VR 5000

VR 5000

GB

Operating Instructions

Spare Parts List

Wirefeeder

42,0426,0080,EN 022009

Dear Reader

Introduction Thank you for choosing Fronius - and congratulations on your new, technically highgrade Fronius product! This instruction manual will help you get to know your new machine. Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you will help to ensure more safety at your product location. And of course, if you treat your product carefully, this definitely helps to prolong its enduring quality and reliability - things which are both essential prerequisites for getting outstanding results.

ud_fr_st_et_00493 012004

Safety rules

DANGER!

WARNING!

CAUTION!

NOTE!

Important!

General remarks

“DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices that may cause property damage.

“NOTE!” indicates a situation which implies a risk of impaired welding result and damage to the equipment.

“Important!” indicates practical hints and other useful special-information. It is no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even closer attention to the contents of the manual!

This equipment has been made in accordance with the state of the art and all recognised safety rules. Nevertheless, incorrect operation or misuse may still lead to danger for

the life and well-being of the operator or of third parties,

the equipment and other tangible assets belonging to the owner/operator,

efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and maintaining the equipment must

be suitably qualified

know about welding and

read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In addition to the instruction manual, copies of both the generally applicable and the local accident prevention and environmental protection rules must be kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

must be kept in a legible condition

must not be damaged, must not be removed

must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are located on the machine, please see the section of your machine’s instruction manual headed “General remarks”.

I ud_fr_st_sv_00467 022009

General remarks

(continued)

Utilisation for intended purpose only

Ambient conditions

Obligations of owner/operator

ud_fr_st_sv_00467 022009

Any malfunctions which might impair machine safety must be eliminated immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

The machine may only be used for jobs as defined by the “Intended purpose”.

The machine may ONLY be used for the welding processes stated on the rating plate.

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.

Utilisation in accordance with the “intended purpose” also comprises

complete reading and following of all the instructions given in this manual

complete reading and following of all the safety instructions and danger warnings

performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

Thawing pipes

Charging batteries/accumulators

Starting engines

The machine is designed to be used in industrial and workshop environments. The manufacturer shall not be liable for any damage resulting from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work results.

Operation or storage of the power source outside the stipulated range is deemed to be “not in accordance with the intended use”. The manufacturer shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:

up to 50 % at 40 °C (104 °F)

up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

The owner/operator undertakes to ensure that the only persons allowed to work with the machine are persons who

are familiar with the basic regulations on workplace safety and accident prevention and who have been instructed in how to operate the machine

have read and understood the sections on “safety rules” and the “warnings“ contained in this manual, and have confirmed as much with their signatures

be trained in such a way that meets with the requirements of the work results

Regular checks must be performed to ensure that personnel are still working in a safety-conscious manner.

II

Obligations of personnel

Mains connection

Protection for yourself and other persons

Before starting work, all persons to be entrusted with carrying out work with

(or on) the machine shall undertake

to observe the basic regulations on workplace safety and accident prevention

to read the sections on “safety rules” and the “warnings” contained in this manual, and to sign to confirm that they have understood these and will comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of injury or damage being caused during their absence.

High-performance devices can affect the quality of the mains power due to their current-input.

This may affect a number of types of device in terms of:

connection restrictions

criteria with regard to maximum permissible mains impedance *)

criteria with regard to minimum short-circuit power requirement *)

*) at the interface with the public mains network see Technical Data

In this case, the plant operator or the person using the device should check whether or not the device is allowed to be connected, where appropriate through discussion with the power supply company.

When welding, you are exposed to many different hazards such as:

flying sparks and hot metal particles

arc radiation which could damage your eyes and skin

harmful electromagnetic fields which may put the lives of cardiac pacemaker users at risk

electrical hazards from mains and welding current

increased exposure to noise

noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable protective clothing with the following characteristics:

flame-retardant

isolating and dry

must cover whole body, be undamaged and in good condition

protective helmet

trousers with no turn-ups

III ud_fr_st_sv_00467 022009

Protection for yourself and other persons

(continued)

Information on noise emission values

Hazards from noxious gases and vapours

“Protective clothing” also includes:

protecting your eyes and face from UV rays, heat and flying sparks with an appropriate safety shield containing appropriate regulation filter glass

wearing a pair of appropriate regulation goggles (with sideguards) behind the safety shield

wearing stout footwear that will also insulate even in wet conditions

protecting your hands by wearing appropriate gloves (electrically insulating, heat-proof)

To lessen your exposure to noise and to protect your hearing against injury, wear ear-protectors!

Keep other people - especially children - well away from the equipment and the welding operation while this is in progress. If there are still any other persons nearby during welding, you must

draw their attention to all the dangers (risk of being dazzled by the arc or injured by flying sparks, harmful welding fumes, high noise immission levels, possible hazards from mains or welding current ...)

provide them with suitable protective equipment and/or

erect suitable protective partitions or curtains.

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW) when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to

EN 60974-1.

It is not possible to provide a workplace-related emission value during welding

(or cutting) as this is influenced by both the process and the environment. All manner of different welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.

The fumes given off during welding contain gases and vapors that are harmful to health.

Welding fumes contain substances which may cause birth defects and cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.

Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an independent air supply.

If you are not sure whether your fume-extraction system is sufficiently powerful, compare the measured pollutant emission values with the permitted threshold limit values.

ud_fr_st_sv_00467 022009

IV

Hazards from noxious gases and vapours

(continued)

Hazards from flying sparks

Hazards from mains and welding current

The harmfulness of the welding fumes will depend on e.g. the following components:

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc radiation.

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from the arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through small cracks and openings. Take suitable measures here to ensure that there is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion, or in enclosed tanks, barrels or pipes, unless these latter have been prepared for welding in accordance with the relevant national and international standards.

Welding must NEVER be performed on containers that have had gases, fuels, mineral oils etc. stored in them. Even small traces of these substances left in the containers are a major explosion hazard.

An electric shock is potentially life-threatening, and can be fatal.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or else use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a dry base or cover that provides adequate insulation against the ground/frame potential. The base or cover must completely cover the entire area between your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly insulated and adequately dimensioned. Immediately replace any loose connections, scorched, damaged or underdimensioned cables or other leads.

V ud_fr_st_sv_00467 022009

Hazards from mains and welding current

(continued)

Stray welding currents

ud_fr_st_sv_00467 022009

Do not loop any cables or other leads around your body or any part of your body.

Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.

Twice the open-circuit voltage of one single welding machine may occur between the welding electrodes of two welding machines. Touching the potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a qualified electrician to ensure that the PE (protective earth) conductor is functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and plugged into a power outlet socket without a protective-conductor contact, this counts as gross negligence and the manufacturer shall not be liable for any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is sufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody inadvertently plugging the machine back into the mains and switching it back on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second person on hand to immediately switch off the machine at the main switch in an emergency.

If the following instructions are ignored, stray welding currents may occur.

These can cause:

fires

overheating of components that are connected to the workpiece

destruction of PE conductors

damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way that it is sufficiently insulated from the floor.

VI

Stray welding currents

(continued)

EMC device classifications

EMC measures

When using current supply distributors, twin head wire feeder fixtures etc., please note the following: The electrode on the unused welding torch/welding tongs is also current carrying. Please ensure that there is sufficient insulating storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

Devices with emission class A:

are only designed for use in an industrial setting

can cause conducted and emitted interference in other areas.

Devices with emission class B:

satisfy the emissions criteria for residential and industrial areas. This also applies to residential areas in which power is supplied from the public low-voltage grid.

EMC device classification as per the rating plate or technical specifications

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g.

when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).

If this is the case, then the operator is obliged to take appropriate action to rectify the situation.

Examine and evaluate any possible electromagnetic problems that may occur on equipment in the vicinity, and the degree of immunity of this equipment, in accordance with national and international regulations:

safety features

mains, signal and data-transmission leads

IT and telecoms equipment

measurement and calibration devices

Ancillary measures for preventing EMC problems: a) Mains supply

If electromagnetic interference still occurs, despite the fact that the mains connection is in accordance with the regulations, take additional measures (e.g. use a suitable mains filter).

b) Welding cables

Keep these as short as possible

Arrange them so that they run close together (to prevent EMI problems as well)

Lay them well away from other leads.

c) Equipotential bonding d) Workpiece grounding (earthing)

where necessary, run the connection to ground (earth) via suitable capacitors.

e) Shielding, where necessary

Shield other equipment in the vicinity

Shield the entire welding installation.

VII ud_fr_st_sv_00467 022009

EMI Precautions

Particular danger spots

ud_fr_st_sv_00467 022009

Electromagnetic fields may cause as yet unknown damage to health.

