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Lasting Connections

URANOS 4000-5000 GSM

INSTRUCTION MANUAL

voestalpine Böhler Welding

www.voestalpine.com/welding

Summary of Contents for Bohler URANOS 4000-5000 GSM

Page 1: ...Lasting Connections URANOS 4000 5000 GSM INSTRUCTION MANUAL voestalpine B hler Welding www voestalpine com welding...

Page 2: ...Cod 91 08 346 Data 11 06 2019 Rev ENGLISH 35 9 Rating plate 385 10 Meaning of power source rating plate 386 11 Diagram 387 12 Connectors 389 13 Spare parts list 390...

Page 3: ...GSM URANOS 5000 GSM conforms to the EU directives 2014 35 EU LOW VOLTAGE DIRECTIVE 2014 30 EU EMC DIRECTIVE 2011 65 EU RoHS DIRECTIVE and that following harmonized standards have been duly applied EN...

Page 4: ...anel 42 3 3 Starting Screen 42 3 4 Test screen 42 3 5 Main Screen 43 3 6 Set up 44 3 7 Synergic curves screen 49 3 8 Programs screen 49 3 9 Interface personalisation 51 3 10 Lock unlock 51 3 11 Extern...

Page 5: ...tion noise heat and gas emissions Wear protective clothing to protect your skin from the arc rays sparks or incandescent metal Clothes must cover the whole body and must be intact and in good conditio...

Page 6: ...pes Pay particular attention during welding operations on pipes or containers even if these are open empty and have been cleaned thoroughly Any residue of gas fuel oil or similar materials might cause...

Page 7: ...er supply requirements See technical data High power equipment may due to the primary current drawn form the mains supply influence the power quality of the grid Therefore connection restrictions or r...

Page 8: ...age to the equipment the selected mains voltage and fuses must be checked BEFORE connecting the machine to the mains Also check that the cable is connected to a socket provided with earth contact Oper...

Page 9: ...to the rear gas con nection Connect the signal cable 14 of the torch to the appropriate connector 15 Connect the gas hose 16 of the torch to the appropriate union connection 17 Connection for MIG MAG...

Page 10: ...be displayed during start up settings current and voltage readings while welding and encoding of the alarms 5 LCD display 3 5 Allows the general welding machine parameters to be displayed during star...

Page 11: ...important infor mation relating to the selected process The synergic curve selected 1a Type of filler metal 1b Wire diameter 1c Type of gas Welding parameters 1d Welding current 1e Part thickness 1f...

Page 12: ...ouble pulsed active 3d MIG MAG Pulsed MIG MAG Display type 4 VRD Voltage Reduction Device Shows that the no load voltage of the equipment is controlled 5 Measurements During the welding operation the...

Page 13: ...ameter set in Volts V Minimum 0V Maximum 99 9V Default 57V 500 Allows the selection of the required graphic interface XE Easy Mode XA Advanced Mode XP Professional Mode Allows access to the higher set...

Page 14: ...etting seconds s Minimum off Maximum 99 9s Default off 20 Post gas Permits setting and adjustment of the gas flow at the end of welding Minimum 0 0s Maximum 99 9s Default syn 203 TIG start HF Allows s...

Page 15: ...the piece of wire outside the torch Minimum 2 00 Maximum 2 00 Default 0 00 16 Post gas Permits setting and adjustment of the gas flow at the end of welding Minimum off Maximum 10 sec Default 2 sec 19...

Page 16: ...d the inser tion of a protection code consult the Lock unlock section 552 Buzzer tone Permits adjustment of the buzzer tone Minimum Off Maximum 10 Default 10 601 Regulation step Allows the regulation...

Page 17: ...r 2 CO2 AlMg5 Ar AlSi5 Ar Al99 5 Ar CuAl8 Ar CuSi3 Ar Basic FCW Ar 18 CO2 Rutil FCW Ar 18 CO2 Metal FCW Ar 18 CO2 CrNi 19 9 FCW Ar 18 CO2 mm 0 8 S 2 S 7 S 12 S 17 S 22 S 27 S 32 S 37 1 0 S 3 S 8 S 13...

Page 18: ...memory location requires cancellation of the memory location by an obligatory procedure Cancel the operation by pressing button 2 Remove the selected program by pressing button 1 Resume the storage p...

Page 19: ...ore the selected parameter in the 7 segment display by pressing button 2 Save and exit the current screen by pressing button 4 Default I1 3 10 Lock unlock Allows all the settings to be locked from the...

