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Fronius RCU 5000i, Operating Instructions & Spare Parts

The Fronius RCU 5000i, a versatile electronic component, guarantees optimal performance for your equipment. Enhance functionality and prolong the lifespan with our comprehensive Operating Instructions & Spare Parts manual, available for easy and free download at manualshive.com. Unlock the full potential of your product today!

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Setting working parameters .......................................................................................................................

36

Setting working parameters ..................................................................................................................

36

Trigger modes.......................................................................................................................................

36

Process .................................................................................................................................................

36

"CMT" process ......................................................................................................................................

39

Switching to extra-large display .................................................................................................................

40

General .................................................................................................................................................

40

Switching to extra-large display ............................................................................................................

40

Setting process settings parameters..........................................................................................................

41

Setting process settings parameters.....................................................................................................

41

Setting additional parameters: special 2-step, special 4-step, spot welding..............................................

42

Setting additional special 2-step parameters ........................................................................................

42

Setting additional special 4-step parameters ........................................................................................

43

Setting additional spot welding parameters ..........................................................................................

44

Setting SynchroPuls parameters ...............................................................................................................

45

General .................................................................................................................................................

45

Setting SynchroPuls parameters (software option)...............................................................................

45

MIG/MAG standard manual welding ..........................................................................................................

46

General .................................................................................................................................................

46

Call up "MIG/MAG standard manual welding" menu item ....................................................................

46

Overview ...............................................................................................................................................

46

Retrieving a welding program ....................................................................................................................

47

Select welding program ........................................................................................................................

47

Setting working parameters .......................................................................................................................

48

Setting working parameters ..................................................................................................................

48

Trigger modes.......................................................................................................................................

48

Switching to extra-large display .................................................................................................................

49

General .................................................................................................................................................

49

Switching to extra-large display ............................................................................................................

49

Setting process settings parameters..........................................................................................................

50

Setting process settings parameters.....................................................................................................

50

Setting additional spot welding parameters ...............................................................................................

51

Setting additional spot welding parameters ..........................................................................................

51

Setting welding program and filler metal....................................................................................................

52

General .................................................................................................................................................

52

Setting welding program and filler metal...............................................................................................

52

Plotting user characteristics - optimising a characteristic ..........................................................................

54

General .................................................................................................................................................

54

The basics of plotting user characteristics ............................................................................................

54

Plotting user characteristics - optimising a characteristic .....................................................................

54

Creating new characteristic points for user characteristics........................................................................

57

General .................................................................................................................................................

57

The basics of plotting new characteristic points....................................................................................

57

Creating a new characteristic point.......................................................................................................

57

Selecting user characteristics ....................................................................................................................

60

Selecting user characteristics ...............................................................................................................

60

MMA welding .............................................................................................................................................

61

Call up "Rod electrode (MMA) welding" menu item ..............................................................................

61

Setting working parameters ..................................................................................................................

61

Switching to extra-large display ............................................................................................................

62

Setting process settings parameters.....................................................................................................

62

TIG welding................................................................................................................................................

63

Call up "TIG welding" menu item ..........................................................................................................

63

Setting working parameters ..................................................................................................................

63

Switching to extra-large display ............................................................................................................

64

CC/CV mode..............................................................................................................................................

65

General .................................................................................................................................................

65

Call up "CC/CV mode" ..........................................................................................................................

65

Setting working parameters ..................................................................................................................

65

Switching to extra-large display ............................................................................................................

66

Setting process settings parameters.....................................................................................................

66

Job welding ................................................................................................................................................

67

Call up the "Job welding" menu item ....................................................................................................

67

Setting working parameters for a job ....................................................................................................

67

Summary of Contents for RCU 5000i

Page 1: ... Perfect Charging Perfect Welding Solar Energy 42 0426 0021 EN 004 03112017 RCU 5000i Operating Instructions Spare parts list Remote control EN ...

Page 2: ...2 ...

Page 3: ...th the product Reading the instructions carefully will enable you to learn about the many different features it has to offer This will allow you to make full use of its advantages Please also note the safety rules to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for excellent r...

Page 4: ...4 ...

Page 5: ...18 Information on OK key 19 Other controls connections mechanical components 20 Operating concept 22 Activities orientation 22 Main menu 22 Clothesline 22 Saving values 23 Description of the displays 24 General 24 Menu screen 24 Data screen 24 Wizard screen 25 Dialogue screen 26 Message screen 26 Error screen 26 Start up 28 Before commissioning 28 System requirements 28 Connecting RCU 5000i 28 Sta...

Page 6: ...rocess settings parameters 50 Setting additional spot welding parameters 51 Setting additional spot welding parameters 51 Setting welding program and filler metal 52 General 52 Setting welding program and filler metal 52 Plotting user characteristics optimising a characteristic 54 General 54 The basics of plotting user characteristics 54 Plotting user characteristics optimising a characteristic 54...

Page 7: ...ted job 86 General 86 Retrieving and changing special 2 step parameters for a job 86 Retrieving and changing special 4 step parameters for a selected job 87 General 87 Retrieving and changing special 4 step parameters for a job 87 Retrieving and changing spot welding parameters for a selected job 88 General 88 Retrieving and changing spot welding parameters for a job 88 Establishing correction bou...

Page 8: ...MT characteristics 118 General 118 Ignition 118 CMT parameters 119 End of welding 120 Guideline values 120 Accepting voltage and current guideline values 121 Parameters of CMT pulse characteristics 122 General 122 Ignition 122 Overview CMT parameters pulse parameters 123 CMT parameters 123 Pulsing parameters 124 CMT Pulsed 124 End of welding 125 Guideline values 125 Accepting voltage and current g...

Page 9: ... Welding log 150 General 150 Displaying welding data from the welding log 150 Event log 152 General 152 Event log 152 Removing a memory card 153 General 153 Removing a memory card 153 Machine pre sets 155 General 155 Call up the Machine pre sets menu item 155 Overview 155 Setting machine pre sets for welding 156 Setting machine pre sets for MIG MAG 156 Setting machine pre sets for TIG 156 Setting ...

Page 10: ...s 196 Setting the language and units of measurement 197 General 197 Setting the language and units of measurement 197 Displaying version data 198 General 198 Displaying version data 198 Creating backup 199 General 199 Creating backup 199 Restoring data 201 General 201 Restoring data 201 Aligning wirefeeder or push pull unit 203 Aligning wirefeeder VR alignment 203 Aligning the push pull unit 204 L...

Page 11: ...isused however it can cause injury or death to the operator or a third party damage to the device and other material assets belonging to the operat ing company inefficient operation of the device All persons involved in commissioning operating maintaining and servicing the device must be suitably qualified have sufficient knowledge of welding and read and follow these operating instructions carefu...

Page 12: ... 14 F to 122 F during transport and storage 15 C to 70 C 5 F to 158 F Relative humidity up to 50 at 40 C 104 F up to 90 at 20 C 68 F The surrounding air must be free from dust acids corrosive gases or sub stances etc Can be used at altitudes of up to 2000 m 6500 ft The operator must only allow persons to work with the device who are familiar with the fundamental instructions regarding safety at wo...

Page 13: ... be susceptible to interference from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avoidance of EMC problems 1 Mains supply If electromagnetic interference arises despite correct mains connec tion additional measures are necessary e g use a suitable line fil ter 2 Welding power lead...

Page 14: ...ot lift or transport operational devices Switch off devices before transport or lifting Before transporting the device allow coolant to drain completely and detach the following components Wirefeeder Wirespool Shielding gas cylinder After transporting the device the device must be visually inspected for dam age before commissioning Any damage must be repaired by trained service technicians before ...

Page 15: ...rements of the rele vant standards for Canada and the USA The user is responsible for the safekeeping of any changes made to the fac tory settings The manufacturer accepts no liability for any deleted personal settings Copyright of these operating instructions remains with the manufacturer The text and illustrations are all technically correct at the time of printing We reserve the right to make c...

Page 16: ... welding using power sources equipped with the Remote control panel Advantages Clear layout thanks to LCD Simple and logical operation 180 pre programmed Synergic welding characteristics Welding characteristics can be optimised Easy to program jobs Up to 1000 jobs can be stored User access management using keycard Parameter monitoring thanks to QMaster function LocalNet connection USB interface fo...

Page 17: ...le protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which cas...

Page 18: ...t button for checking the gas flow Navigation keys 6 Down arrow key for scrolling through a list 7 Up arrow key for scrolling through a list 8 Right arrow key for sideways scrolling e g in the clothesline 9 Left arrow key for sideways scrolling e g in the clothesline Function keys with varying functions 10 F1 function key 11 F2 key function key 12 F3 key function key 13 F4 key function key 14 F5 k...

Page 19: ...there is a border around a function key function this function can be selected by pressing OK 3 Example border around F1 Store as job Example border around F2 Forward Miscellaneous 15 Display black white LCD 16 Keycard reader for identifying different access rights granted by means of a key card 1 2 1 Frame ...

Page 20: ... bracket 18 Adjusting dial for adjusting parameters 19 LocalNet plug with connection cable for connecting to the power source The plug serves as a separation device and must be freely accessible 20 Rubber cover for protecting the memory card slot 21 Rubber cover for protecting the USB PC connection point 9 1 0 2 18 17 21 23 22 23 23 23 22 Bracket 0 95 hinged holder and stand 23 M5 threaded insert ...

Page 21: ...21 EN RCU 5000i side view connections 25 24 24 Memory card slot 25 USB port for connecting to a PC e g for software updates ...

Page 22: ... are highlighted in the main menu The main menu is called up by pressing the menu key 1 A clothesline is assigned to every menu item Clothesline The clothesline principle Individual welding parameters are collected together in various data records These data records are arranged in a loop clothesline Within the clothesline the user can navigate in two directions After the last data record the firs...

Page 23: ...hroughout the rest of the operating instructions the data records are shown as in the example below Options and special functions on the power source e g SynchroPulse are hung on the data records available on a clothesline Navigate within the clothesline by pressing the navigation keys right 8 and left 9 Saving values Adjusted values need not be saved or stored The values are immediately active Sc...