Effects on the health of persons in the vicinity, e.g. users of heart pacemakers and hearing aids

Users of heart pacemakers must take medical advice before going anywhere near welding equipment or welding workplaces

Keep as much space as possible between welding cables and head/body of welder for safety reasons

Do not carrywelding cables and hose pack over shoulder and do not loop around body or or any part of body

Keep your hands, hair, clothing and tools well away from all moving parts, e.g.:

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the wirefeed drive.0

Covers and sideguards may only be opened or removed for as long as is absolutely necessary to carry out maintenance and repair work.

While the machine is in use:

ensure that all the covers are closed and that all the sideguards are properly mounted ...

... and that all covers and sideguards are kept closed.

When the welding wire emerges from the torch, there is a high risk of injury

(the wire may pierce the welder’s hand, injure his face and eyes ...). For this reason, when feeder-inching etc., always hold the torch so that it is pointing away from your body (machines with wirefeeder).

Do not touch the workpiece during and after welding - risk of injury from burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason, continue to wear the regulation protective gear, and to ensure that other persons are suitably protected, when doing post-weld finishing on workpieces.

Allow welding torches - and other items of equipment that are used at high operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observe all relevant national and international regulations.

Power sources for use in spaces with increased electrical danger (e.g.

boilers) must be identified by the (for “safety”) mark.

However, the power source should not be in such rooms.

Risk of scalding from accidental discharge of hot coolant. Before unplugging the connectors for coolant forward flow and return flow, switch off the cooling unit.

VIII

Particular danger spots

(continued)

Danger from shielding-gas cylinders

When hoisting the machines by crane, only use suitable manufacturersupplied lifting devices.

Attach the chains and/or ropes to all the hoisting points provided on the suitable lifting device.

The chains and/or ropes must be at an angle which is as close to the vertical as possible.

Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG units).

When hoisting the wirefeed unit by crane during welding, always use a suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that this strap is ONLY to be used for lifting and carrying the machine by hand.

The carrying strap is NOT suitable for transporting the machine by crane, fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, when using an adapter for the inert gas protection. Seal the adapter thread for the inert gas connection using Teflon tape before assembly.

Shielding-gas cylinders contain pressurized gas and may explode if they are damaged. As shielding-gas cylinders are an integral part of the overall welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed, from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas cylinder.

Use only shielding-gas cylinders that are suitable for the application in question, together with matching, suitable accessories (pressure regulators, hoses and fittings, ...). Only use shielding-gas cylinders and accessories that are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and international rules applying to shielding-gas cylinders and accessories.

IX ud_fr_st_sv_00467 022009

Safety precautions at the installation site and when being transported

Safety precautions in normal operation

ud_fr_st_sv_00467 022009

A machine that topples over can easily kill someone! For this reason, always place the machine on an even, firm floor in such a way that it stands firmly.

An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observe all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m

(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and regional guidelines and accident protection regulations are followed. This applies in particular to guidelines in respect of dangers during transportation and carriage.

Before transportation, completely drain any coolant and dismantle the following components:

- Wire feed

- Wire wound coil

- Gas bottle

Before commissioning and after transportation, a visual check for damage must be carried out. Any damage must be repaired by trained service personnel before commissioning.

Only operate the machine if all of its protective features are fully functional. If any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by your doing so.

At least once a week, check the machine for any damage that may be visible from the outside, and check that the safety features all function correctly.

Always fasten the shielding-gas cylinder firmly, and remove it altogether before hoisting the machine by crane.

Owing to its special properties (in terms of electrical conductivity, frostproofing, materials-compatibility, combustibility etc.), only original coolant of the manufacturer is suitable for use in our machines.

Only use suitable original coolant of the manufacturer.

Do not mix original coolant of the manufacturer with other coolants.

X

Safety precautions in normal operation

(continued)

Preventive and corrective maintenance

Safety inspection

Disposal

If any damage occurs in cases where other coolants have been used, the manufacturer shall not be liable for any such damage, and all warranty claims shall be null and void.

Under certain conditions, the coolant is flammable. Only transport the coolant in closed original containers, and keep it away from sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. A safety data sheet is available from your service centre and on the manufacturer’s homepage.

Before starting welding - while the machine is still cool - check the coolant level.

With parts sourced from other suppliers, there is no certainty that these parts will have been designed and manufactured to cope with the stressing and safety requirements that will be made of them. Use only original spares and wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the relevant part number, as given in the spare parts list. Please also quote the serial number of your machine.

The owner/operator is obliged to have a safety inspection performed on the machine at least once every 12 months.

The manufacturer also recommend the same (12-month) interval for regular calibration of power sources.

A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations

- after any modifications or installations of additional components

- following repairs, care and maintenance

- at least every twelve months.

Observe the relevant national and international standards and directives in connection with the safety inspection.

More detailed information on safety inspections and calibration is available from your regional or national service centre, who will be pleased to provide you with copies of the necessary documents upon request.

Do not dispose of this device with normal domestic waste!

To comply with the European Directive 2002/96/EC on Waste Electrical and

Electronic Equipment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an approved recycling facility Any device that you no longer require must be returned to our agent, or find out about the approved collection and recycling facilities in your area.

Ignoring this European Directive may have potentially adverse affects on the environment and your health!

XI ud_fr_st_sv_00467 022009

Safety markings

Data security

Copyright

Equipment with CE-markings fulfils the basic requirements of the Low-

Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). .

Equipment marked with the CSA-Test Mark fulfils the requirements made in the relevant standards for Canada and the USA.

The user is responsible for the data security of changes made to factory settings. The manufacturer is not liable, if personal settings are deleted.

Copyright to this instruction manual remains the property of the manufacturer.

The text and illustrations are all technically correct at the time of going to print. The right to effect modifications is reserved. The contents of the instruction manual shall not provide the basis for any claims whatever on the part of the purchaser. If you have any suggestions for improvement, or can point out to us any mistakes which you may have found in the manual, we should be most grateful for your comments.

ud_fr_st_sv_00467 022009

XII

Table of contents

General information 5

General .......................................................................................................................................................... 7

Device concept .......................................................................................................................................... 7

Requirements ............................................................................................................................................ 7

Field of application..................................................................................................................................... 7

Warning notices affixed to the device ........................................................................................................ 8

Control elements and connections 9

Description of the control panels ................................................................................................................... 11

General .................................................................................................................................................... 11

Safety ....................................................................................................................................................... 11

Manual control panel .................................................................................................................................... 12

General ................................................................................................................................................... 12

Manual control panel ............................................................................................................................... 12

Adjustment aid for Manual control panel .................................................................................................. 13

Synergic control panel .................................................................................................................................. 14

General ................................................................................................................................................... 14

Layout of the control panel ...................................................................................................................... 14

Synergic A control panel .......................................................................................................................... 14

Synergic B control panel .......................................................................................................................... 16

Connections and mechanical components ................................................................................................... 17

Wirefeeder front ...................................................................................................................................... 17

Wirefeeder rear ....................................................................................................................................... 17

Wirefeeder side ....................................................................................................................................... 18

Wirefeeder underside .............................................................................................................................. 19

Installation and commissioning 21

Before commissioning .................................................................................................................................. 23

Safety ...................................................................................................................................................... 23

Utilisation in accordance with „intended purpose“ .................................................................................... 23

Setup regulations .................................................................................................................................... 23

Placing wirefeeder on power source ............................................................................................................. 24

General ................................................................................................................................................... 24

Placing wirefeeder on power source ........................................................................................................ 24

Connecting wirefeeder to power source ....................................................................................................... 25

General ................................................................................................................................................... 25

Connecting wirefeeder to power source .................................................................................................. 25

Connecting the welding torch ....................................................................................................................... 26

Safety ...................................................................................................................................................... 26

Connecting MIG/MAG welding torches .................................................................................................... 26

Inserting / replacing feed rollers .................................................................................................................... 27

General ................................................................................................................................................... 27

Inserting / replacing feed rollers ............................................................................................................... 27

Inserting the wirespool, inserting the basket-type spool ................................................................................ 28

Safety ...................................................................................................................................................... 28

Inserting the wirespool ............................................................................................................................. 28

Inserting the basket-type spool ................................................................................................................ 28

Feeding in the wire electrode ........................................................................................................................ 29

Feeding in the wire electrode ................................................................................................................... 29

Setting the contact pressure .................................................................................................................... 30

Adjusting the brake ....................................................................................................................................... 31

General ................................................................................................................................................... 31

Adjusting the brake .................................................................................................................................. 31

Design of the brake ................................................................................................................................. 31

1

Commissioning ............................................................................................................................................. 32

General ................................................................................................................................................... 32

Requirements .......................................................................................................................................... 32

Welding 33

MIG/MAG modes .......................................................................................................................................... 35

General ................................................................................................................................................... 35

Symbols .................................................................................................................................................. 35

2-step mode ............................................................................................................................................ 35

4-step mode ............................................................................................................................................ 36

Special 4-step mode ................................................................................................................................ 36

MIG/MAG welding ........................................................................................................................................ 37

