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System components

General

The power sources can be operated with various system components and op-
tions. This makes it possible to optimize procedures and to simplify machine
handling and operation, depending on the field of application for the power
source.

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

▶

All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.

▶

Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this equip-
ment and all system components.

EN-US

Содержание TransSteel 4000 Pulse

Страница 1: ...Operating instructions TransSteel 4000 Pulse TransSteel 5000 Pulse 42 0426 0353 EA 007 04052022 EN US Operating instructions...

Страница 2: ......

Страница 3: ...ation 16 Maintenance and repair 16 Safety Inspection 17 Disposal 17 Safety symbols 17 Data backup 17 Copyright 17 General information 19 General 21 Device concept 21 Operating principle 21 Application...

Страница 4: ...ents overview 52 Place the wirefeeder on the power source 53 Fit the strain relief device of the interconnecting hosepack 53 Connecting the interconnecting hosepack 54 Correct routing of the interconn...

Страница 5: ...entation 91 Activating Easy Documentation 91 Set the date and time 91 Deactivating Easy Documentation 92 Setup Settings 93 Setup Menu 95 General 95 Operation 95 Setup parameters for MIG MAG synergic w...

Страница 6: ...on during MIG MAG welding 123 Average shielding gas consumption during TIG welding 123 Technical data 124 Overview with critical raw materials year of production of the device 124 Special Voltage 124...

Страница 7: ...other material assets belonging to the operating company Inefficient operation of the equipment All persons involved in the commissioning operation maintenance and servicing of the device must Be suit...

Страница 8: ...for any damage resulting from improper use Temperature range of the ambient air During operation 10 C to 40 C 14 F to 104 F During transport and storage 20 C to 55 C 4 F to 131 F Relative humidity Up...

Страница 9: ...ve clothing must have the following properties Flame resistant Insulating and dry Covering the entire body and in good condition with no damage Safety helmet Cuffless pants Protective clothing involve...

Страница 10: ...measures and identifying working conditions can be found on the European Welding Associ ation website under Health Safety https european welding org Keep flammable vapors such as solvent vapors out of...

Страница 11: ...electrodes of two welding systems Touching the potentials of both elec trodes at the same time may be life threatening in some cases Have the grid and device supply lead regularly inspected by an elec...

Страница 12: ...vices in emission class B Satisfy the emissions criteria for residential and industrial areas This is also true for residential areas in which the energy is supplied from the public low voltage grid E...

Страница 13: ...d during maintenance and repair work During operation Ensure that all covers are closed and all side parts have been mounted prop erly Keep all covers and side parts closed The protrusion of welding w...

Страница 14: ...escaping without notice if an adapter is used for the shielding gas connection Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before in stallati...

Страница 15: ...vice can be deadly Set up the device securely on an even solid sur face The maximum permitted tilt angle is 10 Special regulations apply in areas at risk of fire or explosion Follow the appropriate na...

Страница 16: ...due to use of other system components or other coolants the manufacturer accepts no liability for this and all warranty claims are forfeited Cooling Liquid FCL 10 20 is not flammable The ethanol based...

Страница 17: ...and your health Packaging materials Materials collected separately Check the regulations in your area Reduce the volume of cardboard Safety symbols Devices with the CE label satisfy the essential req...

Страница 18: ...18...

Страница 19: ...General information 19...

Страница 20: ...20...

Страница 21: ...al control and regulation unit of the power sources is coupled with a di gital signal processor The central control and regulation unit and signal pro cessor control the entire welding process During...

Страница 22: ...us injury and property dam age Warning notices on the power source Welding is dangerous The following basic requirements must be met Adequate welding qualifications Appropriate protective equipment Ex...

Страница 23: ...arc A short circuit free transfer of material in the high power range Brief description of MIG MAG pulsed synergic welding MIG MAG pulsed synergic MIG MAG pulsed synergic welding is a pulsed arc proce...

Страница 24: ...compressed air The operating parameters for arc air gouging are defined in a special character istic Applications Removal of shrink holes pores or slag inclusions from workpieces Detaching sprues or t...

