FRONIUS VR 5000 noSpool Leitfaden

Operating Instructions

Spare Parts List

Wirefeeder

42,0426,0080,EN 022009

VR 5000

ud_fr_st_et_00493 012004

Dear Reader

Thank you for choosing Fronius - and congratulations on your new, technically high-

grade 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! n 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.

Introduction

ud_fr_st_sv_00467 022009

Safety rules

DANGER!

WARNING!

CAUTION!

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

and damage to the equipment.

NOTE!

This equipment has been made in accordance with the state of the art and

all recognised safety rules. Nevertheless, incorrect operation or misuse may

still lead to danger for

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

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

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and

maintaining the equipment must

- be suitably qualified

- know about welding and

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In

addition to the instruction manual, copies of both the generally applicable

and the local accident prevention and environmental protection rules must be

kept on hand, and of course observed in practice.

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

- must be kept in a legible condition

- must not be damaged, must not be removed

- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are

located on the machine, please see the section of your machine’s instruction

manual headed “General remarks”.

General remarks

Important!

“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 avo-

ided, may result in minor or moderate injury. It may also be used to alert

against unsafe practices that may cause property damage.

“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!

ud_fr_st_sv_00467 022009 II

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)

Ambient

conditions

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.

Utilisation for

intended purpose

only

Any malfunctions which might impair machine safety must be eliminated

immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

The 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 “war-

nings“ 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.

Obligations of

owner/operator

General remarks

(continued)

ud_fr_st_sv_00467 022009

III

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.

Obligations of

personnel

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 pace-

maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

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.

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable pro-

tective 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

ud_fr_st_sv_00467 022009 IV

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 power-

ful, compare the measured pollutant emission values with the permitted

threshold limit values.

Hazards from

noxious gases

and vapours

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.

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 insula-

ting, heat-proof)

- To lessen your exposure to noise and to protect your hearing against

injury, wear ear-protectors!

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.

ud_fr_st_sv_00467 022009

Hazards from

mains and weld-

ing current

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

flying sparks

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.

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

noxious gases

and vapours

(continued)

ud_fr_st_sv_00467 022009 VI

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.

Stray welding

currents

Hazards from

mains and weld-

ing 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.

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