Related Manuals for Fronius TransSteel 4000 Pulse
Summary of Contents for Fronius TransSteel 4000 Pulse
- Page 1 Operating instructions TransSteel 4000 Pulse TransSteel 5000 Pulse EN-US Operating instructions 42,0426,0353,EA 007-04052022...
-
Page 3: Table Of Contents
Table of contents Safety Instructions Explanation of Safety Instructions General Intended Use Environmental Conditions Obligations of the Operating Company Obligations of Personnel Grid Connection Personal Protection and Protection of Others Danger from toxic gases and vapors Danger from Flying Sparks Risks from grid current and welding current Stray welding currents EMC Device Classifications... - Page 4 Installation and Startup Minimum equipment for welding operations General Gas-cooled MIG/MAG welding Water-cooled MIG/MAG welding Manual metal arc welding Minimum equipment for arc air gouging Before installation and initial operation Safety Intended use Setup regulations Grid Connection Connecting the Mains Cable General Stipulated mains cables and strain-relief devices Safety...
- Page 5 Preparation Arc air gouging Easy Documentation General General Documented welding data New CSV file PDF report / Fronius signature Activating / deactivating Easy Documentation Activating Easy Documentation Set the date and time Deactivating Easy Documentation Setup Settings Setup Menu General...
- Page 6 TransSteel 5000 Pulse TransSteel 5000 Pulse nc TransSteel 5000 Pulse MV nc Welding program tables Welding program label on the device Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse US...
-
Page 7: Safety Instructions
Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ▶ Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 8: Intended Use
Intended Use The device is to be used exclusively for its intended purpose. The device is intended exclusively for the welding process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose."... -
Page 9: Grid Connection
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current consumption. This may affect a number of device types in terms of: connection restrictions criteria regarding maximum permissible grid impedance criteria regarding the minimum required short-circuit power both at the interface with the public grid See technical data In this case, the operator or the person using the device should check whether or... -
Page 10: Danger From Flying Sparks
Use at-source extraction source and a room extraction system. If possible, use a welding torch with an integrated extraction device. Keep your head out of the welding fumes and gases. Take the following precautionary measures for fumes and harmful gases: Do not breathe them in. - Page 11 During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers, as well as all pieces of metal that are in contact with the welding wire, are live. Always place the wirefeeder on a sufficiently insulated base or use a suitable in- sulating wirefeeder holder.
-
Page 12: Stray Welding Currents
Stray welding If the following instructions are not observed, stray welding currents may occur, currents which pose a risk of the following: Fire Overheating of parts connected to the workpiece Irreparable damage to ground conductors Damage to the device and other electrical equipment Ensure that the workpiece clamp is securely connected to the workpiece. -
Page 13: Emf Measures
Equipotential bonding Workpiece grounding If necessary, establish grounding using suitable capacitors. Shield, if necessary Shield other devices in the vicinity Shield the entire welding installation EMF measures Electromagnetic fields may cause health problems that are not yet known: Effects on the health of persons close by, e.g., those with pacemakers and hearing aids Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process... -
Page 14: Requirement For The Shielding Gas
When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufacturer's website. Only use suitable load-carrying equipment from the manufacturer to transport devices by crane. Attach chains or ropes to all designated attachments of the suitable load- carrying equipment. -
Page 15: Danger Posed By Shielding Gas Leak
If a valve on a shielding gas cylinder is open, turn your face away from the outlet. When no welding is taking place, close the valve of the shielding gas cylinder. Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected. -
Page 16: Safety Measures In Normal Operation
Safety Measures Only operate the device when all safety devices are fully functional. If the safety in Normal Oper- devices are not fully functional, there is a danger of: ation Injury or death to the operator or a third party Damage to the device and other material assets belonging to the operating company Inefficient operation of the device... -
Page 17: Safety Inspection
Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you... -
Page 19: General Information
General information... -
Page 21: General
