Operating Instructions Spare Parts List GB: Wirefeeder

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.
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Safety rules
DANGER!
WARNING!
CAUTION!
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!
NOTE! indicates a situation which implies a risk of impaired welding result

and damage to the equipment.
Important!
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!
General remarks
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 machines instruction
manual headed General remarks.
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General remarks
(continued)
Any malfunctions which might impair machine safety must be eliminated

immediately - meaning before the equipment is next switched on.
Its your safety thats at stake!
Utilisation for
intended purpose
only
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.
Ambient
conditions
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)
Obligations of
owner/operator
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.
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II
Obligations of
personnel
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.
Mains connection
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.
Protection for
yourself and
other persons
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
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Protection for
yourself and
other persons
(continued)
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.
Information on
noise emission
values
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.
Hazards from
noxious gases
and vapours
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.
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IV
Hazards from
noxious gases
and vapours
(continued)
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.
Hazards from
flying sparks
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.
Hazards from
mains and welding current
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.
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Hazards from
mains and welding current
(continued)
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.
Stray welding
currents
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.
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VI
Stray welding
currents
(continued)
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.
EMC device
classifications
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
EMC measures
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
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EMI Precautions
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
Particular danger
spots
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 welders 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.
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VIII
Particular danger
spots
(continued)
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.
Danger from
shielding-gas
cylinders
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 manufacturers instructions and all relevant national and
international rules applying to shielding-gas cylinders and accessories.
IX
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Safety precautions at the installation site and

when being
transported
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.
Safety precautions in normal

operation
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.
-
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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.
Safety precautions in normal

operation
(continued)
Preventive and
corrective maintenance
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 manufacturers 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.
Safety inspection
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.
Disposal
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
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Safety markings
Equipment with CE-markings fulfils the basic requirements of the LowVoltage 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.
Data security
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
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.
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XII
Table of contents
General information
General ..........................................................................................................................................................
Device concept ..........................................................................................................................................
Requirements ............................................................................................................................................
Field of application .....................................................................................................................................
Warning notices affixed to the device ........................................................................................................
Control elements and connections
7
7
7
7
8
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 ..................................................................................................................................

Safety ......................................................................................................................................................
Utilisation in accordance with intended purpose ....................................................................................
Setup regulations ....................................................................................................................................
Placing wirefeeder on power source .............................................................................................................
General ...................................................................................................................................................
Placing wirefeeder on power source ........................................................................................................
Connecting wirefeeder to power source .......................................................................................................
General ...................................................................................................................................................
Connecting wirefeeder to power source ..................................................................................................
Connecting the welding torch .......................................................................................................................
Safety ......................................................................................................................................................
Connecting MIG/MAG welding torches ....................................................................................................
Inserting / replacing feed rollers ....................................................................................................................
General ...................................................................................................................................................
Inserting / replacing feed rollers ...............................................................................................................
Inserting the wirespool, inserting the basket-type spool ................................................................................
Safety ......................................................................................................................................................
Inserting the wirespool .............................................................................................................................
Inserting the basket-type spool ................................................................................................................
Feeding in the wire electrode ........................................................................................................................
Feeding in the wire electrode ...................................................................................................................
Setting the contact pressure ....................................................................................................................
Adjusting the brake .......................................................................................................................................
General ...................................................................................................................................................
Adjusting the brake ..................................................................................................................................
Design of the brake .................................................................................................................................
1
23
23
23
23
24
24
24
25
25
25
26
26
26
27
27
27
28
28
28
28
29
29
30
31
31
31
31
Commissioning ............................................................................................................................................. 32
General ................................................................................................................................................... 32
Requirements .......................................................................................................................................... 32
Welding
33
MIG/MAG modes ..........................................................................................................................................