Page 24: ... is selected in the main menu Each Data screen contains a clothesline Many different Data screens can be displayed within one menu item By using special functions on the power source or certain parameter settings further Data screens can be hung onto the relevant clothesline In the Data screens parameters can be set or viewed The parameters are repre sented in a list Parameters are selected using ...

Page 25: ...t screen 7 F2 Forward or Done in the final screen 8 F5 Cancel 1 Screen identifying character 9 Time 2 Activity 10 Filler metal wire diameter shield ing gas 3 Welding current 11 Information line 4 User 12 Clothesline with screens A E 5 Screen title 13 Display area 6 Welding voltage 14 Parameter list 7 Sheet thickness 15 Function key functions 8 Date F1 Store as job F2 Create new characteristic poin...

Page 26: ...sage screen appears in front of part of the current screen This makes the cur rent screen turn grey Example Message screen Precautionary query 1 Current screen shown in grey 2 Symbol 3 Message type 4 Dark border 5 F2 Yes 6 F3 No 7 F4 Cancel Error screen Error screens display errors that have occurred during welding Error screens must be reset If an Error screen is ignored it reappears after 2 minu...

Page 27: ... in grey 2 Symbol 3 Error code 4 Error description 5 Dark border 6 F3 OK Example Error screen with function keys Reset and Ignore 1 Current screen shown in grey 2 Symbol 3 Error description 4 Dark border 5 F2 Reset 6 F3 Ignore 1 2 3 4 5 6 2 3 5 6 4 1 ...

Page 28: ...and TS TPS 4000 5000 Procedure Switch the power source mains switch to the 0 position Plug the remote control unit LocalNet plug into the LocalNet connection socket Tighten the union nut on the plug Move the power source mains switch to the I position the remote control is ready the starting sequence appears WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use...

Page 29: ... The language and units metric or imperial can be preset during this time To do this press F3 Starting sequence F3 Language To preset the language and measure ment units press F3 Language Machine pre sets Language and units screen appears Machine pre sets Language and units screen lan guage selected Select the corresponding parameters using down 6 or up 7 keys Alter the parameter value with the ad...

Page 30: ...73 no Host screen The non resettable error 073 no Host appears if the remote control cannot connect to the power source during com missioning Possible causes are for example poor contact with the power source or incorrect LocalNet distributor Once an active link is established error 073 no Host disappears The error 073 no Host can be ignored ...

Page 31: ... Locking the RCU 5000i Holding the keycard up to the keycard reader Hold the keycard up to the keycard reader 16 Info Key The remote control unit is now locked screen The Info Key The remote control unit is now locked screen appears NOTE The key card can be used for locking and unlocking the remote control as long as there are no profiles or keys apart from Administrator and Locked in the Machine ...

Page 32: ...ctory setting of the Locked profile allows access to the wel ding processes Keys are not available in the individual Data screens The parameters in each Data screen can be selected using the down 6 or up 7 keys and altered using the adjusting dial 18 Unlocking the RCU 5000i Holding the keycard up to the keycard reader Hold the keycard up to the keycard reader 16 IMPORTANT The properties in the Loc...

Page 33: ...g Unlock function An Unlock function has been added to the RCU 5000i remote control unit from software version OFFICIAL RCU V1 14 12 This Unlock function changes the Locked profile and enables access to the Profile Keys screen in the machine pre sets in order for example to add an Administrator key or modify the Locked profile More information about the Unlock function can be found in the Machine ...

Page 34: ...d ing menu item Main menu MIG MAG synergic welding menu item selected Press the Menu button 1 Main menu appears Select MIG MAG synergic welding menu item using the adjusting dial 18 Press OK 3 The last Data screen called up appears Overview MIG MAG synergic welding is composed of the following sections Retrieving a welding program Setting working parameters Switching to extra large display Setting...

Page 35: ...m screen by pressing the right arrow key 8 Welding program screen appe ars The Welding program screen contains the following data Filler metal Wire diameter Shielding gas Reference number s for the stored welding program characteristic s e g For AlSi5 with Ø 1 2 mm and shielding gas 100 Ar there is a pulsed characteristic a standard characteristic and a CMT characteristic 1 2 ...

Page 36: ...alter the parameter value A parameter value can only be al tered within the defined setting range The setting range is high lighted The welding amperage welding voltage and sheet thickness values appear in the display area If the wirefeed speed parameter is altered the values in the display area also change accordingly Trigger modes The following trigger modes can be set 2 step Special 2 step 4 st...

Page 37: ...display area The Wirefeed speed parameter cannot be altered Individual parameters are displayed differently depending on the selected process and welding program Pulse correction parameter in the pulse process Dynamic correction parameter in the standard pro cess Process Parameter Pulse Pulse correction Standard Dynamic correction in the CMT process HotStart time Pulse correction HotStart pulse cy...

Page 38: ...ameter for the CMT process Pulse correction parameter for the CMT process Hotstart pulse cycles parameter for the CMT process Boost correction parameter for the CMT process Dynamic correction parameter for the CMT process ...

Page 39: ...n combined with the following components CMT power source e g TPS 4000 CMT CMT wirefeeder e g VR 7000 CMT CMT drive unit with wire buffer e g Robacta Drive CMT CMT interconnecting hosepack The M0842 welding database is required for the CMT Advanced process ...

Page 40: ... MAG synergic welding Extra large display screen Call up MIG MAG synergic welding menu item Select Extra large display screen by pressing the right arrow key 8 Extra large display screen appe ars The value for wire feed speed can be altered in the Extra large dis play screen using the adjusting dial 18 If the Wirefeed speed parameter is alte red the values for welding current and wel ding voltage ...

Page 41: ...tem Select Process settings screen by pressing the right arrow key 8 Process settings screen appears Select the process settings parameters using the down 6 or up 7 keys Change the value of the process set tings parameters using the adjusting dial 18 The value of the process settings parameters can only be altered wi thin the defined setting range The setting range is highlighted 1 2 3 4 ...

Page 42: ... synergic welding menu item Select Working parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the trigger mode parameter using the down 6 or up 7 keys Set to S2 step using adjusting dial 18 Select Special 2 step screen by pres sing the right arrow key 8 Special 2 step screen appears MIG MAG synergic welding Special 2 step screen starting current Is select...

Page 43: ...n by pressing the right arrow key 8 Working parameters screen ap pears Select the trigger mode parameter using the down 6 or up 7 keys Set to S4 step using adjusting dial 18 Select Special 4 step screen by pres sing the right arrow key 8 Special 4 step screen appears MIG MAG synergic welding Special 4 step screen starting current Is selected Select further parameters using down 6 or up 7 keys Chan...

Page 44: ...rameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the trigger mode parameter using the down 6 or up 7 keys Set spot welding using adjusting dial 18 Select Spot welding screen by pres sing the right arrow key 8 Spot welding screen appears MIG MAG synergic welding Spot welding screen wirefeed speed selected Select parameters using the down 6 or up 7 keys Cha...

Page 45: ...re option MIG MAG synergic welding SynchroPuls screen Call up MIG MAG synergic welding menu item Select SynchroPuls screen by pres sing the right arrow key 8 SynchroPuls screen appears Select SynchroPuls parameters using down 6 or up 7 keys Change the values of the SynchroPuls parameters using the adjusting dial 18 The value of the SynchroPuls pa rameters can only be altered wit hin the defined se...

Page 46: ...enu item selected Press the Menu button 1 Main menu appears Select MIG MAG standard manual welding menu item using the adjusting dial 18 Press OK 3 The last Data screen called up appears Overview MIG MAG standard manual welding is composed of the following sections Retrieving a welding program Setting working parameters Switching to extra large display Setting process settings parameters Setting a...

Page 47: ...ogram screen by pressing the right arrow key 8 Welding program screen appe ars The Welding program screen contains the following data Filler metal Wire diameter Shielding gas Reference number s for the stored welding program characteristic s e g For AlSi5 with Ø 1 2 mm and shielding gas 100 Ar there is a pulsed characteristic a standard characteristic and a CMT characteristic 1 2 ...

Page 48: ...parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the corresponding working pa rameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value The parameter value can only be altered within the defined setting range The setting range is high lighted Trigger modes The following trigger modes can be set 2 step 4 step Spot welding ...

Page 49: ...AG standard manual welding Extra large dis play screen Call up MIG MAG standard manual welding menu item Select Extra large display screen by pressing the right arrow key 8 Extra large display screen appe ars The values for wire feed speed and welding voltage can be alte red in the Extra large display screen using the adjusting dial 18 Welding current is a display value during welding actual value...

Page 50: ...menu item Select Process settings screen by pressing the right arrow key 8 Process settings screen appears Select the process settings parameters using the down 6 or up 7 keys Change the value of the process set tings parameters using the adjusting dial 18 The value of the process settings parameters can only be altered wi thin the defined setting range The setting range is highlighted 1 2 3 4 ...

Page 51: ...enu item Select Working parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the trigger mode parameter using the down 6 or up 7 keys Set spot welding using adjusting dial 18 Select Spot welding screen by pres sing the right arrow key 8 Spot welding screen appears MIG MAG synergic welding Spot welding screen wirefeed speed selected Select parameters using t...

Page 52: ...the wizard appe ars Select a filler metal Select required filler metal using the adjusting dial 18 Press F2 Forward The 2nd screen in the wizard ap pears Select a wire diameter Only the wire diameters available for the filler metal selected in the 1st screen are shown Select a wire diameter screen 1 2 mm selected Select corresponding wire diameter using the adjusting dial 18 Press F2 Forward The 3...

Page 53: ...1 100 Ar screen Select a reference Characteristic S0016 selected Select the corresponding process using the down 6 or up 7 keys Select the corresponding characteri stic reference number using the adjus ting dial 18 E g Characteristic C0876 is only suita ble for CMT Press F2 Forward The last screen in the wizard Welding program is shown as a confirmation By pressing F1 Back the screens of the steps...

