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Operating Instructions VR 5000 Spare Parts List Wirefeeder 42,0426,0080,EN 022009...
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Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
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Safety rules DANGER! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.
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General remarks Any malfunctions which might impair machine safety must be eliminated (continued) immediately - meaning before the equipment is next switched on. It’s your safety that’s at stake! Utilisation for The machine may only be used for jobs as defined by the “Intended intended purpose purpose”.
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Obligations of Before starting work, all persons to be entrusted with carrying out work with personnel (or on) the machine shall undertake to observe the basic regulations on workplace safety and accident prevention to read the sections on “safety rules” and the “warnings” contained in this manual, and to sign to confirm that they have understood these and will comply with them.
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Protection for “Protective clothing” also includes: yourself and protecting your eyes and face from UV rays, heat and flying sparks with other persons an appropriate safety shield containing appropriate regulation filter glass (continued) wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield wearing stout footwear that will also insulate even in wet conditions protecting your hands by wearing appropriate gloves (electrically insula-...
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Hazards from The harmfulness of the welding fumes will depend on e.g. the following noxious gases components: and vapours the metals used in and for the workpiece (continued) the electrodes coatings cleaning and degreasing agents and the like For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.
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Hazards from Do not loop any cables or other leads around your body or any part of your mains and weld- body. ing current (continued) Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.
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Stray welding When using current supply distributors, twin head wire feeder fixtures etc., currents please note the following: The electrode on the unused welding torch/welding (continued) tongs is also current carrying. Please ensure that there is sufficient insula- ting storage for the unused welding torch/tongs. In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
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EMI Precautions Electromagnetic fields may cause as yet unknown damage to health. Effects on the health of persons in the vicinity, e.g. users of heart pace- makers and hearing aids Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces Keep as much space as possible between welding cables and head/body of welder for safety reasons...
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Particular danger When hoisting the machines by crane, only use suitable manufacturer- spots supplied lifting devices. (continued) Attach the chains and/or ropes to all the hoisting points provided on the suitable lifting device. The chains and/or ropes must be at an angle which is as close to the vertical as possible.
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Safety precauti- A machine that topples over can easily kill someone! For this reason, always ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly. lation site and An angle of inclination of up to 10° is permissible. when being transported Special regulations apply to rooms at risk from fire and/or explosion.
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Safety precauti- If any damage occurs in cases where other coolants have been used, the ons in normal manufacturer shall not be liable for any such damage, and all warranty operation claims shall be null and void. (continued) Under certain conditions, the coolant is flammable. Only transport the coolant in closed original containers, and keep it away from sources of ignition.
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Safety markings Equipment with CE-markings fulfils the basic requirements of the Low- Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). . Equipment marked with the CSA-Test Mark fulfils the requirements made in the relevant standards for Canada and the USA. Data security The user is responsible for the data security of changes made to factory settings.
Table of contents General information General ................................7 Device concept ............................7 Requirements ............................7 Field of application ............................. 7 Warning notices affixed to the device ......................8 Control elements and connections Description of the control panels ........................11 General ..............................11 Safety ...............................
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Commissioning ............................. 32 General ..............................32 Requirements ............................32 Welding MIG/MAG modes ............................35 General ..............................35 Symbols ..............................35 2-step mode ............................35 4-step mode ............................36 Special 4-step mode ..........................36 MIG/MAG welding ............................37 Safety ..............................37 General tasks before MIG/MAG welding ....................
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Displayed service codes .......................... 61 Troubleshooting the wirefeeder ....................... 65 Care, maintenance and disposal ........................67 General ..............................67 At every start-up ............................67 Every 6 months ............................67 Disposal ..............................67 Annex Technical data .............................. 71 VR 5000 ..............................71 Fronius Worldwide...
VR 5000 wirefeeder Requirements The VR 5000 wirefeeders can be operated with the TransSteel 3500 / 5000 power sources. Field of applicati- The VR 5000 series of wirefeeders, in combination with any of the standard protective...
Warning notices The wirefeeder is fitted with safety symbols on the rating plate. The safety symbols must affixed to the NOT be removed or painted over. The symbols warn against operating the equipment device incorrectly, as this may result in serious injury and damage. Welding is dangerous.
Description of the control panels General The functions on the control panels are all arranged in a very logical way. The various parameters needed for welding are easy to select, by pressing the appropriate button, and can easily be altered using buttons or the adjusting dial displayed on the digital display during welding Thanks to the synergic function, whenever you alter any one parameter, appropriate changes will automatically be made to all the other parameters.