General ...................................................................................................................................................
Symbols ..................................................................................................................................................
2-step mode ............................................................................................................................................
4-step mode ............................................................................................................................................
Special 4-step mode ................................................................................................................................
MIG/MAG welding ........................................................................................................................................
Safety ......................................................................................................................................................
General tasks before MIG/MAG welding .................................................................................................
Overview .................................................................................................................................................
MIG/MAG standard synergic welding ...........................................................................................................
General ...................................................................................................................................................
MIG/MAG standard synergic welding ......................................................................................................
Adjustments while welding - manual control panel ...................................................................................
MIG/MAG standard manual welding .............................................................................................................
General ...................................................................................................................................................
Available parameters ...............................................................................................................................
MIG/MAG standard manual welding - manual control panel ....................................................................
MIG/MAG standard manual welding - Synergic A control panel ...............................................................
Corrections during welding - Synergic A control panel .............................................................................
MMA welding ................................................................................................................................................
Safety ......................................................................................................................................................
Preparations ............................................................................................................................................
MMA welding - manual control panel .......................................................................................................
MMA welding - Synergic A control panel ..................................................................................................
Adjustments while welding - Synergic A control panel ..............................................................................
Hotstart function ......................................................................................................................................
Anti-stick function ....................................................................................................................................
Saving and retrieving operating points ..........................................................................................................
General ...................................................................................................................................................
Saving operating points ...........................................................................................................................
Retrieving operating points ......................................................................................................................
Setup parameters
35
35
35
35
36
36
37
37
37
37
38
38
38
39
40
40
40
40
41
42
43
44
44
44
44
45
45
46
46
47
48
48
48
48
49
Process set-up menu ...................................................................................................................................

General ...................................................................................................................................................
Process set-up menu - manual control panel ..........................................................................................
Process set-up menu - Synergic A control panel .....................................................................................
Parameters for MIG/MAG welding in the Process set-up menu ..............................................................
Parameters for rod electrode (MMA) welding in the Process set-up menu ..............................................
Mode set-up menu .......................................................................................................................................
General ...................................................................................................................................................
Mode set-up menu - Synergic A control panel .........................................................................................
Parameters for Special 4-step mode in the mode set-up menu .............................................................
Set-up menu - Level 2 ..................................................................................................................................
Set-up menu level 2 - manual control panel .............................................................................................
Set-up menu Level 2 - Synergic control panel .........................................................................................
Set-up menu Level 2 - Synergic control panel .........................................................................................
Parameters for MIG/MAG welding in the set-up menu level 2 .................................................................
51
51
51
52
53
53
54
54
54
55
56
56
57
58
58
Troubleshooting and maintenance
59
Troubleshooting ............................................................................................................................................
General ...................................................................................................................................................
Displayed service codes ..........................................................................................................................
Troubleshooting the wirefeeder ...............................................................................................................
Care, maintenance and disposal ..................................................................................................................
General ...................................................................................................................................................
At every start-up ......................................................................................................................................
Every 6 months .......................................................................................................................................
Disposal ..................................................................................................................................................
Annex
61
61
61
65
67
67
67
67
67
69
Technical data .............................................................................................................................................. 71

VR 5000 .................................................................................................................................................. 71
Fronius Worldwide
General information
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.
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
Control elements and connections
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:
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, CO2 100 %
No. Function
(1) Adjustment aid applies with the specified material / protective gas shield
combination
e.g.:
Steel
Material
1.0 mm
Wire diameter
CO2 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
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.
Layout of the
control panel
Synergic A control panel
The Synergic control panel is split.
Synergic B control panel

Control panel sections A and B
Synergic A
control panel
(9)
(8)
(1)
(2)
(3)
(4)
(7)
(6)
Synergic control panel
14
(5)
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
- harder, more stable arc
0 neutral arc
The relevant symbol lights up when a parameter is selected.
(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.
(3) Right adjusting dial
for modifying the arc length correction, welding voltage and arc-force dynamic
parameters
(4) Left adjusting dial
for modifying the sheet thickness, welding current and wirefeed speed parameters
(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)
(2)
(3)
Synergic B control panel
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
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
(3)
(2)
(4) Position
for option (+) - current socket with
bayonet latch
(1)
(5) Position
for LocalNet connection socket option
(5)
(4)
VR 5000 - Front view
Wirefeeder rear
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
(1)
(2)
(3)
(5) Water return connection (red) option

