Fronius VR 5000 Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Fronius Manuals
  4. Industrial Equipment
  5. VR 5000
  6. Operating instructions manual

Fronius VR 5000 Operating Instructions Manual

Wire-feed unit
Hide thumbs Also See for VR 5000:
Table of Contents

Advertisement

Quick Links

/ Perfect Charging /
Perfect Welding
VR 5000, VR 5000 noSpool
42,0426,0080,EN 027-21122018
/ Solar Energy
Operating Instructions
Spare parts list
Wire-feed unit

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the VR 5000 and is the answer not in the manual?

Questions and answers

Subscribe to Our Youtube Channel

Related Manuals for Fronius VR 5000

Summary of Contents for Fronius VR 5000

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions VR 5000, VR 5000 noSpool Spare parts list Wire-feed unit 42,0426,0080,EN 027-21122018...
  • Page 3 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.

  • Page 5: Table Of Contents

    Contents Safety rules ..............................General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Protecting yourself and others ......................Danger from toxic gases and vapours ....................Danger from flying sparks ........................Risks from mains current and welding current..................Meandering welding currents........................
  • Page 6 Wire-feed unit side ..........................Wire-feed unit underside........................Installation and commissioning Before commissioning..........................Safety..............................Intended purpose ..........................Setup regulations ..........................Placing wire-feed unit on power source ..................... General information ..........................Placing wire-feed unit on power source ....................Connecting wire-feed unit to power source....................General information ..........................
  • Page 7 Every start-up............................104 Every 6 months ............................. 104 Disposal ..............................104 Technical data and settings tables Technical data............................107 VR 5000 ..............................107 VR 5000 noSpool..........................107 Manual control panel settings tables......................109 Settings tables ............................109 Welding program tables ..........................115 TransSteel 3500 Euro welding program tables ..................
  • Page 8 TransSteel 5000 US welding program tables ..................118 TransSteel 3500 Yard welding program tables ..................119 TransSteel 5000 Yard welding program tables ..................120 Quick reference............................121 Appendix Spare parts list: VR 5000 ........................... 124...

  • Page 9: Safety Rules

    Safety rules 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.

  • Page 10: Obligations Of The Operator

    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.

  • Page 11: Danger From Toxic Gases And Vapours

    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 reg- ulation filter Wear regulation protective goggles with side protection behind the protective visor...

  • Page 12: Risks From Mains Current And Welding Current

    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.

  • Page 13: Meandering Welding Currents

    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.

  • Page 14: Emf Measures

    Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite correct mains connection, addition- al measures are necessary (e.g. use a suitable line filter). 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 Equipotential bonding Earthing of the workpiece...

  • Page 15: Factors Affecting Welding Results

    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 cool- ant flow or return lines.

  • Page 16: Danger From Escaping Shielding Gas

    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 cylin- ders 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.

  • Page 17: Safety Measures In Normal Operation

    Safety measures Only operate the device when all safety devices are fully functional. If the safety devices in normal opera- are not fully functional, there is a risk of tion 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...

  • Page 18: Disposal

    (e.g. relevant product standards of the EN 60 974 se- ries). 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...

  • Page 19: General Information

    General information...

  • Page 21: General

    VR 5000 series are also suitable for long hosepacks. Due to their compact design, the VR 5000 wire-feed units can be used in many different ways. 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.
  • Page 22 Model No. Part No. A-4600 Wels Ser. No. www.fronius.com IEC 60 974-5/-10 Cl.A IP 23 24 V 4.0 A 24 V 2.0 A 1.0-25 m/min 360A/100% 450A/60% 500A/40% 40,0006,3035 Welding is dangerous. The following Do not use the functions described here...

  • Page 23: Description Of Warning Notices On The Device

    Description of On certain device versions, warning notices are attached to the device. Warning Notices on the Device The arrangement of the symbols may vary. Warning! Watch Out! There are possible hazards as shown by the symbols. Drive rolls can injure fingers. Welding wire and drive parts are at welding voltage during operation Keep hands and metal objects away.
  • Page 24 Welding sparks can cause explosion or fire. Keep flammables away from welding. Don’t weld near flammables. Welding sparks can cause fires.Have a fire extinguisher nearby and have a watch- person ready to use it. Do not weld on drums or any closed containers. Arc rays can burn eyes and injure skin.