Страница 25: ...r source Safety WARNING Danger from incorrect operation and work that is not carried out properly This can result in serious personal injury and damage to property All the work and functions described...

Страница 26: ...verview 1 2 3 4 5 6 7 8 1 Welding torch 2 Wirefeeder 3 Wirefeeder holder 4 Interconnecting hosepacks 5 Power source 6 Cooling unit 7 Trolley and gas cylinder holders 8 Grounding and electrode cable 26...

Страница 27: ...nstruction period cofferdams Ditches Mines Rain Areas partially covered by water Spray water zones The VRD option reduces the voltage between the electrode and the workpiece In the safe state the indi...

Страница 28: ...Applies to MMA welding mode Within 0 3 seconds of the end of welding VRD is active again Restriction of the output voltage to 35 V is ensured again 28...

Страница 29: ...Operating controls and connec tions 29...

Страница 30: ...30...

Страница 31: ...described in these Operating Instructions or vice versa In addition individual figures may also differ slightly from the operating ele ments of your device However the function of these operating elem...

Страница 32: ...on button right a for selecting the following parameters Arc length correction For correcting the arc length Welding voltage in V Before welding begins the device automatically displays a standard val...

Страница 33: ...nu 2 Parameter selection button left a for selecting the following parameters Sheet thickness Sheet thickness in mm or in If the welding current to be selected is not known it is sufficient to enter t...

Страница 34: ...ating points 6 Process button For selecting the welding process MIG MAG standard manual welding MIG MAG standard synergic welding MIG MAG pulsed synergic welding Manual metal arc welding 7 Mode button...

Страница 35: ...n shielding gas flow stops If the Gas test button is not tapped again the shielding gas flow will stop after 30 s 13 SF spot stitch SynchroPulse welding indicator Lights up if a value is set for the s...

Страница 36: ...ding process if one of these parameters is selected then the synergic function ensures that all other parameters including the welding voltage parameter are adjusted automatically In conjunction with...

Страница 37: ...r Available parameters Explanation Example 1 00 4 21 Firmware version Example 2 491 Welding program configuration Example r 2 290 Number of the currently selected welding program Example 654 32 1 65 4...

Страница 38: ...ameter settings can be retrieved Any assigned Save button can be retrieved provided that an assigned Save button was selected when the keylock was enabled Activating deactivating the keylock 1 Keylock...

Страница 39: ...or switching the power source on and off 3 Current socket with bayonet latch Used for Connecting the mains cable from the interconnecting hosepack for MIG MAG welding Connecting the electrode cable or...

Страница 40: ...40...

Страница 41: ...Installation and Startup 41...

Страница 42: ...42...

Страница 43: ...VR 5000 Remote Gas cooled interconnecting hosepack Wire electrode Water cooled MIG MAG weld ing Power source Cooling unit Grounding cable Water cooled MIG MAG welding torch Gas connection shielding g...

Страница 44: ...been discharged Intended use The power source is intended exclusively for MIG MAG MMA and TIG welding Utilization for any other purpose or in any other manner shall be deemed to be not in accordance w...

Страница 45: ...ck Any electrically conductive dust e g from grinding work must not be allowed to be sucked into the device Grid Connection The devices are designed for the grid voltage stated on the rating plate If...

Страница 46: ...e AWG 6 4G10 Canada US cable type Extra hard usage Strain relief devices for other cable cross sections must be designed accord ingly Stipulated mains cables and strain relief devices Power source Gri...

Страница 47: ...ction voltage must be fitted before commissioning The ground conductor should be approx 10 15 mm 0 4 0 6 in longer than the phase conductors A graphic representation of the mains cable connection is p...

Страница 48: ...ting the strain relief device for Europe 3 1 2 5 4 7 1 3 4 100m m 4inch PE 2 2 3 1 3 3 3 3 3 4 4x 3 1 2 Nm 4 1 4 3 2 5 6 5 IMPORTANT Tie the phase conduct ors near the block terminal using cable ties...

