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Summary of Contents for Fronius TransSteel 4000 Pulse
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions TransSteel 4000 Pulse TransSteel 5000 Pulse MIG/MAG Power source 42,0426,0353,EA 002-31082020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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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 ........................ - 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 ........................Before installation and initial operation ...................... Safety..............................Intended use ............................Setup regulations ..........................Grid Connection ............................ Connecting the Mains Cable........................
- Page 5 Every 6 Months ............................. 108 Disposal ..............................108 Appendix Technical data............................111 Special Voltage ............................. 111 Explanation of the Term Duty Cycle ..................... 111 TransSteel 4000 Pulse TransSteel 4000 Pulse nc ................112 TransSteel 4000 Pulse MV nc ......................113...
- Page 6 TransSteel 5000 Pulse MV nc ......................115 Welding program tables ..........................117 Welding program label on the device....................117 Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse ........118 Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse US ........ 120...
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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: Environmental Conditions
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 ac- cordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use. -
Page 9: Personal Protection And Protection Of Others
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 not the device is allowed to be connected, where appropriate through discussion with the power supply company. -
Page 10: Danger From Flying Sparks
Take the following precautionary measures for fumes and harmful gases: Do not breathe them in. Extract them from the work area using appropriate equipment. Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow rate of at least 20 m³... -
Page 11: Stray Welding Currents
Ensure suitable personal protection with dry temporary backing or cover with sufficient in- sulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential. All cables and leads must be secured, undamaged, insulated, and adequately dimen- sioned. -
Page 12: Emc Device Classifications
Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts. Observe the following when using electrical distributors, double-headed retainers, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric poten- tial. -
Page 13: Emf Measures
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 im- mediate vicinity of the device and the welding process Keep distances between welding cables and the head/torso of the welder as large as possible for safety reasons... -
Page 14: Requirement For The Shielding Gas
In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices). If the device is equipped with a carrier belt or handle, then this is used exclusively for trans- port by hand. -
Page 15: Safety Measures At The Setup Location And During Transport
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage. Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour. Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply. -
Page 16: Maintenance And Repair
Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.) Only use appropriate original coolant from the manufacturer. Do not mix original coolant from the manufacturer with other coolants. Only connect system components from the manufacturer to the cooling unit circuit. -
Page 17: Safety Symbols
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 have any suggestions for im- provement, or can point out any mistakes that you have found in the Operating Instruc- tions, we will be most grateful for your comments. -
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 in- verter power sources. A modular design and ability to easily ex- tend the system ensure high flexibility. The devices are designed for the following welding processes: MIG/MAG pulse welding MIG/MAG standard synergic welding... - Page 22 Warning notices on the power source Welding is dangerous. The following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Exclusion of unauthorized persons Do not use the functions described here until you have fully read and understood the fol- lowing documents: These Operating Instructions All system component Operating Instructions, especially the safety rules...
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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 processes, pro- cedures, and welding characteristics are available on the power source. Brief description MIG/MAG standard synergic of MIG/MAG stan- dard synergic MIG/MAG standard synergic welding is a MIG/MAG welding process covering the entire... -
Page 24: System Components
System components General The power sources can be operated with various system components and options. 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 due to incorrect operation. -
Page 25: Overview
Overview Welding torch Wirefeeder Wirefeeder holder Interconnecting hosepacks Power source Cooling unit Trolley and gas cylinder holders Grounding and electrode cable... -
Page 26: Vrd: Safety Function
VRD: Safety function VRD: Safety func- The Voltage Reduction Device (VRD) is an optional safety device for voltage reduction. It tion is recommended for environments where arc welding significantly increases 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 27 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...
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Page 29: Operating Controls And Connections
Operating controls and connections... -
Page 31: Control Panel
Control Panel General The functions are all arranged in a logical way on the control panel. The individual param- eters 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 *) - Page 33 Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding. Pulse / arc-force dynamic correction For continuously correcting the droplet detachment force in MIG/MAG pulsed syn- ergic welding - ...