General Device concept The TransSteel (TSt) 4000 Pulse and TransSteel 5000 Pulse power sources are fully digitized, microprocessor- controlled inverter power sources. A modular design and ability to easily extend the system ensure high flexibil- ity. The devices are designed for the fol- lowing welding processes: MIG/MAG pulse welding MIG/MAG standard synergic weld-... -
Page 22: Warning Notices On The Device
Warning notices Warning notices and safety symbols are affixed to the power source. These warn- on the device ing notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and property dam- age. -
Page 23: Welding Processes, Procedures, And Welding Characteristics For Mig/Mag Welding
Welding processes, procedures, and welding char- acteristics for MIG/MAG welding General In order to process a wide range of materials effectively, various welding pro- cesses, procedures, and welding characteristics are available on the power source. Brief description MIG/MAG standard synergic of MIG/MAG standard syner- MIG/MAG standard synergic welding is a MIG/MAG welding process covering the... -
Page 24: Brief Description Of The Gouging (Arc Air Gouging)
Brief description In arc air gouging, an arc is ignited between a carbon electrode and the work- of the gouging piece; the parent material is melted and blown out with compressed air. (Arc Air Gou- The operating parameters for arc air gouging are defined in a special character- ging) istic. -
Page 25: System Components
System components General The power sources can be operated with various system components and op- tions. This makes it possible to optimize procedures and to simplify machine handling and operation, depending on the field of application for the power source. Safety WARNING! Danger from incorrect operation and work that is not carried out properly. -
Page 26: Overview
Overview Welding torch Wirefeeder Wirefeeder holder Interconnecting hosepacks Power source Cooling unit Trolley and gas cylinder holders Grounding and electrode cable... -
Page 27: Vrd: Safety Function
VRD: Safety function VRD: Safety The Voltage Reduction Device (VRD) is an optional safety device for voltage re- function duction. It is recommended for environments where arc welding significantly in- creases the risk of electric shock or electrical accident: Due to low body resistance of the welder If the welder is exposed to a significant risk of touching the workpiece or other parts of the welding circuit A low body resistance is likely in the event of:... - Page 28 Applies to MMA welding mode: Within 0.3 seconds of the end of welding: VRD is active again Restriction of the output voltage to 35 V is ensured again...
-
Page 29: Operating Controls And Connections
Operating controls and connec- tions... -
Page 31: Control Panel
Control Panel General The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be Selected by means of buttons Changed using buttons or the selection dial Shown on the digital display during welding. Due to the synergic function, all other parameters are also adjusted if a single parameter is changed. -
Page 32: Control Panel
Control panel (13) (14) (15)(16) (17) (12) (11) (10) Function "Parameter selection" button (right) a) for selecting the following parameters Arc length correction For correcting the arc length Welding voltage in V *) Before welding begins, the device automatically displays a standard value based on the programmed parameters. - Page 33 Pulse / arc-force dynamic correction For continuously correcting the droplet detachment force in MIG/MAG pulsed synergic welding - ... reduced droplet detachment force 0 ... neutral droplet detachment force + ... increased droplet detachment force For influencing the short-circuiting dynamic at the instant of droplet transfer in MIG/MAG standard synergic welding, MIG/MAG standard manual welding, and manual metal arc welding - ...
- Page 34 For changing parameters in the Setup menu Selection dial (left) For changing the sheet thickness, welding current, and wire speed para- meters For selecting parameters in the Setup menu EasyJob save buttons For saving up to 5 operating points "Process" button For selecting the welding process MIG/MAG standard manual welding MIG/MAG standard synergic welding...
- Page 35 When the shielding gas is selected, the LED behind the corresponding shielding gas lights up. "Wire diameter" button For selecting the wire diameter used. The SP parameter is reserved for additional wire diameters. When the wire diameter is selected, the LED behind the corresponding wire diameter lights up.
- Page 36 menu – EnE parameter. The value continuously rises during welding in line with the permanently increasing energy input. The final value is stored after the end of welding until welding starts again or the power source is switched back on - the HOLD indicator lights up. During the MIG/MAG standard synergic welding process and MIG/MAG pulsed synergic welding process, if one of these parameters is selected, then the synergic function ensures that all other parameters, including...