Manual control panel General The Manual control panel allows welding parameters to be set manually in a very straightforward process. Manual control panel Manual control panel No. Function (1) „Process“ button for selecting the process MIG/MAG welding STICK - MMA welding to select parameters in the Set-up menu (2) „Mode“...
„Hold“ indicator lights up. Adjustment aid For selected material / protective gas shield combinations, the VR 5000 includes adjust- for Manual cont- ment aids in the form of foils that can be easily attached to and removed from the rol panel Manual control panel.
Synergic control panel General The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and protective gas shield to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually as required.
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Synergic A No. Function control panel (1) „Parameter selection“ button (right) (continued) for selecting the following parameters Arc length correction for correcting the arc length Welding voltage Welding voltage in V. Before the start of welding, the machine automatically displays a standard value based on the programmed parameters.
Synergic A No. Function control panel (6) „Mode“ button (continued) for selecting the mode 2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode (7) „Save“ buttons for saving up to 5 operating points (8) Transition arc indicator between the dip-transfer arc and the spray arc, a spatter-prone „transition arc“...
(4) Position for option (+) - current socket with bayonet latch (5) Position for LocalNet connection socket option VR 5000 - Front view Wirefeeder rear No. Function (1) (+) - Socket with bayonet latch for interconnecting hosepack...
Wirefeeder side VR 5000 - side view No. Function (1) Wirespool holder with brake for holding standard wirespools with a max. diameter of 300 mm (11.81 in) and max. weight of 19 kg (41.89 lbs.) (2) Synergic control panel section B...
Wirefeeder No. Function underside (1) Socket for swivel pin for placing the wirefeeder on the swivel pin in the swivel pin holder VR 5000 - view from below...
Before commissioning Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules WARNING! An electric shock can be fatal.
The wirefeeders can be placed on the power source if a swivel pin holder is available, e.g.: „PickUp“ swivel pin holder VR 5000, for use with the „PickUp 5000“ trolley Placing wirefee- CAUTION! Risk of injury and damage from falling wirefeeder. Make sure that...
Connecting wirefeeder to power source General The wirefeeder is connected to the power source using the interconnecting hosepack. Connecting WARNING! Fitting the equipment incorrectly can cause serious injury and wirefeeder to damage. Do not carry out the steps described here until you have read and power source completely understood all the operating instructions.
Connecting the welding torch Safety NOTE! When connecting the welding torch, check that all connections are connected properly all cables, leads and hosepacks are undamaged and correctly insulated. Connecting MIG/ when the optional water connection MAG welding and the water-cooled welding torch torches are installed...
Inserting / replacing feed rollers 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! Use only feed rollers that match the wire electrode. An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.
Inserting the wirespool, inserting the basket-type spool Safety CAUTION! Risk of injury from springiness of spooled wire electrode. When inserting the wirespool/basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. CAUTION! Risk of injury from falling wirespool / basket-type spool.
Feeding in the wire electrode Feeding in the CAUTION! Risk of injury from springiness of spooled wire electrode. When wire electrode 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 electro- de.
Feeding in the wire electrode (continued) Setting the NOTE! Adjust the contact pressure in such a way that the wire electrode is not contact pressure deformed, but is nevertheless transported properly. Contact pressure guideline values U-grooved rollers Steel 4 - 5 CrNi 4 - 5 Tubular cored electrodes...
Adjusting the brake General Important! After releasing the torch trigger the wirespool should stop unreeling. Adjust brake if necessary. Adjusting the brake STOP STOP Design of the WARNING! Fitting the equipment brake incorrectly can cause serious injury and damage. Do not dismantle the brake. Maintenance and servicing of brakes to be carried out by trained, qualified personnel...
Commissioning General 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 The wirefeeder is commissioned by pressing the torch trigger (for manual applications) or by means of a welding start-up signal (for automatic applications).
MIG/MAG modes General WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules For details of the meaning, setting, setting range and units of the available parameters (e.g.
4-step mode „4-step mode“ is suitable for longer weld seams. 4-step mode Special 4-step „Special 4-step mode“ is particularly suitable for welding in higher power ranges. In mode special 4-step mode the arc starts at relatively low power, making it easier to stabilise. Special 4-step mode...
MIG/MAG welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules WARNING! An electric shock can be fatal.
MIG/MAG standard synergic welding General The MIG/MAG standard synergic welding process is only available in combination with the Synergic control panel. On Synergic B control panel: MIG/MAG stan- dard synergic Press the „Material“ button to select the filler metal used. welding The assignment of SP depends on the welding database used for the power source.