(4)
(5)
(6)
(6) Water flow connection (black) option

VR 5000 - rear view
17
Wirefeeder side
(1)
(2)
(3)
(4)
VR 5000 - side view
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
No. Function
(1) Socket for swivel pin
for placing the wirefeeder on the
swivel pin in the swivel pin holder
(1)
VR 5000 - view from below
19
20
Installation and commissioning
21
22
Before commissioning
Safety
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.
24
Connecting wirefeeder to power source

General
The wirefeeder is connected to the power source using the interconnecting hosepack.
Connecting
wirefeeder to
power source
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
1
1
1
3
6
7
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

NOTE! When connecting the welding torch, check that
- all connections are connected properly
- all cables, leads and hosepacks are undamaged and correctly insulated.
Safety
Connecting MIG/
MAG welding
torches
1
1
3
6
3
2
2
26
when the optional water connection

and the water-cooled welding torch
are installed
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
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.
1
1
2
4
5
13
2
8
6
7
1
5
1
2
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
Inserting the
basket-type
spool
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
28
Feeding in the wire electrode

Feeding in the
wire electrode
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.
1
1
1
2
3
2
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
Wire feed speed

(m/min or ipm)
t (s)
1
2 2.5 3
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
1
2
5
4
Setting the
contact pressure
NOTE! Adjust the contact pressure in such a way that the wire electrode is not
deformed, but is nevertheless transported properly.
1
1
Contact pressure guideline values
U-grooved rollers
Steel
4-5
CrNi
4-5
Tubular cored electrodes
2-3
30
Adjusting the brake

General
Adjusting the
brake
Important! After releasing the torch trigger the wirespool should stop unreeling. Adjust
brake if necessary.
2
2
1
STOP
STOP
OK
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
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
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
Press the torch trigger

Press torch trigger symbol
2-step mode
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
GPr
2-step mode
35
GPo
4-step mode
4-step mode is suitable for longer weld seams.
GPr
GPo
4-step mode
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.
GPr
I-S
SL
Special 4-step mode
36
SL
I-E
GPo
MIG/MAG welding
Safety
safety rules
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.
3.
Plug in the mains plug

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

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.
3.
Use the Protective gas shield button to select the protective gas shield used.
On Synergic A control panel:

4.
Press the Process button to select the desired welding process:

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

Engage the feed rollers
7.
Adjustments
while welding manual control
panel
Press the torch trigger and start welding
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
0
+
shorter arc length

neutral arc length
longer arc length
Arc-force dynamic
+

soft, low-spatter arc
39
Korrek
Schwe

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

welding - manual
control panel
1.

MIG/MAG welding
2.

2-step mode
4-step mode
(e.g. remote control unit) may not be able to be changed on the wire-feed unit
control panel.
3.
4.
Set the required wire feed speed using the wire feed speed adjuster
Set the required welding voltage using the welding voltage adjuster
The parameter values are shown in the digital indicator located above them.
40

welding - manual
control panel
(continued)
5.
6.

-

7.
Adjustments
panel
1.

Arc-force dynamic
41

welding - Synergic A control
panel
On Synergic A control panel:

1.

2.

2-step mode
4-step mode
In MIG/MAG standard manual welding, Special 4-step mode corresponds to
conventional 4-step operation.
(e.g. remote control unit) might not be able to be changed on the wirefeeder control
panel.
3.
4.
5.
6.
Press the Parameter selection button and select the wirefeed speed parameter
Use the adjusting dial to set the wirefeed speed to the desired value
Press the Parameter selection button and select the welding voltage parameter
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.
8.