Page 54: ...eristic Determine the power range of the user characteristic If necessary complete the user characteristic by plotting additional characteristic points Important basic settings are transferred into the new characteristic using this procedure Plotting user characteristics optimising a char acteristic In each Data screen set a similar welding program or the welding program to be changed Press F3 Opt...

Page 55: ... area for current voltage and sheet thickness depend directly on the power values entered Optimize characteristic screen Selecting the syner gic line Press F2 Forward The 2nd screen in the wizard ap pears Optimize characteristic Select corresponding characteristic using the adjusting dial 18 If an existing characteristic is to be overwritten a precautionary query appears Precautionary query for ov...

Page 56: ...ti mize characteristics screen ap pears Optimize characteristic screen Selecting the syner gic line Press F2 Forward The 3rd screen in the wizard ap pears as confirmation Optimize characteristic By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Optimize characteristic wizard confirmation of opti mised characteristic Press F2 Done The last Da...

Page 57: ...ristic point screen No 6 Al99 5 1 2 I1 mod selected Call up the welding program for which a characteristic point is to be created Set the wirefeed speed for which the characteristic point is to be created In the relevant Data screen press F2 Create new characteristic point The 1st screen in the wizard appe ars Create new characteristic point Select corresponding characteristic using the adjusting ...

Page 58: ...n error messa ge appears Error message characteristic point cannot be saved Press F3 OK The 1st screen in the wizard appe ars Create new characteristic point Create new characteristic point screen No 7 Empty characteristic selected Select another characteristic using the adjusting dial 18 Press F3 Name characteristic to name the characteristic Name characteristic screen ap pears 5 6 7 8 ...

Page 59: ...istic point screen appears Create new characteristic point screen Press F2 Forward The 2nd screen in the wizard ap pears as confirmation Create new characteristic point Create new characteristic point screen confirmation of the saved characteristic point Press F2 Done The characteristic point is saved the corresponding Data screen appears By pressing F1 Back the screens of the steps already per fo...

Page 60: ...d ap pears Select a user characteri stic Select a user characteristic screen no 2 CuSi3 10 I1 mod selected Select corresponding user characteri stic using the adjusting dial 18 Press F2 Forward The 3rd screen in the wizard Welding program is shown as a confirmation By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Welding program screen conf...

Page 61: ... working parameters Rod electrode MMA welding Working parameters screen welding current selected Call up Rod electrode MMA welding menu item Select Working parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the corresponding working pa rameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value The parameter value can only be...

Page 62: ...dial 18 Welding voltage is a display value during welding actual value following welding hold value Setting process settings parame ters Rod electrode MMA welding Process settings screen hotstart current HCU selected Call up Rod electrode MMA welding menu item Select Process settings screen by pressing the right arrow key 8 Process settings screen appears Select the process settings parameters usi...

Page 63: ...ng parameters TIG welding Working parameters screen main cur rent selected Call up TIG welding menu item Select Working parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select the corresponding working pa rameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value The parameter value can only be altered within the defined setting ...

Page 64: ...lay screen Call up TIG welding menu item Select Extra large display screen by pressing the right arrow key 8 Extra large display screen appe ars The value for the welding ampera ge can be altered in the Extra lar ge display screen by using the adjusting dial 18 Welding voltage is a display value during welding actual value following welding hold value 1 2 ...

Page 65: ...V mode Main menu CC CV mode menu item selected Press the Menu button 1 Main menu appears Select CC CV mode menu item using the adjusting dial 18 Press OK 3 The last Data screen called up appears Setting working parameters CC CV mode Working parameters screen current command value selected Call up CC CV mode Select Working parameters screen by pressing the right arrow key 8 Working parameters scree...

Page 66: ... alte red in the Extra large display screen using the adjusting dial 18 Welding voltage is a display value during welding actual value following welding hold value 1 Wire feed unit motor current 2 Push pull unit motor current Setting process settings parame ters CC CV mode Process settings screen Call up CC CV mode Select Process settings screen by pressing the right arrow key 8 Process settings s...

Page 67: ...reen actual po wer correction for job no 22 from group 2 selected ex ample for a MIG MAG job Call up the Job welding menu item Select Working parameters screen by pressing the right arrow key 8 Working parameters screen ap pears Select group no parameter using the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select d...

Page 68: ...can be adjus ted within the defined correction boundaries for the job selected using the adjusting dial 18 Welding current and welding vol tage are purely display values 1 Wire feed unit motor current 2 Push pull unit motor current Changing the welding process during CMT Ad vanced welding A 5 3 0 A 6 0 1 2 1 2 NOTE Neither the welding process nor the currently selected characteristic can be change...

Page 69: ... certain parameter settings are to be stored as a job Store as job Group screen no 6 Empty group selected In the corresponding Data screen press F1 Store as job The 1st screen in the wizard appe ars Store as job Group Select corresponding group using the adjusting dial 18 Press F3 Name group to name the group Name group screen appears Name group screen Select corresponding characters using the adj...

Page 70: ...Select corresponding job using the ad justing dial 18 Press F3 Name job to name the job Name job screen appears Name job screen Select corresponding characters using the adjusting dial 18 Press F4 to enter the next charac ter Corrections can be carried out by pressing F3 or F2 Delete Press F1 Accept when finished The new name is accepted Store as job Memory location screen appears 7 8 9 10 11 12 ...

Page 71: ...orward The 3rd screen in the wizard ap pears as confirmation Store as job By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Store as job screen as confirmation Press F2 Done The last selected Data screen appears 13 14 ...

Page 72: ...e desired parameter entry The user can switch between internal and external parameter entry in the following menu items MIG MAG synergic welding CC CV mode MIG MAG standard manual welding Job welding MMA welding Optimizing managing jobs TIG welding Internal parameter entry Int External parameter entry Ext The parameters to be set are entered and altered on the RCU 5000i remote control unit The sel...

Page 73: ...nconnected remote control unit F5 Int Ext greyed out IMPORTANT The F5 Int Ext function key is only active when a remote control is con nected If the remote control is not connected the F5 Int Ext function key is greyed out ...

Page 74: ...nu appears Select Optimizing managing jobs menu item using the adjusting dial 18 Press OK 3 Precautionary query Do you want to edit the jobs online appears The following screens are shown in the case of MIG MAG synergic jobs Administration data SynchroPuls 1 Welding program Q Master values Working parameters Special 2 step 2 Process settings Special 4 step 3 Correction boundaries Spot welding 4 Jo...

Page 75: ...posed of the following sections Managing jobs Retrieving administration data for a selected job Retrieving and changing a welding program for a selected job Retrieving and changing working parameters for a selected job Retrieving and changing process settings for a selected job Retrieving and changing special 2 step parameters for a selected job Retrieving and changing special 4 step parameters fo...

Page 76: ...l 18 Press F3 Name group to name a group Name group screen appears Name group screen Select corresponding characters using the adjusting dial 18 Press F4 to enter the next charac ter Corrections can be carried out by pressing F3 or F2 Delete Press F1 Accept when finished The new name is accepted Ma nage jobs Group screen appe ars Optimizing and managing jobs Manage jobs Group screen Press F2 Forwa...

Page 77: ...Press F4 to enter the next charac ter Corrections can be carried out by pressing F3 or F2 Delete Press F1 Accept when finished The new name is accepted Store as job Memory location screen appears By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Store as job Memory location screen Job 3 Left side up selected Press F2 Done The last selected D...

Page 78: ...d 0 99 using the adjusting dial 18 Press F4 Delete group Precautionary query Do you real ly want to delete the complete group 0 appears Delete group precautionary query Press F2 Yes The selected group is deleted the 1st screen in the wizard appears Manage jobs Group Manage jobs Group screen with deleted group Press F2 Forward The 2nd screen in the wizard ap pears Manage jobs Memory location IMPORT...

Page 79: ...Press F4 Delete job Precautionary query Do you real ly want to delete job 3 appears Delete job precautionary query Press F2 Yes The selected job is deleted the 2nd screen in the wizard appears Manage jobs Memory locati on Manage jobs Memory location screen Press F2 Done The last selected Data screen appears 7 8 9 10 ...

Page 80: ...justing dial 18 If a job is selected from the next group the group displayed also changes accordingly Different adminis tration data dis plays depending on job type Depending on the type of job selected the administration data display differs e g 1 2 3 4 5 6 The following are displayed for MIG MAG synergic jobs Welding current welding voltage and material strength each depending on the wire feed s...

Page 81: ... using the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accordingly Select Welding program screen by pressing the right arrow key 8 Welding program screen appe ars Changing a job welding prog...

Page 82: ...ss F2 Forward The 3rd screen in the wizard ap pears Select a shielding gas Only the gases available for the fil ler metal selected in the 1st screen and wire diameter selected in the 2nd screen are shown Select a shielding gas screen I1 100 Ar selected Select corresponding gas using the ad justing dial 18 Press F2 Forward The Select a reference screen only appears if there are several characterist...

Page 83: ...l 18 E g Characteristic C0876 is only suita ble for CMT Press F2 Forward The 4th screen in the wizard Welding program is shown as a confirmation By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Optimizing managing jobs Welding program screen Press F2 Done Optimizing managing jobs Welding program screen The set welding program is accepted We...

Page 84: ...essing the right arrow key 8 Working parameters screen appears Optimizing and managing jobs Working parameters screen Select the corresponding parameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value A parameter value can only be al tered within the defined setting range The setting range is high lighted Instructions on changing the wire feed speed value Working ...

Page 85: ...l 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Optimizing and managing jobs Process settings screen Select Process settings screen by pressing the right arrow key 8 Process settings screen appears Select the corresponding parameters using down 6 or ...

Page 86: ...the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select Special 2 step screen by pressing the right arrow key 8 Special 2 step screen appears Optimizing and managing jobs Special...

Page 87: ...ng the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select Special 4 step screen by pressing the right arrow key 8 Special 4 step screen appears Optimizing and managing jobs Spec...