MIG/MAG stan- Open the gas cylinder valve dard manual welding - manual Set the shielding gas flow rate: control panel If a Feeder inching / Gas test button is fitted: (continued) Press upwards and hold the „Feeder inching“ / „Gas test“ button Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate Release the „Feeder inching“...
MIG/MAG standard manual welding General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function. Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.
MIG/MAG stan- Open the gas cylinder valve dard manual welding - manual Set the shielding gas flow rate: control panel If a Feeder inching / Gas test button is fitted: (continued) Press upwards and hold the „Feeder inching“ / „Gas test“ button Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate Release the „Feeder inching“...
MIG/MAG stan- On Synergic A control panel: dard manual welding - Syner- Press the „Process“ button to select the desired welding process: gic A control MIG/MAG standard manual welding panel Press the „Mode“ button to select the desired MIG/MAG mode: 2-step mode 4-step mode In MIG/MAG standard manual welding, „Special 4-step“...
MIG/MAG stan- CAUTION! Risk of injury and damage from electric shock and from wire dard manual electrode emerging from the torch. When you press the torch trigger: welding - Syner- hold the torch so that it points away from your face and body gic A control do not point the welding torch at people panel...
MMA welding Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safety rules WARNING! An electric shock can be fatal.
MMA welding - If the rod electrode (MMA) welding process is selected, any cooling unit present is manual control automatically deactivated. It is not possible to switch it on. panel (continued) Important! Parameters that have been set on a system component control panel (e.g.
MMA welding - Press the „Parameter selection“ button and select the welding current parameter. Synergic A Use the adjusting dial to set the desired amperage. control panel The amperage value is displayed in the left-hand digital display. (continued) All parameter command values that have been set by means of the adjusting dial will remain stored until the next time they are changed.
Hotstart function Legend I (A) (continued) Hti ..Hot-current time, 0 - 2 s, factory setting: 0.5 s HCU ..Hot-start current, 0 - 200%, HCU > I factory setting 150 % ..Main current = Pre-set welding current Mode of operation During the specified hot-current time (Hti), the welding current is increased to a certain value.
Saving and retrieving operating points General The „Save“ buttons allow up to 5 tried-and-tested operating points to be saved. The settings do not need to be documented manually. The current settings on the control panel are saved. Important! Set-up parameters are not saved at this time. Saving operating Press and hold down one of the „Save“...
Process set-up menu General The Process set-up menu provides simple access to expert knowledge in the power source and to additional functions. The Process set-up menu can be used to make simple adjustments of the parameters to the various job settings. Process set-up The setting of the process parameters is described on the basis of the „MIG/MAG menu - manual...
Process set-up Setting process parameters is described here with reference to the MIG/MAG standard menu - Synergic synergic welding process. The procedure for changing other process parameters is A control panel identical. Open the Process set-up menu Use the „Process“ button to select the MIG/MAG standard synergic welding process Press and hold the Mode button Press the Process button...
Parameters for The parameters available in the Process set-up menu are described below for the MIG/MAG wel- following MIG/MAG welding processes: ding in the Pro- MIG/MAG standard manual welding cess set-up menu MIG/MAG standard synergic welding „min.“ and „max.“ are used for setting ranges that differ according to power source, wire- feed unit, welding program, etc.
Mode set-up menu General The Mode set-up menu provides simple access to expert knowledge in the power source and to additional functions. The Mode set-up menu can be used to make simple adjust- ments of the parameters to the various job settings. Mode set-up Setting the Mode parameters is described by reference to „Special 4-step mode - S 4 T“...
Parameters for „Special 4-step I (current) - Starting: Starting current mode“ in the Unit % (of welding current) mode set-up Setting range 0 - 200 menu Factory setting Slope: 0 - 9.9 s Unit Setting range 0 - 9,9 Factory setting I (current) - End: Final current Unit % of welding current...
Set-up menu - Level 2 Set-up menu Opening the set-up menu level 2 - manual Press and hold the Mode button control panel Press the Process button Release the Mode and Process buttons The control panel is now in the set-up menu - the last parameter that was selected is displayed.
Set-up menu Exiting from the set-up menu Level 2 - manual 13. Press and hold the Mode button control panel (continued) 14. Press the Process button 15. Release the Mode and Process buttons Set-up menu Opening the set-up menu Level 2 - Syner- Press and hold the Mode button gic control panel Press the Process button...
