Table of Contents
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Summary of Contents for Fronius VR 5000rob
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions VR 5000rob Wire-feed unit 42,0426,0085,EN 019-15052020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
- 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.
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Page 5: Table Of Contents
Insulated routing of wire electrode to wire-feed unit ................Feeding in the wire electrode........................ Setting the contact pressure ......................... Care, maintenance and disposal ....................... General ..............................Safety..............................Every start-up............................Every 6 months ............................. Preparing the VR 5000rob for replacing the inner liners on the welding torch........Disposal .............................. - Page 6 Troubleshooting ............................General ..............................Safety..............................Fault diagnosis............................Technical data............................VR 5000rob............................
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Page 7: Safety Rules
Safety rules Explanation of DANGER! safety notices 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. ►... -
Page 8: Environmental Conditions
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. -
Page 9: Protecting Yourself And Others
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 sup- ply company. -
Page 10: Danger From Flying Sparks
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. -
Page 11: Meandering Welding Currents
Make sure that you and others are protected with an adequately insulated, dry base or cov- er 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 dimen- sioned. -
Page 12: Emc Device Classifications
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 elec- trode 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. -
Page 13: Emf Measures
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 de- vice 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... -
Page 14: Requirement For The Shielding Gas
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. -
Page 15: Safety Measures At The Installation Location And During Transport
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox- ygen 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. -
Page 16: Commissioning, Maintenance And Repair
Only the manufacturer's original coolant is suitable for use with our devices due to its prop- erties (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. -
Page 17: Safety Symbols
(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 18: General Information
General information 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. -
Page 19: Standard Overview
Cooling unit e.g. FK 5000 with optional flow watchdog Power source e.g. TransSteel 3500 Interconnecting hosepack Power source - robot interface Wire-feed unit mount VR 5000rob wire-feed unit Robacta W/CB-PAP or G/CB hosepack Robacta PAP CrashBox Robacta robot welding torch... -
Page 20: Intended Purpose
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. -
Page 21: Options
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. -
Page 22: Controls, Connections And Mechanical Components
► Read and understand all the Operating Instructions for the system components, espe- cially the safety rules. Mechanical com- ponents VR 5000rob Standard VR 5000rob PAP Function Feeder inching button For threading the wire electrode into the torch hosepack with no accompanying flow of gas or current. -
Page 23: Vr 5000Rob Pap Connections
VR 5000rob PAP connections VR 5000rob PAP - front VR 5000rob PAP - rear Function Welding torch connection Shielding gas connection Enhanced LocalNet connection For enhanced LocalNet with lines for motor supply and motor control Blanking cover For optional gas pressure sensor or external CAT signal... - Page 24 Function Welding torch connection Blanking cover Blanking cover For optional external CAT Blanking cover For optional gas pressure sensor Enhanced LocalNet connection For enhanced LocalNet with lines for motor supply and motor control Shielding gas connection Blanking cover For optional blow-off...
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Page 25: Fitting The Wire-Feed Unit
Fitting the wire-feed unit Safety 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. -
Page 27: 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. USA wire-feed In the USA, all wire-feed units are delivered without feed rollers. -
Page 29: Feeding In The Wire Electrode
Feeding in the wire electrode Insulated routing WARNING! of wire electrode to wire-feed unit 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 rout- ed from the welding wire drum, large wire-feed unit spool or wirespool to the wire-feed unit (e.g. -
Page 30: Setting The Contact Pressure
CAUTION! 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 ... - Page 31 Contact pressure U-groove roll- standard values Steel 4 - 5 CrNi 4 - 5 Tubular cored electrodes 2 - 3...
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Page 32: 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 33: Disposal
Disposal Dispose of in accordance with the applicable national and local regulations. - Page 34 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 35 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 36 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 37 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 38 Technical data VR 5000rob Supply voltage for motor 55 V Supply voltage for control 24 V Current input for control Current input for motor 1.2 A Welding current at 10 min/40 °C (104 °F) 40 % d.c.* 500 A 60 % d.c.* 450 A 100 % d.c.* 360 A...
- Page 40 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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