-
Page 37: Service Parameters
Service para- Various service parameters can be retrieved by pressing the "Parameter selec- meters tion" buttons at the same time. Opening the display The first parameter "Firmware version" will be displayed, e.g., "1.00 | 4.21" Selecting parameters Use the "Mode" and "Process" buttons or the left-hand selection dial to select the required setup parameter Available parameters... -
Page 38: Keylock
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the control panel. As long as the keylock is active: Settings cannot be adjusted on the control panel Only parameter settings can be retrieved Any assigned "Save" button can be retrieved provided that an assigned "Save" button was selected when the keylock was enabled Activating/deactivating the keylock: Keylock activated:... -
Page 39: Connections, Switches, And Mechanical Components
Connections, Switches, and Mechanical Compon- ents TransSteel 4000/5000 Pulse connec- tions Function (-) Current socket with bayonet latch Used for Connecting the grounding cable for MIG/MAG welding Connecting the electrode cable or grounding cable for manual metal arc welding (depending on the type of electrode used) Power switch For switching the power source on and off (+) Current socket with bayonet latch... -
Page 41: Installation And Startup
Installation and Startup... -
Page 43: Minimum Equipment For Welding Operations
Minimum equipment for welding operations General Depending on the welding process, a minimum level of equipment is required to work with the power source. The following describes the welding processes and the corresponding minimum equipment for welding operations. Gas-cooled Power source MIG/MAG weld- Grounding cable Gas-cooled MIG/MAG welding torch... -
Page 44: Before Installation And Initial Operation
Before installation and initial operation Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 45: Grid Connection
WARNING! Danger of electrical current due to electrically conductive dust in the device. This can result in severe personal injury and damage to property. ▶ Only operate the device if an air filter is fitted. The air filter is a very import- ant safety device for achieving IP 23 protection. -
Page 46: Connecting The Mains Cable
A strain-relief device for the following cable cross-sections is fitted to the power source: Power source Cable cross-section Fitted strain-relief device Europe Canada/US TransSteel 4000 Pulse AWG 12 *) 4G2.5 TransSteel 5000 Pulse AWG 10 *) TransSteel 4000 MV AWG 10 *) -
Page 47: Safety
Safety WARNING! Danger from work that is not carried out properly. This can result in severe personal injury and damage to property. ▶ The work described below may only be performed by trained specialist per- sonnel. ▶ Follow national standards and guidelines. CAUTION! Danger from improperly prepared mains cable. -
Page 48: Fitting The Strain-Relief Device For Europe
Fitting the strain-relief device for Europe 1,2 Nm IMPORTANT! Tie the phase conduct- ors near the block terminal using cable ties. -
Page 49: Fitting The Strain-Relief Device For Canada / Us
Fitting the strain-relief device for Canada / US 3,5 Nm IMPORTANT! Tie the phase conduct- ors near the block terminal using cable ties. -
Page 50: Generator-Powered Operation
Generator-Powered Operation Generator- The power source is generator-compatible. powered opera- tion The maximum apparent power S of the power source must be known in order 1max to select the correct generator output. The maximum apparent power S of the power source is calculated for 3- 1max phase devices as follows: x √3... -
Page 51: Commissioning
Commissioning Safety WARNING! An electric shock can be fatal. If the power source is connected to the grid during installation, there is a danger of serious personal injury and property damage. ▶ Only carry out work on the device when the power source's power switch is in the - O - position. -
Page 52: Assembling System Components (Overview)
Assembling sys- WARNING! tem components (overview) Work performed incorrectly can cause serious injury and damage. ▶ The following activities must only be carried out by trained and qualified per- sonnel. ▶ Please note the information in the "Safety instructions" chapter! The following diagram is intended to provide you with an overview of how the in- dividual system components are put together. -
Page 53: Place The Wirefeeder On The Power Source
Place the CAUTION! wirefeeder on the power source Danger of personal injury and damage to equipment due to falling wirefeeder. ▶ Ensure that the wirefeeder is firmly seated on the pivot pin and that the devices, upright brackets, and trolley are positioned securely. Fit the strain-re- lief device of the interconnecting... -
Page 54: Connecting The Interconnecting Hosepack