- Page 34 For changing parameters in the Setup menu Selection dial (left) For changing the sheet thickness, welding current, and wire speed parameters 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 For selecting the filler metal used. The SP parameter is reserved for additional ma- terials. When the material type is selected, the LED behind the corresponding filler metal lights up. (11) "Wire threading" button Press and hold the button: Gasless wire threading into the torch hosepack While the button is being held, the wire drive operates at feeder inching speed.
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Page 36: Service Parameters
Service parame- Various service parameters can be retrieved by pressing the "Parameter selection" buttons ters at the same time. Opening the display Press and hold the "Parameter selecti- on" button (left) Press the "Parameter selection" button (right) Release the "Parameter selection" but- tons The first parameter "Firmware version"... -
Page 37: 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 Activate/deactivate the keylock as follows: Press and hold the "Mode"... -
Page 38: Connections, Switches, And Mechanical Components
Connections, Switches, and Mechanical Compo- nents TransSteel 4000/ 5000 Pulse con- nections 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... -
Page 39: Installation And Startup
Installation and Startup... -
Page 41: 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 equip- ment for welding operations. Gas-cooled MIG/ Power source MAG welding Grounding cable... -
Page 42: Before Installation And Initial Operation
Before installation and initial operation Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules. -
Page 43: Grid Connection
The ventilation channel is a very important safety device. When selecting the setup loca- tion, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked into the device. -
Page 44: 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 for Canada/US Europe TransSteel 4000 Pulse AWG 12 *) 4G2.5 TransSteel 5000 Pulse AWG 10 *) TransSteel 4000 MV... -
Page 45: Connecting The Mains Cable
CAUTION! Danger from improperly prepared mains cable. Short circuits and damage to property may result. ► Fit ferrules to all phase conductors and the ground conductor of the stripped mains ca- ble. Connecting the If no mains cable is connected, a mains cable that is suitable for the connection voltage mains cable must be fitted before commissioning. -
Page 46: Fitting The Strain-Relief Device For Canada / Us
1,2 Nm IMPORTANT! Tie the phase conductors near the block terminal using cable ties. Fitting the strain- relief device for Canada / US... - Page 47 3,5 Nm IMPORTANT! Tie the phase conductors near the block terminal using cable ties.
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Page 48: Generator-Powered Operation
Generator-Powered Operation Generator-pow- The power source is generator-compatible. ered operation The maximum apparent power S of the power source must be known in order to select 1max the correct generator output. The maximum apparent power S of the power source is calculated for 3-phase devices 1max as follows: x √3... -
Page 49: 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 50: 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 personnel. ► Please note the information in the "Safety instructions" chapter! The following diagram is intended to provide you with an overview of how the individual system components are put together. -
Page 51: Place The Wirefeeder On The Power Source
Place the wire- CAUTION! feeder 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 52: 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 understood the Operating Instructions. NOTE! When connecting the interconnecting hosepack, check that ►... -
Page 53: Correct Routing Of The Interconnecting Hosepack
Correct routing of IMPORTANT! The duty cycle values (D.C.) of the interconnecting hosepack can only be the interconnect- achieved if it is correctly routed. ing hosepack Correct routing of the interconnecting hosepack... -
Page 54: 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 55: Establishing A Ground Earth Connection
Establishing a NOTE! ground earth con- nection 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 56: Other Activities
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 wirefeed- Feed in the wire electrode Set the contact pressure Adjust the brake... -
Page 57: Mig/Mag Welding
MIG/MAG welding... -
Page 59: 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 60: Mig/Mag Operating Modes
MIG/MAG Operating Modes General WARNING! Operating the device incorrectly can cause serious injury and damage to property. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules. -
Page 61: 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 62: 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 current duration) parameters to a value >... -
Page 63: 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 - welding current phase over the SPt spot welding time duration - GPo gas post-flow time. If the torch trigger is pressed again before the end of the spot welding time (<... -
Page 64: 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 material. -
Page 65: Mig/Mag Welding
MIG/MAG welding Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules. -
Page 66: 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 appendix. - Page 67 All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter. Open the gas cylinder valve Adjust quantity of shielding gas: Tap the Gas-test button...
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Page 68: Corrections During Welding
Corrections The arc length correction and arc-force dynamic parameters can be used to optimize the during welding 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 69 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...
