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Summary of Contents for Fronius VR 5000 Case
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions VR 5000 Case VR 5000 Case D300 Wire-feed unit 42,0426,0150,EN 026-12052020 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
Application area ............................ Options..............................Warning notices on the device......................Description of Warning Notices on the Device..................Transporting the VR 5000 Case / VR 5000 Case D300 by crane............Control elements and connections Description of the control panels........................ General information .......................... - Page 6 Overview of connections for the welding torch ..................Front of wire-feed unit ........................... Wire-feed unit side ..........................Installation and commissioning Before commissioning..........................Safety..............................Intended purpose ..........................Setup regulations ..........................Connecting wire-feed unit to power source....................General information ..........................Connecting the wire-feed unit to the power source................Connecting the welding torch........................
- Page 7 Every 6 months ............................. 107 Disposal ..............................107 Technical data and settings tables Technical data............................111 VR 5000 Case............................111 VR 5000 Case D300 ..........................112 HP 70i ..............................112 HP 95i ..............................112 Manual control panel settings tables......................113 Settings tables ............................113 Appendix Quick reference............................
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Page 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: Requirement For The Shielding Gas
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). -
Page 17: Danger From Escaping Shielding Gas
Danger from es- Risk of suffocation from the uncontrolled escape of shielding gas caping shielding 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 18: Commissioning, Maintenance And Repair
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. 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. -
Page 19: 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 21: General Information
General information... -
Page 23: General
Application area The VR 5000 Case and VR 5000 Case D300 wire-feed units are suitable for manual shield- ing gas welding tasks in steel applications in conjunction with all standard shielding gases. The VR 5000 Case /VR 5000 Case D300 is primarily used for the following applications:... - Page 24 Attention: Les pièces peuvent être à la tension de soudage Warning notices on the device, e.g. on VR 5000 Case D300 Do not dispose of used devices with domestic waste. Dispose of them accord- ing to the safety rules.
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Page 25: 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 26: Transporting The Vr 5000 Case / Vr 5000 Case D300 By Crane
Do not remove or paint over (cover) the label. identifying number to order label from manufacturer Transporting the The VR 5000 Case and VR 5000 Case D300 wire-feed units can be transported by crane VR 5000 Case / using the handle. - Page 27 ► Always attach the lifting tackle to both ends of the handle according to the diagram be- low. Note the following when transporting the VR 5000 Case / VR 5000 Case D300 by crane: feed out the wire electrode, remove the wirespool...
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Page 29: Control Elements And Connections
Control elements and connections... -
Page 31: 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 32: 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 33: 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 34: 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 35 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-...
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Page 36: 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 37 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.
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Page 38: 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 39: 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 40: 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 41 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-...
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Page 42: Connections And Mechanical Components
Appendix. welding torch Front of wire-feed unit VR 5000 Case VR 5000 Case D300 Welding torch connection for connecting the welding torch Coolant flow connection (blue) - option when the optional water connection is installed, otherwise blanking cover... -
Page 43: Wire-Feed Unit Side
Shielding gas connection Coolant flow connection (blue) - option when the optional water connection is installed, otherwise blanking cover Blanking cover position for VR 5000 Case gas flow meter option Blanking cover position for VR 5000 Case power switch option... - Page 44 Blanking cover position for VR 5000 Case external start signal option Blanking cover position for VR 5000 Case current socket option (10) Wirespool holder with brake for holding standard wirespools VR 5000 Case: max. diameter 200 mm (7.87 in.), max. weight 5 kg (11.02 Ibs.) VR 5000 Case D300: max.
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Page 45: Installation And Commissioning
Installation and commissioning... -
Page 47: Before Commissioning
60° to the vertical The VR 5000 Case / VR 5000 Case D300 can be set up and operated outdoors in accord- ance with protection class IP 23. Avoid direct wetting (e.g. from rain). -
Page 48: Connecting Wire-Feed Unit To Power Source
Do not carry out the steps described here until you have read and completely understood all the operating instructions. NOTE! When connecting the interconnecting hosepack, check that ► all connections are connected properly ► all cables, leads and hosepacks are undamaged and correctly insulated VR 5000 Case: VR 5000 Case D300:... - Page 49 IMPORTANT! To prevent wear and tear, leave some slack when connecting the cables.
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Page 50: Connecting The Welding Torch
► all connections are connected properly ► all cables, leads and hosepacks are undamaged and correctly insulated. Connecting MIG/ VR 5000 Case VR 5000 Case D300 MAG manual welding torches when the optional water connection and the water-cooled welding torch are fitted... -
Page 51: 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 52: Inserting The Wirespool, Inserting The Basket-Type Spool
Inserting the wirespool, inserting the basket-type spool Safety WARNING! An electric shock can be fatal. Before starting the work described below: ► turn the power source mains switch to the "O" position ► disconnect the power source from the mains ►... -
Page 53: Inserting A Wirespool: D300 Device
Inserting a wire- spool: D300 de- vice Inserting a bas- CAUTION! ket-type spool: D300 device Risk of injury and material damage from falling basket-type spool. Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways. -
Page 54: 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 55: Setting The Contact Pressure
If you release the "Wire threading" button and press it again before one second has elapsed, the sequence starts again from the beginning. This makes it possible to continu- ously position the wire at a low wire feed speed of 1 m/min or 39.37 ipm where necessary. If there is no "Wire threading"/"Gas-test"... - Page 56 Contact pressure U-slot rollers standard values Steel 4 - 5 CrNi 4 - 5 Tubular cored electrodes 2 -3...