  • Page 25: Control Elements And Connections

    Control elements and connections...

  • Page 27: Description Of The Control Panels

    Description of the control panels General informa- The functions on the control panels are all arranged in a very logical way. The various weld- tion ing parameters needed for welding are easy to select, by pressing the appropriate button, and can easily be altered using buttons or the adjusting dial displayed on the digital display during welding Thanks to the synergic function, whenever one parameter is altered, the appropriate...

  • Page 28: Manual Control Panel

    Manual control panel General The control panel allows straightforward manual setting of the welding parameters. Manual control panel Function "Process" button for selecting the welding process MIG/MAG welding STICK manual metal arc welding for selecting welding parameters in the Setup menu "Mode"...

  • Page 29: Adjustment Aid For Manual Control Panel

    "Dynamic" buttons for influencing the short-circuiting dynamic at the moment of droplet transfer - ... harder, more stable arc + ... soft, low-spatter arc HOLD indicator Every time you finish a welding operation, the actual values for welding current and welding voltage are stored, and the HOLD indicator lights up.

  • Page 30: Keylock

    Scales for sheet thickness in mm The two adjusters must be set to the appropriate value for the sheet thickness be- ing used in order to obtain the basic setting according to the adjustment aid. Dynamic Recommended dynamics settings are specified for three ranges of sheet thick- ness.
  • Page 31 Explanation Example: Firmware version 1.00 | 4.21 Example: Welding program configuration 2 | 491 Example: Number of the currently selected welding program 2 | 290 Example: Motor current for wire drive in A iFd | 0.0 The value changes as soon as the motor is running. Indicates the actual arc time since using for the first time 654 | 32.1 Note: The arc time indicator is not suitable as a basis for calcu-...

  • Page 32: Synergic 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 shielding gas to calculate the best weld- ing parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually.
  • Page 33 Function "Parameter selection" button (right) a) for selecting the following welding parameters Arc length correction for correcting the arc length Welding voltage in V Before the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

  • Page 34: Synergic B Control Panel Overview

    "Mode" button for selecting the operating mode 2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode "Save" buttons (Easy Job) for saving up to 5 operating points Intermediate arc indicator Between the dip transfer arc and the spray arc, a spatter-prone "intermediate arc" occurs.

  • Page 35: Synergic B Control Panel

    Synergic B con- trol panel Synergic B - Steel control panel Synergic B - Yard control panel Synergic B - Steel USA control panel Function "Material" button for selecting the filler metal to be used. Welding parameter SP is reserved for filler metals.

  • Page 36: Keylock

    "Wire diameter" button For selecting the wire diameter to be used. Welding parameter SP is reserved for additional wire diameters. When a wire diameter is selected, the LED behind the relevant wire diameter lights "Shielding gas" button For selecting the shielding gas to be used. Welding parameter SP is reserved for additional shielding gases.
  • Page 37 Available parameters Explanation Example: Firmware version 1.00 | 4.21 Example: Welding program configuration 2 | 491 Example: Number of the currently selected welding program 2 | 290 Example: Motor current for wire drive in A iFd | 0.0 The value changes as soon as the motor is running. Indicates the actual arc time since using for the first time 654 | 32.1 Note: The arc time indicator is not suitable as a basis for calcu-...

  • Page 38: Connections And Mechanical Components

    Connections and mechanical components Overview of con- An overview of the connections available for the welding torch can be found in the spare nections for the parts list in the Appendix. welding torch Front of wire-feed Welding torch connection unit for connecting the welding torch Coolant flow connection (blue) - option...

  • Page 39: Wire-Feed Unit Side

    Coolant return connection (red) - option when the optional water connection is installed, otherwise blanking cover Coolant flow connection (blue) - option when the optional water connection is installed, otherwise blanking cover Wire-feed unit side Function Holder for braked wirespool for holding standard wirespools with a max.

  • Page 40: Wire-Feed Unit Underside

    4-roller drive Optional Wire threading / Gas test button Push button downwards: for threading the wire electrode into the welding torch hosepack with no accompa- nying flow of gas or current. While the button is being held down, the wire-feed unit runs at wire threading speed.

  • Page 41: Installation And Commissioning

    Installation and commissioning...

