Fronius VR 5000 Remote Operating Instructions Manual
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Fronius VR 5000 Remote Operating Instructions Manual

Fronius VR 5000 Remote Operating Instructions Manual

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Perfect Welding
/ Perfect Charging /
VR 5000 Remote
42,0426,0292,EN 003-29042020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
Wire-feed unit
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  • Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions VR 5000 Remote Wire-feed unit 42,0426,0292,EN 003-29042020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Warning notices on the device......................Description of Warning Notices on the Device..................Wirefeeder options..........................Connections, switches and mechanical components ................VR 5000 Remote - front of wirefeeder ....................Rear of wirefeeder ..........................Side of wirefeeder ..........................Underside of wirefeeder........................Start-up ..............................
  • Page 4 Accessing the Setup menu ........................Setup parameters ..........................Service parameters..........................Troubleshooting ............................General ..............................Safety..............................Fault diagnosis............................Care, maintenance and disposal ....................... General ..............................Safety..............................At every start-up............................ Every 6 months ............................. Disposal ..............................Technical data............................VR 5000 Remote ..........................

  • Page 5: 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 6: 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 7: 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 8: 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 9: 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 10: 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 11: 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 12: 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 13: 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 14: 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 15: 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 16: General

    General Device concept The VR 5000 Remote is the standard wire- feeder for the following power sources: TSt 3500 / 5000 Syn TSt 4000 / 5000 Pulse The VR 5000 Remote is designed for wire- spools with a max. diameter of 300 mm (11.81 in.).

  • Page 17: Warning Notices On The Device

    They warn against incorrect op- eration, as this may result in serious injury and damage. 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...

  • Page 18: 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 19 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 20: Wirefeeder Options

    Wirefeeder op- The following options are available for the VR 5000 Remote wirefeeder: tions Synergic control panel Pulse control panel Wire threading/gas-test button I-kit water cooling system I-kit remote control socket I-kit front current socket I-kit crane attachment I-kit side-mounted aluminium runner...

  • Page 21: Connections, Switches And Mechanical Components

    Connections, switches and mechanical components VR 5000 Remote - Welding torch connection front of wirefeed- for connecting the welding torch Coolant flow connection (blue) - option when the optional water connection is installed, otherwise blanking co- Coolant return connection (red) -...

  • Page 22: Side Of Wirefeeder

    Side of wirefeeder Function Wirespool holder with brake for holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a max. weight of up to 19 kg (41.89 lbs.) Program selector (option) 4-roller drive Optional "Wire threading / Gas-test" button Push button downwards: For threading the wire electrode into the torch hosepack with no accompanying flow of gas or current.

  • Page 23: Underside Of Wirefeeder

    Underside of Function wirefeeder Socket for swivel pin For placing the wirefeeder on the swivel pin in the swivel pin holder...

  • Page 24: Start-Up

    Start-up General Commissioning a power source is described by reference to a manual water-cooled MIG/ MAG application. Placing the wire- CAUTION! feeder on the power source Risk of injury and material damage from falling wirefeeder. ► Make sure that the wirefeeeder is located securely on the swivel pin and that the de- vices, upright consoles and trolleys are stable.

  • Page 25: Connecting A Mig/Mag Welding Torch

    Connecting a MIG/MAG welding * when the optional water connection and torch the water-cooled welding torch are fitted Inserting/replac- CAUTION! ing feed rollers Danger from feed roller holders flying upwards. This can result in severe injuries. ► When unlocking the clamping lever, keep fingers away from the area to the left and right of the lever.

  • Page 26: Inserting The Wirespool

    Inserting the wire- CAUTION! spool Risk of injury due to springiness of spooled wire electrode. ► While inserting the wirespool, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of injury from falling wirespool. ►...

  • Page 27: Inserting The Basket-Type Spool

    Inserting the bas- CAUTION! ket-type spool Risk of injury due to springiness of spooled wire electrode. ► When inserting the basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of injury from falling basket-type spool.

  • Page 28: Feeding In The Wire Electrode

    CAUTION! 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. Feeding in the CAUTION! wire electrode Risk of injury due to springiness of spooled wire electrode.
  • Page 29 CAUTION! Risk of injury from emerging wire electrode. ► When pressing the wire threading button or the torch trigger, 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 se- quences are possible when the wire threading button is pressed and held down.
  • Page 30 CAUTION! Risk of injury and damage from electric shock and from the wire electrode emerging from the torch. When pressing the torch trigger: ► Keep the welding torch away from your face and body ► Wear suitable protective goggles ► Do not point the welding torch at people ►...

  • Page 31: Setting The Contact Pressure

    Setting the con- CAUTION! tact pressure Risk from excessive contact pressure. This can result in severe damage to property and poor weld properties. ► Set the contact pressure in such a way that the wire electrode is not deformed, but is nevertheless transported properly.

  • Page 32: Design Of The Brake

    STOP Design of the brake WARNING! Danger from incorrect installation. This can result in severe personal injury and damage to property. ► Do not dismantle the brake. ► Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only.