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Page 70: 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 param- eters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question. -
Page 71: Corrections During Welding
Press the "Parameter selection" button to select the welding voltage parameter Use the selection dial to set the desired welding voltage value The welding parameter values are shown in the digital display located above. All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. -
Page 72: Spot And Stitch Welding
Spot 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 accessible on one side. -
Page 73: Stitch Welding
Procedure for establishing a welding spot: Keep the welding torch vertical Press and release the torch trigger Maintain the position of the welding torch Wait for the gas post-flow time Raise the welding torch Stitch welding In the Setup menu, set the stitch pause time SPb Stitch welding is enabled. - Page 74 Procedure for stitch welding: Keep the welding torch vertical Depending on the stitch mode set under the Int parameter: Press and hold the torch trigger (2-step mode) Press and release the torch trigger (4-step mode) Maintain the position of the welding torch Wait for the welding interval Position the welding torch at the next point To stop stitch welding, depending on the stitch mode set under the Int parameter:...
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Page 75: 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 76: 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 settings using Job operating 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 77: Manual Metal Arc Welding
Manual Metal Arc Welding... -
Page 79: Manual Metal Arc Welding
Manual Metal Arc Welding Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ► Do not use the functions described here until you have fully read and understood the Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules. -
Page 80: Manual Metal Arc Welding
Manual metal arc CAUTION! welding Danger of injury and damage from electric shock. When the power switch is switched to position - I -, the rod electrode in the electrode holder is live. ► Ensure that the rod electrode is not touching any people or electrically conductive or grounded parts (housing, etc.). -
Page 81: Hotstart Function
HotStart function To obtain the best possible welding result, the HotStart function will sometimes 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 fewer cold-shut defects Slag inclusions largely avoided The setting of the available parameters is described in the section "Setup settings", "Setup... -
Page 83: Setup Settings
Setup Settings... -
Page 85: 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 easily adjust the param- eters for various tasks. Operation Accessing the Setup menu is described with reference to the MIG/MAG standard synergic welding process. -
Page 86: Setup Parameters For Mig/Mag Synergic Welding
Setup parameters The specifications "min." and "max." are used for setting ranges that vary according to the for MIG/MAG syn- power source, welding program, etc. ergic welding Gas pre-flow time Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9... - Page 87 NOTE! The Ito function (length of wire fed until safety cut-out trips) is a safety function. At high wire speeds in particular, the length of wire fed until the safety cut-out trips can de- viate from the set wire length. Spot welding time / interval welding time Unit: s Setting range: 0.3 - 5...
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Page 88: Setup Parameters For Mig/Mag Standard Manual Welding
Setup parameters The specifications "min." and "max." are used for setting ranges that vary according to the for MIG/MAG power source, welding program, etc. standard manual Gas pre-flow time welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9... -
Page 89: Setup Parameters For Mma Welding
Interval Displayed only if a value has been set for SPb Unit: 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"... -
Page 90: 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 91 To exit the Setup menu: Press and hold the "Mode" button Press the "Process" button MANUAL STD SYNERGIC PULSE SYNERGIC Release the "Mode" and "Process" MANUAL STD SYNERGIC buttons PULSE SYNERGIC A parameter is displayed in the first le- vel of the Setup menu. Press and hold the "Mode"...
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Page 92: Parameters For Mig/Mag Synergic Welding In Setup Menu 2Nd Level
Parameters for Country-specific setting (Standard/USA) ... Hour/US MIG/MAG syner- gic welding in Unit: Setup menu 2nd Setting range: Std, US (Standard/USA) level Factory setting: Standard version: Std (dimensions: cm / mm) USA version: US (dimensions: in.) Synergic programs/characteristics Standards EN / AWS Unit: Setting range: EUr / US Factory setting:... - Page 93 Welding circuit inductivity (in microhenrys) See the section "Displaying the welding circuit inductivity L" from page 98. Electrical energy of the arc in relation to the welding speed Unit: kJ Setting range: On / OFF Factory setting: OFF Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three- digit display, the following display format has been selected: Value in kJ / indicator on display: 1 to 999 / 1 to 999...