  • Page 43: Before Commissioning

    60° from the vertical The VR 5000 standard version with an integrated wirespool holder can be set up and op- erated outdoors in line with IP23 protection. Avoid direct wetting (e.g. from rain).
  • Page 44 The VR 5000 noSpool without an integrated wirespool holder may only be set up and op- erated in closed areas.

  • Page 45: Placing Wire-Feed Unit On Power Source

    General informa- The wire-feed units can be placed on the power source if a swivel pin holder is available, tion e.g.: VR 5000 swivel pin holder, for use with the PickUp 5000 trolley Placing wire-feed CAUTION! unit on power source Danger from falling wire-feed unit.

  • Page 46: General Information

    Connecting wire-feed unit to power source General informa- The wire-feed unit is connected to the power source using the interconnecting hosepack. tion Connecting wire- WARNING! feed unit to power source Fitting the equipment incorrectly can cause serious injury and damage. Do not carry out the steps described here until you have read and completely understood all the operating instructions.

  • Page 47: Connecting The Welding Torch

    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/ MAG manual * when the optional water connection and welding torches the water-cooled welding torch are fitted...

  • Page 48: Inserting/Replacing Feed Rollers

    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! Only use feed rollers that match the wire electrode. An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.

  • Page 49: Inserting The Wirespool, Inserting The Basket-Type Spool

    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.

  • Page 50: Inserting The Basket-Type Spool

    Inserting the bas- NOTE! ket-type spool When working with basket-type spools, only use the basket-type spool adapter in- cluded 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 place the locking ring as shown in the diagram on the left.

  • Page 52: Feeding In The Wire Electrode

    Feeding in the wire electrode Feeding in the CAUTION! wire electrode 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.

  • Page 53: Setting The Contact Pressure

    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 po- sition the wire at a low wire feed speed of 1 m/min or 39.37 ipm where necessary. If there is no Feeder inching/Gas test button, the torch trigger can be used in the same way.
  • Page 54 Contact pressure U-groove roll- standard values Steel 4 - 5 CrNi 4 - 5 Tubular cored electrodes 2 - 3...

  • Page 55: Adjust The Brake

    Adjust the brake General NOTE! After releasing the torch trigger the wirespool must stop unreeling. If it continues unreeling, readjust the brake. Adjusting the brake STOP STOP...

  • Page 56: Design Of The Brake

    Design of the brake WARNING! Fitting the equipment incorrectly can cause serious injury and damage. ► Do not dismantle the brake. ► Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only. The brake is only available as a complete unit.

  • Page 57: Start-Up

    Start-up General informa- WARNING! tion Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules The wire-feed unit is commissioned by pressing the torch trigger (for manual applications) or by means of a welding start-up signal (for automatic applications).

  • Page 59: Welding

    Welding...

  • Page 61: Power Limitation

    Power limitation Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety. Wire feed speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished.

  • Page 62: Mig/Mag Modes

    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 fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules For details of the meaning, settings, setting range and units of the available welding pa- rameters (e.g.

  • Page 63: 2-Step Mode

    2-step mode "2-step mode" is suitable for Tacking work Short weld seams 4-step mode "4-step mode" is suitable for longer weld seams. Special 4-step Special 4-step mode allows the starting and mode final current to be configured in addition to the advantages of 4-step mode.

  • Page 64: 2-Step Stitch Welding

    2-step stitch The "2-step stitch welding" mode is suitable welding for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the base material. 4-step stitch The "4-step stitch welding" mode is suitable welding for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the base material.

  • Page 65: Mig/Mag Welding

    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 fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules WARNING! An electric shock can be fatal.

  • Page 66: Mig/Mag Standard Synergic Welding

    MIG/MAG standard synergic welding General The MIG/MAG standard synergic welding process is only available in combination with the Synergic control panel. MIG/MAG stand- On Synergic B control panel: ard synergic welding Press the Material button to select the filler metal to be used. Assignment of the SP position depends on the welding database used for the power source.

  • Page 67: Corrections During Welding

    To display the actual welding current during welding: Press the Parameter selection button to select the welding current parameter The actual welding current is shown on the digital display during welding. Open the gas cylinder valve Set the shielding gas flow rate: If there is a Feeder inching/Gas test button: Press the Feeder inching/Gas test button upwards Turn the adjusting screw on the underside of the pressure regulator until the pres-...

