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TransSteel 4000 Pulse
Fronius TransSteel 4000 Pulse User Manual
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2-step mode
t
I
+
I
GPr
GPo
"2-step mode
" is suitable f
or
-
T
acking work
-
Short weld seams
-
Automa
tic and robot oper
ation
4-step mode
t
I
+
I
GPr
GPo
+
"4-step mode
" is suitable f
or longer weld seams.
63
EN-US
62
64
Table of Contents
Table of Contents
3
Safety Instructions
7
Explanation of Safety Instructions
7
General
7
Intended Use
8
Environmental Conditions
8
Obligations of the Operating Company
8
Obligations of Personnel
8
Grid Connection
9
Personal Protection and Protection of Others
9
Danger from Toxic Gases and Vapors
9
Danger from Flying Sparks
10
Risks from Grid Current and Welding Current
10
Stray Welding Currents
12
EMC Device Classifications
12
EMC Measures
12
EMF Measures
13
Particular Hazard Areas
13
Requirement for the Shielding Gas
14
Danger from Shielding Gas Cylinders
14
Danger Posed by Shielding Gas Leak
15
Safety Measures at the Setup Location and During Transport
15
Safety Measures in Normal Operation
16
Maintenance and Repair
16
Safety Inspection
17
Disposal
17
Safety Symbols
17
Data Backup
17
Copyright
17
General Information
19
General
21
Device Concept
21
Operating Principle
21
Application Areas
21
Warning Notices on the Device
22
Welding Processes, Procedures, and Welding Characteristics for MIG/MAG Welding
23
General
23
Brief Description of MIG/MAG Standard Synergic Welding
23
Brief Description of MIG/MAG Pulsed Synergic Welding
23
Brief Description of Synchropulse Welding
23
Brief Description of the Gouging (Arc Air Gouging)
24
System Components
25
General
25
Safety
25
Overview
26
VRD: Safety Function
27
VRD: Safety Principle
27
Operating Controls and Connections
29
Control Panel
31
General
31
Safety
31
Control Panel
32
Service Parameters
37
Keylock
38
Connections, Switches, and Mechanical Components
39
Transsteel 4000/5000 Pulse Connections
39
Installation and Startup
41
Minimum Equipment for Welding Operations
43
General
43
Gas-Cooled MIG/MAG Welding
43
Water-Cooled MIG/MAG Welding
43
Manual Metal Arc Welding
43
Minimum Equipment for Arc Air Gouging
43
Before Installation and Initial Operation
44
Safety
44
Intended Use
44
Setup Regulations
44
Grid Connection
45
Connecting the Mains Cable
46
General
46
Stipulated Mains Cables and Strain-Relief Devices
46
Safety
47
Connecting the Mains Cable
47
Fitting the Strain-Relief Device for Europe
48
Fitting the Strain-Relief Device for Canada / US
49
Generator-Powered Operation
50
Commissioning
51
Safety
51
General
51
Information on System Components
51
Assembling System Components (Overview)
52
Place the Wirefeeder on the Power Source
53
Fit the Strain-Relief Device of the Interconnecting Hosepack
53
Connecting the Interconnecting Hosepack
54
Correct Routing of the Interconnecting Hosepack
55
Connecting the Gas Cylinder
56
Establishing a Ground Earth Connection
57
Connecting a MIG/MAG Welding Torch
58
Other Activities
58
Setting the Date and Time When Starting for the First Time
58
MIG/MAG Welding
59
Power Limitation
61
Safety Function
61
MIG/MAG Operating Modes
62
General
62
Symbols and Explanations
62
2-Step Mode
63
Special 2-Step Mode
64
Special 4-Step Mode
64
Spot Welding
65
2-Step Stitch Welding
65
4-Step Stitch Welding
66
MIG/MAG Welding
67
Safety
67
Preparation
67
Overview
67
MIG/MAG Synergic Welding
68
Corrections During Welding
70
Synchropulse Welding
70
MIG/MAG Standard Manual Welding
72
General
72
Available Parameters
72
Corrections During Welding
73
Spot Welding and Stitch Welding
74
General
74
Spot Welding
74
Stitch Welding
75
Easyjob Mode
77
General
77
Saving Easyjob Operating Points
77
Retrieving Easyjob Operating Points
77
Deleting Easyjob Operating Points
77
Retrieving Easyjob Operating Points on the Up/Down Welding Torch
78
MMA Welding, Arc Air Gouging
79
Manual Metal Arc Welding
81
Safety
81
Preparation
81
Manual Metal Arc Welding
82
Corrections During Welding
83
Hotstart Function
84
Anti-Stick Function
84
Arc Air Gauging
85
Safety
85
Preparation
85
Arc Air Gouging
85
Easy Documentation
87
General
89
Documented Welding Data
89
New CSV File
90
PDF Report / Fronius Signature
90
Activating / Deactivating Easy Documentation
91
Activating Easy Documentation
91
Set the Date and Time
91
Setup Settings
93
Setup Menu
95
General
95
Operation
95
Setup Parameters for MIG/MAG Synergic Welding
96
Setup Parameters for MIG/MAG Standard Manual Welding
98
Setup Parameters for MMA Welding
99
Setup Menu 2Nd Level
100
Limitations
100
Operation (Setup Menu 2Nd Level)
100
Parameters for MIG/MAG Synergic Welding in Setup Menu 2Nd Level
101
Parameters for MIG/MAG Standard Manual Welding in Setup Menu 2Nd Level
103
Parameters for Manual Metal Arc Welding in Setup Menu 2Nd Level
105
Measuring the Welding Circuit Resistance R
106
General
106
Measuring the Welding Circuit Resistance (MIG/MAG Welding)
106
Measuring the Welding Circuit Resistance (MMA Welding)
107
Displaying the Welding Circuit Inductivity L
108
General
108
Displaying the Welding Circuit Inductivity
108
Laying the Hosepacks Correctly
108
Troubleshooting and Maintenance
109
Troubleshooting
111
General
111
Safety
111
Displayed Service Codes
111
Displayed Service Codes in Connection with OPT Easy Documentation
116
Service, Maintenance and Disposal
118
General
118
Safety
118
At Every Start-Up
118
Every 2 Months
118
Every 6 Months
119
Disposal
119
Appendix
121
Average Consumption Values During Welding
123
Average Wire Electrode Consumption During MIG/MAG Welding
123
Average Shielding Gas Consumption During MIG/MAG Welding
123
Average Shielding Gas Consumption During TIG Welding
123
Technical Data
124
Overview with Critical Raw Materials, Year of Production of the Device
124
Special Voltage
124
Explanation of the Term Duty Cycle
124
Transsteel 4000 Pulse Transsteel 4000 Pulse Nc
126
Transsteel 4000 Pulse MV Nc
128
Transsteel 5000 Pulse Transsteel 5000 Pulse Nc
130
Transsteel 5000 Pulse MV Nc
132
Welding Program Tables
134
Welding Program Label on the Device
134
Welding Program Tables for Transsteel 4000 Pulse, Transsteel 5000 Pulse
135
Welding Program Tables for Transsteel 4000 Pulse, Transsteel 5000 Pulse US
137
4
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Fronius TransSteel 4000 Pulse Specifications
General
Brand
Fronius
Model
TransSteel 4000 Pulse
Category
Welding System
Language
English
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