Fronius TransSteel 5000 Pulse - Installation and Startup

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Installation and Startup

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Table of Contents3
Safety Instructions7
Explanation of Safety Instructions7
General7
Intended Use8
Environmental Conditions8
Obligations of the Operating Company8
Obligations of Personnel8
Grid Connection9
Personal Protection and Protection of Others9
Danger from Toxic Gases and Vapors9
Danger from Flying Sparks10
Risks from Grid Current and Welding Current10
Stray Welding Currents12
EMC Device Classifications12
EMC Measures12
EMF Measures13
Particular Hazard Areas13
Requirement for the Shielding Gas14
Danger from Shielding Gas Cylinders14
Danger Posed by Shielding Gas Leak15
Safety Measures at the Setup Location and During Transport15
Safety Measures in Normal Operation16
Maintenance and Repair16
Safety Inspection17
Disposal17
Safety Symbols17
Data Backup17
Copyright17
General Information19
General21
Device Concept21
Operating Principle21
Application Areas21
Warning Notices on the Device22
Welding Processes, Procedures, and Welding Characteristics for MIG/MAG Welding23
General23
Brief Description of MIG/MAG Standard Synergic Welding23
Brief Description of MIG/MAG Pulsed Synergic Welding23
Brief Description of Synchropulse Welding23
Brief Description of the Gouging (Arc Air Gouging)24
System Components25
General25
Safety25
Overview26
VRD: Safety Function27
VRD: Safety Principle27
Operating Controls and Connections29
Control Panel31
General31
Safety31
Control Panel32
Service Parameters37
Keylock38
Connections, Switches, and Mechanical Components39
Transsteel 4000/5000 Pulse Connections39
Installation and Startup41
Minimum Equipment for Welding Operations43
General43
Gas-Cooled MIG/MAG Welding43
Water-Cooled MIG/MAG Welding43
Manual Metal Arc Welding43
Minimum Equipment for Arc Air Gouging43
Before Installation and Initial Operation44
Safety44
Intended Use44
Setup Regulations44
Grid Connection45
Connecting the Mains Cable46
General46
Stipulated Mains Cables and Strain-Relief Devices46
Safety47
Connecting the Mains Cable47
Fitting the Strain-Relief Device for Europe48
Fitting the Strain-Relief Device for Canada / US49
Generator-Powered Operation50
Commissioning51
Safety51
General51
Information on System Components51
Assembling System Components (Overview)52
Place the Wirefeeder on the Power Source53
Fit the Strain-Relief Device of the Interconnecting Hosepack53
Connecting the Interconnecting Hosepack54
Correct Routing of the Interconnecting Hosepack55
Connecting the Gas Cylinder56
Establishing a Ground Earth Connection57
Connecting a MIG/MAG Welding Torch58
Other Activities58
Setting the Date and Time When Starting for the First Time58
MIG/MAG Welding59
Power Limitation61
Safety Function61
MIG/MAG Operating Modes62
General62
Symbols and Explanations62
2-Step Mode63
Special 2-Step Mode64
Special 4-Step Mode64
Spot Welding65
2-Step Stitch Welding65
4-Step Stitch Welding66
MIG/MAG Welding67
Safety67
Preparation67
Overview67
MIG/MAG Synergic Welding68
Corrections During Welding70
Synchropulse Welding70
MIG/MAG Standard Manual Welding72
General72
Available Parameters72
Corrections During Welding73
Spot Welding and Stitch Welding74
General74
Spot Welding74
Stitch Welding75
Easyjob Mode77
General77
Saving Easyjob Operating Points77
Retrieving Easyjob Operating Points77
Deleting Easyjob Operating Points77
Retrieving Easyjob Operating Points on the Up/Down Welding Torch78
MMA Welding, Arc Air Gouging79
Manual Metal Arc Welding81
Safety81
Preparation81
Manual Metal Arc Welding82
Corrections During Welding83
Hotstart Function84
Anti-Stick Function84
Arc Air Gauging85
Safety85
Preparation85
Arc Air Gouging85
Easy Documentation87
General89
Documented Welding Data89
New CSV File90
PDF Report / Fronius Signature90
Activating / Deactivating Easy Documentation91
Activating Easy Documentation91
Set the Date and Time91
Setup Settings93
Setup Menu95
General95
Operation95
Setup Parameters for MIG/MAG Synergic Welding96
Setup Parameters for MIG/MAG Standard Manual Welding98
Setup Parameters for MMA Welding99
Setup Menu 2Nd Level100
Limitations100
Operation (Setup Menu 2Nd Level)100
Parameters for MIG/MAG Synergic Welding in Setup Menu 2Nd Level101
Parameters for MIG/MAG Standard Manual Welding in Setup Menu 2Nd Level103
Parameters for Manual Metal Arc Welding in Setup Menu 2Nd Level105
Measuring the Welding Circuit Resistance R106
General106
Measuring the Welding Circuit Resistance (MIG/MAG Welding)106
Measuring the Welding Circuit Resistance (MMA Welding)107
Displaying the Welding Circuit Inductivity L108
General108
Displaying the Welding Circuit Inductivity108
Laying the Hosepacks Correctly108
Troubleshooting and Maintenance109
Troubleshooting111
General111
Safety111
Displayed Service Codes111
Displayed Service Codes in Connection with OPT Easy Documentation116
Service, Maintenance and Disposal118
General118
Safety118
At Every Start-Up118
Every 2 Months118
Every 6 Months119
Disposal119
Appendix121
Average Consumption Values During Welding123
Average Wire Electrode Consumption During MIG/MAG Welding123
Average Shielding Gas Consumption During MIG/MAG Welding123
Average Shielding Gas Consumption During TIG Welding123
Technical Data124
Overview with Critical Raw Materials, Year of Production of the Device124
Special Voltage124
Explanation of the Term Duty Cycle124
Transsteel 4000 Pulse Transsteel 4000 Pulse Nc126
Transsteel 4000 Pulse MV Nc128
Transsteel 5000 Pulse Transsteel 5000 Pulse Nc130
Transsteel 5000 Pulse MV Nc132
Welding Program Tables134
Welding Program Label on the Device134
Welding Program Tables for Transsteel 4000 Pulse, Transsteel 5000 Pulse135
Welding Program Tables for Transsteel 4000 Pulse, Transsteel 5000 Pulse US137

Fronius TransSteel 5000 Pulse - Installation and Startup

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