Страница 49: ...Fitting the strain relief device for Canada US 3 1 2 5 4 7 1 2 3 1 3 3 3 3 3 4 4x 3 3 5 Nm 4 1 4 3 2 5 6 5 IMPORTANT Tie the phase conduct ors near the block terminal using cable ties 49 EN US...

Страница 50: ...max and U1 according to the device rating plate and technical data The generator apparent power SGEN needed is calculated using the following rule of thumb SGEN S1max x 1 35 A smaller generator can be...

Страница 51: ...in severe personal injury and damage to property Only operate the device if an air filter is fitted The air filter is a very import ant safety device for achieving IP 23 protection General Commissioni...

Страница 52: ...njury and damage The following activities must only be carried out by trained and qualified per sonnel Please note the information in the Safety instructions chapter The following diagram is intended...

Страница 53: ...ackets and trolley are positioned securely 1 1 Fit the strain re lief device of the interconnecting hosepack 1 2 3 4 Fit the strain relief device on the trolley 1 2 1 3 4 Fit the strain relief device...

Страница 54: ...y read and under stood the Operating Instructions NOTE When connecting the interconnecting hosepack check that All connections are connected properly All cables leads and hosepacks are undamaged and c...

Страница 55: ...ting of the intercon necting hosep ack IMPORTANT The duty cycle values D C of the interconnecting hosepack can only be achieved if it is correctly routed Correct routing of the interconnecting hosepac...

Страница 56: ...ng the cylinder strap in the upper area of the gas cylinder but not on the neck of the cylin der 3 Remove the protective cap of the gas cylinder 4 Briefly open the gas cylinder valve to remove any dir...

Страница 57: ...le provide a large cable cross section Do not cross over grounding cables Avoid ferromagnetic materials between the grounding cables and the inter connecting hosepack Do not wind long grounding cables...

Страница 58: ...rt wirespool or basket type spool with basket type spool adapter into the wirefeeder 3 Feed in the wire electrode 4 Set the contact pressure 5 Adjust the brake Setting the date and time when starting...

Страница 59: ...MIG MAG welding 59...

Страница 60: ...60...

Страница 61: ...s smaller and smaller and may be extinguished In order to prevent this the welding power is lowered If the MIG MAG standard synergic welding or MIG MAG pulsed synergic weld ing process is selected the...

Страница 62: ...ble welding parameters e g gas pre flow time please refer to the Setup paramet ers chapter Symbols and ex planations Press the torch trigger Hold the torch trigger Release the torch trigger GPr Gas pr...

Страница 63: ...2 step mode t I I GPr GPo 2 step mode is suitable for Tacking work Short weld seams Automatic and robot operation 4 step mode t I I GPr GPo 4 step mode is suitable for longer weld seams 63 EN US...

Страница 64: ...ep mode 1 Select 2 step mode 2 In the Setup menu set the t S starting current duration and t E final cur rent duration parameters to a value 0 Special 2 step mode is activated 3 In the Setup menu set...

Страница 65: ...the SPt spot welding time duration GPo gas post flow time If the torch trigger is pressed again before the end of the spot welding time SPt the process is canceled immediately 2 step stitch welding GP...

Страница 66: ...welding I I GPr SPt SPt SPb GPo 4 step stitch welding The 4 step stitch welding mode is suitable for welding longer weld seams on thin sheets to prevent the weld seams from dropping through the parent...

Страница 67: ...em from the grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electrically charged component...

Страница 68: ...the welding program tables in the ap pendix 4 Press the Process button to select the desired welding process MIG MAG standard synergic welding MIG MAG pulsed synergic welding 5 Press the Mode button t...

Страница 69: ...pplies even if the power source is switched off and on again To display the actual welding current during welding select the welding current parameter 8 Open the gas cylinder valve 9 Adjust quantity o...

Страница 70: ...with aluminum alloys whose weld seams should have a rippled appearance This effect is achieved using a welding power that changes between two operating points The two operating points result from a po...

Страница 71: ...SynchroPulse works when used in Special 4 step mode I S starting current phase SL Slope I E crater fill phase v wire speed I vD Al 2 L S L S dFd 1 F v I S dFd t I E SynchroPulse mode of operation 71 E...