-

42

welding - Synergic A control
panel
(continued)
electrode emerging from the torch. When you press the torch trigger:
9.
Corrections
during welding Synergic A
control panel
To obtain the best possible welding results, the dynamic parameter will sometimes need
to be adjusted.
1.
2.
Press the Parameter selection button and select the dynamic parameter
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
0 harder, more stable arc

10 soft, low-spatter arc
43
MMA welding
Safety
safety rules
Preparations
1.
2.
3.
Turn the mains switch to the O position

Unplug the device from the mains
Remove the MIG/MAG welding torch
Important! Check the rod electrode packaging to determine whether the rod electrodes are for (+) or (-) welding.
4.
5.
6.
7.
MMA welding manual control

panel
Plug the grounding (earthing) cable into either the (-) or the (+) current socket,
depending on the type of electrode, and latch it in firmly
With the other end of the earthing (grounding) cable, establish a connection to the
workpiece
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
Plug in the mains plug
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.
2.
Move the mains switch to the I position: All the indicators on the control panel light
up briefly
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.
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.
Adjustments
panel
Start welding
1.

Arc-force dynamic
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.
2.
Move the mains switch to the I position: All the indicators on the control panel light
up briefly
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.
control panel.
45
MMA welding Synergic A

control panel
(continued)
3.
4.
Press the Parameter selection button and select the welding current parameter.
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.
Adjustments
while welding Synergic A
control panel
Start welding
In order to obtain the best possible welding results, the following parameter can be
corrected in certain circumstances:
1.
2.
Press the Parameter selection button and select the dynamic correction parameter
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)
Legend
Hti ........ Hot-current time,
0 - 2 s, factory setting: 0.5 s
HCU .... Hot-start current, 0 - 200%,
factory setting 150 %
IH .......... Main current = Pre-set welding
current
Hti
300
HCU > IH
200
HCU
IH
t (s)
0,5
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 (IH).
1,5
Example of Hotstart function
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.:
Retrieving operating points
2.
Release the Save button
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.
9.
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.
3.
4.
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.
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

8.
9.
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:
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
s
0 - 9,9
0,1
GPo
Gas post-flow time
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
s
0 - 2,0
0,5
HCU
Hot-start current
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.
3.
4.
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.
6.
Change the value of the parameter using the Parameter Selection button or the right adjusting dial

8.
9.
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
% (of welding current)

0 - 200
100
SL
Slope: 0 - 9.9 s
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

2.
3.
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
6.
7.
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
11. Press the Process button
12. Release the Mode and Process buttons
56
Set-up menu
Level 2 - manual
control panel
(continued)

Set-up menu
Level 2 - Synergic control panel
Opening the set-up menu

2.
3.
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

6.
7.
9.
Change the value of the parameter using the Dynamic button or

the right adjusting dial
Exiting from the set-up menu - level 2

57
Set-up menu
Level 2 - Synergic control panel
(continued)

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 50C, 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

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:
Software not supported by power source

Contact After-Sales Service
ESr | 254
Cause:
Remedy:

EPr | 0 to EPr | 12
Cause:
Remedy:
Welding database power source defective

ELn | 2
Cause:
Remedy:
Synergic B control panel, data connection interrupted

Err | PE
Cause:
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:
Phase failure
Check the mains fuse, the mains lead and the mains plug
Err | 51
Cause:
Remedy:
Mains undervoltage: The mains voltage has fallen below the tolerance range
Check the mains voltage
Err | 52
Cause:
Remedy:
Mains overvoltage: The mains voltage has risen above the tolerance
range
Check the mains voltage
Err | IP
Cause:
Remedy:
Primary overcurrent
EPS | 7
Cause:
Remedy:
Defective welding current sensor

EFd | 5
Cause:
Remedy:
Incorrect wirefeeder connected

Connect correct wirefeeder or contact After-Sales Service
EFd | 7
Cause:
Remedy:
Motor current sensor faulty