  • Page 33: Synergic Control Panel (Option)

    Synergic control panel (option) General IMPORTANT! The Synergic control panel can only be operated in conjunction with the fol- lowing power sources: TransSteel 4000 Syn TransSteel 5000 Syn 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.
  • Page 34 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. The actual value is displayed during weld- ing.
  • Page 35 Adjusting dial (left) For changing the sheet thickness, welding current and wire speed welding param- eters For selecting welding parameters in the Setup menu ***) "Process" button For selecting the welding process MANUAL - MIG/MAG standard manual welding SYNERGIC - MIG/MAG standard synergic welding STICK - Manual metal arc (MMA) welding "Mode"...

  • Page 36: Synergic B Control Panel

    Synergic B con- "Material" button trol panel For selecting the filler metal to be used. The SP parameter is reser- ved for additional filler metals. When a material is selected, the LED behind the relevant filler metal lights up. "Wire diameter" button For selecting the wire diameter to be used.

  • Page 37: Accessing The Setup Menu

    Accessing the Accessing the Setup menu Setup menu Use the "Process" button to select the required welding process 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 of the chosen welding process - the last Setup parameter that was selected is displayed.

  • Page 38: Setup Parameters

    Exiting the Level 2 Setup menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons Exiting the Setup menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons Setup parameters See TransSteel 3500-5000 Syn instruction manual (42,0426,0258,XX)
  • Page 39 Available parameters Explanation Example: Firmware version 1.00 | 4.21 Example: Welding program configuration 2 | 491 Example: Number of the currently selected welding 2 | 290 program Example: Motor current for wire drive in A iFd | 0.0 The value changes as soon as the motor is running.

  • Page 40: Pulse Control Panel (Option)

    Pulse control panel (option) General IMPORTANT! The Pulse control panel can only be operated in conjunction with the follow- ing power sources: TransSteel 4000 Pulse TransSteel 5000 Pulse The power source uses the Pulse control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters.
  • Page 41 Real Energy Input For displaying the energy applied during the welding operation. The Real Energy Input display must be activated in level 2 of the Setup menu - EnE parameter. The value continuously rises during welding in line with the permanent- ly increasing energy yield.
  • Page 42 ***) "Process" button For selecting the welding process MIG/MAG standard manual welding MIG/MAG standard synergic welding / MIG/MAG pulse synergic welding MMA welding "Mode" button For selecting the operating mode 2-step mode 4-step mode Spot welding / Stitch welding / Special 4-step mode "Save"...

  • Page 43: Setting Mig/Mag Pulse Synergic Welding And Spot/Stitch Welding

    The synergic function means that if one of these parameters is selected during MIG/MAG standard synergic welding or MIG/MAG pulse synergic welding, then all other parameters including the welding voltage parameter are automatically set as well. The Real Energy Input display must be activated in level 2 of the Setup menu – EnE parameter.

  • Page 44: Pulse B Control Panel

    Pulse B control "Material" button panel For selecting the filler metal to be used. The SP parameter is reser- ved for additional filler metals. When a material is selected, the LED behind the relevant filler metal lights up. "Wire diameter" button For selecting the wire diameter to be used.

  • Page 45: Accessing The Setup Menu

    Accessing the Accessing the Setup menu Setup menu Use the "Process" button to select the required welding process 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 of the chosen welding process - the last Setup parameter that was selected is displayed.

  • Page 46: Setup Parameters

    Exiting the Level 2 Setup menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons Exiting the Setup menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons Setup parameters See TransSteel 4000 / 5000 Pulse Operating Instructions (42,0426,0353,XX)
  • Page 47 Available parameters Explanation Example: Firmware version 1.00 | 4.21 Example: Welding program configuration 2 | 491 Example: Number of the currently selected welding 2 | 290 program Example: Motor current for wire drive in A iFd | 0.0 The value changes as soon as the motor is running.

  • Page 48: 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 49 Power source does not function Mains switch is on, but indicators are not lit up Cause: There is a break in the mains lead; the mains plug is not plugged in Remedy: Check the mains lead, ensure that the mains plug is plugged in Cause: Mains socket or mains plug faulty Remedy:...
  • Page 50 No welding current Mains switch is ON and indicators are lit up Cause: Grounding (earthing) connection is incorrect Remedy: Check the grounding (earthing) connection for correct polarity Cause: There is a break in the power cable in the welding torch Remedy: Replace the welding torch No protective gas shield...
  • Page 51 Welding torch becomes very hot Cause: The specification of the welding torch is inadequate Remedy: Observe the duty cycle and loading limits Cause: Only on water-cooled systems: Inadequate coolant flow Remedy: Check coolant level, coolant flow, for coolant contamination, etc. For further information refer to the cooling unit operating instructions.

  • Page 52: 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 53: Technical Data

    Technical data VR 5000 Remote Supply voltage 24 V Current consumption of control Current consumption of 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 Maximum shielding gas pressure 5 bar / 72.49 psi...
  • Page 56 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E-Mail: sales@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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