Fronius VR 5000rob, Operating Instructions Manual

Page 1: ...s on elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0085 EN 019 15052020 VR 5000rob Operating Instructions Wire...

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Page 3: ...h the product Reading the instructions carefully will enable you to learn about the many different features it has to offer This will allow you to make full use of its advantages Please also note the...

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Page 5: ...osal 16 Safety symbols 17 Data protection 17 Copyright 17 General information 18 Device concept 18 PAP overview 18 Standard overview 19 Intended purpose 20 Field of application 20 Warning notices affi...

Page 6: ...6 Troubleshooting 34 General 34 Safety 34 Fault diagnosis 34 Technical data 38 VR 5000rob 38...

Page 7: ...he device All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read and follow these operating instr...

Page 8: ...and storage 20 C to 55 C 4 F to 131 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or substances etc Can be used at a...

Page 9: ...ith no turn ups Protective clothing refers to a variety of different items Operators should Protect eyes and face from UV rays heat and sparks using a protective visor and reg ulation filter Wear regu...

Page 10: ...s supply if no welding is taking place Danger from fly ing sparks Flying sparks may cause fires or explosions Never weld close to flammable materials Flammable materials must be at least 11 metres 36...

Page 11: ...a mains supply with ground conductor and a connector system with ground conductor contact for proper operation Operation of the device on a mains supply without ground conductor and on a socket with o...

Page 12: ...ven though a device complies with the standard limit values for emis sions it may affect the application area for which it was designed e g when there is sen sitive equipment at the same location or i...

Page 13: ...s with wire feed unit and wear suitable protective goggles Never touch the workpiece during or after welding risk of burns Slag can jump off cooling workpieces The specified protective equipment must...

Page 14: ...om shielding gas cyl inders Shielding gas cylinders contain gas under pressure and can explode if damaged As the shielding gas cylinders are part of the welding equipment they must be handled with the...

Page 15: ...ly When transporting the device observe the relevant national and local guidelines and ac cident prevention regulations This applies especially to guidelines regarding the risks aris ing during transp...

Page 16: ...cations alterations etc to the device without the manufac turer s consent Components that are not in perfect condition must be replaced immediately When ordering please give the exact designation and...

Page 17: ...address http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA Data protection The user is responsible for the safekeepin...

Page 18: ...evice has a Power limitation safety feature This means that the power source can be operated at the power limit without compromising process safety Details can be found in the Welding mode section of...

Page 19: ...d over view No Function 1 Cooling unit e g FK 5000 with optional flow watchdog 2 Power source e g TransSteel 3500 3 Interconnecting hosepack Power source robot interface 4 Wire feed unit mount 5 VR 50...

Page 20: ...ed inspection and servicing work Utilisation not in accordance with the intended purpose comprises wire feeding for applications other than MIG MAG welding feeding in wires that are unsuitable for the...

Page 21: ...rch using compressed air max 7 bar 101 49 psi Wirefeeding hose For protected transport of the wire from the wirespool to the VR 5000rob available in different lengths The wirefeeding hose also ensures...

Page 22: ...ting Instructions for the system components espe cially the safety rules Mechanical com ponents VR 5000rob Standard VR 5000rob PAP No Function 1 Feeder inching button For threading the wire electrode...

Page 23: ...ction For enhanced LocalNet with lines for motor supply and motor control 4 Blanking cover For optional gas pressure sensor or external CAT signal 5 Blanking cover For optional blow off 6 Blanking cov...

Page 24: ...3 Blanking cover For optional external CAT 4 Blanking cover For optional gas pressure sensor 5 Enhanced LocalNet connection For enhanced LocalNet with lines for motor supply and motor control 6 Shiel...

Page 25: ...egular basis and in the event of unusual operating situations e g a system crash that all screw connections between the robot wirefeeder mount and wire feed unit are secure Fitting the VR 5000rob conv...

Page 26: ...26 3 4 5 6 3 4 5 6...

Page 27: ...rollers Before commissioning in sert suitable feed rollers into the wire feed unit Inserting replac ing feed rollers CAUTION Danger from feed roller holders flying upwards This can result in severe i...

Page 28: ...28 3 4 3 8 6 7 9 3 1 2 2 5 4 4 3 4 5 5 6 1 2 3 4...

Page 29: ...lectrode and the earthed enclosure of a robot cell chafed wirefeeding hoses exposing the wire electrode To avoid earth contact or short circuit Use wirefeeding hoses for insulated routing of wire elec...

Page 30: ...ver the next 1 5 seconds Hold the button for longer than 2 5 se conds after a total of 2 5 seconds the wire is fed at a constant rate equal to the wire feed speed set for the Fdi welding parameter If...

Page 31: ...31 EN 1 Contact pressure standard values U groove roll ers Steel 4 5 CrNi 4 5 Tubular cored electrodes 2 3 1 1...

Page 32: ...lified personnel All instructions in the section headed Safety rules must be observed Every start up Check welding torch interconnecting hosepack and grounding earthing connection for signs of damage...

Page 33: ...33 EN 1 2 3 Disposal Dispose of in accordance with the applicable national and local regulations 1 1 2 3...

Page 34: ...table measuring device check to make sure that electrically charged com ponents e g capacitors have discharged CAUTION Inadequate PE conductor connections can cause serious injury and damage The housi...

Page 35: ...ice codes to is displayed Detailed information on the service codes to0 to to6 can be found in the section Displayed ser vice codes Cause Overload Remedy Take the duty cycle into account Cause Thermos...

Page 36: ...liner in welding torch Remedy Check the inner liner for kinks dirt etc and replace if necessary Cause The feed rollers are not suitable for the wire electrode being used Remedy Use suitable feed roll...

Page 37: ...valve torch gas con nection etc Cause Welding torch is leaking Remedy Change the welding torch Cause Wrong contact tip or contact tip is worn out Remedy Replace the contact tip Cause Wrong wire alloy...

Page 38: ...r 2 A 1 2 A Welding current at 10 min 40 C 104 F 40 d c 500 A 60 d c 450 A 100 d c 360 A Maximum shielding gas pressure 5 bar 72 49 psi Wire feed speed 0 5 25 m min 19 69 984 25 ipm Wire drive 4 rolle...

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Page 40: ...INTERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and lo...