  • Page 68: Mig/Mag Standard Manual Welding

    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 param- eters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

  • Page 69: Adjustments While Welding - Manual Control Panel

    CAUTION! Risk of injury and damage from electric shock and from the wire electrode emerging at speed from the torch. When pressing the torch trigger: ► keep the welding torch away from your face and body ► wear suitable protective goggles ►...
  • Page 70 Press the Parameter selection button to select the welding voltage parameter Use the adjusting dial to set the desired value for the welding voltage The welding parameter values are shown in the digital display located above them. All welding parameter set values that have been set using the adjusting dial or buttons on the welding torch remain stored until the next time they are changed.

  • Page 71: Adjustments While Welding - Synergic A Control Panel

    Adjustments To obtain the best possible welding results, the arc-force dynamic parameter will some- while welding - times need to be adjusted. Synergic A con- trol panel Press the "Parameter selection" button to select the arc-force dynamic parameter Use the adjusting dial to set the desired arc-force dynamic value The welding parameter value is shown in the digital display located above it.

  • Page 72: Mma Welding

    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 fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules WARNING! An electric shock can be fatal.

  • Page 73: Adjustments While Welding - Manual Control Panel

    If the MMA welding process is selected, any cooling unit present is automatically de- activated. It is not possible to switch it on. IMPORTANT! Welding parameters that have been set on a control panel for a system component (TR 2000 and TR 3000) may not be changed on the control panel of the wire-feed unit under certain circumstances.

  • Page 74: Corrections During Welding

    Corrections dur- To obtain the best possible welding results, the arc-force dynamic parameter will some- ing welding times need to be adjusted. Press the "Parameter selection" button to select the arc-force dynamic parameter Use the adjusting dial to set the desired arc-force dynamic value The welding parameter value is shown in the digital display located above it.

  • Page 75: Saving And Retrieving Operating Points

    Saving and retrieving operating points General The "Save" buttons allow up to 5 operating points to be saved. Every operating point matches the settings on the control panel. IMPORTANT! Setup parameters are not saved at this time. Saving operating Press and hold one of the "Save" buttons to save the current settings on the control points panel, e.g.: The left indicator displays "Pro"...
  • Page 76 Number 3 Number 4 Number 5...

  • Page 77: Setup Settings

    Setup settings...

  • Page 79: Setup Menu

    Setup menu General remarks The Setup menu provides simple access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the pa- rameters to suit the various job settings. Setup menu - Setting the setup parameters is described here with reference to the "MIG/MAG welding"...
  • Page 80 Press the "Process" button Release the "Mode" and "Process" buttons The control panel is now in the setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed. Changing welding parameters Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the required setup parameter Use the "Parameter selection"...

  • Page 81: Setup Parameters For Mig/Mag Standard Manual Welding

    Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, wire- for MIG/MAG feed unit, welding program, etc. standard manual Gas pre-flow time welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.5 Gas post-flow time Unit: s Setting range: 0 - 9.9...
  • Page 82 Factory setting: Off NOTE! The "Ignition time-out" function (ito) is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the preset wire length, particularly when the wire is being fed at fast wire feed speeds. The "Ignition time-out"...

  • Page 83: Setup Parameters For Mig/Mag Standard Synergic Welding

    Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, wire- for MIG/MAG feed unit, welding program, etc. standard syner- Gas pre-flow time gic welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9...

  • Page 84: Setup Parameters For Mma Welding

    The "Ignition time-out" function (ito) is explained in the "Special functions and options" sec- tion. Spot time - spot / stitch welding time Unit: s Setting range: OFF, 0.1 - 5 Factory setting: OFF Spot break - stitch pause time Unit: s Setting range: OFF, 0.1 - 10 (in 0.1 s increments) Factory setting: OFF...

  • Page 85: Welding Parameters For "Special 4-Step Mode" In The Mode Setup Menu

    Welding parame- I (current) - Starting: Starting current ters for "Special Unit: % (of welding current) 4-step mode" in Setting range: 0 - 200 the Mode setup Factory setting: 100 menu Slope: 0 - 9.9 s Unit: s Setting range: 0 - 9.9 Factory setting: 0 I (current) - End: Final current Unit: % of welding current...

