voestalpine Bohler URANOS 4000-5000 GSM Instruction Manual
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voestalpine Bohler URANOS 4000-5000 GSM Instruction Manual

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Lasting Connections
URANOS 4000-5000 GSM
INSTRUCTION MANUAL
voestalpine Böhler Welding
www.voestalpine.com/welding

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  • Page 1 Lasting Connections URANOS 4000-5000 GSM INSTRUCTION MANUAL voestalpine Böhler Welding www.voestalpine.com/welding...
  • Page 2 Cod. 91.08.346 Data 11/06/2019 Rev. ENGLISH ....................................35 9 Rating plate..........385 10 Meaning of power source rating plate......386 11 Diagram............................387 12 Connectors........................389 13 Spare parts list............................390...
  • Page 3 ENGLISH CE - DECLARATION OF CONFORMITY Company SELCO s.r.l. - Via Palladio, 19 - 35019 ONARA DI TOMBOLO (Padova) - ITALY Tel. +39 049 9413111 - Fax +39 049 9413311 - E-mail: selco@selcoweld.com - www.selcoweld.com URANOS 4000 GSM hereby declares that the equipment: URANOS 5000 GSM conforms to the EU directives: 2014/35/EU...

  • Page 4: Table Of Contents

    INDEX 1 WARNING ..............................37 1.1 Work environment ..........................37 1.2 User's and other persons' protection..................... 37 1.3 Protection against fumes and gases ...................... 38 1.4 Fire/explosion prevention ........................38 1.5 Prevention when using gas cylinders ....................38 1.6 Protection from electrical shock ......................38 1.7 Electromagnetic fields &...

  • Page 5: Warning

    1 WARNING Always use regulation shoes that are strong and ensure insulation from water. Before performing any operation on the machine, make sure that you have thoroughly read and understood the contents of this booklet. Always use regulation gloves ensuring electrical and Do not perform modifications or maintenance thermal insulation.

  • Page 6: Protection Against Fumes And Gases

    Ensure the cooling unit is switched off before dis- or containers even if these are open, empty and have been connecting the pipes of the cooling liquid. The hot cleaned thoroughly. Any residue of gas, fuel, oil or similar liquid coming out of the pipes might cause burning materials might cause an explosion.

  • Page 7: Electromagnetic Fields

    The arc striking and stabilizing device is designed Mains power supply requirements (See technical data) for manual or mechanically guided operation. High power equipment may, due to the primary current drawn form the mains supply, influence the power quality of the grid. Therefore connection restrictions or requirements regarding the maximum permissible mains impedance (Zmax) or the required Increasing the length of torch or welding cables...

  • Page 8: Installation

    2 INSTALLATION 2.3 Connection Installation should be performed only by expert personnel authorised by the manufacturer. The equipment is provided with a power supply cable for con- nection to the mains. During installation, ensure that the power source The system can be powered by: is disconnected from the mains.

  • Page 9: Installation

    2.4 Installation Connection for TIG welding Connection for MMA welding The connection shown in the figure produces reverse polarity welding. To obtain straight polar- ity welding, reserve the connection. - Connect (10) the earth clamp to the positive socket (+) (11) ofthe power source.

  • Page 10: System Presentation

    Power on Indicates the presence of voltage on the equipment outlet connections. 7-segment display Allows the general welding machine parameters to be displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms. LCD display (3.5") Allows the general welding machine parameters to be displayed during start-up, settings, current and voltage readings, while welding, and encoding of the alarms.

  • Page 11: Main Screen

    Heading Heading Allows the display of certain pieces of important infor- Allows the display of certain pieces of important infor- mation relating to the selected process. mation relating to the selected process: 3.5 Main Screen Allows the control of the system and of the welding process, showing the main settings.