Page 88: ...g the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select Spot welding screen by pressing the right arrow key 8 Spot welding screen appears Optimizing and managing jobs Spot weld...

Page 89: ...aging jobs menu item Whatever screen is showing select Group n parameter using the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select Correction boundaries screen by pressing th...

Page 90: ...n value as for upper power correction limit 5 0 upper limit for welding power 15 8 m min set wirefeed speed E g 15 0 m min value as for lower power correction limit 3 0 lower limit for welding power 14 6 m min The correction range for arc length is made up as follows set arc length correction value E g 10 0 value as for arc length correction bounda ries 20 0 upper limit for arc length 30 0 set arc...

Page 91: ...imizing managing jobs menu item Whatever screen is showing select Group n parameter using the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select Job specific doc screen by press...

Page 92: ...ld seam 2 In job welding the present welding values in the selected job are documented at every 2nd weld seam 100 In job welding the present welding values in the selected job are documented at every 100 weld seams maximum Every n seconds Off The present welding values of the selected job are documented once per seam 0 1 The present welding values in the selected job are documented in job welding ...

Page 93: ...ing the down 6 or up 7 keys Select desired group 0 99 using the adjusting dial 18 Select Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select SynchroPuls screen by pressing the right arrow key 8 SynchroPuls screen appears Optimizing and managing jobs SynchroPu...

Page 94: ...ected from the next group the group displayed also changes accord ingly Select QMaster screen by pressing the right arrow key 8 QMaster screen appears Optimizing and managing jobs QMaster screen Select the corresponding parameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value A parameter value can only be al tered within the defined setting range The setting rang...

Page 95: ...set value E g 338 0 A value in A for upper current limit 6 0 A upper welding current limit value 344 0 A Current set value E g 338 0 A value in A for lower current limit 6 0 A lower welding current limit value 332 0 A Maximum duration of current deviation E g 0 3 s Reaction E g Warning Voltage command value E g 28 6 V value in V for upper voltage limit 0 2 V upper voltage limit 28 8 V Voltage comm...

Page 96: ...elect Job n parameter using the down 6 or up 7 keys Select desired job 0 999 using the adjusting dial 18 If a job is selected from the next group the group displayed also changes accord ingly Select QMaster vD screen by pressing the right arrow key 8 QMaster vD screen appears Optimizing and managing jobs QMaster vD screen Select the corresponding parameters using down 6 or up 7 keys Use the adjust...

Page 97: ... feed speed command value 1 E g 15 0 m min Value for the lower wirefeed speed limit 0 5 m min upper welding current limit value 14 5 m min Wire feed speed command value 1 E g 15 0 m min Value for the upper wirefeed speed limit 0 5 m min upper wirefeed speed limit value 15 5 m min Maximum duration of current deviation E g 0 3 s Reaction 2 E g Warning 1 According to Working parameters screen 2 Accor...

Page 98: ...r F3 No Online editing F2 Yes The power source changes to a setup menu independent of the current power source settings Data changed on the remote con trol unit e g wirefeed speed are also shown on the power source if the facility to do so exists Online editing F3 No Current power source settings re main unaffected Data changed on the remote control unit appear only on the remote control unit The ...

Page 99: ...ics Managing characteristic points Parameters of standard characteristics Parameters of pulse characteristics Parameters of CMT characteristics Parameters of CMT pulse characteristics Parameters of CMT Advanced characteristics Parameters of CMT Pulsed Advanced characteristics Changing characteristic parameters ...

Page 100: ...p appears Whatever screen is showing press F1 Managing characteristics The 1st screen in the wizard appe ars Managing characteristics Managing characteristics screen Select the desired characteristic using the adjusting dial 18 Press F1 Select characteristic Example of a Data screen for characteristic XYZ The last Data screen called up for the selected characteristic appears 1 2 3 4 ...

Page 101: ...ars Managing characteristics Managing characteristics screen Select the desired characteristic using the adjusting dial 18 Press F1 Select characteristic Name characteristic screen ap pears Name characteristic screen Select corresponding characters using the adjusting dial 18 Press F4 to enter the next charac ter Corrections can be carried out by pressing F3 or F2 Delete Press F1 Accept when finis...

Page 102: ...een called up appears Deleting charac teristic Example of a Data screen for characteristic XYZ Call up Optimizing managing cha racteristics menu item The last Data screen called up appears Whatever screen is showing press F1 Managing characteristics The 1st screen in the wizard appe ars Managing characteristics 8 1 2 ...

Page 103: ...recautionary query Do you real ly want to delete Synergic ap pears Precautionary query Do you really want to delete Sy nergic Press F2 Yes The characteristic is deleted Ma naging characteristics screen ap pears Managing characteristics screen with deleted cha racteristic To go back to the previous Data screen press F4 Cancel 3 4 5 6 ...

Page 104: ...t before the current one appears The first point in the characteristic F2 Previous point is greyed out F5 Next point the characteri stic point after the current one ap pears With the last point in the characteristic F5 Next point is greyed out Inserting charac teristic points Example of a Data screen for characteristic XYZ Call up Optimizing managing cha racteristics menu item The last Data screen...

Page 105: ...stic point Calculate characteristic point screen entering wire feed speed using the adjusting dial 18 enter wi refeed speed for which the new cha racteristic point is to be calculated Press F2 Forward The 3rd screen in the wizard ap pears as confirmation Calculate characteristic point By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Calcula...

Page 106: ...ponding Data screen appears Insert characteristic point screen Copy selected Copying a characteristic point Press F2 Forward The 2nd screen in the wizard ap pears as confirmation Characte ristic point now copied By pressing F1 Back the screens of the steps already per formed can be displayed again Changes can be made Characteristic point now copied screen Press F2 Done 5 6 ...

Page 107: ...Optimizing managing cha racteristics menu item The last Data screen called up appears Press F1 Managing characteristics and select the characteristic from which a characteristic point is to be de leted Whatever screen is showing select the characteristic point to be deleted using F2 Previous point or F5 Next point Press F4 Delete point Precautionary query Do you real ly want to delete Point appe a...

Page 108: ...108 Example of a Data screen for characteristic XYZ The selected characteristic point is deleted the corresponding Data screen appears ...

Page 109: ...to wire electrode pen etrating the welding material Effects of an excessively low wirefeed speed arc too long scoring may appear around the weld seam Welding wire may weld fast to the contact tip Base current Even at low currents the base current A guarantees a stable arc in the dip transfer arc burning phase Effects of an excessively high base current wire electrode welded on too hard large drops...

Page 110: ...teristic 1 Static range 9 Short circuit 2 Dynamic range 10 Welding current 3 Current rise 0 11 short circuit current 4 Current rise 12 Special dynamic 5 Special dynamic 13 short circuit current 6 Current rise 65535 Special arc force dynamic 0 7 Current decrease 65535 Special dynamic 65535 8 Current drop 0 Special dynamic With the special dynamic a specific current value can be added to the present...

Page 111: ...on dition for good ignition The parameter value must be greater than 0 otherwise there will be no current pulse 0 no current pulse at end of welding max max current pulse at end of welding depends on the power source Burn off pulse time The length of time ms the current pulse is active at end of welding 0 no current pulse at end of welding 50 max duration for the current pulse when welding stops G...

Page 112: ... at the power source Perform test weld During the welding process the present values for welding voltage and welding current appear as ac tual values on the remote control unit The values cannot be altered during the welding process the selection bar appears completely black At the end of welding the last active hold values for welding voltage and welding current are accepted as volta ge and curre...

Page 113: ... or burned Pulsing parame ters Overview of the pulsing parameters Feeder creep speed Wire feed speed m min before welding begins 0 currently set wire feed speed Ignition current time The length of time ms the ignition current set when welding begins is active 0 no ignition current 40 max duration for ignition current 1 Pulsing current time 6 Droplet detachment current 2 Droplet detachment time 7 C...

Page 114: ... on the material and diameter of the wire electrode as well as the shielding gas used The lower the pulsing current and or the greater the diameter of the wire electrode the longer the selected pulse time must be in order to permit a short circuit free material transfer Effects of an excessively high pulse time High energy supply means fine spatter Effects of an excessively low pulse time Poor dro...

Page 115: ...ctrode may weld fast to the contact tube Effects of excessively low voltage arc too short The wire electrode is not sufficiently melted heavy spatter due to wire electrode pen etrating the welding material Fact I_b control pi Effect of deviations on the base current 0 50 Fact I_p1 control pi Effect of deviations on the pulsing current 0 50 Tau current drop Time of transition ms from a linear slope...

Page 116: ...the pulsing current 0 50 Fact f correction Effect of arc length correction on the frequency 0 50 The factors Fact I_b correction Fact I_p1 correction and Fact f correction enable arc length correction at a constant current Control parameters 1 Pulse current 4 Fact I_b control pi 2 Ground current 5 Frequency 1 t 3 Fact I_p1 control pi 6 Fact f control p I A I A I A I A t s t s t s t s 4 3 6 5 1 2 ...

Page 117: ...e and current guideline values Voltage and current guideline values are accepted by the remote control unit directly from the test weld Voltage and current guideline values during test weld continuous black selection bar Set welding voltage and welding cur rent at the power source Perform test weld During the welding process the present values for welding voltage and welding current appear as ac t...

Page 118: ..._1 Off_0 I_ignition I_ignition t_ignition t_ignition U_hotstart t_hotstart vd_ignition Wire feed speed command value m min before welding begins 30 30 30 backward movement of the wire electrode at 30 m min 30 forward movement of the wire electrode at 30 m min I_ignition Command value for the ignition current A set when welding begins The ignition current depends on the filler metal and wire diamet...

Page 119: ...y slag drops off the wire electrode and ignition occurs The ignition parameter for aluminium is slaghammer 0 1 CMT cycle time 4 Boost phase 2 Short circuit phase 5 Burn phase 3 Plasma phase 6 I_sc_wait Current command value A following the boost phase until the dipping of the wire electrode into the weld pool 7 vd_sc_wait Wirefeed speed m min following the boost phase until the dipping of the wire...