Safety ...................................................................................................................................................... 37

General tasks before MIG/MAG welding ................................................................................................. 37

Overview ................................................................................................................................................. 37

MIG/MAG standard synergic welding ........................................................................................................... 38

General ................................................................................................................................................... 38

MIG/MAG standard synergic welding ...................................................................................................... 38

Adjustments while welding - manual control panel ................................................................................... 39

MIG/MAG standard manual welding ............................................................................................................. 40

General ................................................................................................................................................... 40

Available parameters ............................................................................................................................... 40

MIG/MAG standard manual welding - manual control panel .................................................................... 40

Adjustments while welding - manual control panel ................................................................................... 41

MIG/MAG standard manual welding - Synergic A control panel ............................................................... 42

Corrections during welding - Synergic A control panel ............................................................................. 43

MMA welding ................................................................................................................................................ 44

Safety ...................................................................................................................................................... 44

Preparations ............................................................................................................................................ 44

MMA welding - manual control panel ....................................................................................................... 44

Adjustments while welding - manual control panel ................................................................................... 45

MMA welding - Synergic A control panel .................................................................................................. 45

Adjustments while welding - Synergic A control panel.............................................................................. 46

Hotstart function ...................................................................................................................................... 46

Anti-stick function .................................................................................................................................... 47

Saving and retrieving operating points .......................................................................................................... 48

General ................................................................................................................................................... 48

Saving operating points ........................................................................................................................... 48

Retrieving operating points ...................................................................................................................... 48

Setup parameters 49

Process set-up menu ................................................................................................................................... 51

General ................................................................................................................................................... 51

Process set-up menu - manual control panel .......................................................................................... 51

Process set-up menu - Synergic A control panel ..................................................................................... 52

Parameters for MIG/MAG welding in the Process set-up menu .............................................................. 53

Parameters for rod electrode (MMA) welding in the Process set-up menu .............................................. 53

Mode set-up menu ....................................................................................................................................... 54

General ................................................................................................................................................... 54

Mode set-up menu - Synergic A control panel ......................................................................................... 54

Parameters for „Special 4-step mode“ in the mode set-up menu ............................................................. 55

Set-up menu - Level 2 .................................................................................................................................. 56

Set-up menu level 2 - manual control panel............................................................................................. 56

Set-up menu Level 2 - Synergic control panel ......................................................................................... 57

Set-up menu Level 2 - Synergic control panel ......................................................................................... 58

Parameters for MIG/MAG welding in the set-up menu level 2 ................................................................. 58

2

Troubleshooting and maintenance 59

Troubleshooting ............................................................................................................................................ 61

General ................................................................................................................................................... 61

Displayed service codes .......................................................................................................................... 61

Troubleshooting the wirefeeder ............................................................................................................... 65

Care, maintenance and disposal .................................................................................................................. 67

General ................................................................................................................................................... 67

At every start-up ...................................................................................................................................... 67

Every 6 months ....................................................................................................................................... 67

Disposal .................................................................................................................................................. 67

Annex 69

Technical data .............................................................................................................................................. 71

VR 5000 .................................................................................................................................................. 71

Fronius Worldwide

3

4

General information

5

6

General

Device concept

Wirefeeders in the VR 5000 series are equipped with a cover for wirespools with a maximum diameter of 300 mm (11.81 in.).

The standard 4-roll drive has good wirefeeding properties. The wirefeeders in the

VR 5000 series are also suitable for long hosepacks.

Due to their compact design, the VR 5000 wirefeeders can be used in many different ways.

VR 5000 wirefeeder

Requirements

The VR 5000 wirefeeders can be operated with the TransSteel 3500 / 5000 power sources.

Field of application

The VR 5000 series of wirefeeders, in combination with any of the standard protective gas shields, is suitable for all MIG/MAG welding tasks.

7

Warning notices affixed to the device

The wirefeeder is fitted with safety symbols on the rating plate. The safety symbols must

NOT be removed or painted over. The symbols warn against operating the equipment incorrectly, as this may result in serious injury and damage.

Welding is dangerous. The following basic requirements must be met:

Welders must be sufficiently qualified

Suitable protective equipment

Keep all persons not involved in the welding process at a safe distance

Warning notices on the wirefeeder

Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

8

Control elements and connections

9

10

Description of the control panels

General

The functions on the control panels are all arranged in a very logical way. The various parameters needed for welding are easy to select, by pressing the appropriate button, and can easily be

altered using buttons or the adjusting dial

displayed on the digital display during welding

Thanks to the synergic function, whenever you alter any one parameter, appropriate changes will automatically be made to all the other parameters.

NOTE! Owing to software updates, you may find that your device has certain functions that are not described in these operating instructions, or vice versa.

Certain illustrations may also differ slightly from the actual control elements on your device. However, these control elements function in exactly the same way.

Important! Parameters that must be entered at a wirefeeder control panel cannot be changed at the power source. Parameters can only be changed at the wirefeeder.

Safety

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

11

Manual control panel

General

The Manual control panel allows welding parameters to be set manually in a very straightforward process.

Manual control panel

(6)

(5)

(5)

(4)

(3)

(2) (1)

Manual control panel

No. Function

(1) „Process“ button

for selecting the process

MIG/MAG welding

STICK - MMA welding to select parameters in the Set-up menu

(2) „Mode“ button

for selecting the mode

2-step mode

4-step mode to select parameters in the Set-up menu

(3) Welding voltage adjuster

for selecting the welding voltage in V

The welding voltage is directly related to the length of the arc.

(4) Wirefeed speed adjuster

for selecting the wirefeed speed in m/min or ipm.

If the welding voltage remains (3) constant, the welding current increases as the wirefeed speed (4) increases.

12

Manual control panel

(continued)

(5) „Dynamic“ buttons

for influencing the short-circuiting dynamic at the instant of droplet transfer

harder, more stable arc

+ soft, low-spatter arc to change parameters in the Set-up menu

(6) 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.

Adjustment aid for Manual control panel

For selected material / protective gas shield combinations, the VR 5000 includes adjustment aids in the form of foils that can be easily attached to and removed from the

Manual control panel. The adjustment aids have additional scales that correspond to the sheet thickness used. If both the adjusters are set to the current value for the sheet thickness, this will produce a good basic setting for the respective material / protective gas shield combination.

(2)

(1)

Adjustment aid for the Manual control panel, e.g. for steel 1.0 mm, CO

2

100 %

No. Function

(1) Adjustment aid applies with the specified material / protective gas shield combination

e.g.:

Steel Material

Ø 1.0 mm Wire diameter

CO

2

100 % Protective gas shield

(2) Scales for sheet thickness

in mm

The two adjusters must be set to the appropriate value for the sheet thickness being used in order to obtain the basic setting according to the adjustment aid.

13

Synergic control panel

General

Layout of the control panel

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and protective gas shield to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually as required. The Synergic control panel also allows parameters to be defined totally manually.

Synergic A control panel

The Synergic control panel is split.

Synergic A control panel

Synergic B control panel

Control panel sections A and B

(9)

(8)

(7)

Synergic control panel

(6) (5)

14

(1)

(2)

(3)

(4)

Synergic A control panel

(continued)

No. Function

(1) „Parameter selection“ button (right)

for selecting the following parameters

Arc length correction

for correcting the arc length

Welding voltage

Welding voltage in V.

Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Arc-force dynamic

for influencing the short-circuiting dynamic at the instant of droplet transfer

harder, more stable arc

0 neutral arc

+ soft, low-spatter arc

The relevant symbol lights up when a parameter is selected.

to change parameters in the Set-up menu

(2) „Parameter selection“ button (left)

for selecting the following parameters

Sheet thickness

*)

Sheet thickness in mm or in.

Welding current

*)

Welding current in A

Before the start of welding, the machine automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wirefeed speed

*)

Wirefeed speed (m/min or ipm).

The relevant symbol lights up when a parameter is selected.

*) In the MIG/MAG standard synergic welding process, if one of these parameters is selected then the Synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically.

to change parameters in the Set-up menu

(3) Right adjusting dial

for modifying the arc length correction, welding voltage and arc-force dynamic parameters to change parameters in the Set-up menu

(4) Left adjusting dial

for modifying the sheet thickness, welding current and wirefeed speed parameters to change parameters in the Set-up menu

(5) „Process“ button

for selecting the process

MANUAL - MIG/MAG standard manual welding

SYNERGIC - MIG/MAG standard synergic welding

STICK - MMA welding

15

Synergic A control panel

(continued)

No. Function

(6) „Mode“ button

for selecting the mode

2 T - 2-step mode

4 T - 4-step mode

S 4 T - Special 4-step mode

(7) „Save“ buttons

for saving up to 5 operating points

(8) Transition arc indicator

between the dip-transfer arc and the spray arc, a spatter-prone „transition arc“ occurs. To alert you to this critical area - and help you avoid it - the transition arc indicator lights up.