  • Page 86: Setup Menu - Level 2

    Setup menu - Level 2 Level 2 setup Accessing the setup menu menu - manual control panel 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 - the last setup parameter that was selected is displayed.
  • Page 87 Press the "Process" button Release the "Mode" and "Process" buttons The control panel is now in the setup menu - the last setup parameter that was selected is displayed. Selecting the "2nd" parameter Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the "2nd"...

  • Page 88: Welding Parameters For Mig/Mag Welding In The Setup Menu Level 2

    Welding parame- Cooling unit control ters for MIG/MAG welding in the Unit: - Setup menu level Setting range: Aut, On, Off Factory setting: Aut Aut: The cooling unit cuts out after a 2-minute welding off-time. IMPORTANT! If the coolant temperature and flow monitoring options have been installed in the cooling unit, the cooling unit cuts out as soon as the return-flow temperature drops below 50°C, but at the earliest after a 2-minute welding off- time.

  • Page 89: Parameters For Manual Metal Arc (Mma) Welding In The Setup Menu Level 2

    Permanent Feeder Speed - wire feed speed is permanently displayed Unit: mm (in.) Setting range: ON / OFF Factory setting: OFF If the setting is "ON", the wire feed speed (m/min) is permanently displayed on the manual control panel instead of the welding current (A). In this case the hold value for the welding current (A) is deactivated.

  • Page 90: Measuring Welding Circuit Resistance R

    Measuring welding circuit resistance r General Measuring the welding circuit resistance r makes it possible to have a constant welding re- sult at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack.

  • Page 91: Displaying Welding Circuit Inductivity L

    Displaying welding circuit inductivity L General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result. Displaying weld- The setup parameter "L"...

  • Page 93: Troubleshooting And Maintenance

    Troubleshooting and maintenance...

  • Page 95: Troubleshooting

    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.
  • Page 96 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:...
  • Page 97 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:...

  • Page 98: Displayed Service Codes

    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.
  • Page 99 ELn | 8 Cause: The connected wire-feed unit is not supported Remedy: Connect supported wire-feed unit ELn | 12 Cause: Different control panels for selecting materials are in the system Remedy: Connect similar control panels to select materials ELn | 13 Cause: Invalid change of welding process during welding Remedy:...
  • Page 100 E-Stop Cause: "External stop" has tripped Remedy: Remedy the event that triggered the external stop -St | oP- Cause: At the robot interface the flag was not deleted by the robot Remedy: Delete the signal robot ready at the robot interface PHA | SE Cause: Phase failure...
  • Page 101 to1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature on the booster located in the power source Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on to2 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the secondary circuit of the power source...
  • Page 102 tu1 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the booster located in the power source Remedy: Place power source in a heated room and allow it to warm up tu2 | xxx Remark: xxx stands for a temperature value Cause: Undertemperature in the power source secondary circuit Remedy:...
  • Page 103 no | Prg Cause: No preconfigured program has been selected Remedy: Select a configured program no | IGn Cause: "Ignition time out" function is active; no current started flowing before the length of wire specified in the set-up menu had been fed. The power source safety cut-out has tripped.

  • Page 104: Care, Maintenance And Disposal

    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 weld- ing system remains in a usable condition for many years. Safety WARNING! An electric shock can be fatal.

  • Page 105: Technical Data And Settings Tables

    Technical data and settings tables...

  • Page 107: Technical Data

    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. Weight of VR 5000 Yard 18 kg 39.68 Ib. * D.C. = Duty cycle VR 5000 noSpool Supply voltage...
  • Page 108 Wire diameter 0.8 - 1.6 mm 0.03 - 0.06 in. Protection IP 20 Dimensions l x w x h 311 x 248 x 242 mm 12.25 x 9.76 x 9.54 in. Weight 6 kg 13.23 Ib. * D.C. = Duty cycle...