Connecting the WARNING! interconnecting hosepack Fitting the device incorrectly can cause serious injury and damage to property. ▶ Do not perform the steps described here until you have fully read and under- stood the Operating Instructions. NOTE! When connecting the interconnecting hosepack, check that ▶... -
Page 55: Correct Routing Of The Interconnecting Hosepack
Correct routing IMPORTANT! The duty cycle values (D.C.) of the interconnecting hosepack can of the intercon- only be achieved if it is correctly routed. necting hosep- Correct routing of the interconnecting hosepack... -
Page 56: Connecting The Gas Cylinder
Connecting the WARNING! gas cylinder Danger of severe injury and damage to property if gas cylinders fall over. When using gas cylinders: ▶ Place them on a solid, level surface in such a way that they remain stable ▶ Secure the gas cylinders to prevent them from falling over ▶... -
Page 57: Establishing A Ground Earth Connection
Establishing a NOTE! ground earth connection When establishing a ground earth connection, observe the following points: ▶ Use a separate grounding cable for each power source ▶ Keep positive cables and grounding cables together as long and as close as possible ▶... -
Page 58: Connecting A Mig/Mag Welding Torch
Connecting a * with integrated water connection op- MIG/MAG weld- tion and water-cooled welding torch ing torch Other activities Carry out the following steps according to the Operating Instructions for the wirefeeder: Insert feed rollers into the wirefeeder Insert wirespool or basket-type spool with basket-type spool adapter into the wirefeeder Feed in the wire electrode Set the contact pressure... -
Page 59: Mig/Mag Welding
MIG/MAG welding... -
Page 61: Power Limitation
Power Limitation Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety. Wire speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. -
Page 62: Mig/Mag Operating Modes
MIG/MAG Operating Modes General WARNING! Operating the device incorrectly can cause serious injury and damage to prop- erty. ▶ Do not use the functions described here until you have fully read and under- stood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and under- stood all of the Operating Instructions of the system components, especially the safety rules. -
Page 63: 2-Step Mode
2-step mode "2-step mode" is suitable for Tacking work Short weld seams Automatic and robot operation 4-step mode "4-step mode" is suitable for longer weld seams. -
Page 64: Special 2-Step Mode
Special 2-step mode "Special 2-step mode" is ideal for welding in higher power ranges. In special 2- step mode, the arc starts at a lower power, which makes it easier to stabilize. To activate special 2-step mode: Select 2-step mode In the Setup menu, set the t-S (starting current duration) and t-E (final cur- rent duration) parameters to a value >... -
Page 65: Spot Welding
Spot welding < SPt The "Spot welding" mode is suitable for welded joints on overlapped sheets. Start by pressing and releasing the torch trigger - GPr gas pre-flow time - weld- ing current phase over the SPt spot welding time duration - GPo gas post-flow time. -
Page 66: 4-Step Stitch Welding
4-step stitch welding 4-step stitch welding The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the parent materi-... -
Page 67: Mig/Mag Welding
MIG/MAG welding Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 68: Mig/Mag Synergic Welding
MIG/MAG synergic welding MIG/MAG syner- Press the "Material" button to select the filler metal to be used. gic welding Press the "Wire diameter" button to select the diameter of the wire electrode used. Press the "Shielding gas" button to select the shielding gas to be used. The assignment of the SP position is in the welding program tables in the ap- pendix. - Page 69 Use the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power: Sheet thickness Welding current Wire speed Welding voltage Use the appropriate selection dial to set the welding parameter. The value of the parameter is displayed on the digital display located above. The sheet thickness, welding current, wire speed, and welding voltage paramet- ers are directly linked.
-
Page 70: Corrections During Welding
Corrections dur- The arc length correction and arc-force dynamic parameters can be used to op- ing welding timize the welding result. Arc length correction: = shorter arc, reduced welding voltage = neutral arc = longer arc, increased welding voltage Pulse / arc-force dynamic correction For continuous correction of the droplet detachment force in MIG/MAG pulsed synergic welding reduced droplet detachment force... - Page 71 How SynchroPulse works when used in "Special 4-step" mode I-S = starting-current phase, SL = Slope, I-E = crater-fill phase, v = wire speed Al.2 SynchroPulse mode of operation...