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Page 57: Adjust The Brake
Adjust the brake General CAUTION! Risk of injury and material damage from the welding current and accidental ignition of an arc. Before starting work, disconnect the ground earth connection between the welding system and the workpiece. CAUTION! Risk of injury and damage from wire electrode emerging. While working: ►... -
Page 58: Setting The Brake: D300 Device
STOP Setting the brake: D300 device STOP STOP... -
Page 59: Brake Setup: D200 Device
Brake setup: WARNING! D200 device 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. This illustration is for information purposes only. -
Page 60: Start-Up
Start-up 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 Requirements When commissioning the wire-feed unit, the following requirements must be met: Wire-feed unit connected to the power source using the interconnecting hosepack... -
Page 61: Welding
Welding... -
Page 63: Mig/Mag Modes
MIG/MAG modes 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 For details of the meaning, settings, setting range and units of the available welding pa- rameters (e.g. -
Page 64: 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 65: 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 66: 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 67: 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 68: 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 69 Welding parameter values are shown in the indicators located above them. Arc length correction for correcting the arc length - shorter arc length 0 neutral arc length + longer arc length Dynamic for influencing the short circuit dynamic at the instant of particle transfer - harder, more stable arc 0 neutral arc + soft, low-spatter arc...
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Page 70: 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 71: 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 72 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.
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Page 73: 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 74: 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 75: Adjustments While Welding - Manual Control Panel
Press the "Process" button to select the MMA welding process: The welding voltage is connected to the welding socket with a 3-second time lag. 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 76: 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 in the digital display 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. -
Page 77: 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 78: Retrieving Operating Points On The Up/Down Welding Torch
After a short time, the left indicator switches to the original value, e.g.: Keep the "Save" button held down The left display shows "CLr". After a while, both displays show "---" Release the "Save" button Retrieving operat- One of the "Save" buttons on the control panel must be pressed to retrieve the saved set- ing points on the tings using the up/down welding torch. - Page 79 Number 4 Number 5...
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Page 81: Setup Settings
Setup settings... -
Page 83: 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 84 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"...
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Page 85: 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 86 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"...
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Page 87: 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 88: 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 89: 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 90: 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 91 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"...
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Page 92: 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 93 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.
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Page 94: 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 95 Fit the gas nozzle back onto the welding torch...
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Page 96: 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 97: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 99: 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 100 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 101 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:...
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Page 102: 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 103 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: During welding do not carry out any illegal change of the welding process, re- set error message by pressing any button Err | PE Cause:...
- Page 104 to0 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on to1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature on the booster located in the power source...
- Page 105 tu0 | xxx Remark: xxx stands for a temperature value Cause: Undertemperature in the power source primary circuit Remedy: Place power source in a heated room and allow to warm up tu1 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the booster located in the power source Remedy:...
- Page 106 hot | H2O Cause: The coolant temperature is too high Remedy: Allow cooling unit and cooling circuit to cool down, until "hot | H2O" is no longer displayed. Open the cooling unit and clean the cooler, check fan is working properly. Robot interface or field bus coupler: before resuming weld- ing, set the "Source error reset"...
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Page 107: 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 109: Technical Data And Settings Tables
Technical data and settings tables... -
Page 111: Technical Data
Technical data VR 5000 Case Supply voltage 24 V Current input for control Current input for motor 2.5 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 112: Vr 5000 Case D300
VR 5000 Case Supply voltage 24 V D300 Current input for control Current input for motor 2.5 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 113: 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 114 Shielding gas: Argon + CO Material: G3 Si 1 Wire diameter: 1.0 mm (.04 in.) Ignition current: 500 A 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.)
- Page 115 Shielding gas: Argon + CO Material: G3 Si 1 Wire diameter: 1.4 mm (.06 in.) Ignition current: 650 A Sheet thickness Wire feed speed Welding voltage Dynamic 1 mm (.04 in.) 1.2 m/min (47.24 ipm) 13.7 V 1.5 mm (.06 in.) 1.7 m/min (66.93 ipm) 15 V 2 mm (.08 in.)
- Page 116 Shielding gas: CO Material: G3 Si 1 Wire diameter: 0.8 mm (.3 in.) Ignition current: 400 A Sheet thickness Wire feed speed Welding voltage Dynamic 0.8 mm (.03 in.) 1.5 m/min (59.06 ipm) 16 V 1 mm (.04 in.) 3 m/min (118.11 ipm) 16.8 V 1.5 mm (.06 in.) 5 m/min (196.85 ipm)
- Page 117 Shielding gas: CO Material: G3 Si 1 Wire diameter: 1.0 mm (.04 in.) Ignition current: 500 A Sheet thickness Wire feed speed Welding voltage Dynamic 0.8 mm (.03 in.) 1.6 m/min (62.99 ipm) 16.7 V 1 mm (.04 in.) 2 m/min (78.74 ipm) 17.6 V 1.3 mm (.05 in.) 2.6 m/min (102.36 ipm)
- Page 118 Shielding gas: CO Material: G3 Si 1 Wire diameter: 1.4 mm (.06 in.) Ignition current: 650 A Sheet thickness Wire feed speed Welding voltage Dynamic 1 mm (.04 in.) 1.4 m/min (55.12 ipm) 18.2 V 1.5 mm (.06 in.) 1.7 m/min (66.93 ipm) 19.1 V 2 mm (.08 in.) 2.2 m/min (86.61 ipm)
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Page 119: Appendix
Appendix... -
Page 120: Quick Reference
Quick reference... - Page 124 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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