Set-up menu Exiting from the set-up menu Level 2 - Syner- 13. Press and hold the Mode button gic control panel (continued) 14. Press the Process button 15. Release the Mode and Process buttons Parameters for MIG/MAG wel- Cooling unit control ding in the set-up Unit menu level 2...
Troubleshooting General WARNING! An electric shock can be fatal. Before opening the device 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 instrument, check to make sure that electri- cally charged components (e.g.
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Displayed service PHA | SE codes Cause: Phase failure (continued) Remedy: Check the mains fuse, the mains lead and the mains plug Err | 51 Cause: Mains undervoltage: The mains voltage has fallen below the toleran- ce range Remedy: Check the mains voltage Err | 52 Cause: Mains overvoltage: The mains voltage has risen above the tolerance...
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Displayed service to3 | xxx codes Note: xxx stands for a temperature value (continued) Cause: Overtemperature in the wirefeeder motor Remedy: Allow wirefeeder to cool down to4 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in welding torch Remedy: Allow welding torch to cool down to5 | xxx...
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Displayed service Err | tf0 codes Cause: Faulty temperature sensor in the power source primary circuit (continued) Remedy: Contact After-Sales Service Err | tf1 Cause: Faulty temperature sensor in the power source control gear Remedy: Contact After-Sales Service Err | tf2 Cause: Faulty temperature sensor in the power source secondary circuit Remedy:...
Troubleshooting Nothing happens when the torch trigger is pressed the wirefeeder Power source mains switch is on, power source ON indication is lit up on the power source, indications on wirefeeder are lit up Cause: Control plug not connected in the case of a welding torch with external control connector Remedy: Connect the control plug...
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Troubleshooting Irregular wirefeed speed the wirefeeder The wire electrode forms a loop between the feed rollers and the wire inlet nozzle of the (continued) welding torch Cause: The braking force has been set too high Remedy: Loosen the brake Cause: The borehole of the contact tube is too narrow Remedy: Use a suitable contact tube...
Care, maintenance and disposal General Under normal operating conditions the wirefeeder 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. WARNING! An electric shock can be fatal.
Technical data VR 5000 Supply voltage 24 V Control current input Motor current input Gear ratio 16 : 1 Wirefeed speed 1 - 25 m/min 39.37 - 984.25 ipm. Wirefeed drive 4 roller drive Wire diameter 0.8 – 1.6 mm 0.03 - 0.06 in.
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Ersatzteilliste Spare Parts List Liste de pièces de rechange Lista parti di ricambio Lista de repuestos Lista de peças sobresselentes Onderdelenlijst Reservdelsliste Seznam náhradních dílů Ñïèñîê çàïàñíûõ ÷àñòåé SK Zoznam náhradných dielov ud_fr_st_tb_00150 012008...
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Motorplatte Alu 4R s 44,0001,1405 -FSR U 0,8 44,0001,1406 -FSR U 0,9-1,0 44,0001,1407 -FSR U 1,2 44,0001,1408 -FSR U 1,4-1,6 42,0405,1095 t o r 42,0407,0667 t o r 42,0404,0384 44,0001,1413 42,0405,1097 42,0405,0687 42,0401,1098 (8x) 42,0001,3750 42,0407,0665 44,0001,1399 42,0407,0680 42,0405,1096 42,0403,0153 42,0405,1093 42,0001,3751 42,0405,1094,Z...
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G 1,2m 50mm² 4,047,408 5m 50mm² 4,047,409 10m 50mm² 4,047,410 W 1,2m 70mm² 4,047,260 W 1,6m 70mm² 4,047,324 W 5,0m 70mm² 4,047,261 W 10m 70mm² 4,047,262 32,0405,0226 W 15m 70mm² 4,047,290 42,0407,0482 W 20m 70mm² 4,047,277 G 1,2m 70mm² 4,047,287 G 5,0m 70mm²...
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G 4m 50mm² 4,047,411 G 8m 70mm² 4,047,412 W 4m 95mm² 4,047,291 W 8m 95mm² 4,047,292 W 8m 95mm² 4,047,292,800 32,0405,0226 42,0407,0482 40,0001,0095 - * 42,0405,0239 42,0407,0482 42,0407,0063 32,0405,0226 42,0402,0053 40,0001,0012 - * 42,0001,0942 42,0001,0943 42,0405,0239 44,0450,0281 - G 1/4" 43,0003,0251 43,0003,0253 42,0407,0048...
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FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations. ud_fr_st_so_00082 012008...