(9) 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.

Synergic B control panel

No. Function

(1) „Material“ button

for selecting the filler metal to be used. Parameter SP is reserved for filler metals.

When a material type is selected, the

LED behind the relevant filler metal lights up.

(1)

Synergic B control panel

(2) (3)

No. Function

(2) „Wire diameter“ button

for selecting the wire diameter to be used. Parameter SP is reserved for additional wire diameters.

When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(3) „Protective gas shield“ button

for selecting the protective gas shield to be used. Parameter SP is reserved for additional protective gas shields.

When a protective gas shield is selected, the LED behind the relevant protective gas shield lights up.

16

Connections and mechanical components

Wirefeeder front

(3)

(2)

(1)

No. Function

(1) Welding torch connection

for connecting the welding torch

(2) Water flow connection (black) option

when the optional water connection is installed, otherwise blanking cover

(3) Water return connection (red) option

when the optional water connection is installed, otherwise blanking cover

(4) Position

for option (+) - current socket with bayonet latch

(5) Position

for LocalNet connection socket option

(5) (4)

VR 5000 - Front view

Wirefeeder rear

(1)

(2)

(3)

(4)

(5)

(6)

VR 5000 - rear view

No. Function

(1) (+) - Socket with bayonet latch

for interconnecting hosepack

(2) Blanking cover

(3) Enhanced LocalNet connection

for enhanced LocalNet with lines for motor supply and motor control

(4) Protective gas shield connection option

when the optional protective gas shield connection is installed, otherwise blanking cover

(5) Water return connection (red) option

when the optional water connection is installed, otherwise blanking cover

(6) Water flow connection (black) option

when the optional water connection is installed, otherwise blanking cover

17

Wirefeeder side

(1)

VR 5000 - side view

(2) (3) (4)

No. Function

(1) Wirespool holder with brake

for holding standard wirespools with a max. diameter of 300 mm (11.81 in) and max.

weight of 19 kg (41.89 lbs.)

(2) Synergic control panel section B

in conjunction with the Synergic control panel

(3) 4 roller drive

(4) „Feeder inching“ / „Gas test“ button - option

Push button downwards: to feed the wire electrode into the welding torch hosepack with no accompanying flow of gas or current. While the button is being held down, the wire-feed unit runs at feeder inching speed.

Push button upwards: to set the required quantity of gas at the pressure regulator.

- Tap button once: protective gas flows out

- Tap button again: protective gas flow stops

If the „Gas test“ button is not tapped again, the protective gas flow will stop after 30 s.

18

Wirefeeder underside

(1)

No. Function

(1) Socket for swivel pin

for placing the wirefeeder on the swivel pin in the swivel pin holder

VR 5000 - view from below

19

20

Installation and commissioning

21

22

Before commissioning

Safety

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

WARNING! An electric shock can be fatal. If the device is plugged into the mains supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when

the mains switch is in the „O“ position,

the device is unplugged from the mains.

Utilisation in accordance with

„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.

Utilisation in accordance with the „intended purpose“ also includes

following all the instructions in this manual

carrying out all the specified inspection and servicing work

Setup regulations

WARNING! A machine that topples over or falls from its stand can easily kill someone. Place devices, upright consoles and trolleys on a solid, level surface in such a way that they remain stable. If a swivel pin holder is being used, make sure that the wirefeeder is seated securely on the swivel pin.

23

Placing wirefeeder on power source

General

The wirefeeders can be placed on the power source if a swivel pin holder is available, e.g.:

„PickUp“ swivel pin holder VR 5000, for use with the „PickUp 5000“ trolley

Placing wirefeeder on power source

CAUTION! Risk of injury and damage from falling wirefeeder. Make sure that the wirefeeder is located securely on the swivel pin and that the devices, upright consoles and trolleys are stable.

1

1

24

Connecting wirefeeder to power source

General

The wirefeeder is connected to the power source using the interconnecting hosepack.

Connecting wirefeeder to power source

1

1

WARNING! 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.

NOTE! When connecting the interconnecting hosepack, check that

all connections are connected properly

all cables, leads and hosepacks are undamaged and correctly insulated

2

1

2

3

4

6

7

5

2

4

3

Important! To prevent wear and tear, form a loop towards the inside when connecting the cables. A strain-relief device is not provided in the case of 1.2 m (3 ft. 11.24 in.) interconnecting hosepacks.

25

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 welding torches

1

1

5

4

3

2

2

3

6

*

7

*

*

when the optional water connection and the water-cooled welding torch are installed

26

Inserting / replacing feed rollers

General

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

Important! Use only feed rollers that match the wire electrode.

An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.

Inserting / replacing feed rollers

1

1

CAUTION! Risk of injury if the feed roller holders fly upwards. When unlocking the lever, keep fingers away from the area to the left and right of the lever.

2

2

3

4

5

3

5

31

2

3

7

6

4

3

3

6

5

3

4

8

7

2

1

2

4

2

2

3

2

1

3

4

27

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. Make sure that the wirespool or basket-type spool with adapter is fitted securely to the wirespool holder.

Inserting the wirespool

1

1

2

4

3

Inserting the basket-type spool

1

NOTE! When working with basket-type spools, use only the basket-type spool adapter supplied with the wire-feed unit!

CAUTION! Risk of injury from falling basket-type spool. Place basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways.

1

2

1

2

1

3

2

2

28

Feeding in the wire electrode

Feeding in the wire electrode

1

1

CAUTION! 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. Deburr the end of the wire electrode well before feeding in.

2

1

2

2

1

2

3

5

4

CAUTION! Risk of injury from wire electrode emerging at speed. Keep the welding torch away from face and body when pressing the „Feeder inching“ button.

Important! To facilitate exact positioning of the wire electrode, the following sequences are possible when the feeder inching button is pressed and held down:

Feeder inching / Gas test button

10

1

Wire feed speed

(m/min or ipm)

1 2 2.5

3 4 t (s)

5

Hold down the button for up to one

second ...For the first second, the wire feed speed remains at 1 m/min or 39.37 ipm.

Hold down the button for up to 2.5

seconds ... After the end of a 1second period, the wire feed speed increases at a uniform rate over the next 1.5 seconds.

Hold down the button for longer than

2.5 seconds ... After a total of 2.5

seconds the wire feed speed remains constant at 10 m/min or 393.7 ipm.

Passage over time of the wire feed speed when the feeder inching button is pressed and held down

If the feeder inching button is released and pressed again before the end of the 1second period, the sequence starts again from the beginning. This makes it possible to position the wire continuously at the low wire feed speed of 1 m/min or 39.37 ipm when necessary.

29

Feeding in the wire electrode

(continued)

3

1

2

3

4

5

4

2

1

1

3

Setting the contact pressure

1

NOTE! Adjust the contact pressure in such a way that the wire electrode is not deformed, but is nevertheless transported properly.

1

Contact pressure guideline values

Steel

CrNi

Tubular cored electrodes

U-grooved rollers

4 - 5

4 - 5

2 - 3

30

Adjusting the brake

General

Important! After releasing the torch trigger the wirespool should stop unreeling. Adjust brake if necessary.

Adjusting the brake

2

1

1

3

STOP

5

2

6

4

2

1

7

3

1

STOP

3

2

OK

4

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 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.

31

Commissioning

General

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

The wirefeeder is commissioned by pressing the torch trigger (for manual applications) or by means of a welding start-up signal (for automatic applications).

Requirements

When commissioning the wirefeeder, the following requirements must be met:

Wirefeeder connected to the power source using the interconnecting hosepack

Welding torch connected to wirefeeder

Feed rollers inserted in the wirefeeder

Wirespool or basket-type spool and adapter inserted in the wirefeeder

Wire electrode fed in

Braking force set

Feed roller contact pressure set

All covers closed, all side panels in place, all protection devices intact and in their proper place

32

Welding

33

34

MIG/MAG modes

General

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

For details of the meaning, setting, setting range and units of the available parameters

(e.g. GPr), please refer to the section entitled „Set-up parameters“.

Symbols

2-step mode

Press the torch trigger

Press torch trigger symbol

Hold the torch trigger

Hold torch trigger symbol

Release the torch trigger

Release torch trigger symbol

„2-step mode“ is suitable for

tacking-work

short seams

automatic and robot welding

+

I

I GPo t

GPr

2-step mode

35

4-step mode

„4-step mode“ is suitable for longer weld seams.

+

I

+

GPr

4-step mode

I GPo t

Special 4-step mode

„Special 4-step mode“ is particularly suitable for welding in higher power ranges. In special 4-step mode the arc starts at relatively low power, making it easier to stabilise.

+ +

I

GPr I-S SL

Special 4-step mode

I SL

I-E GPo t

36

MIG/MAG welding

Safety

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

WARNING! An electric shock can be fatal. If the device is plugged into the mains supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when

the mains switch is in the „O“ position,

the device is unplugged from the mains.