Page 120: ..._boostup Non linear current rise rate ms at the start of the boost phase 0 08 5 00 11 I_boost Non linear current rise rate ms at the start of the boost phase 0 08 5 00 12 t_I_boost Duration ms of the boost phase from the start of the boost current rise until the start of the boost current decrease 0 no boost phase 99 98 maximum duration of the boost phase ms 13 d_boostdown Linear rate of current d...

Page 121: ...ontinuous black selection bar Set welding voltage and welding cur rent at the power source Perform test weld During the welding process the present values for welding voltage and welding current appear as ac tual values on the remote control unit The values cannot be altered during the welding process the selection bar appears completely black At the end of welding the last active hold values for ...

Page 122: ...electrode at 30 m min I_ignition Command value for the ignition current A set when welding begins The ignition current depends on the filler metal and wire diameter t_ignition Length of time ms that the parameters Vd_ignition and I_ignition are active when weld ing begins 0 no ignition current no wire feed speed 99 98 max duration for ignition current and wirefeed speed command value U_hotstart Pa...

Page 123: ...command value A following the boost phase until the dipping of the wire electrode into the weld pool 5 vd_sc_wait Wirefeed speed m min following the boost phase until the dipping of the wire elec trode into the weld pool 6 I_sc2 Current command value A with short circuit 7 I_boost Current command value A during the boost phase 8 t_I_boost Duration ms of the boost phase from the start of the boost ...

Page 124: ... decrease rate A ms 0 no decrease in pulsing current 1000 maximum pulsing current drop 14 tau_pulsdown Non linear rate of decrease in the pulsing current ms 0 08 5 15 I_base Current command value A during the base current phase 16 t_base The length of time ms that the parameter I_base is active base current phase 0 no base current phase 99 98 maximum duration of the base current phase IMPORTANT Th...

Page 125: ...ing a test weld Accepting volt age and current guideline values Voltage and current guideline values are accepted by the remote control unit directly from the test weld Voltage and current guideline values during test weld continuous black selection bar Set welding voltage and welding cur rent at the power source Perform test weld During the welding process the present values for welding voltage a...

Page 126: ...lication in question slaghammer On_1 Off_0 Function for removing slag at the end of the wire electrode The wire electrode carries out a quick forward and reverse movement and touches the surface of the workpiece until any slag drops off the wire electrode and ignition occurs The ignition parameter for aluminium is slaghammer 0 I_ignition Command value for the ignition current A set when welding be...

Page 127: ...ayed in the screens CMT Param1 and CMT Param2 The EN CMT parameters in the negative cycle are displayed on the CMT Param1 and CMT Param2 screens Overview of the CMT Advanced characteristic parameters EN Electrode Negative 1 Short circuit phase 3 Boost phase 2 Plasma phase 4 Burn phase Negative cycle 5 I_sc_wait 5 EN_I_sc_wait Current command value A following the boost phase until the dipping of t...

Page 128: ...ise rate ms at the start of the boost phase 0 08 5 00 10 I_boost 10 EN_I_boost Current command value during the boost phase 11 t_I_boost 11 EN_t_I_boost Duration ms of the boost phase from the start of the boost current rise until the start of the boost current decrease 0 no boost phase 99 98 maximum duration of the boost phase ms 12 d_boostdown 12 EN_d_boostdown Linear rate of current decrease A ...

Page 129: ...e guideline value V is normally determined by trial and error or by performing a test weld On the TS 4000 5000 and TPS 2700 4000 5000 power sources the voltage guideline value corresponds to the voltage on the contact tube Wirefeed speed The guideline value for the wire feed speed m min is normally determined by trial and er ror or by performing a test weld I_drop_melt EN_I_drop_melt Current comma...

Page 130: ... at the power source Perform test weld During the welding process the present values for welding voltage and welding current appear as ac tual values on the remote control unit The values cannot be altered during the welding process the selection bar appears completely black At the end of welding the last active hold values for welding voltage and welding current are accepted as volta ge and curre...

Page 131: ...removing slag at the end of the wire electrode The wire electrode carries out a quick forward and reverse movement and touches the surface of the workpiece until any slag drops off the wire electrode and ignition occurs The ignition parameter for aluminium is slaghammer 0 I_ignition Command value for the ignition current A set when welding begins The ignition current depends on the filler metal an...

Page 132: ...hort circuit phase 1 CMT cycle BoP Boost phase 2 Pulse cycles BrP Burn phase 3 Plasma phase Negative cycle KSP KSP 3 1 2 BoP BrP 18 17 16 14 13 12 9 6 5 4 I A U V t s t s t s 0 15 19 VD m s 0 0 7 8 10 11 4 vd_sc_wait Wirefeed speed m min following the boost phase until the dipping of the wire elec trode into the weld pool 5 I_sc2 Current command value A with short circuit 6 d_boostup Linear curren...

Page 133: ...ease A ms following the boost phase 0 no current decrease 1000 maximum decrease in current 11 tau_boostdown Non linear current decrease rate ms following the boost phase 0 08 20 12 d_Ip1 Linear rate of rise in the pulsing current A ms 0 1 no pulsing current rise 2200 maximum pulsing current rise 13 tau_Ip1 Non linear pulsing current rise rate ms 14 I_p1 Current command value A during the pulse pha...

Page 134: ...2 Droplet detachment current A must be greater than I_base other wise there is a risk of an arc break t_p2 Length of time ms that the droplet detachment current is active 0 50 0 no droplet detach ment current d_I_base Linear droplet detachment current decrease rate A ms 0 1 no decrease in droplet detachment current 2200 maximum droplet detachment current decrease tau_I_base Non linear droplet deta...

Page 135: ...e value The voltage guideline value V is normally determined by trial and error or by performing a test weld On the TS 4000 5000 and TPS 2700 4000 5000 power sources the voltage guideline value corresponds to the voltage on the contact tube k_I_p1_reg_gain Effect of deviations on the pulsing current k_Vd_reg_gain Effect of deviations on the wirefeed speed k_I_b_reg_gain Effect of arc length correc...

Page 136: ...136 Wirefeed speed The guideline value for the wire feed speed m min is normally determined by trial and er ror or by performing a test weld ...

Page 137: ...ptimum range In this way there is enough reserve for controlling the welding process The process controller is of no significance for standard characteristics and CMT charac teristics Screens dis played for differ ent characteristics 1 optimum range 2 actual value 2 1 Screen Pulse Standard CMT CMT P CMT ADV CMT P ADV Ignition X X X X X X Hotstart X X Weld start X CMT Param1 X X X X CMT Param2 X X ...

Page 138: ...characteristic point before the current one appears The first point in the characteristic F2 Previous point is greyed out F5 Next point the characteristic point after the current one appears With the last point in the characteristic F5 Next point is greyed out Select the characteristic parameter to be changed using the down 6 or up 7 key Use the adjusting dial 18 to alter the parameter value A par...

Page 139: ...tware option is installed on the power source Job welding Evaluating weld ing data The documented welding data can be evaluated in two ways Direct evaluation of welding data Storing welding data on a memory card subsequent evaluation 1 RCU 5000i 2 3 1 RCU 5000i 2 5 4 1 Power source 4 Card reader 2 PC laptop RCU Data Receiver 5 Memory card 3 LocalNet RS 232 interface Requirements Requirements PC or...

Page 140: ...creen called up appears Overview Documentation is composed of the following sections Establishing basic settings for the documentation Establishing QMaster values Setting maximum motor current Part number counter Welding log Event log Removing a memory card RCU 5000i remote control RCU 5000i remote control If there is no LocalNet connection free on the power source LocalNet passive distributor If ...

Page 141: ...g the documentation function Range On Off On The actual welding values of all welds carried out within the MIG MAG synergic welding MIG MAG standard manual welding and CC CV mode menu items are documented according to the parameters Every n th seam and Every n seconds Off No documentation within the menu items MIG MAG synergic welding MIG MAG standard manual welding and CC CV mode Every n th seam ...

Page 142: ...actual welding values are documented every 9 9 seconds maxi mum e g in the case of long welds A common value for the Every n seconds parameter is 0 5 sec Job documentation for activating deactivating the documentation function for a selected job Range Off on per job Off In job welding the actual welding values are not documented regardless of what is stored in the job concerned On In job welding t...

Page 143: ...after approx 6400 h Example 4 Example 5 Example 6 Welding and weld off times 1 h 1 h 1 h Duty cycle 65 35 65 35 65 35 Every n th seam 1 1 1 Every n seconds 0 1 s 0 5 s Off Actual welding data Yes Yes No Default values Yes Yes Yes Storage rate 400 kB h 100 kB h 5 kB h Change memory card after approx 80 h after approx 320 h after approx 6400 h IMPORTANT At maximum documentation rates Every n th seam...

Page 144: ...in the defined setting range The setting range is high lighted Explanation of QMaster values Example Storing a job with a welding current of 250 A and a welding voltage of 35 V the actual QMaster values are accepted as a pre set The following limit values result for the job If the actual welding current during job welding is greater than 275 A or less than 236 A for more than 0 8 sec the power sou...

Page 145: ...the power source switches off Welding voltage according to job E g 35 0 V value in V for upper voltage limit 2 1 V upper voltage limit 37 1 V Welding voltage according to job E g 35 0 V value in V for lower voltage limit 3 6 V lower voltage limit 31 4 V Maximum duration of current deviation E g 0 8 s Reaction E g Shutdown ...

Page 146: ...action Setting maximum motor current Documentation Motor current screen Call up the Documentation menu item Select Motor current screen by pres sing the right arrow key 8 Motor current screen appears Select the corresponding parameters using down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value A parameter value can only be al tered within the defined setting range The setting...

Page 147: ... ponent number The component number can be any alphanumeric expression with a maximum length of 20 characters Entering separators allows the characters before the separator to be fixed Then when the component number is increased only the characters after the separator will be incremented The number of digits in a component number is determined by the number of characters entered or the number of c...