Page 20: ...remote control output CH1 CH2 CH3 CH4 by pressing button 1 Select the required parameter Min Max parameter by pressing the encoder button Adjust the required parameter Min Max parameter by rotating th...

Page 21: ...he arc consult the Set up section Parameters 802 803 804 3 13 Alarms screen Allows the intervention of an alarm to be indicated and provides the most important indications for the solution of any prob...

Page 22: ...it exceeded Warning E61 Speed limit exceeded Alarm E69 Speed limit exceeded Warning E70 Incompatible WARNING alarm E71 Liquid coolant overtemperature alarm E72 Blocked motor alarm E73 Wire supply alar...

Page 23: ...he RC control and vice versa 4 2 RC 100 remote control The RC 100 is a remote control unit designed to manage the display and the adjustment of the welding current and voltage Consult the instruction...

Page 24: ...AG torches allowing the main welding parameters to be controlled welding current Synergic MIG MAG process arc length Synergic MIG MAG process wire speed Manual MIG MAG process welding voltage Manual M...

Page 25: ...t Contact the nearest service centre to have the sys tem repaired Cause The system has overheated temperature alarm yellow LED on Solution Wait for the system to cool down without switching it off Cau...

Page 26: ...se the distance between the electrode and the piece Decrease the welding voltage Cause Incorrect welding parameters Solution Decrease the welding voltage Cause Incorrect arc regulation Solution Increa...

Page 27: ...fficient shielding gas Solution Adjust the gas flow Check that the diffuser and the gas nozzle of the torch are in good condition Cause The weld pool solidifies too quickly Solution Decrease the trave...

Page 28: ...r come in contact with the workpiece for this reason the welding power source is usually equipped with an arc striking device that generates a high frequency high voltage discharge between the tip of...

Page 29: ...ng of copper follow the same directions as for TIG welding of steel or special instructions 7 3 Continuous wire welding MIG MAG Introduction A MIG system consists of a direct current power source wire...

Page 30: ...eld bead can be varied according to requirements by manually moving the torch to obtain variable deposits with constant voltage The wire feeding speed is proportional to the welding cur rent Fig 2 and...

Page 31: ...nd good mechani cal properties On the other hand the use of this gas creates considerable problems with the final chemical composition of the joints as there is a loss of easily oxidisable elements wi...

Page 32: ...y factor 40 C x 40 x 50 x 60 400A x 100 360A MIG MAG duty factor 25 C x 80 x 100 400A Adjustment range I2 3 400A Open circuit voltage Uo 73Vdc Peak voltage Vp 10 1kV IP Protection rating IP23S Insulat...

Page 33: ...or 40 C x 50 500A x 60 470A x 100 420A MIG MAG duty factor 25 C x 80 500A x 100 470A Adjustment range I2 3 500A Open circuit voltage Uo 73Vdc Peak voltage Vp 10 1kV IP Protection rating IP23S Insulati...

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Page 35: ...accordance with national law electrical equipment that has reached the end of its life must be col lected separately and returned to an environmentally compatible recycling facility As the owner of th...

Page 36: ...oltage 11 Max Min current range and corresponding conventio nal load voltage 12 Intermittent cycle symbol 13 Rated welding current symbol 14 Rated welding voltage symbol 15 16 17 Intermittent cycle va...

Page 37: ...URANOS 4000 GSM LCD 3 5 3x400V 11 Diagram...

Page 38: ...388 388 URANOS 5000 GSM LCD 3 5 3x400V...

Page 39: ...389 12 Connectors URANOS 4000 GSM LCD 3 5 3x400V URANOS 5000 GSM LCD 3 5 3x400V...

Page 40: ...390 55 04 022 55 04 023 13 Spare parts list URANOS 4000 GSM LCD 3 5 3x400V URANOS 5000 GSM LCD 3 5 3x400V...

Page 41: ...oard Power pc board spare kit 400A Power pc board spare kit 500A Fan Spacer Diode Flange Diode Choke CODE 01 02 04502 01 02 04602 01 06 02707 01 03 06802 03 07 378 03 07 377 74 90 075 01 04 29501 01 0...

Page 42: ...Cable assembly Wiring HF Power cable Wiring DGMIG A instruction manual B instruction manual CODE 11 14 006 14 70 058 15 14 535 15 14 536 10 13 003 14 70 059 15 14 431 15 14 537 05 18 010 14 05 098 05...

Page 43: ...voestalpine B hler Welding www voestalpine com welding...

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