General tasks before MIG/MAG welding

1.

Only where a cooling unit and water-cooled welding torch are used:

Connect the water hoses of the welding torch to the correct plug-type connectors on the wirefeeder

2.

Plug in the mains plug

3.

Move the mains switch to the „I“ position:

All the indicators on the control panel light up briefly

where applicable, the cooling unit starts to run

Important! Follow the safety rules and note operating conditions in the cooling unit operating instructions.

Overview

„MIG/MAG welding“ is composed of the following sections:

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Special functions and options

37

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 standard synergic welding

On Synergic B control panel:

1.

Press the „Material“ button to select the filler metal used.

The assignment of SP depends on the welding database used for the power source.

2.

Press the „Wire diameter“ button to select the diameter of the wire electrode used.

The assignment of SP depends on the welding database used for the power source.

3.

Use the „Protective gas shield“ button to select the protective gas shield used.

The assignment of SP depends on the welding database used for the power source.

On Synergic A control panel:

4.

Press the „Process“ button to select the desired welding process:

MIG/MAG standard synergic welding

5.

Press the „Mode“ button to select the desired MIG/MAG mode:

2-step mode

4-step mode

Special 4-step mode

Important! Parameters that have been set on a system component control panel

(e.g. remote control unit) might not be able to be changed on the wirefeeder control panel.

6.

Press the „Parameter selection“ buttons to select the welding parameters to be used to specify the welding power:

Sheet thickness

Welding current

Wirefeed speed

Welding voltage

38

MIG/MAG standard manual welding - manual control panel

(continued)

5.

Open the gas cylinder valve

6.

Set the shielding gas flow rate:

If a Feeder inching / Gas test button is fitted:

Press upwards and hold the „Feeder inching“ / „Gas test“ button

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the „Feeder inching“ / „Gas test“ button

If a Feeder inching / Gas test button is not fitted:

Disengage the feed rollers

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When pressing the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

Press and hold the torch trigger

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the torch trigger

Engage the feed rollers

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When pressing the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

7.

Press the torch trigger and start welding

Adjustments while welding manual control panel

To obtain the best possible welding results, the dynamic correction parameter will sometimes need to be adjusted.

1.

Set the required arc-force dynamic using the Dynamic buttons.

The value of the parameter is indicated by the LEDs located between the buttons.

Arc length correction

for correcting the arc length

shorter arc length

0 neutral arc length

+ longer arc length

Arc-force dynamic

for influencing the short-circuiting dynamic at the instant of droplet transfer

harder, more stable arc

+ soft, low-spatter arc

Korrek

Schwe

39

MIG/MAG standard manual welding

General

The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function.

Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

Available parameters

The following parameters are available in MIG/MAG standard manual welding:

Wirefeed speed

1 m/min (39.37 ipm) - maximum wirefeed speed, e.g. 25.0 m/min (984.25 ipm)

Welding voltage

TSt 3500: 14.5 – 31.5 V

TSt 5000: 14.5 – 39 V

Arc-force dynamic

... for influencing the short-circuiting dynamic at the instant of droplet transfer

Welding current

only the actual value is displayed

MIG/MAG standard manual welding - manual control panel

1.

Press the Process button to select the desired welding process:

MIG/MAG welding

2.

Press the Mode button to select the desired MIG/MAG mode:

2-step mode

4-step mode

Important! Parameters that have been set on a system component control panel

(e.g. remote control unit) may not be able to be changed on the wire-feed unit control panel.

3.

Set the required wire feed speed using the wire feed speed adjuster

4.

Set the required welding voltage using the welding voltage adjuster

The parameter values are shown in the digital indicator located above them.

40

MIG/MAG standard manual welding - manual control panel

(continued)

5.

Open the gas cylinder valve

6.

Set the shielding gas flow rate:

If a Feeder inching / Gas test button is fitted:

Press upwards and hold the „Feeder inching“ / „Gas test“ button

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the „Feeder inching“ / „Gas test“ button

If a Feeder inching / Gas test button is not fitted:

Disengage the feed rollers

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When pressing the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

Press and hold the torch trigger

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the torch trigger

Engage the feed rollers

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When pressing the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

7.

Press the torch trigger and start welding

Adjustments while welding manual control panel

To obtain the best possible welding results, the dynamic correction parameter will sometimes need to be adjusted.

1.

Set the required arc-force dynamic using the Dynamic buttons.

The value of the parameter is indicated by the LEDs located between the buttons.

Arc-force dynamic

for influencing the short-circuiting dynamic at the instant of droplet transfer

harder, more stable arc

+ soft, low-spatter arc

41

MIG/MAG standard manual welding - Synergic A control panel

On Synergic A control panel:

1.

Press the „Process“ button to select the desired welding process:

MIG/MAG standard manual welding

2.

Press the „Mode“ button to select the desired MIG/MAG mode:

2-step mode

4-step mode

In MIG/MAG standard manual welding, „Special 4-step“ mode corresponds to conventional 4-step operation.

Important! Parameters that have been set on a system component control panel

(e.g. remote control unit) might not be able to be changed on the wirefeeder control panel.

3.

Press the „Parameter selection“ button and select the wirefeed speed parameter

4.

Use the adjusting dial to set the wirefeed speed to the desired value

5.

Press the „Parameter selection“ button and select the welding voltage parameter

6.

Use the adjusting dial to set the welding voltage to the desired value

Parameter values are shown in the digital indicator located above them.

All parameter command values that have been set using the adjusting dial or the buttons on the welding torch are stored until the next time they are changed. This is true even if the power source is switched off and on again in the meantime.

To display the actual welding current during welding:

Press the „Parameter selection“ button and select the welding current parameter.

The actual welding current is displayed in the digital indicator during welding.

7.

Open the gas cylinder valve

8.

Set the shielding gas flow rate:

If a Feeder inching / Gas test button is fitted:

Press upwards and hold the „Feeder inching“ / „Gas test“ button

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the „Feeder inching“ / „Gas test“ button

If a Feeder inching / Gas test button is not fitted:

Disengage the feed rollers

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When pressing the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

Press and hold the torch trigger

Turn the adjusting screw on the underside of the pressure regulator until the pressure gauge shows the desired shielding gas flow rate

Release the torch trigger

Engage the feed rollers

42

MIG/MAG standard manual welding - Synergic A control panel

(continued)

CAUTION! Risk of injury and damage from electric shock and from wire electrode emerging from the torch. When you press the torch trigger:

hold the torch so that it points away from your face and body

do not point the welding torch at people

make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.

9.

Press the torch trigger and start welding

Corrections during welding -

Synergic A control panel

To obtain the best possible welding results, the dynamic parameter will sometimes need to be adjusted.

1.

Press the „Parameter selection“ button and select the dynamic parameter

2.

Use the adjusting dial to set the dynamic to the desired value

The parameter value is shown in the digital indicator located above it.

Arc-force dynamic

for influencing the short-circuiting dynamic at the instant of droplet transfer

0 harder, more stable arc

10 soft, low-spatter arc

43

MMA welding

Safety

WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:

these operating instructions

all the operating instructions for the system components, especially the safety rules

WARNING! An electric shock can be fatal. If the device is plugged into the mains supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when

the mains switch is in the „O“ position,

the device is unplugged from the mains.

Preparations

1.

Turn the mains switch to the „O“ position

2.

Unplug the device from the mains

3.

Remove the MIG/MAG welding torch

Important! Check the rod electrode packaging to determine whether the rod electrodes are for (+) or (-) welding.

4.

Plug the grounding (earthing) cable into either the (-) or the (+) current socket, depending on the type of electrode, and latch it in firmly

5.

With the other end of the earthing (grounding) cable, establish a connection to the workpiece

6.

Plug the bayonet current plug of the electrode holder cable into the free current socket with the opposite polarity, according to the type of electrode, and twist it clockwise to latch it in place

7.

Plug in the mains plug

MMA welding manual control panel

CAUTION! Risk of injury and damage from electric shock. As soon as the mains switch is in the „I“ position, the rod electrode in the electrode holder is

LIVE. Make sure that the rod electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing etc.)

1.

Move the mains switch to the „I“ position: All the indicators on the control panel light up briefly

2.

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.

44

MMA welding manual control panel

(continued)

If the rod electrode (MMA) welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

Important! Parameters that have been set on a system component control panel

(e.g. remote control unit) may not be able to be changed on the wire-feed unit control panel.

3.

Use the wirespeed adjuster to set the desired amperage.

The parameter values are shown in the digital indicator located above them.

4.

Start welding

Adjustments while welding manual control panel

To obtain the best possible welding results, the dynamic correction parameter will sometimes need to be adjusted.

1.

Set the required arc-force dynamic using the Dynamic buttons.

The value of the parameter is indicated by the LEDs located between the buttons.

