Fronius VR 5000 - Safety in Normal Operation and Maintenance

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Table of contents
General information 5
General .......................................................................................................................................................... 7
Device concept .......................................................................................................................................... 7
Requirements ............................................................................................................................................ 7
Field of application..................................................................................................................................... 7
Warning notices affixed to the device ........................................................................................................ 8
Control elements and connections 9
Description of the control panels ................................................................................................................... 11
General .................................................................................................................................................... 11
Safety ....................................................................................................................................................... 11
Manual control panel .................................................................................................................................... 12
General ................................................................................................................................................... 12
Manual control panel ............................................................................................................................... 12
Adjustment aid for Manual control panel.................................................................................................. 13
Synergic control panel .................................................................................................................................. 14
General ................................................................................................................................................... 14
Layout of the control panel ...................................................................................................................... 14
Synergic A control panel .......................................................................................................................... 14
Synergic B control panel .......................................................................................................................... 16
Connections and mechanical components ................................................................................................... 17
Wirefeeder front ...................................................................................................................................... 17
Wirefeeder rear ....................................................................................................................................... 17
Wirefeeder side ....................................................................................................................................... 18
Wirefeeder underside .............................................................................................................................. 19
Installation and commissioning 21
Before commissioning .................................................................................................................................. 23
Safety ...................................................................................................................................................... 23
Utilisation in accordance with „intended purpose“ .................................................................................... 23
Setup regulations .................................................................................................................................... 23
Placing wirefeeder on power source ............................................................................................................. 24
General ................................................................................................................................................... 24
Placing wirefeeder on power source ........................................................................................................ 24
Connecting wirefeeder to power source ....................................................................................................... 25
General ................................................................................................................................................... 25
Connecting wirefeeder to power source .................................................................................................. 25
Connecting the welding torch ....................................................................................................................... 26
Safety ...................................................................................................................................................... 26
Connecting MIG/MAG welding torches .................................................................................................... 26
Inserting / replacing feed rollers .................................................................................................................... 27
General ................................................................................................................................................... 27
Inserting / replacing feed rollers............................................................................................................... 27
Inserting the wirespool, inserting the basket-type spool ................................................................................ 28
Safety ...................................................................................................................................................... 28
Inserting the wirespool ............................................................................................................................. 28
Inserting the basket-type spool ................................................................................................................ 28
Feeding in the wire electrode ........................................................................................................................ 29
Feeding in the wire electrode ................................................................................................................... 29
Setting the contact pressure .................................................................................................................... 30
Adjusting the brake ....................................................................................................................................... 31
General ................................................................................................................................................... 31
Adjusting the brake .................................................................................................................................. 31
Design of the brake ................................................................................................................................. 31