-
Page 72: Mig/Mag Standard Manual Welding
MIG/MAG Standard Manual Welding General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function. Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted indi- vidually, as dictated by the welding process in question. -
Page 73: Corrections During Welding
IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system compon- ent - such as remote control or wirefeeder - on the control panel of the power source. -
Page 74: Spot Welding And Stitch Welding
Spot welding and stitch welding General The spot welding and stitch welding modes are MIG/MAG welding processes. The spot welding and stitch welding modes are activated on the control panel. Spot welding is used on welded joints on overlapping sheets that are only access- ible on one side. -
Page 75: Stitch Welding
CAUTION! Danger of injury and damage from electric shock and from the wire electrode emerging from the torch. When you press the torch trigger: ▶ Keep the welding torch away from your face and body ▶ Wear suitable protective goggles ▶... - Page 76 Depending on the welding process selected, select the desired welding para- meters and adjust them using the appropriate selection dial Open the gas cylinder valve Adjust quantity of shielding gas CAUTION! Danger of injury and damage from electric shock and from the wire electrode emerging from the torch.
-
Page 77: Easyjob Mode
EasyJob mode General The "Save" buttons allow up to five EasyJob operating points to be saved. Each operating point corresponds to the settings made on the control panel. EasyJobs can be stored for each welding process. IMPORTANT! Setup parameters are not saved at this time. Saving EasyJob Press and hold one of the "Save"... -
Page 78: Retrieving Easyjob Operating Points On The Up/Down Welding Torch
Retrieving Easy- Press one of the "Save" buttons on the control panel to retrieve the saved set- Job operating tings using the Up/Down welding torch. points on the Up/ Down welding Press one of the "Save" buttons on the control panel, e.g.: torch The control panel will show the saved settings. -
Page 79: Mma Welding, Arc Air Gouging
MMA welding, arc air gouging... -
Page 81: Manual Metal Arc Welding
Manual Metal Arc Welding Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. -
Page 82: Manual Metal Arc Welding
Manual metal CAUTION! arc welding Danger of injury and damage from electric shock. When the power switch is switched to position - I -, the rod electrode in the elec- trode holder is live. ▶ Ensure that the rod electrode is not touching any people or electrically con- ductive or grounded parts (housing, etc.). -
Page 83: Corrections During Welding
Corrections dur- To obtain the best possible welding results, the arc-force dynamic parameter will ing welding sometimes need to be adjusted. Press the "Parameter selection" button to select the arc-force dynamic para- meter Use the selection dial to set the desired arc-force dynamic value The welding parameter value is shown in the digital display located above it. -
Page 84: Hotstart Function
HotStart func- To obtain the best possible welding result, the HotStart function will sometimes tion need to be adjusted. Advantages Improved ignition properties, even when using electrodes with poor ignition properties Better fusion of the parent material during the start-up phase, meaning few- er cold-shut defects Slag inclusions largely avoided The setting of the available parameters is described in the section "Setup set-... -
Page 85: Arc Air Gauging
Arc Air Gauging Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. - Page 86 CAUTION! Risk of personal injury due to loud operating noise. ▶ Use suitable hearing protection during arc air gouging! Set the power switch to position - I -: all indicators on the control panel briefly illuminate Press the "Process" button to select the MMA welding process: The welding voltage is applied to the welding socket with a three second time lag.
-
Page 87: Easy Documentation
Easy Documentation... -
Page 89: General
CSV file on a USB thumb drive. A Fronius signature is stored with the welding data, which can be used to check and guarantee the authenticity of the data. -
Page 90: New Csv File
By scanning this link... Fronius signa- A PDF report of the selected welding data can be created ture The authenticity of the welding data can be checked and guaranteed via the Fronius signature read out with the welding data. https://easydocu.weldcube.com... -
Page 91: Activating / Deactivating Easy Documentation
Activating / deactivating Easy Documentation Activating Easy The power source display shows: Documentation USB 3.1 FAT32 Easy Documentation is activated. doc | on is also displayed when the power source is switched off and on again with the USB thumb drive con- nected. - Page 92 To set the date and time: Left-hand selection dial: select parameter Right-hand selection dial: change values Setting ranges: Year (20yy; 0 - 99) Month (mm; 1 -1 12) Day (dd; 1 - 31) Hour (hh; 0 - 24) Minute (mm; 0 - 59) NOTE! If the power source is reset to factory settings via setup parameter FAC, the date and time remain stored.