Arc-force dynamic

for influencing the short-circuiting dynamic at the instant of droplet transfer

harder, more stable arc

+ soft, low-spatter arc

MMA welding -

Synergic A control panel

CAUTION! Risk of injury and damage from electric shock. As soon as the mains switch is in the „I“ position, the rod electrode in the electrode holder is

LIVE. Make sure that the rod electrode does not touch any persons or electrically conducting or earthed parts (e.g. the housing etc.)

1.

Move the mains switch to the „I“ position: All the indicators on the control panel light up briefly

2.

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 rod electrode (MMA) welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

Important! Parameters that have been set on a system component control panel

(e.g. remote control unit) may not be able to be changed on the wire-feed unit control panel.

45

MMA welding -

Synergic A control panel

(continued)

3.

Press the „Parameter selection“ button and select the welding current parameter.

4.

Use the adjusting dial to set the desired amperage.

The amperage value is displayed in the left-hand digital display.

All parameter command values that have been set by means of the adjusting dial will remain stored until the next time they are changed. This applies even if the power source is switched off and on again in the meantime.

5.

Start welding

Adjustments while welding -

Synergic A control panel

In order to obtain the best possible welding results, the following parameter can be corrected in certain circumstances:

1.

Press the „Parameter selection“ button and select the dynamic correction parameter

2.

Use the adjusting dial to set the dynamic correction to the desired value

The parameter value is shown in the digital indicator located above it.

Arc-force dynamic

for influencing the short-circuiting amperage at the instant of droplet transfer

0 harder, more stable arc

100 soft, low-spatter arc

Hotstart function

To obtain optimum welding results, it will sometimes be necessary to adjust the Hotstart function.

Advantages

Improved ignition, even when using electrodes with poor ignition properties

Better fusion of the base metal in the start-up phase, meaning fewer cold-shut defects

Largely prevents slag inclusions

For details on setting the available parameters, please refer to „Set-up parameters“,

„Set-up menu - level 2“.

46

Hotstart function

(continued)

I (A)

300

200

Hti

HCU

I

H

0,5

Example of „Hotstart“ function

1

HCU > I

H

1,5 t (s)

I

Legend

Hti ........ Hot-current time,

0 - 2 s, factory setting: 0.5 s

HCU .... Hot-start current, 0 - 200%,

H factory setting 150 %

.......... Main current = Pre-set welding current

Mode of operation

During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (I

H

).

Anti-stick function

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to „stick“. This may also cause „burn-out“ of the rod electrode.

Electrode burn-out is prevented if the anti-stick function has been activated. If the rod electrode begins to stick, the power source immediately switches the welding current off.

After the rod electrode has been detached from the workpiece, the welding operation can be continued without difficulty.

The anti-stick function can be activated and deactivated in the set-up parameters in „Setup menu: level 2“.

47

Saving and retrieving operating points

General

The „Save“ buttons allow up to 5 tried-and-tested operating points to be saved. The settings do not need to be documented manually. The current settings on the control panel are saved.

Important! Set-up parameters are not saved at this time.

Saving operating points

1.

Press and hold down one of the „Save“ buttons in order to save the current settings on the control panel, e.g.:

The left indicator reads „Pro“.

Once the left indicator has reverted to its original content, e.g.:

2.

Release the „Save“ button

Retrieving operating points

1.

To retrieve saved settings press the corresponding „Save“ button briefly, e.g.:

The control panel will show the saved settings, e.g.:

48

Setup parameters

49

50

Process set-up menu

General

The Process set-up menu provides simple access to expert knowledge in the power source and to additional functions. The Process set-up menu can be used to make simple adjustments of the parameters to the various job settings.

Process set-up menu - manual control panel

The setting of the process parameters is described on the basis of the „MIG/MAG welding“ process. The procedure for changing other process parameters is identical.

Open the Process set-up menu

1.

Use the Process button to select the „MIG/MAG welding“ process

2.

Press and hold the Mode button

3.

Press the Process button

4.

Release the Mode and Process buttons

The control panel is now in the set-up menu for the „MIG/MAG welding“ process - the last parameter that was selected is displayed.

Changing a parameter

5.

Use the Mode and Process buttons to select the desired parameter

6.

use the Dynamic buttons to change the value of the parameter

Exiting from the set-up menu

7.

Press and hold the Mode button

8.

Press the Process button

9.

Release the Mode and Process buttons

51

Process set-up menu - Synergic

A control panel

Setting process parameters is described here with reference to the MIG/MAG standard synergic welding process. The procedure for changing other process parameters is identical.

Open the Process set-up menu

1.

Use the „Process“ button to select the MIG/MAG standard synergic welding process

2.

Press and hold the Mode button

3.

Press the Process button

4.

Release the Mode and Process buttons

The control panel is now in the set-up menu for the „MIG/MAG standard synergic welding“ process - the last parameter that was selected is displayed.

Changing a parameter

5.

Select the required parameter using the Mode and Process buttons or the left adjusting dial

6.

Change the value of the parameter using the Parameter Selection button or the right adjusting dial

Exiting from the set-up menu

7.

Press and hold the Mode button

8.

Press the Process button

9.

Release the Mode and Process buttons

52

Parameters for

MIG/MAG welding in the Process set-up menu

The parameters available in the Process set-up menu are described below for the following MIG/MAG welding processes:

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

„min.“ and „max.“ are used for setting ranges that differ according to power source, wirefeed unit, welding program, etc.

GPr

Gas pre-flow time

Unit

Setting range

Factory setting

GPo

Gas post-flow time s

0 - 9,9

0,1

Unit

Setting range

Factory setting s

0 - 9,9

0,5

FAC

Reset power source to factory setting

Press and hold down the Dynamic (manual control panel) or the Parameter Selection

(Synergic A control panel) button for 2 s to restore the factory settings - when „PrG“ appears on the digital display, the power source has been reset

Important! When the power source is reset, all the customised settings in the set-up menu are lost.

When the power source is reset, jobs are not deleted but are retained in the memory.

The functions in the second level of the set-up menu (2nd) are not deleted either. Exception: The „Ignition time-out“ parameter (ito).

2nd

Second level of the set-up menu (see “Set-up menu - level 2”)

Parameters for rod electrode

(MMA) welding in the Process setup menu

Important! If you reset the power source using the Factory parameter FAC, the hotcurrent time (Hti) and hot-start current (HCU) parameters are also reset.

Hti

Hot-current time

Unit

Setting range

Factory setting

HCU

Hot-start current s

0 - 2,0

0,5

Unit

Setting range

Factory setting

%

0 - 200

150

2nd

Second level of the set-up menu (see “Set-up menu - level 2”)

53

Mode set-up menu

General

The Mode set-up menu provides simple access to expert knowledge in the power source and to additional functions. The Mode set-up menu can be used to make simple adjustments of the parameters to the various job settings.

Mode set-up menu - Synergic

A control panel

Setting the Mode parameters is described by reference to „Special 4-step mode - S 4 T“ for the Synergic A control panel.

Enter the Mode set-up menu

1.

Use the Mode button to select „Special 4-step mode - S 4 T“

2.

Press and hold the Mode button

3.

Press the Process button

4.

Release the Mode and Process buttons

The control panel is now in the set-up menu for „Special 4-step mode - S 4 T“ - the last parameter that was selected is displayed.

Changing a parameter

5.

Select the required parameter using the Mode and Process buttons or the left adjusting dial

6.

Change the value of the parameter using the Parameter Selection button or the right adjusting dial

Exiting from the set-up menu

7.

Press and hold the Mode button

8.

Press the Process button

9.

Release the Mode and Process buttons

54

Parameters for

„Special 4-step mode“ in the mode set-up menu

I-S

I (current) - Starting: Starting current

Unit

Setting range

Factory setting

SL

Slope: 0 - 9.9 s

% (of welding current)

0 - 200

100

Unit

Setting range

Factory setting s

0 - 9,9

0

I-E

I (current) - End: Final current

Unit

Setting range

Factory setting

% of welding current

0 - 200

50

55

Set-up menu - Level 2

Set-up menu level 2 - manual control panel

Opening the set-up menu

1.

Press and hold the Mode button

2.

Press the Process button

3.

Release the Mode and Process buttons

The control panel is now in the set-up menu - the last parameter that was selected is displayed.

Select parameter „2nd“

4.

Use the Mode and Process buttons to select the parameter

„2nd“

Accessing the set-up menu: Level 2

5.

Press and hold the Mode button

6.

Press the Process button

7.

Release the Mode and Process buttons

Changing a parameter

8.

Use the Mode and Process buttons to select the desired parameter

9.

Use the Dynamic buttons to change the value of the parameter

Exiting from the set-up menu - level 2

10. Press and hold the Mode button

11. Press the Process button

12. Release the Mode and Process buttons

56

Set-up menu

Level 2 - manual control panel

(continued)

Exiting from the set-up menu

13. Press and hold the Mode button

14. Press the Process button

15. Release the Mode and Process buttons

Set-up menu

Level 2 - Synergic control panel

Opening the set-up menu

1.