  • Page 12: Set Up

    Functions MIG/MAG - Pulsed MIG/MAG Allow the setting of the most important process func- Double pulsed inactive tions and welding methods. Double pulsed active MIG/MAG - Pulsed MIG/MAG Display type VRD Voltage Reduction Device Shows that the no-load voltage of the equipment is Allows the selection of the welding process controlled.
  • Page 13 Hot start Allows access to the higher set-up levels: Allows adjustment of the hot start value in MMA. USER: user Permits an adjustable hot start in the arc striking phases, SERV: service facilitating the start operations. vaBW: vaBW Parameter set as a percentage (%) of the welding current. Lock/unlock Minimum Off, Maximum 500%, Default 80% Allows the locking of the panel controls and the insertion...
  • Page 14 On first pressing the torch button, the pre-gas starts, Spot welding the arc strikes and the initial current will be used when Allows you to enable the "spot welding" process and welding. establish the welding time. On first releasing it, the raising ramp of the welding current Allows the timing of the welding process.
  • Page 15 Coolant temperature reading Post-gas Allow the real value of coolant temperature reading to Permits setting and adjustment of the gas flow at the be displayed. end of welding. Guard limits Minimum off, Maximum 10 sec., Default 2 sec. Allows the setting of the warning limits and of the guard Duty cycle (double pulsed) limits.
  • Page 16 Crater filler time External parameter CH1, CH2, CH3, CH4 Lets you set the “crater filler” time. Lets you automate Allows the management of external parameter (mini- the "crater filler” function. mum value, maximum value, default value, parameter Minimum 0.1s, Maximum 99.9s, Default Off selected).

  • Page 17: Synergic Curves Screen

    3.7 Synergic curves screen Pulsed MIG General Ø (mm) Allows the selection of the required welding method. G3/4 Si1 CO 2 G3/4 Si1 Ar 18%CO 2 (P) 7 (P) 8 (P) 9 (P) 10 CrNi 19 9 Ar 2%CO 2 (P) 14 (P) 15 (P) 12...
  • Page 18 Program retrieval ù Retrieve the 1st program available by pressing button Select the required program (or the empty memory) (5) by rotating the encoder. Program stored Memory empty Cancel the operation by pressing button (2) Save all the current settings on the selected program by pressing button (3) Select the required program by pressing button Select the required program by rotating the encoder.

  • Page 19: Interface Personalisation

    3.9 Interface personalisation 7 segment display personalisation Allows the parameters to be customized on the main menu. Allows the selection of the required graphic interface: XE (Easy Mode) XA (Advanced Mode) XP (Professional Mode) PROCESS PARAMETER TIG DC Enter set-up by pressing the encoder button for at least MIG/MAG 5 seconds.

  • Page 20: External Controls Management

    3.12 Guard limits Allows the welding process to be controlled by setting warning limits and guard limits for the main measurable parameters : Welding current Welding voltage Gas flow Access the panel functionalities temporarily (5 minutes) by Automation movement rotating the encoder and entering the correct password. Confirm the change made by pressing button/encoder.

  • Page 21: Alarms Screen

    Alarm codes E01, E02, E03 Temperature alarm Current too high alarm Power module alarm (Boost) Wire feed motor supply alarm 7 Warning limits line 8 Alarm limits line Blocked motor alarm 9 Minimum levels column 10 Maximum levels column Power module alarm (Inverter) Select the required box by pressing the encoder key (the select- ed box is displayed with reverse contrast).

  • Page 22: Rear Panel

    Emergency switch alarm Wire supply alarm Wire stuck alarm Motor 1 current level exceeded (Warning) Unsupported settings alarm Motor 2 current level exceeded (Warning) Anti-collision alarm Liquid coolant flow level exceeded (Warning) External flow switch alarm Coolant temperature level exceeded (Warning) General alarm Active maintenance alarm...

  • Page 23: Sockets Panel

    3.15 Sockets panel 4.3 RC 120 pedal remote control unit for TIG welding The output current is controlled from a minimum to a maximum value (can be entered from SETUP) by varying the foot pressure on the pedal surface. A micros- witch provides the start trigger signal at minimum pressure.

  • Page 24: General

    4.7 ST...U/D series torches 4.10 DIGIMIG - MIG/MAG series torches The U/D series torches are digital TIG torches allowing the main The MB501D PLUS series torches are digital MIG/MAG torches welding parameters to be controlled: allowing the main welding parameters to be controlled: - welding current - welding current (Synergic MIG/MAG process) - program recall...