EFd | 81, EFd | 83

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
Cause:
Remedy:
Overtemperature in the power source control gear

to2 | xxx
Cause:
Remedy:
Overtemperature in the secondary circuit of the power source

62
Displayed service
codes
(continued)
to3 | xxx
Cause:
Remedy:
Overtemperature in the wirefeeder motor

Allow wirefeeder to cool down
to4 | xxx
Cause:
Remedy:
Overtemperature in welding torch

Allow welding torch to cool down
to5 | xxx
Cause:
Remedy:
Overtemperature in cooling unit

Allow cooling unit to cool down.
to6 | xxx
Cause:
Remedy:
Overtemperature in the power source transformer

tu0 | xxx
Cause:
Remedy:
Undertemperature in the power source primary circuit

Place power source in a heated room and allow to warm up
tu1 | xxx
Cause:
Remedy:
Undertemperature in the power source control gear

tu2 | xxx
Cause:
Remedy:
Undertemperature in the power source secondary circuit

tu3 | xxx
Cause:
Remedy:
Undertemperature in the wirefeeder motor

Place wirefeeder in a heated room and allow to warm up
tu4 | xxx
Cause:
Remedy:
Undertemperature in the welding torch

Place welding torch in a heated room and allow to warm up
tu5 | xxx
Cause:
Remedy:
Undertemperature in the cooling unit

Place cooling unit in a heated room and allow to warm up
tu6 | xxx
Cause:
Remedy:
Overtemperature in the power source transformer

63
Displayed service
codes
(continued)
Err | tf0
Cause:
Remedy:
Faulty temperature sensor in the power source primary circuit

Err | tf1
Cause:
Remedy:
Faulty temperature sensor in the power source control gear

Err | tf2
Cause:
Remedy:
Faulty temperature sensor in the power source secondary circuit

Err | tf3
Cause:
Remedy:
Faulty temperature sensor in wirefeeder motor

Err | tf4
Cause:
Remedy:
Faulty temperature sensor in welding torch

Err | tf5
Cause:
Remedy:
Faulty temperature sensor in cooling unit

Err | tf6
Cause:
Remedy:
Faulty temperature sensor in power source transformer

no | Prg
Cause:
Remedy:
No preconfigured program has been selected

select a configured program
EPG | 1 to EPG | 6
Cause:
Remedy:
Welding database power source defective

EPG | 17 to EPG | 21
Cause:
Remedy:

Ebo | 2 and Ebo | 3

Cause:
Remedy:
Fault in the power source control gear

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:
The gas cylinder is empty

Change the gas cylinder
Cause:
Remedy:
Gas pressure regulator is faulty

Change the gas pressure regulator
Cause:
Remedy:
The gas hose is not connected, or is damaged

Mount/change the gas hose
Cause:
Remedy:
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:
Poor grounding (earthing) connection

Ensure good contact to workpiece
Cause:
Remedy:
Inadequate protective gas shield, or none at all

Check the pressure regulator, gas hose, gas solenoid valve, torch
gas connection, etc.
Cause:
Remedy:
Welding torch is leaking

Change the welding torch
Cause:
Remedy:
Wrong contact tube, or contact tube is worn out

Change the contact tube
Cause:
Remedy:
Wrong wire alloy or wrong wire diameter

Check the wire spool that has been inserted
Cause:
Remedy:
Wrong wire alloy or wrong wire diameter

Check the weldability of the base material
Cause:
Remedy:
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:
The braking force has been set too high

Loosen the brake
Cause:
Remedy:
The borehole of the contact tube is too narrow

Use a suitable contact tube
Cause:
Remedy:
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
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
Every 6 months
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
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
24 V
Control current input