Press and hold the Mode button

2.

Press the Process button

3.

Release the Mode and Process buttons

The control panel is now in the set-up menu - the last parameter that was selected is displayed.

Select parameter „2nd“

4.

Use the Mode and Process buttons or the left adjustment dial to select the parameter „2nd“

Accessing the Set-up menu: Level 2

5.

Press and hold the Mode button

6.

Press the Process button

7.

Release the Mode and Process buttons

Changing a parameter

8.

Select the required parameter using the Mode and Process buttons or the left adjusting dial

9.

Change the value of the parameter using the Dynamic button or the right adjusting dial

Exiting from the set-up menu - level 2

10. Press and hold the Mode button

11. Press the Process button

12. Release the Mode and Process buttons

57

Set-up menu

Level 2 - Synergic control panel

(continued)

Exiting from the set-up menu

13. Press and hold the Mode button

14. Press the Process button

15. Release the Mode and Process buttons

Parameters for

MIG/MAG welding in the set-up menu level 2

C-C

Cooling unit control

Unit

Setting range

Factory setting

-

Aut, On, Off

Aut

Aut: The cooling unit cuts out after a 2-minute welding off-time

Important! If the „Thermostat“ option has 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.

On: The cooling unit is permanently ON

Off: The cooling unit is permanently OFF

Important! If the FAC parameter is used, the C-C parameter is not reset to the factory setting.

C-t

Cooling time - time from when the rate-of-flow watchdog is triggered until the „no | H2O“ service code is output. For example, if there are air bubbles in the cooling system, the cooling unit will not cut out until the end of this pre-set time.

Unit

Setting range

Factory setting s

5 - 25

10

Important! Each time the power source is switched on, the cooling unit carries out a test run for 180 seconds.

SEt

Setting - country-specific setting (Standard / USA) ... Std / US

Unit

Setting range

Factory setting

-

Std, US (Standard / USA)

Standard version: Std (measurements in cm / mm)

USA version: US (measurements in in.)

ASt

Anti-stick

Unit

Setting range

Factory setting

-

On, Off

Off

58

Troubleshooting and maintenance

59

60

Troubleshooting

General

WARNING! An electric shock can be fatal. Before opening the device

Turn the mains switch to the „O“ position

Unplug the device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again

Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have discharged

CAUTION! Inadequate PE conductor connections can cause serious injury and damage. The housing screws provide a suitable PE conductor connection for earthing (grounding) the housing and must NOT be replaced by any other screws that do not provide a reliable PE conductor connection.

Displayed service codes

If an error message that is not described here appears on the displays, then the fault is one that can only be put right by a service engineer. Make a note of the error message shown in the display, and of the serial number and configuration of the power source, and contact our After-Sales Service team with a detailed description of the error.

ESr | 1 to ESr | 5, ESr | 8 and ESr | 10

Cause:

Remedy:

Power source software error

Switch off the power source, wait for 10 seconds and then switch it on again. If you have tried this several times and the error keeps recurring, contact After-Sales Service.

ESr | 12

Cause:

Remedy:

ESr | 254

Cause:

Remedy:

Software not supported by power source

Contact After-Sales Service

Power source software error

Switch off the power source, wait for 10 seconds and then switch it on again. If you have tried this several times and the error keeps recurring, contact After-Sales Service.

EPr | 0 to EPr | 12

Welding database power source defective

Contact After-Sales Service

Cause:

Remedy:

ELn | 2

Cause:

Remedy:

Err | PE

Cause:

Synergic B control panel, data connection interrupted

Contact After-Sales Service

Remedy:

The earth current watchdog has triggered the safety cut-out of the power source.

Switch off the power source, connect the grounding (earthing) cable to a point on the workpiece that is closer to the arc, wait for 10 seconds and then switch it on again. If you have tried this several times and the error keeps recurring, contact After-Sales Service.

61

Displayed service codes

(continued)

PHA | SE

Cause:

Remedy:

Err | 51

Cause:

Phase failure

Check the mains fuse, the mains lead and the mains plug

Remedy:

Err | 52

Cause:

Mains undervoltage: The mains voltage has fallen below the tolerance range

Check the mains voltage

Remedy:

Err | IP

Cause:

Remedy:

EPS | 7

Cause:

Remedy:

EFd | 5

Cause:

Remedy:

EFd | 7

Mains overvoltage: The mains voltage has risen above the tolerance range

Check the mains voltage

Primary overcurrent

Contact After-Sales Service

Defective welding current sensor

Contact After-Sales Service

Incorrect wirefeeder connected

Connect correct wirefeeder or contact After-Sales Service

Cause:

Remedy:

EFd | 81, EFd | 83

Motor current sensor faulty

Contact After-Sales Service

Cause:

Remedy:

Fault in the wirefeed system (overcurrent in wirefeeder drive)

Arrange the hosepack in as straight a line as possible; check that there are no kinks or dirt in the inner liner; check the contact pressure on the 4 roller drive

Cause:

Remedy:

Wirefeeder motor is sticking or defective

Check the wirefeeder motor or contact After-Sales Service

to0 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the primary circuit of the power source

Allow power source to cool down

to1 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the power source control gear

Allow power source to cool down

to2 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the secondary circuit of the power source

Allow power source to cool down

62

Displayed service codes

(continued)

to3 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the wirefeeder motor

Allow wirefeeder to cool down

to4 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in welding torch

Allow welding torch to cool down

to5 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in cooling unit

Allow cooling unit to cool down.

to6 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the power source transformer

Allow power source to cool down

tu0 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the power source primary circuit

Place power source in a heated room and allow to warm up

tu1 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the power source control gear

Place power source in a heated room and allow to warm up

tu2 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the power source secondary circuit

Place power source in a heated room and allow to warm up

tu3 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the wirefeeder motor

Place wirefeeder in a heated room and allow to warm up

tu4 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the welding torch

Place welding torch in a heated room and allow to warm up

tu5 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Undertemperature in the cooling unit

Place cooling unit in a heated room and allow to warm up

tu6 | xxx

Note: xxx stands for a temperature value

Cause:

Remedy:

Overtemperature in the power source transformer

Place power source in a heated room and allow to warm up

63

Displayed service codes

(continued)

Err | tf0

Cause:

Remedy:

Err | tf1

Cause:

Remedy:

Err | tf2

Cause:

Remedy:

Err | tf3

Cause:

Remedy:

Err | tf4

Cause:

Remedy:

Err | tf5

Cause:

Remedy:

Err | tf6

Faulty temperature sensor in the power source primary circuit

Contact After-Sales Service

Faulty temperature sensor in the power source control gear

Contact After-Sales Service

Faulty temperature sensor in the power source secondary circuit

Contact After-Sales Service

Faulty temperature sensor in wirefeeder motor

Contact After-Sales Service

Faulty temperature sensor in welding torch

Contact After-Sales Service

Faulty temperature sensor in cooling unit

Contact After-Sales Service

Cause:

Remedy:

no | Prg

Faulty temperature sensor in power source transformer

Contact After-Sales Service

Cause:

Remedy:

EPG | 1 to EPG | 6

No preconfigured program has been selected select a configured program

Cause:

Remedy:

Welding database power source defective

Contact After-Sales Service

EPG | 17 to EPG | 21

Cause:

Remedy:

Ebo | 2 and Ebo | 3

Power source software error

Switch off the power source, wait for 10 seconds and then switch it on again. If you have tried this several times and the error keeps recurring, contact After-Sales Service.

Cause:

Remedy:

Fault in the power source control gear

Switch off the power source, wait for 10 seconds and then switch it on again. If you have tried this several times and the error keeps recurring, contact After-Sales Service.

64

Troubleshooting the wirefeeder

Nothing happens when the torch trigger is pressed

Power source mains switch is on, power source ON indication is lit up on the power source, indications on wirefeeder are lit up

Cause:

Remedy:

Control plug not connected in the case of a welding torch with external control connector

Connect the control plug

Cause:

Remedy:

Welding torch or welding torch control line defective

Replace welding torch

Nothing happens when the torch trigger is pressed

Power source mains switch is on, power source ON indication is lit up on the power source, indications on wirefeeder are not lit up

Cause:

Remedy:

The interconnecting hosepack is faulty or not connected properly

Check interconnecting hosepack

No protective gas shield

All other functions are OK

Cause:

Remedy:

Cause:

Remedy:

The gas cylinder is empty

Change the gas cylinder

Gas pressure regulator is faulty

Change the gas pressure regulator

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

The gas hose is not connected, or is damaged

Mount/change the gas hose

The welding torch is defective

Change the welding torch

Cause:

Remedy:

Gas solenoid valve is defective

Replace gas solenoid valve

Poor weld properties

Cause:

Remedy:

Incorrect welding parameters

Check the settings

Cause:

Remedy:

Cause:

Remedy:

Poor grounding (earthing) connection

Ensure good contact to workpiece

Inadequate protective gas shield, or none at all

Check the pressure regulator, gas hose, gas solenoid valve, torch gas connection, etc.