  • Page 25: Troubleshooting

    Carry out the following periodic checks on the Cause The system has overheated (temperature alarm - power source: yellow LED on). - Clean the power source inside by means of low- Solution Wait for the system to cool down without switching pressure compressed air and soft bristle brushes.
  • Page 26 Cause Damaged torch liner. Cause Incorrect arc regulation Solution Increase the equivalent circuit inductive value setting. Solution Replace the faulty component. Contact the nearest service centre to have the sys- tem repaired. Cause Insufficient shielding gas. Solution Adjust the gas flow. Cause No power supply to the wire feeder.

  • Page 27: Welding Theory

    Sticking Cause Insufficient shielding gas. Cause Incorrect arc length. Solution Adjust the gas flow. Solution Increase the distance between the electrode and Check that the diffuser and the gas nozzle of the the piece. torch are in good condition. Increase the welding voltage. Cause The weld pool solidifies too quickly.

  • Page 28: Tig Welding (Continuos Arc)

    Choosing the welding current Another type of start is also possible, with reduced tungsten The range of welding current related to the type of electrode inclusions: the lift start, which does not require high frequency, used is specified by the manufacturer usually on the electrode but only an initial short-circuit at low current between the elec- packaging.

  • Page 29: Steel Tig Welding

    7.3 Continuous wire welding (MIG/MAG) 7.2.1 Steel TIG welding The TIG procedure is very effective for welding both carbon and Introduction alloyed steel, for first runs on pipes and for welding where good A MIG system consists of a direct current power source, wire appearance is important.
  • Page 30 Welding parameters The visibility of the arc reduces the need for the user to strictly observe the adjustment tables as he can directly monitor the weld pool. - The voltage directly affects the appearance of the bead, but the dimensions of the weld bead can be varied according to requirements by manually moving the torch to obtain variable deposits with constant voltage.
  • Page 31 SELECTION GUIDE OF WELDING PARAMETERS WITH REFERENCE TO THE MOST TYPICAL APPLICATIONS AND MOST COMMONLY USED WIRES Wire diameter - weight per metre Voltage arc (v) 0,8 mm 1,0-1,2 mm 1,6 mm 2,4 mm Low penetration for thin Good penetration and Good flat and vertical Not used materials...

  • Page 32: Technical Specifications

    8 TECHNICAL SPECIFICATIONS URANOS 4000 GSM Power supply voltage U1 (50/60Hz) 3x400Vac ±15% Zmax (@PCC) 57mΩ * Slow blow line fuse Communication bus DIGITAL MMA maximum input power (kVA) 16.9 kVA MMA maximum input power (kW) 16.1 kW TIG maximum input power (kVA) 12.6 kVA TIG maximum input power (kW) 12.1 kW...
  • Page 33 URANOS 5000 GSM Power supply voltage U1 (50/60Hz) 3x400Vac ±15% Zmax (@PCC) 49mΩ * Slow blow line fuse Communication bus DIGITAL MMA maximum input power (kVA) 23.6 kVA MMA maximum input power (kW) 22.5 kW TIG maximum input power (kVA) 18.2 kVA TIG maximum input power (kW) 17.4 kW...
  • Page 35 9 Rating plate European product Do not dispose of electrical equipment together with normal waste! In observance of European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation in accordance with national law, electrical equipment that has reached the end of its life must be col- lected separately and returned to an environmentally compatible recycling facility.
  • Page 36 10 Meaning of power source rating plate ENGLISH Trademark Name and address of manufacturer Machine model Serial no. Welding unit symbol Reference to construction standards Welding process symbol Symbol for equipments suitable for operation in environments with increased electrical shock risk Welding current symbol Rated no load voltage...
  • Page 37 11 Diagram URANOS 4000 GSM LCD 3.5" (3x400V)
  • Page 38 URANOS 5000 GSM LCD 3.5" (3x400V)
  • Page 39 12 Connectors URANOS 4000 GSM LCD 3.5" (3x400V) URANOS 5000 GSM LCD 3.5" (3x400V)
  • Page 40 13 Spare parts list 55.04.022 URANOS 4000 GSM LCD 3.5" (3x400V) 55.04.023 URANOS 5000 GSM LCD 3.5" (3x400V)
  • Page 43 Böhler Welding www.voestalpine.com/welding...

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