Page 148: ... F1 Accept when finished Component counter screen with new component number The new component number is accepted the Component counter screen appears Example of a part number with separator This gives a range of possible component numbers from K10 0002 to K10 9999 5 6 7 K10 0002 4 digit final number will be increased up to max 9999 Separator Characters before the separator remain unchanged ...

Page 149: ...t parameter to Manual using the adjusting dial 18 To increment the part number press F2 to reduce the number press F1 The component number is in cremented or decremented Component counter screen with incrementing of component number by job no 5 Incrementing by job Set Increment parameter to Job using the adjusting dial 18 Enter the number of the job whose component number is to be incremen ted usi...

Page 150: ...screen appears Select the desired welding operation using the adjusting dial 18 The entry contains information on Welding process Date time duration of the weld Welding current Welding voltage Wire feed speed Job Violating upper lower limit values Press F1 Open The selected welding operation is displayed in detail with all availab le sections in the Welding infor mation screen Welding information ...

Page 151: ...151 EN Welding information screen for seam 2 section 1 The welding data of the respective section is displayed ...

Page 152: ...ent log Event log screen Call up the Documentation menu item Select Event log screen by pressing the right arrow key 8 The Event log screen appears Select the desired entry using the ad justing dial 18 If no detailed information is availa ble for the selected entry the F1 key Open is greyed out Press F1 Open to display detailed in formation The detailed information for the selected entry is displa...

Page 153: ...checks whether any welding data remains in the cache memory If there is no data in the cache me mory the Information No data available screen appears If data remains in the cache me mory the Save data precautio nary query appears Save data precautionary query To save the data press F2 Yes Information Save complete screen appears NOTE When documenting to a memory card always press F5 Remove SD card...

Page 154: ...154 Information Save complete screen Removing a memory card Save complete The memory card can now be removed 2 ...

Page 155: ...The last Data screen called up appears Overview 1 2 3 Machine pre sets is composed of the following sections Setting machine pre sets for weld ing RCU 5000i Unlock function Setting the language and units of measurement Ethernet setting RCU 5000i displaying version data Setting date and time Robot interface robot welding Creating backup Profiles Keys Restoring data Recommendation for creating pro f...

Page 156: ...in the defined setting ran ge The setting range is highlighted Setting machine pre sets for TIG Machine pre sets TIG screen Call up the Machine pre sets menu item Select TIG screen by pressing the right arrow key 8 TIG screen appears Select the corresponding pre set using down 6 or up 7 keys Alter the value of the pre sets using the adjusting dial 18 The Comfort Stop sensitivity pre set only appea...

Page 157: ...ters Power corr limit High Power corr limit Low and Arc length corr boundary are entered in the Optimizing managing jobs menu item for a selected job the parameter values from the Machine pre sets menu item Job screen are automatically applied when a job is being saved Machine pre sets Job screen Call up the Machine pre sets menu item Select Job screen by pressing the right arrow key 8 Job screen ...

Page 158: ...sets Ethernet setting screen Call up the Machine pre sets menu item Select Ethernet setting screen by pressing the right arrow key 8 The Ethernet setting screen is displayed Press F3 Change The Modify Ethernet setting screen is displayed To reset the UBST setting to the factory set tings Press F5 UBST factory Machine pre sets Ethernet setting screen Select the desired Ethernet parameter using the ...

Page 159: ...the relevant network administrator Default gateway The default gateway is a network specific parameter of the local network Setting the De fault gateway parameter is carried out on site by the relevant network administrator Firewall IP The Firewall IP parameter is used to define the access rights to the power source con cerned The access rights apply to all computers connected to the local network...

Page 160: ...u item Select Time date screen by pressing the right arrow key 8 Time date screen appears Select the corresponding parameter using the down 6 or up 7 keys Alter the parameter using the adjusting dial 18 A parameter value can only be al tered within the defined setting range The setting range is high lighted 1 2 3 4 ...

Page 161: ... external parameter con trol Through a process of selective external internal switching parameters selected with exter nal parameter control are altered and set internally at the remote control unit Internal parame ter control in ro bot welding Machine pre sets Robot interface screen general parameter control internal Call up the Machine pre sets menu item Select Robot interface screen by pressing...

Page 162: ...ts menu item Select Robot interface screen by pressing the right arrow key 8 Robot interface screen appears Set general parameter control para meter to External using the adjusting dial 18 The RCU 5000i remote control unit changes to external parame ter control The parameters to be set are en tered and altered via the robot control Example of external parameter entry continuous black bar arc lengt...

Page 163: ...th correction selected With external parameter control call up the parameters to be altered call up the relevant menu item select corresponding Data screen by pressing the right arrow key 8 select the parameter to be altered using down 6 or up 7 keys The parameter is displayed with a continuous black bar Press F5 Int Ext The selected parameter is conver ted to internal parameter control black bar ...

Page 164: ...s grey e g Example 1 Menu screen in robot welding Job wel ding currently selected by robot shown as black Machine pre sets menu item selected by the user Example 2 Menu screen in robot welding MIG MAG synergic welding currently selected by robot shown as black and also selected by the user If the welding process currently selected by the robot is changed this is also shown in the Menu screen Chang...

Page 165: ...the robot The signal informs the robot that one or more parameters on the remote control are set to internal e g when the gen Parameter control param eter in the Robot interface screen has been set to internal or in the case of selective external internal switching of selected parameters TouchSensing If the TouchSensing robot signal is active in robot welding the Information Touchsens ing is activ...

Page 166: ...tem number 43 0001 1168 Users are as signed different profiles depending on their level of training or qualifications Ten different profiles and a total of one thousand users keys can be set in the Profiles Keys screen User management in the Profiles Keys screen example 1 User management 5 Administrator profile 2 Remote control 6 MIG MAG welders profile 3 Key cards 7 TIG welders profile 4 Several ...

Page 167: ...trator An administrator has unlimited access rights to all functions on the remote control The ad ministrator s duties include creating profiles editing and managing user data assigning access rights updating the RCU 5000i software backing up data etc User management User management encompasses all users registered on the remote control Users are as signed different profiles depending on their lev...

Page 168: ...e deleted or renamed The Locked profile can be edited in order to enable various screens and functions as necessary The Locked profile is activated if no other key is logged onto the remote control No keys can be assigned to the Locked profile The factory setting for the Locked profile can be found in the Example profiles section ...

Page 169: ...es are needed Which rights will be assigned to each profile How many users are there Please also use the example profiles as an aid when choosing profiles Create profiles Assign key cards users to the profiles Check that the set key cards have access to the relevant profiles NOTE Incorrectly created profiles and keys can have serious consequences In correctly created profiles and keys can lead to ...

Page 170: ...es Keys screen Adminis trator profile selected Call up the Machine pre sets menu item Call up Profiles Keys screen by pressing the right arrow key 8 Profiles Keys screen appears Select Administrator profile using the adjusting dial 18 Press F1 New key The 1st screen in the wizard appe ars Enter name Enter name screen Press F3 Name key Name key screen appears 1 2 3 4 5 ...

Page 171: ... onwards once the new name has been accepted the Enter name screen appears once more In this case press F2 Forward The 2nd screen in the wizard ap pears Register transponder Register transponder screen Hold the keycard to be registered transponder or transponder key up to the keycard reader 16 If a key card was already registe red the Error key already exists screen appears Error key already exist...

Page 172: ...e sets menu item Call up Profiles Keys screen by pressing the right arrow key 8 Profiles Keys screen appears Press F3 New profile The Information Administrator key setup screen only appears if no administrator key has been created Information Administrator key setup screen Press F3 OK Create administrator key Otherwise the 1st screen appears Enter the profile name 12 1 2 3 4 5 ...

Page 173: ...obs menu item activated Optimizing managing characteristics Documen tation and Machine pre sets menu items not activa ted Machine pre sets menu item with greyed out screens Select menu items and screens permit ted for the profile in question using the adjusting dial 18 Press F4 Select to activate a menu item or screen An activated menu item or screen is denoted by an X in the check box In the case...

Page 174: ...n MIG MAG synergic welding MIG MAG manual welding optimizing and managing jobs Create jobs MIG MAG synergic welding CC CV mode Creating a new characteristic point MIG MAG synergic welding MIG MAG manual welding Optimize characteristic MIG MAG synergic welding Switching between Int Ext MIG MAG synergic welding MIG MAG manual welding rod electrode MMA welding TIG weld ing CC CV mode job welding opti...

Page 175: ...ofiles Keys screen with new profile The Profiles Keys screen appears with the new profile Opening closing profiles Machine pre sets Profiles Keys screen Adminis trator profile selected Select desired profile using the adjus ting dial 18 Press F2 Open profile The profile is opened the keys as signed to the profile appear 15 16 1 2 ...

Page 176: ...file Machine pre sets Profiles Keys screen Adminis trator profile selected The profile is closed Editing profile Machine pre sets Profiles Keys screen Welders profile selected Select desired profile using the adjus ting dial 18 Press F4 Edit profile The 1st screen in the wizard appe ars Change profile name 3 1 2 ...

Page 177: ... corresponding characters using the adjusting dial 18 Press F4 to enter the next charac ter Corrections can be carried out using F3 or F2 Delete Press F1 Accept when finished The new name is accepted Ch ange profile name screen appe ars Change profile name screen Press F2 Forward The 2nd screen in the wizard ap pears Menus and screens 3 4 5 6 7 ...

Page 178: ...he higher level menu item must also be activated in order to activate screens 8 9 10 11 12 IMPORTANT To activate function key functions at least one higher level menu item must be activated Function key function Higher level menu items Material selection MIG MAG synergic welding MIG MAG manual welding optimizing and managing jobs Create jobs MIG MAG synergic welding CC CV mode Creating a new chara...

Page 179: ...ars Confirmation Press F2 Done Machine pre sets Profiles Keys screen with new profile The Profiles Keys screen appears with the new profile Factory Default machine settings Modify UBST IP Default machine settings Managing jobs Optimizing managing jobs Managing characteristics Optimizing managing characteristics Manage keys profiles Default machine settings Function key function Higher level menu i...

