mechanical components
(1)
(4)
(2)
(3)
(5)
Safety
Mechanical components
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious injury and damage to property.
► Read and understand this document.
► Read and understand all the Operating Instructions for the system components, espe-
cially the safety rules.
(3)
(4)
(2)
(5)
(1)
VR 5000rob Standard VR 5000rob PAP
No. Function
(1) Feeder inching button
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 wire threading speed.
(2) Wire infeed tube
(3) VR 5000rob cover
(4) 4-roller drive
(5) Welding torch connection
22
VR 5000rob PAP
(1)
(3)
(4)
(2)
(5)
(6)
(7)
(1)
(2)
(3)
(4)
connections
EN
VR 5000rob PAP - front VR 5000rob PAP - rear
No. Function
(1) Welding torch connection
(2) Shielding gas connection
(3) Enhanced LocalNet connection
For enhanced LocalNet with lines for motor supply and motor control
VR 5000rob
Standard connections
(4) Blanking cover
For optional gas pressure sensor or external CAT signal
(5) Blanking cover
For optional blow-off
(6) Blanking cover
For optional external CAT signal
(7) Blanking cover
(7)
(6)
VR 5000rob Standard - front VR 5000rob Standard - rear
(5)
23
No. Function
(1) Welding torch connection
(2) Blanking cover
(3) Blanking cover
For optional external CAT
(4) Blanking cover
For optional gas pressure sensor
(5) Enhanced LocalNet connection
For enhanced LocalNet with lines for motor supply and motor control
(6) Shielding gas connection
(7) Blanking cover
For optional blow-off
24
Fitting the wire-feed unit
7x
M6x16
6x
6FSt
6FSt
1x
1x
M6x16
2
1
2
EN
Safety
Fitting the VR
5000rob conventional
WARNING!
Risk of serious injury and damage from articles being dropped or falling over.
Check on a regular basis, and in the event of unusual operating situations, e.g. a system
crash, that all screw connections between the robot, wirefeeder mount and wire-feed unit
are secure.
1 2
1
2
1
4
3
6
5
8
7
**
*
9
10
11
Mounting the VR
5000rob PAP
* 2 * M8 x 20 mm
** 4 * M8 x 25 mm
1 2
25
3 4
4
6
3
5 6
5
26
Inserting/replacing feed rollers
2
1
4
4
5
6
3
1
6
3
31
2
4
5
7
2
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.
EN
USA wire-feed
units
Inserting/replacing feed rollers
In the USA, all wire-feed units are delivered without feed rollers. Before commissioning, insert suitable feed rollers into the wire-feed unit.
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
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.
27
3 4
3
8
6
7
9
3
1
2
2
5
4
4
4
3
3
2
4
1
5
5
6
28
Feeding in the wire electrode
2
1
4
3
2
EN
Insulated routing
of wire electrode
to wire-feed unit
Feeding in the
wire electrode
WARNING!
Risk of serious injury and material damage or an inferior weld as a result of earth
contact or short-circuit of a non-insulated wire electrode.
In the case of automated applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wire-feed unit spool or wirespool to the wire-feed unit
(e.g. by using a wirefeeding hose).
An earth contact or short-circuit can be caused by:
- a non-insulated, exposed length of wire electrode coming into contact with a conductive object during the welding process
- missing insulation between the wire electrode and the earthed enclosure of a robot cell
- chafed wirefeeding hoses, exposing the wire electrode
To avoid earth contact or short-circuit:
- Use wirefeeding hoses for insulated routing of wire electrode to wire-feed unit
- Prevent chafing by not routing the wirefeeding hoses over sharp edges
- Use hose holders or hose protectors where necessary
- Coupling pieces and hoods for welding wire drums are recommended to ensure safe
transport of 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
29
CAUTION!
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
1
2
4
5
3
1
4
Risk of injury from wire electrode emerging at speed.
When pressing the feeder inching button, 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 welder presses and holds the feeder inching button:
- 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 longer than 2.5 se-
conds ... after a total of 2.5 seconds,
the wire is fed at a constant rate equal
to the wire feed speed set for the Fdi
welding parameter.
If the feeder inching 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 feed speed of 1 m/min or 39.37 ipm where necessary.
1 2
3
1
2
1
3
Setting the contact pressure
NOTE!
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 nev-
ertheless ensures proper wirefeeding.
30
1
1
1
Contact pressure
standard values
U-groove rollers
Steel 4 - 5
EN
CrNi 4 - 5
Tubular cored electrodes 2 - 3
31
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.
Every start-up - Check welding torch, interconnecting hosepack and grounding (earthing) connection
- Check feed rollers and inner liners for signs of damage
- Check contact pressure of feed rollers and adjust if necessary
- Check that all screw connections between the robot, wirefeeder mount and wire-feed
WARNING!
components (e.g. capacitors) have been discharged
WARNING!
for signs of damage
unit are secure
Every 6 months
Preparing the VR
5000rob for replacing the inner
liners on the
welding torch
32
NOTE!
Risk of damage to electronic components.
Do not bring the air nozzle too close to electronic components.
- Remove the cover from the device and clean the inside with dry reduced compressed
air
WARNING!
If one of these machines topples over or falls it could cause serious or even fatal
injury.
Do not carry out any robot movements until the wire-feed unit has been retracted and
locked as shown in the the following illustrations.
1 2
2
3
1
3
EN
1
Disposal Dispose of in accordance with the applicable national and local regulations.
33
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
34
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
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
EN
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
35
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 long hosepacks
Cause: Incorrect arrangement of hosepack
Remedy: Arrange the hosepack in as straight a line as possible, avoid tight bends
Welding torch becomes very hot
Cause: The specification of the welding torch is inadequate
Remedy: Observe the duty cycle and loading limits
36
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
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
EN
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
37
Technical data
VR 5000rob
Supply voltage for motor
Supply voltage for control
Current input for control
Current input for motor
Welding current at 10 min/40 °C (104 °F) 40 % d.c.* 500 A
Maximum shielding gas pressure 5 bar
Wire feed speed 0.5 - 25 m/min
Wire drive 4 roller drive
Wire diameter 0.8 - 1.6 mm
Degree of protection IP 20
Dimensions l x w x h 210 x 186 x 175 mm
Weight 5.8 kg
*) d.c. = duty cycle
55 V
24 V
2 A
1.2 A
60 % d.c.* 450 A
100 % d.c.* 360 A
72.49 psi.
19.69 - 984.25 ipm.
.03 - .06 in.
8.27 x 7.32 x 6.89 in.
12.79 Ib.
38
EN
39
FRONIUS INTERNATIONAL GMBH
Froniusstraße 1
A-4643 Pettenbach
AUSTRIA
contact@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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