-
Page 93: Setup Settings
Setup Settings... -
Page 95: Setup Menu
Setup Menu General The Setup menu offers easy access to expert knowledge related to the power source, as well as additional functions. The Setup menu makes it possible to eas- ily adjust the parameters for various tasks. Operation Accessing the Setup menu is described with reference to the MIG/MAG standard synergic welding process. -
Page 96: Setup Parameters For Mig/Mag Synergic Welding
Setup paramet- The specifications "min." and "max." are used for setting ranges that vary accord- ers for ing to the power source, welding program, etc. MIG/MAG syner- Gas pre-flow time gic welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9... - Page 97 NOTE! The Ito function (length of wire fed until safety cut-out trips) is a safety func- tion. At high wire speeds in particular, the length of wire fed until the safety cut-out trips can deviate from the set wire length. Spot welding time / interval welding time Unit: s Setting range: 0.3 - 5...
-
Page 98: Setup Parameters For Mig/Mag Standard Manual Welding
Setup paramet- The specifications "min." and "max." are used for setting ranges that vary accord- ers for ing to the power source, welding program, etc. MIG/MAG Gas pre-flow time standard manual Unit: s welding Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9... -
Page 99: Setup Parameters For Mma Welding
Setting range: 2T (2-step), 4T (4-step) Factory setting: 2T (2-step) Reset power source to factory settings Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings - when "PrG" appears on the digital display, the power source has been re- IMPORTANT! If the power source is reset, all the personal settings in the Setup menu are lost. -
Page 100: Setup Menu 2Nd Level
Setup Menu 2nd Level Limitations The following restrictions occur in relation to the Setup menu 2nd level: Setup menu 2nd level cannot be selected: during welding if the "Gas test" function is active if the "Wire threading" function is active if the "Wire withdrawal"... -
Page 101: Parameters For Mig/Mag Synergic Welding In Setup Menu 2Nd Level
Exiting the Setup menu A parameter is displayed in the first MANUAL STD SYNERGIC level of the Setup menu. PULSE SYNERGIC MANUAL STD SYNERGIC PULSE SYNERGIC Parameters for Country-specific setting (Standard/USA) ... Std/US MIG/MAG syner- Unit: - gic welding in Setting range: Std, US (Standard/USA) Setup menu 2nd Factory setting:... - Page 102 the cooling unit is always switched off, even if the switch is in the "On" po- sition. Cooling time (only when the cooling unit is connected) Time from when flow monitoring 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 preset time.
-
Page 103: Parameters For Mig/Mag Standard Manual Welding In Setup Menu 2Nd Level
changes at the same time. The left display then shows the original value again, e.g., welding current. EasyJob Trigger To activate/deactivate switching between EasyJobs using the torch trigger Unit: - Setting range: On/OFF Factory setting: OFF Function with MIG/MAG torch trigger Press torch trigger briefly (<... - Page 104 AUt: The cooling unit cuts out after a 2-minute welding off-time. IMPORTANT! If the coolant temperature and flow monitoring option has been installed in the cooling unit, the cooling unit cuts out as soon as the return-flow temperature drops below 50 °C, but at the earliest after a 2- minute welding off-time.