Page 180: ...18 Press F5 Delete profile Precautionary query Do you real ly want to delete the profile in cluding all associated keys appears Precautionary query Do you really want to delete the profile including all associated keys Press F2 Yes Machine pre sets Profiles Keys screen The selected profile is deleted the Profiles Keys screen appears 1 2 3 ...

Page 181: ... shown in their entirety The size of the display on the remote control unit determines the way the lists are dis played The individual list entries are selected using the adjusting dial 18 Locked Factory settings for Locked profile Menus and screens screen More settings screen Main menu in the Locked profile ...

Page 182: ... MIG MAGwelding specialist Tasks Determining parameters for weld seams Create jobs Optimizing and managing jobs Menus and screens screen More settings screen Main menu in MIG MAG welding specialist profile ...

Page 183: ...83 EN Robot program mer Tasks Establishing communication between robot control and welding machine Control function Menus and screens screen More settings screen Main menu in the Robot programmer profile ...

Page 184: ...g jobs Performing backups Simple maintenance e g replacing welding torch wearing parts gas nozzle contact tube etc replacing feed rollers wirespool Menus and screens screen More settings screen Main menu in the Welder worker profile ...

Page 185: ...card is to be as signed Press F1 New key The 1st screen in the wizard appe ars Enter name Enter name screen Press F3 Name key Name key screen appears Name key screen Select corresponding characters using the adjusting dial 18 Press F4 to enter the next charac ter Corrections can be carried out using F3 or F2 Delete Press F1 Accept when finished The new name is accepted Enter name screen appears 1 ...

Page 186: ... be registered up to the keycard reader 16 Only when a key card has already been registered does the Error key already exists screen appear Error key already exists screen Press F3 OK Register other key cards Otherwise the last screen in the wizard appears Confirmation IMPORTANT Do not duplicate any keys Assign one key card to each user 7 8 9 10 ...

Page 187: ...Keys screen Mr Y key selected Open profile to which the key to be al tered is assigned Select corresponding key using the ad justing dial 18 Press F2 Edit key The 1st screen in the wizard appe ars Change name Change name screen Press F3 Name key to change the name Name key screen appears 11 1 2 3 4 ...

Page 188: ...new name is accepted Ch ange name screen appears Change name screen Press F2 Forward The 2nd screen in the wizard ap pears Register transponder Change transponder screen Hold the keycard to be registered up to the keycard reader 16 Only when a key card has already been registered does the Error key already exists screen appear 5 6 7 IMPORTANT Do not duplicate any keys Assign one key card to each u...

Page 189: ...tion Confirmation screen Press F2 Done Profiles Keys screen appears Deleting users keys Profiles Keys screen Mr Y key selected Open profile to which the key to be al tered is assigned Select corresponding key using the ad justing dial 18 Press F4 Delete key Precautionary query Do you real ly want to delete key appears 10 11 12 1 2 3 ...

Page 190: ...190 Precautionary query Do you really want to delete key Press F2 Yes Machine pre sets Profiles Keys screen The selected key is deleted the Profiles Keys screen appears 4 ...

Page 191: ...g on using an unregistered key card the following info screen appears Info Key screen Logging on a user Once logged on the profile to which the corresponding key card is assigned opens Depending on the profile various functions are available to the user A user can always log on to the RCU 5000i remote control unit even if another user is currently logged on Holding the keycard up to the keycard re...

Page 192: ...ing logged on users On the RCU 5000i remote control logged on users are shown in the information bar in the Data screens e g Machine pre sets Profiles Keys screen user A2 logged on Job welding Working parameters screen user Mr X logged on Working parameters screen function keys with no function ...

Page 193: ...ey user logged in screen appears Info Key user logged out screen The Locked profile is activated Displaying Locked profile If the Locked profile is activated on the RCU 5000i remote control this is shown in the information bar in the Data screens e g MIG MAG synergic welding Welding program screen Locked profile activated 16 1 ...

Page 194: ...Press the Info key during the starting sequence The information The unlock file for your RCU 5000i has been cre ated on the SD card is displayed Information File has been created screen Press F3 OK The memory card now contains a text file called UREQUEST TXT This file contains a number letter code that identifies the RCU 5000i Take the memory card out of the RCU 5000i and transfer UREQUEST TXT to ...

Page 195: ...ch anges the Locked profile The information message Your RCU 5000i has been unlocked is displayed Main menu in Locked profile after being changed using the Unlock function In the Machine pre sets menu item Profile Keys screen after changing the Locked profile using the Unlock function the Profile Keys screen can be selected IMPORTANT The name of the text file used to activate the Profile Keys scre...

Page 196: ... F4 key Change profile and then pressing F2 Forward More settings screen in the Locked profile after being changed using the Unlock function Further actions Add new administrator key see Recommendation for creating profiles and keys and Creating and editing keys Reset the Locked profile to the factory setting as described in Example profiles see Creating profiles and keys 1 2 ...

Page 197: ...pre sets Language and units screen Call up the Machine pre sets menu item Select Language and units screen by pressing right arrow key 8 Language and units screen ap pears Select the corresponding parameter using the down 6 or up 7 keys Use the adjusting dial 18 to alter the parameter value A parameter value can only be al tered within the defined setting range The setting range is high lighted Ge...

Page 198: ... DSP and wire feed unit SR 41 as well as for the remote control are shown in the Version screen Displaying ver sion data Machine pre sets Version screen Call up the Machine pre sets menu item Select Version screen by pressing the right arrow key 8 Version screen appears The version data are for display only and cannot be altered V3 21 004 V4 0 123 V1 70 21 V1 03 18 1 2 ...

Page 199: ... card into the memo ry card slot 24 Call up the Machine pre sets menu item Using the right key 8 select a screen that has Backup and Restore on keys F1 and F2 Whatever screen is showing press F1 Backup Name backup screen appears The current date and time are pro posed as the backup name e g Name backup screen Select corresponding characters using the adjusting dial 18 Press F4 to enter the next ch...

Page 200: ...200 Backup screen All data from the remote control unit are sa ved onto the memory card ...

Page 201: ...n is showing press F2 Restore The 1st screen in the wizard Restore from memory card ap pears Restore from memory card screen Select corresponding backup using the adjusting dial 18 Press F2 Forward The 2nd screen in the wizard Restore from memory card ap pears Restore from memory card screen Select data that are to be restored using the adjusting dial 18 Press F4 Select to select the approp riate ...

Page 202: ...202 Restore screen The last Data screen called up appears ...

Page 203: ...3 VR alignment The 1st screen in the wizard appe ars Disengage the wire Disengage the wire screen Follow the instructions given in the Di sengage the wire screen The Disengage the wire screen relates to a push pull system As long as the wire feed unit to be aligned is disengaged begin the VR alignment by pressing F2 For ward Press F2 Forward The VR alignment is started the 2nd in the wizard appear...

Page 204: ...efeed er software is updated If the push pull unit is not aligned the standard parameters will be used which may result in the welding result not being satisfactory Machine pre sets MIG MAG screen Call up the Machine pre sets menu item Select MIG MAG screen by pressing the right arrow key 8 MIG MAG screen appears Press F3 VR alignment The 1st screen in the wizard appe ars Select the push pull moto...

Page 205: ...the wizard ap pears Disengage the wire Disengage the wire screen Follow the instructions given in the Di sengage the wire screen Press F2 Forward The VR alignment is started the 3rd in the wizard appears No load alignment Disengage the wire screen Once no load alignment is complete the 4th screen in the wizard appears Engage the wire 4 5 6 7 ...

Page 206: ...th screen in the wizard appears Alignment under load Alignment under load screen Once VR alignment is complete the 6th screen in the wizard appears Confirmati on Confirmation screen Press F2 Done CAUTION Risk of injury from wire electrode emerging at speed Hold the welding torch so that it points away from your face and body 8 9 10 ...

Page 207: ...207 EN Machine pre sets MIG MAG screen MIG MAG screen appears ...

Page 208: ... pre sets e g MIG MAG screen Call up the Machine pre sets menu item Select MIG MAG screen by pressing the right arrow key 8 MIG MAG screen for L R align ment for MIG MAG welding TIG screen for L R alignment for TIG welding Rod electrode MMA welding screen for L R alignment during rod electrode MMA welding The corresponding Data screen ap pears Press F4 L R alignment The 1st screen in the wizard ap...

Page 209: ...t tube firmly in place Press F2 Forward L R alignment is started the 3rd screen in the wizard appears More settings L R alignment screen Once the L R alignment is complete the values obtained for welding circuit resistan ce R and inductivity L appear in the 4th screen of the wizard Confirmation Confirmation screen Press F2 Done IMPORTANT Contact between the earth ing clamp and workpiece must be es...

Page 210: ...210 Machine pre sets e g MIG MAG screen The last Data screen called up appears ...

Page 211: ...ettings For example Version screen with Factory button Call up the Machine pre sets menu item The last Data screen called up appears Press F5 Factory Precautionary query Do you real ly want to reset all user data ap pears By pressing F2 Yes all data on the remote control is deleted To create a backup press F3 No the reset is cancelled Precautionary query Do you really want to reset all user data P...

Page 212: ...r registered TechGuide users TechGuide Online http www fronius com techguide or via Fronius customer service Before first up date installing LocalNet USB driver Insert the Software Tools CD ROM into your computer s CD drive If the CD ROM does not open automatically open CD ROM Start page appears Software Tools CD ROM start page Select language Download Information page appears Software Tools CD RO...

Page 213: ... file to your PC s local drive Run LocalNetUSB exe WinZip Self Extractor LocalNetUSB exe window appears WinZip Self Extractor LocalNetUSB exe window Select desired saving location using the Browse button Click Unzip WinZip Self Extractor confirmation appears the LocalNetUSB driver is installed on the PC 5 6 7 8 ...