Welding torch is leaking

Change the welding torch

Wrong contact tube, or contact tube is worn out

Change the contact tube

Wrong wire alloy or wrong wire diameter

Check the wire spool that has been inserted

Wrong wire alloy or wrong wire diameter

Check the weldability of the base material

The protective gas shield is not suitable for this wire alloy

Use the correct protective gas shield

65

Troubleshooting the wirefeeder

(continued)

Irregular wirefeed speed

The wire electrode forms a loop between the feed rollers and the wire inlet nozzle of the welding torch

Cause:

Remedy:

Cause:

Remedy:

Cause:

Remedy:

The braking force has been set too high

Loosen the brake

The borehole of the contact tube is too narrow

Use a suitable contact tube

Faulty inner liner in welding torch

Check the inner liner for kinks, dirt etc.

Cause:

Remedy:

The wirefeed rollers are not suitable for the wire electrode being used

Use suitable wirefeed rollers

Cause:

Remedy:

Feed rollers have the wrong contact pressure

Optimise the contact pressure

Wirefeed problems

when using long hosepacks

Cause:

Remedy:

Incorrect arrangement of hosepack

Arrange the hosepack in as straight a line as possible, avoid tight bends

The welding torch becomes very hot

Cause:

Remedy:

The design dimensions of the welding torch are not sufficient for this task

Observe the duty cycle and loading limits

Cause:

Remedy:

Only on water-cooled machines: Coolant flow is insufficient

Check the water level, water flowrate, its cleanliness, etc.

66

Care, maintenance and disposal

General

Under normal operating conditions the wirefeeder requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.

WARNING! An electric shock can be fatal. Before opening the device

Turn the mains switch to the „O“ position

Unplug the device from the mains

Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again

Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have discharged

At every start-up

Check welding torch, interconnecting hosepack and grounding (earthing) connection for signs of damage

Perform a visual check on the feed rollers and inner liners for signs of damage

Check contact pressure of feed rolls and adjust if necessary

Every 6 months

Dismantle device side panels and clean inside of device with dry reduced compressed air

NOTE! Risk of damage to electronic components. Do not bring air nozzle too close to electronic components.

Disposal

Dispose of in accordance with the applicable national and local regulations.

67

68

Annex

69

70

Technical data

VR 5000

Supply voltage

Control current input

Motor current input

Gear ratio

Wirefeed speed

Wirefeed drive

Wire diameter

Wirespool diameter

Wirespool weight

Degree of protection

Dimensions l x w x h

Weight

24 V

2 A

4 A

16 : 1

1 - 25 m/min

39.37 - 984.25 ipm.

4 roller drive

0.8 – 1.6 mm

0.03 - 0.06 in.

max. 300 mm max. 11.81 in.

max. 19 kg max. 41.89 lb.

IP 23

640 x 270 x 365 mm

25.20 x 10.63 x 14.37 in.

12.5 kg

27.56 lb.

71

72

D Ersatzteilliste

GB Spare Parts List

F Liste de pièces de rechange

I

Lista parti di ricambio

E Lista de repuestos

P

Lista de peças sobresselentes

NL Onderdelenlijst

N Reservdelsliste

CZ Seznam náhradních dílů

RUS

Ñïèñîê çàïàñíûõ ÷àñòåé

SK Zoznam náhradných dielov ud_fr_st_tb_00150 012008

VR 5000 4R/G/FSC Manual 4,049,002

VR 5000C 4,049,002,C

VR 5000 4R/W/FSC Manual 4,049,002,630

VR 5000 4R/G/FSC Synergic 4,049,003

VR 5000 4R/W/FSC Synergic 4,049,003,630

44,0550,0060

42,0400,0352

40,0006,2692

42,0300,2600

42,0406,0093

42,0406,0315

42,0406,0123

44,0001,1402

43,0001,3336 - manual

43,0001,3337 - synergic

42,0401,1114 (4x)

BY2,0201,3064 - manual

42,0409,3270 - synergic

42,0300,2880

42,0404,1013

44,0001,1400

42,0405,0656

42,0405,0688

42,0405,0656

43,0004,4059

32,0405,0214

42,0405,0702

42,0405,0700

40,0006,3003

4,071,111

42,0300,2566

42,0407,0357

44,0001,1401,Z

45,0405,0005,Z

42,0407,0063

42,0405,1076

43,0004,4058

42,0300,1564

43,0013,0015

BY4,0490,0001

42,0405,0717

42,0405,0716

42,0401,0959 (8x)

43,0001,1095

42,0405,0699,Z

40,0001,0012 -*

42,0001,1509

42,0001,6262

42,0405,0697

42,0409,3269

42,0407,0063

42,0405,0189

42,0405,0186 - RED

42,0405,0187 - BLACK

44,0001,1145

40,0006,3035

42,0405,0701

42,0401,1115 (27x)

40,0006,3035

VR 5000

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/1 el_fr_st_dv_01717 012009

Motorplatte Alu 4R s

44,0001,1405 -FSR U 0,8

44,0001,1406 -FSR U 0,9-1,0

44,0001,1407 -FSR U 1,2

44,0001,1408 -FSR U 1,4-1,6

Motor

Connector

44,0001,1413

42,0405,1097

42,0401,1098 (8x)

44,0001,1399

42,0403,0153

42,0405,1096

42,0405,1095

42,0407,0667

42,0404,0384

42,0405,0687

42,0001,3750

42,0407,0665

42,0407,0680

42,0405,1093

42,0001,3751

42,0405,1094,Z

Motorplate Alu 4R s

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/1 el_fr_st_mp_01718 012009

G 1,2m 50mm² 4,047,408

G 5m 50mm² 4,047,409

G 10m 50mm² 4,047,410

W 1,2m 70mm² 4,047,260

W 1,6m 70mm² 4,047,324

W 5,0m 70mm² 4,047,261

W 10m 70mm² 4,047,262

W 15m 70mm² 4,047,290

W 20m 70mm² 4,047,277

G 1,2m 70mm² 4,047,287

G 5,0m 70mm² 4,047,288

G 10m 70mm² 4,047,289

W 20m 95mm² 4,047,669

G 20m 95mm² 4,047,670

32,0405,0226

42,0407,0482

40,0001,0095 - *

42,0407,0482

42,0405,0239

32,0405,0226

42,0405,0239

42,0001,1506

40,0003,0078 - *

44,0450,0281 - G 1/4" 42,0407,0063

40,0003,0014-* 50mm²

40,0003,0021-* 70mm²

40,0003,0015-* 95mm²

42,0407,0048

32,0405,0180

32,0405,0231

43,0003,0486 43,0003,0019 - 50-70mm²

43,0003,0301 - 70-90mm²

40,0001,0012 - *

42,0407,0063

42,0402,0053

42,0001,0942

42,0001,0943

44,0450,0281 - G 1/4"

43,0003,0485

32,0405,0232

32,0405,0180

42,0407,0048

43,0003,0063 - 50mm²

43,0003,0064 - 70mm²

43,0003,0385 - 95mm²

Connection hose pack

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2 el_fr_st_vp_01716 012009

G 4m 50mm² 4,047,411

G 8m 70mm² 4,047,412

W 4m 95mm² 4,047,291

W 8m 95mm² 4,047,292

W 8m 95mm² 4,047,292,800

40,0001,0095 - *

42,0407,0482

32,0405,0226

42,0407,0482

40,0001,0012 - *

42,0407,0063

42,0405,0239

42,0405,0239

32,0405,0226

42,0402,0053

42,0001,0942

42,0001,0943

44,0450,0281 - G 1/4"

43,0003,0251

43,0003,0253

42,0407,0048

42,0001,1506

42,0001,3543 - 5/8"-18UNF

44,0450,0281 - G 1/4"

40,0003,0343 - *

42,0407,0063

40,0003,0014-* 50mm²

40,0003,0021-* 70mm²

40,0003,0015-* 95mm²

42,0407,0048

43,0003,0253

43,0003,0252

43,0003,0019 - 50-70mm²

43,0003,0301 - 70-95mm²

43,0003,0063 - 50mm²

43,0003,0064 - 70mm²

43,0003,0385 - 95mm²

Connection hose pack

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2 el_fr_st_vp_01716 012009

FRONIUS INTERNATIONAL GMBH

Buxbaumstraße 2, A-4600 Wels, Austria

Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940

E-Mail: [email protected]

www.fronius.com

www.fronius.com/addresses

Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations.

ud_fr_st_so_00082 012008

Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement

Table of contents