-
Page 105: Parameters For Manual Metal Arc Welding In Setup Menu 2Nd Level
10000 to 99999 / 10.0 to 99.9 (without unit or tens digit, e.g., 23580 kJ -> 23.6) EasyJob Trigger To activate/deactivate switching between EasyJobs using the torch trigger Unit: - Setting range: On/OFF Factory setting: OFF Function with MIG/MAG torch trigger Press torch trigger briefly (<... -
Page 106: Measuring The Welding Circuit Resistance R
Measuring the Welding Circuit Resistance r General Measuring the welding circuit resistance makes it possible to have a constant welding result at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. -
Page 107: Measuring The Welding Circuit Resistance (Mma Welding)
The measurement is finished when the welding circuit resistance is shown on the display in mOhm (for example 11.4). Fit the gas nozzle back onto the welding torch Measuring the NOTE! welding circuit resistance (MMA Incorrect measurement of the welding circuit resistance can have a negative ef- fect on the welding result. -
Page 108: Displaying The Welding Circuit Inductivity L
Displaying the welding circuit Inductivity L General The way that the hosepack is arranged has a very significant effect on the weld- ing circuit inductivity and therefore affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result. Displaying the The setup parameter "L"... -
Page 109: Troubleshooting And Maintenance
Troubleshooting and Maintenance... -
Page 111: Troubleshooting
Troubleshooting General The devices are equipped with an intelligent safety system, which largely negates the need for melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again. Safety WARNING! Danger from incorrect operation and work that is not carried out properly. - Page 112 Contact our After-Sales Service team with a detailed description of the error ESr | 20 Cause: The cooling unit used is not compatible with the power source Remedy: Connect compatible cooling unit ----- Cause: An invalid welding process was called up on the robot interface (no. 37) or an empty flag was selected (no.
- Page 113 Err | PE Cause: The earth current watchdog has triggered the safety cut-out of the power source. Remedy: Switch off the power source Place the power source on an insulating surface Connect the grounding cable to a section of the workpiece that is closer to the arc Wait for 10 seconds and then switch the power source on again If you have tried this several times and the error keeps recurring,...
- Page 114 EFd | 81, EFd | 83 Cause: Fault in the wirefeed system (overcurrent in wirefeeder drive) Remedy: 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 pres- sure on the 4 roller drive Cause: Wirefeeder motor is sticking or faulty...
- Page 115 to7 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the power source Remedy: Allow power source to cool down, check air filter and clean if neces- sary, check that fan is on tu0 | xxx Note: xxx stands for a temperature value Cause: Undertemperature in the power source primary circuit Remedy:...
-
Page 116: Displayed Service Codes In Connection With Opt Easy Documentation
no | H2O Cause: Coolant flow rate too low Remedy: Check coolant flow rate and cooling unit, including cooling circuit (for minimum coolant flow, see "Technical Data" chapter in the Oper- ating Instructions for the device) hot | H2O Cause: The coolant temperature is too high Remedy: Allow cooling unit and cooling circuit to cool down, until "hot | H2O"... - Page 117 bAt | oFF Welding is not possible Cause: The battery of the OPT Easy Documentation is empty Remedy: To reset the service code, press the arrow key - the display shows no | dAt; Contact service (to change the battery); After changing the battery, the date and time in the are displayed in the 2nd level of the service menu: see page...
-
Page 118: Service, Maintenance And Disposal
Service, maintenance and disposal General Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, several points must be observed in order for the welding system to remain operational for years to come. Safety WARNING! Danger from electrical current. -
Page 119: Every 6 Months
Every 6 Months CAUTION! Danger due to the effect of compressed air. This can result in damage to property. ▶ Do not bring the air nozzle too close to electronic parts. Dismantle device side panels and blow the inside of the device clean with dry, reduced compressed air Also clean the cooling air ducts if there is a large accumulation of dust WARNING! -
Page 121: Appendix
Appendix... -
Page 123: Average Consumption Values During Welding
Average consumption values during welding Average wire Average wire electrode consumption at a wire speed of 5 m/min electrode con- 1.0 mm wire 1.2 mm wire 1.6 mm wire sumption during electrode dia- electrode dia- electrode dia- MIG/MAG weld- meter meter meter Steel wire electrode... -
Page 124: Technical Data
An overview of which critical raw materials are contained in this device can be terials, year of found at the following Internet address. production of www.fronius.com/en/about-fronius/sustainability. the device To calculate the year of production of the device: Each device is provided with a serial number... - Page 125 60 % 6 Min. 4 Min. 150 A 0 Min. 6 Min. 10 Min. To use the device without interruptions: Search for a 100% ED value in the technical data, which corresponds to the existing ambient temperature. Reduce the power or amperage value correspondingly so that the device can operate without a cool-down phase.