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Page 94: Parameters For Mig/Mag Standard Manual Welding In Setup Menu 2Nd Level
Parameters for Country-specific setting (Standard/USA) ... Hour/US MIG/MAG stan- dard manual Unit: welding in Setup Setting range: Std, US (Standard/USA) menu 2nd level Factory setting: Standard version: Std (dimensions: cm / mm) USA version: US (dimensions: in.) Cooling unit control (only when the cooling unit is connected) Unit: Setting range: AUt, On, OFF... -
Page 95: Parameters For Manual Metal Arc Welding In Setup Menu 2Nd Level
Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three- digit display, the following display format has been selected: Value in kJ / indicator on display: 1 to 999 / 1 to 999 1000 to 9999 / 1.00 to 9.99 (without unit digit, e.g., 5270 kJ ->... -
Page 96: 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 re- sult 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 97: 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 re- sistance (MMA Incorrect measurement of the welding circuit resistance can have a negative effect welding) on the welding result. -
Page 98: 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 welding 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 99: Troubleshooting And Maintenance
Troubleshooting and Maintenance... -
Page 101: 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! Work performed incorrectly can cause serious injury and damage to property. - Page 102 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. 32) Remedy: Call up a valid welding process or select assigned "Save"...
- Page 103 Err | Ur Cause: If the VRD option is available, the open circuit voltage limit of 35 V has been exceeded. Remedy: Switch off the power source Wait for 10 seconds and then switch the power source on again no | UrL Cause: The VRD option has tripped too early.
- Page 104 to1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature on the booster located in the power source Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on to2 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the secondary circuit of the power source...
- Page 105 tu1 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the booster located in the power source Remedy: Place power source in a heated room and allow it to warm up tu2 | xxx Note: xxx stands for a temperature value Cause: Undertemperature in the power source secondary circuit Remedy:...
- Page 106 no | Prg Cause: No preconfigured program has been selected Remedy: Select a configured program no | IGn Cause: "Ignition time-out" function is active; current did not start flowing before the length of wire specified in the Setup menu had been fed. The power source safety cut-out has tripped Remedy: Shorten the wire stick-out;...
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Page 107: 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 sys- tem to remain operational for years to come. Safety WARNING! An electric shock can be fatal. -
Page 108: 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 109: Appendix
Appendix... -
Page 111: Technical Data
Technical data Special Voltage For devices designed for special voltages, the technical data on the rating plate applies. The following applies for all devices with a permitted grid voltage of up to 460 V: The stan- dard mains plug allows the user to operate with a grid voltage of up to 400 V. For grid volt- ages up to 460 V fit a mains plug permitted for such use or install the mains supply directly. -
Page 112: Transsteel 4000 Pulse Transsteel 4000 Pulse Nc
TransSteel 4000 Grid 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... -
Page 113: Transsteel 4000 Pulse Mv Nc
TransSteel 4000 Grid 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 114: Transsteel 5000 Pulse Transsteel 5000 Pulse Nc
TransSteel 5000 Grid 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. -
Page 115: Transsteel 5000 Pulse Mv Nc
TransSteel 5000 Grid 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 116 Weight 43.6 kg / 96.1 lb. Efficiency at 250 A and 26.5 V Max. noise emission (L 75 dB (A) Interface to a 230/400 V, 50 Hz public grid D.C. = duty cycle...
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Page 117: 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 de- vice Welding program label on the power source... -
Page 118: Welding Program Tables For Transsteel 4000 Pulse, Transsteel 5000 Pulse
Welding program The welding programs are active if tables for Trans- The "SEt" setup parameter is set to Steel 4000 Pulse, "Std" (Standard) TransSteel 5000 Pulse The VR 5000 Remote wirefeeder is equipped with the VR Pulse control pa- nel option. Welding program database: DB 3994 Standard welding characteristics Material... - Page 119 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...
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Page 120: Welding Program Tables For Transsteel 4000 Pulse, Transsteel 5000 Pulse Us
Welding program The welding programs are active if tables for Trans- The"SEt" setup parameter is set to Steel 4000 Pulse, "US" (USA) TransSteel 5000 Pulse US The VR 5000 Remote wirefeeder is equipped with the VR Pulse control pa- nel option. Welding program database: DB 3994 Standard welding characteristics Material... - Page 121 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...
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