Page 214: ...connection 25 on the remote control unit Found new hardware window appears Found new hardware window Welcome to the Found New Hardware Wizard window appears Welcome to the Found New Hardware Wizard window Click Next Found New Hardware Wizard Install Hardware Device Drivers window appears 9 10 11 ...

Page 215: ...t Search for a suitable driver for my device recommended Click Next Found New Hardware Wizard Locate Driver Files window appears Found New Hardware Wizard Locate Driver Files window Select Specify a location Click Next Found New Hardware Wizard Insert window appears 12 13 14 15 ...

Page 216: ...ed in point 7 Click the OK button Found New Hardware Wizard Driver Files Search Results window appears Found New Hardware Wizard Driver Files Search Results window Click Next Completing the Found New Hardware Wizard window appears Completing the Found New Hardware Wizard window 16 17 18 ...

Page 217: ...SICLoad soft ware Select BSL tool Software Tools CD ROM Firmware RCU 5000i page BSL Tool page appears BSL Tool CD ROM Download the latest version of BASICLoad save the file locally on your PC Run BASICLoad_V exe InstallShield Self extracting EXE window appears InstallShield Self extracting EXE window 19 1 2 3 ...

Page 218: ...re complete the BASICLoad V2 83 2 page and Wel come window appear BASICLoad V2 83 2 page Welcome window Click the Next button Software License Agreement window appears BASICLoad V2 83 2 page Software License Agreement window Read the contents of the Software License Agreement and accept 4 5 6 ...

Page 219: ...on window Enter name and company Click the Next button Choose Destination Location window appears BASICLoad V2 83 2 page Choose Destination Location window Select desired saving location using the Browse button Click the Next button Select Program Folder window appears 7 8 9 10 ...

Page 220: ...w Enter desired folder name existing folders are displayed Click the Next button Setup process runs Setup Complete window appears BASICLoad V2 83 2 page Setup Complete window Click the Finish button BASICLoad Setup V2 83 2 c FRONIUS window appears 11 12 13 ...

Page 221: ...emote control unit Run current RCU 5000i software double click The software is transferred to the remote control BASICLoad V2 83 2 c FRONIUS Internatio window appears BASICLoad V2 83 2 c FRONIUS Internatio window 14 IMPORTANT Keep to the relevant version of the welding program database NOTE When updating software saved jobs may become unusable due to changed characteristics It is recommended to cr...

Page 222: ...plug USB cable from USB port 25 on the remote control The current version of the RCU 5000i software as well as the welding program data base can be checked in the Machine pre sets menu item Version screen Machine pre sets Version screen 5 1 03 47 V3 21 004 V4 0 123 V1 70 21 ...

Page 223: ...parameters Power corr limit High and Power corr limit Low in the Correction boundaries screen Anti Stick for switching the anti stick function on and off in MMA welding pre vents a sticking electrode from burning out by switching off the cur rent ASt Unit Range On Off Arc length correction for correcting the arc length as a SynchroPulse parameter it corrects the arc length in the lower operating p...

Page 224: ...between wire feed unit stop and current stop at end of welding bbc Unit s Range 0 0 4 Burn off pulse time The length of time the current pulse is active at end of welding Unit ms Range 0 50 Burning voltage limit for presetting the burning voltage limit during MMA welding Uco Unit V Range Off 5 max Characteristic for setting the characteristic for electrode welding Eln Unit Range Constant current 0...

Page 225: ...e between wire feed unit stop and current stop at end of welding bbc Unit s Range 0 0 4 Burn off pulse time The length of time the current pulse is active at end of welding Unit ms Range 0 50 Burning voltage limit for presetting the burning voltage limit during MMA welding Uco Unit V Range Off 5 max Characteristic for setting the characteristic for electrode welding Eln Unit Range Constant current...

Page 226: ...influence on the welding param eters Unit A Range 0 max Current rise With a standard arc the current rise parameter determines the speed at which the weld ing current increases for the duration of the short circuit Unit Range 0 65535 Current rise when pulse begins The characteristic parameter describes the linear increase of the current when pulsing begins Unit A ms Range 0 1000 Current rise short...

Page 227: ...racteristics Unit A ms Range 0 1000 Day for presetting the day in the date display Unit Range 1 31 Default gateway Network specific parameter of a local network allocated on site by the relevant network administrator Unit Range 0 255 per item Documentation for activating deactivating the documentation function Unit Range On Off Doc on SD card memory card for activating deactivating documentation o...

Page 228: ...MT Advanced characteristics Unit A Range 5 0 600 0 EN_I_drop_melt current set value for globule formation at the end of welding for CMT characteristics Unit A Range 3 0 500 0 EN_I_sc_wait negative current set value following the boost phase until the dipping of the wire electrode into the weld pool for CMT Advanced characteristics Unit A Range 5 0 600 0 EN_I_sc2 negative current set value with sho...

Page 229: ...ams after which documentation is to occur Unit Range 1 100 Fact f control p effect of control deviations on the frequency Unit Range 0 50 Fact f correction alteration facility for constant current Unit Range 0 50 Fact I_b control pi Effect of deviations on the base current Unit Range 0 50 Fact I_b correction effect of the arc length correction on the base current Unit Range 0 50 Fact I_p1 control ...

Page 230: ...twork Unit Range 0 255 per item Flow watchdog filter time for presetting the time from when the flow watchdog is triggered until the no H2O ser vice code is output Unit s Range 5 25 Frequency for setting the frequency for SynchroPulse F Unit Hz Range Off 0 5 10 Gas factor for setting the correction factor when a different shielding gas is used for the selected filler metal than the one programmed ...

Page 231: ... s Range 0 2 HotStart Arc Length Start for setting an increased arc length for welding start up for MIG MAG synergic welding standard welding process ALS Unit Range 0 100 HotStart current HCU HotStart current for setting the HotStart current for MMA welding e g for improved ignition properties HCU Unit Range 0 100 HotStart pulse cycles for setting the HotStart pulse cycles in the case of CMT chara...

Page 232: ...istics Unit A Range 5 0 650 0 I_p2 the droplet detachment current in the falling edge of the pulse with CMT Advanced Pulse characteristics must be greater than the I_base otherwise there is a risk of an arc break Unit A Range 0 max I_sc_wait current set value following the boost phase until the dipping of the wire electrode into the weld pool for CMT characteristics Unit A Range 5 0 600 0 I_sc2 cu...

Page 233: ...when that job is selected Unit Range 0 999 JobMaster special display for presetting whether the special display for JobMaster is to be switched on or off Gun Unit Range Off 1 Jobslope defines the time between the job that is currently selected and the next job JSL Unit s Range Off 0 1 9 9 k_I_b_reg_gain the effect of the arc length correction on the base current with CMT Advanced Pulse char acteri...

Page 234: ...wer voltage limit with reference to the set value Unit V Range 0 10 Lower wirefeed speed limit for setting the lower wire feed speed limit Unit m min ipm Range 0 5 0 195 Main current Main welding current for TIG welding Unit A Range 3 max Maximum duration of current exceed PPU for setting the maximum duration of current exceed for a push pull unit Unit s Range Off 0 1 9 9 maximum duration of volta...

Page 235: ...nth for presetting the month in the date display Unit Range January December N_CMT_Cycles number of CMT cycles with CMT Advanced Pulse characteristics Unit Range N_Puls_Cycles number of pulsed cycles with CMT Advanced Pulse characteristics Unit Range Negative_weldstart_cycles Number of negative weld start cycles Unit Range Part number for specifying the part number Unit Range Any alphanumeric expr...

Page 236: ...Range 0 500 Pulse correction for correcting the pulsing range of a pulsed arc dYn Unit Range 5 5 Pulse current characteristic parameter for setting the pulse current i e time according to the base cur rent Unit A Range 0 max Pulse current time time during which the pulse current is active Unit ms Range 0 50 Pulse frequency characteristic parameter with CMT Advanced Pulse characteristics for settin...

Page 237: ... mode for presetting the special 4 step mode switching from one job to the next using the JobMaster welding torch S4t Unit Range normal 1 Special dynamic With the special dynamic a specific current value can be added to the present welding current for the duration of the short circuit Unit Range 0 65535 Spot welding time duration of the spot welding process SPt Unit s Range 0 1 5 Standard for pres...

Page 238: ...e length of time that the change in the arc length is active when welding be gins Unit ms Range 0 00 654 98 t_I_boost for setting the duration of the boost phase how long the current command value is active in the boost phase Unit ms Range 0 00 99 98 t_ignition for setting how long the ignition current and the wire feed speed are active before the start of welding Unit ms Range 0 00 99 98 t_p1 for...

Page 239: ...aracteristics Unit Range tau_pulsdown for setting the non linear rate of decrease in the pulse current for CMT Pulse character istics Unit ms Range 0 08 5 00 tau_pulsup for setting the non linear rate of rise in the pulse current for CMT Pulse characteristics Unit ms Range 0 08 5 00 Wire threading speed for setting the wire feed speed at which the welding wire is fed into the torch hosepack Fdi Un...

Page 240: ...ation of CMT Ad vanced Pulse characteristics Unit V Range min max Upper current limit for setting the upper current limit with reference to the set value Unit A Range 0 max Upper voltage limit for setting the upper voltage limit with reference to the set value Unit V Range 0 10 Upper wire feed speed limit for setting the upper wire feed speed limit Unit m min ipm Range 0 5 0 195 Vd_ignition for se...

Page 241: ... Range 0 max Wire feed speed deviation for setting the wire feed speed deviation in SynchroPulse the set wire feed speed is alternately increased decreased by the wire feed speed deviation The parameters concerned adapt themselves to this wire feed speed acceleration delay accordingly dFd Unit m min Range min max Wire feed speed for setting the wire feed speed for MIG MAG synergic welding MIG MAG ...

Page 242: ...242 ...

Page 243: ...Appendix ...

Page 244: ...244 Spare parts list RCU 5000i ...

Page 245: ...245 ...

Page 246: ...246 ...

Page 247: ...247 ...

Page 248: ... 1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of our Sales service partners and Locations ...

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