-
Page 126: Transsteel 4000 Pulse Transsteel 4000 Pulse Nc
TransSteel 4000 Mains voltage (U 3 x 380 V/400 V/460 V Pulse TransSteel Max. effective primary current (I 4000 Pulse nc 1eff 3 x 380/400 V 25.0 A 3 x 460 V 27.0 A Max. primary current (I 1max 3 x 380/400 V 32.0 A 3 x 460 V 22.0 A... - Page 127 Idle state power consumption at 400 31.2 W Power source efficiency at 400 A / 36 V Interface to a 230/400-V and 50-Hz public grid ED = Duty cycle A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid.
-
Page 128: Transsteel 4000 Pulse Mv Nc
TransSteel 4000 Mains voltage (U 3 x 200 V / 230 V / 400 V / 460 V Pulse MV nc Max. effective primary current (I 1eff 3 x 230 V 33.0 A 3 x 400 V 19.0 A 3 x 460 V 16.0 A Max. - Page 129 Dimensions l x w x h 747 x 300 x 497 mm 29.4 x 11.8 x 19.6 in. Weight 37.3 kg / 82 lb. Max. noise emission (L 74 dB (A) Idle state power consumption at 400 82.7 W Power source efficiency at 400 A / 36 V Interface to a 230/400-V and 50-Hz public grid ED = Duty cycle...
-
Page 130: Transsteel 5000 Pulse Transsteel 5000 Pulse Nc
TransSteel 5000 Mains voltage (U 3 x 380 V / 400 V / 460 V Pulse TransSteel Max. effective primary current (I 5000 Pulse nc 1eff 3 x 380/400 V 28 A 3 x 460 V 24.0 A Max. primary current (I 1max 3 x 380/400 V 44.0 A... - Page 131 Idle state power consumption at 400 31.2 W Power source efficiency at 500 A / 40 V Interface to a 230/400-V and 50-Hz public grid ED = Duty cycle A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low-voltage grid.
-
Page 132: Transsteel 5000 Pulse Mv Nc
TransSteel 5000 Mains voltage (U 3 x 200 V / 230 V / 400 V / 460 V Pulse MV nc Max. effective primary current (I 1eff 3 x 200 V 39.5 A 3 x 230 V 36.3 A 3 x 400 V 20.6 A 3 x 460 V 18.1 A... - Page 133 Protection class IP 23 Type of cooling Insulation class Overvoltage category Pollution degree according to IEC60664 EMC emission class Safety symbols S, CE, CSA Dimensions l x w x h 747 x 300 x 497 mm 29.4 x 11.8 x 19.6 in. Weight 43.6 kg / 96.1 lb.
-
Page 134: Welding Program Tables
Welding program tables Welding program A label with the most common welding programs is affixed to the power source: label on the device Welding program label on the power source... -
Page 135: Welding Program Tables For Transsteel 4000 Pulse, Transsteel 5000 Pulse
Welding program The welding programs are active if tables for The "SEt" setup parameter is set TransSteel 4000 to "Std" (Standard) Pulse, TransSteel 5000 The VR 5000 Remote wirefeeder is Pulse equipped with the VR Pulse con- trol panel option. Welding program database: DB 3994 Standard welding characteristics Material... - Page 136 Additional welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘ 1/16‘‘ S2423 S2424 S2425 CrNi/Stainless Ar + 18% CO P4014 P4013 P4015 S2440 S2441 S2442 S2443 CrNi/Stainless root Ar + 18% CO S2471...
-
Page 137: Welding Program Tables For Transsteel 4000 Pulse, Transsteel 5000 Pulse Us
Welding program The welding programs are active if tables for The "Set" setup parameter is set to TransSteel 4000 "US" (USA) Pulse, TransSteel 5000 The VR 5000 Remote wirefeeder is Pulse US equipped with the VR Pulse con- trol panel option. Welding program database: DB 3994 Standard welding characteristics Material... - Page 138 Additional welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘ 1/16‘‘ S2423 S2424 S2425 CrNi/Stainless Ar + 15-25% CO P4014 P4013 P4015 S2440 S2441 S2442 S2443 CrNi/Stainless root Ar + 2,5% CO S2471...
Need help?
Do you have a question about the TransSteel 4000 Pulse and is the answer not in the manual?
Questions and answers