  • Page 109: Manual Control Panel Settings Tables

    Manual control panel settings tables Settings tables Shielding gas: Argon + CO Material: G3 Si 1 Wire diameter: 0.8 mm (.03 in.) Ignition current: 400 A Sheet thickness Wire feed speed Welding voltage Dynamic 0.8 mm (.03 in.) 2.1 m/min (82.68 ipm) 13.7 V 1 mm (.04 in.) 2.8 m/min (110.24 ipm)
  • Page 110 Sheet thickness Wire feed speed Welding voltage Dynamic 0.8 mm (.03 in.) 1.6 m/min (62.99 ipm) 14.3 V 1 mm (.04 in.) 2 m/min (78.74 ipm) 14.5 V 1.3 mm (.05 in.) 2.5 m/min (98.43 ipm) 14.6 V 1.5 mm (.06 in.) 3.1 m/min (122.05 ipm) 15.9 V 2 mm (.08 in.)
  • Page 111 Sheet thickness Wire feed speed Welding voltage Dynamic 4 mm (.16 in.) 3.8 m/min (149.61 ipm) 17.8 V 5 mm (.2 in.) 4.3 m/min (169.29 ipm) 18.6 V 6 mm (.24 in.) 4.8 m/min (188.98 ipm) 21.5 V 8 mm (.31 in.) 5.5 m/min (216.54 ipm) 26 V 10 mm (.39 in.)
  • Page 112 Sheet thickness Wire feed speed Welding voltage Dynamic 8 mm (.31 in.) 20 m/min (787.40 ipm) 27 V 10 mm (.39 in.) 22 m/min (866.14 ipm) 28.5 V 12 mm (.47 in.) 25 m/min (984.25 ipm) 31.5 V Shielding gas: CO Material: G3 Si 1 Wire diameter: 0.9 mm (.035 in.) Ignition current: 450 A...
  • Page 113 Sheet thickness Wire feed speed Welding voltage Dynamic 0.8 mm (.03 in.) 1 m/min (39.37 ipm) 17.5 V 1 mm (.04 in.) 1.5 m/min (59.06 ipm) 18.0 V 2 mm (.08 in.) 2 m/min (78.74 ipm) 18.8 V 3 mm (.12 in.) 3 m/min (118.11 ipm) 19.3 V 4 mm (.16 in.)
  • Page 114 Sheet thickness Wire feed speed Welding voltage Dynamic 20 mm (.79 in.) 7.1 m/min (279.53 ipm) 33 V 25 mm (.98 in.) 9 m/min (354.33 ipm) 40 V...

  • Page 115: Welding Program Tables

    Welding program tables TransSteel 3500 Welding program database: Euro welding pro- TransSteel 3500 Euro Pos. gram tables VAT ID 3431 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘...

  • Page 116: Transsteel 5000 Euro Welding Program Tables

    TransSteel 5000 Welding program database: Euro welding pro- TransSteel 5000 Euro Pos. gram tables VAT ID 2546 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘...

  • Page 117: Transsteel 3500 Us Welding Program Tables

    TransSteel 3500 Welding program database: US welding pro- TransSteel 3500 US Pos. gram tables VAT ID 3431 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘...

  • Page 118: Transsteel 5000 Us Welding Program Tables

    TransSteel 5000 Welding program database: US welding pro- TransSteel 5000 US Pos. gram tables VAT ID 2539 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘...

  • Page 119: Transsteel 3500 Yard Welding Program Tables

    TransSteel 3500 Welding program database: Yard welding pro- TransSteel 3500 Yard Pos. gram tables VAT ID 2544 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘...

  • Page 120: Transsteel 5000 Yard Welding Program Tables

    TransSteel 5000 Welding program database: Yard welding pro- TransSteel 5000 US Pos. gram tables VAT ID 2546 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘...

  • Page 121: Quick Reference

    Quick reference...

  • Page 123: Appendix

    Appendix...

  • Page 124: Spare Parts List: Vr 5000

    4,049,012,808 VR 5000 Yard Basic 4R/G/FSC Synergic 4,049,018 VR 5000 Yard Basic 4R/G/E Synergic 4,049,018,001 VR 5000 Yard Basic 4R/W/FSC Synergic 4,049,019 VR 5000 Yard Basic 4R/W/E Synergic 4,049,019,001 VR 5000 4R/G/TW Syn nS 4,049,043,808 VR 5000 4R/G/FSC Syn nS...
  • Page 126 Connectors FSC = Fronius system connection TW = Tweco connection E = Euro connection F++ = Fronius connection...
  • Page 127 Motor Plate Alu 4R s t o r t o r...
  • Page 132 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, 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...

This manual is also suitable for:

Vr 5000 nospool

Table of Contents

Save PDF