Motor current input
2A
4A
Gear ratio
16 : 1
Wirefeed speed
1 - 25 m/min
39.37 - 984.25 ipm.
Wirefeed drive
4 roller drive
Wire diameter
0.8 1.6 mm
0.03 - 0.06 in.
Wirespool diameter
max. 300 mm
max. 11.81 in.
Wirespool weight
max. 19 kg
max. 41.89 lb.
Degree of protection
IP 23
Dimensions l x w x h
640 x 270 x 365 mm

25.20 x 10.63 x 14.37 in.
Weight
12.5 kg
27.56 lb.
71
72
Ersatzteilliste
GB Spare Parts List
Liste de pices de rechange
Lista parti di ricambio
Lista de repuestos
Lista de peas sobresselentes
NL Onderdelenlijst
Reservdelsliste
CZ Seznam nhradnch dl
RUS
SK Zoznam nhradnch dielov
ud_fr_st_tb_00150
012008
VR 5000 4R/G/FSC Manual

VR 5000C
VR 5000 4R/W/FSC Manual
VR 5000 4R/G/FSC Synergic
VR 5000 4R/W/FSC Synergic
4,049,002
4,049,002,C
4,049,002,630
4,049,003
4,049,003,630
42,0400,0352
40,0006,2692
42,0300,2600
44,0550,0060
43,0001,3336 - manual
43,0001,3337 - synergic
42,0300,2880
42,0401,1114 (4x)
BY2,0201,3064 - manual
42,0409,3270 - synergic
42,0404,1013
42,0405,0717
42,0405,0656
42,0405,0688
42,0406,0093
44,0001,1400
BY4,0490,0001
42,0406,0315
42,0406,0123
32,0405,0214
42,0405,0656
43,0004,4059
44,0001,1402
42,0300,2566
42,0407,0357
44,0001,1401,Z
45,0405,0005,Z
42,0407,0063
42,0405,0702
42,0405,1076
42,0405,0716
43,0004,4058
42,0405,0700
42,0401,0959 (8x)
42,0300,1564
43,0013,0015
40,0006,3003
4,071,111
43,0001,1095
42,0405,0699,Z
40,0001,0012 -*
42,0001,1509
42,0001,6262
42,0405,0697
42,0409,3269
42,0405,0701
42,0407,0063
42,0401,1115 (27x)
42,0405,0189
42,0405,0186 - RED
42,0405,0187 - BLACK
44,0001,1145
40,0006,3035
40,0006,3035
VR 5000
Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi
el_fr_st_dv_01717
1/1
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
42,0405,1095
to
ec
42,0407,0667
nn
Co
Mo
tor
42,0404,0384
44,0001,1413
42,0405,1097
42,0405,0687
42,0401,1098 (8x)
42,0001,3750
42,0407,0665
44,0001,1399
42,0407,0680
42,0403,0153
42,0405,1096
42,0405,1093
42,0001,3751
42,0405,1094,Z
Motorplate Alu 4R s
el_fr_st_mp_01718
1/1
012009
G
G
G
W
W
W
W
W
W
G
G
G
W
G
1,2m 50mm
5m 50mm
10m 50mm
1,2m 70mm
1,6m 70mm
5,0m 70mm
10m 70mm
15m 70mm
20m 70mm
1,2m 70mm
5,0m 70mm
10m 70mm
20m 95mm
20m 95mm
4,047,408
4,047,409
4,047,410
4,047,260
4,047,324
4,047,261
4,047,262
4,047,290
4,047,277
4,047,287
4,047,288
4,047,289
4,047,669
4,047,670
32,0405,0226
42,0407,0482
40,0001,0095 - *
42,0405,0239
42,0407,0482
42,0407,0063
32,0405,0226
40,0001,0012 - *
42,0402,0053
42,0001,0942
42,0001,0943
44,0450,0281 - G 1/4"
42,0405,0239
43,0003,0485
32,0405,0232
32,0405,0180
42,0407,0048
42,0001,1506
40,0003,0078 - *
42,0407,0063
44,0450,0281 - G 1/4"
40,0003,0014-* 50mm
40,0003,0021-* 70mm
40,0003,0015-* 95mm
43,0003,0063 - 50mm
43,0003,0064 - 70mm
43,0003,0385 - 95mm
42,0407,0048
32,0405,0180
32,0405,0231
43,0003,0486
43,0003,0019 - 50-70mm
43,0003,0301 - 70-90mm
Connection hose pack

el_fr_st_vp_01716
1/2
012009
G
G
W
W
W
4m
8m
4m
8m
8m
50mm
70mm
95mm
95mm
95mm
4,047,411
4,047,412
4,047,291
4,047,292
4,047,292,800
32,0405,0226
42,0407,0482
40,0001,0095 - *
42,0405,0239
42,0407,0482
42,0407,0063
32,0405,0226
40,0001,0012 - *
42,0402,0053
42,0001,0942
42,0001,0943
42,0405,0239
44,0450,0281 - G 1/4"
43,0003,0251
43,0003,0253
42,0407,0048
42,0001,1506
42,0001,3543 - 5/8"-18UNF
40,0003,0343 - *
42,0407,0063
44,0450,0281 - G 1/4"
40,0003,0014-* 50mm
40,0003,0021-* 70mm
40,0003,0015-* 95mm
43,0003,0063 - 50mm
43,0003,0064 - 70mm
43,0003,0385 - 95mm
42,0407,0048
43,0003,0253
43,0003,0252
43,0003,0019 - 50-70mm
43,0003,0301 - 70-95mm
Connection hose pack

el_fr_st_vp_01716
2/2
012009
FRONIUS INTERNATIONAL GMBH

Buxbaumstrae 2, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
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Operating Instructions Spare Parts List GB: Wirefeeder

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Operating Instructions Spare Parts List GB: Wirefeeder

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VR 5000

DANGER! indicates an imminently hazardous situation which, if not

WARNING! indicates a potentially hazardous situation which, if not

NOTE! indicates a situation which implies a risk of impaired welding result

Important! indicates practical hints and other useful special-information. It

Any malfunctions which might impair machine safety must be eliminated

Operation or storage of the power source outside the stipulated range is

The owner/operator undertakes to ensure that the only persons allowed to

at the interface with the public mains network

see Technical Data

electrical hazards from mains and welding current

increased exposure to noise

noxious welding fumes and gases.

Protective clothing also includes:

Flying sparks can cause fires and explosions!

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

Devices with emission class A:

Electromagnetic fields may cause as yet unknown damage to health.

Safety precautions at the installation site and

Safety precautions in normal

Safety precautions in normal

The owner/operator is obliged to have a safety inspection performed on the

Do not dispose of this device with normal domestic waste!

Copyright to this instruction manual remains the property of the

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

Before commissioning ..................................................................................................................................

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

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

Troubleshooting and maintenance

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

Wirefeeders in the VR 5000 series are

Welding is dangerous. The following

Do not use the functions described until

Control elements and connections

Description of the control panels

Manual control panel

Manual control panel

(5) Dynamic buttons

Synergic control panel

Synergic A control panel

The Synergic control panel is split.

Synergic B control panel

Synergic B control panel

Connections and mechanical components

VR 5000 - Front view

(5) Water return connection (red) option

(6) Water flow connection (black) option

VR 5000 - rear view

VR 5000 - side view

VR 5000 - view from below

Installation and commissioning

The device is intended exclusively for wire feeding in MIG/MAG welding.

Placing wirefeeder on power source

Placing wirefeeder on power

Connecting wirefeeder to power source

Connecting the welding torch

when the optional water connection

Inserting / replacing feed rollers

Inserting / replacing feed rollers

Inserting the wirespool, inserting the basket-type spool

CAUTION! Risk of injury from springiness of spooled wire electrode. When

Feeding in the wire electrode

CAUTION! Risk of injury from springiness of spooled wire electrode. When