Страница 72: ...nual welding Wire speed 1 m min 39 37 ipm maximum wire speed e g 25 m min 984 25 ipm Welding voltageTransSteel 4000 Pulse 15 5 31 5 V TransSteel 5000 Pulse 14 5 39 V Arc force dynamic For influencing...

Страница 73: ...welding current para meter The actual welding current is shown on the digital display during welding 7 Open the gas cylinder valve 8 Adjust quantity of shielding gas Tap the Gas test button Turn the...

Страница 74: ...Setup menu set the spot welding time stitch welding time SPt IMPORTANT Stitch pause time SPb OFF must be set for spot welding 2 Only for synergic welding Use the corresponding buttons to select the fi...

Страница 75: ...st flow time 5 Raise the welding torch Stitch welding 1 In the Setup menu set the stitch pause time SPb Stitch welding is enabled The Int Interval parameter is displayed in the Setup menu 2 In the Set...

Страница 76: ...that the wire electrode does not touch any conductive or groun ded parts e g housing etc 10 Stitch welding Procedure for stitch welding 1 Keep the welding torch vertical 2 Depending on the stitch mode...

Страница 77: ...eads Pro After a short time the left display switches to the original value 2 Release the Save button Retrieving Easy Job operating points 1 To retrieve saved settings press the corresponding Save but...

Страница 78: ...Save buttons on the control panel e g The control panel will show the saved settings The Save buttons can now be selected using the buttons on the Up Down weld ing torch Vacant Save buttons are skipp...

Страница 79: ...MMA welding arc air gouging 79...

Страница 80: ...80...

Страница 81: ...he grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electrically charged components such as...

Страница 82: ...le to turn it on IMPORTANT Under certain circumstances it may not be possible to change welding parameters that have been set on the control panel of a system compon ent such as remote control or wire...

Страница 83: ...Parameter selection button to select the arc force dynamic para meter 2 Use the selection dial to set the desired arc force dynamic value The welding parameter value is shown in the digital display lo...

Страница 84: ...n current set welding cur rent Function During the specified hot current time Hti the welding current is increased to a certain value This value HCU is higher than the selected welding cur rent IH Ant...

Страница 85: ...ged Preparation IMPORTANT A grounding cable with a cable cross section of 120 mm is re quired for arc air gouging 1 Set the power switch to O 2 Unplug the mains plug 3 Remove the MIG MAG welding torch...

Страница 86: ...In the setup menu for MMA welding set the AAG parameter to on to enter the setup menu see page 95 NOTE Settings of the break voltage and the starting current time are ignored 4 Exit the setup menu fo...

Страница 87: ...Easy Documentation 87...

Страница 88: ...88...

Страница 89: ...irmware version of power source Firmware of PC board DOCMAG Easy Documentation Document version https www easydocu weldcube com A PFDF report of selected welding data can be created under this link Nr...

Страница 90: ...has been reached The welding data are documented as average values in the main process phase and for each welding operation New CSV file A new CSV file is generated When the USB thumb drive is discon...

Страница 91: ...Easy Documentation remains activ ated 2 Acknowledge the display by pressing the arrow key 3 Set the date and time Set the date and time Setting the date and time is carried out in the 2nd level of th...

Страница 92: ...rameter FAC the date and time remain stored Deactivating Easy Document ation CAUTION Risk of data loss or data damage due to premature disconnection of the USB thumb drive Do not disconnect the USB th...

Страница 93: ...Setup Settings 93...

Страница 94: ...94...

Страница 95: ...ses Accessing the Setup menu MANUAL STD SYNERGIC PULSE SYNERGIC 1 Press the Process button to select the MIG MAG standard synergic welding process MANUAL STD SYNERGIC PULSE SYNERGIC 2T 4T 2 The contro...

Страница 96: ...ode and special 4 step mode Unit of welding current Setting range 0 200 Factory setting 50 t S Starting current duration only for special 2 step mode Unit s Setting range 0 0 9 9 Factory setting 0 0 t...

Страница 97: ...F dFd Delta wire feed Offset welding power for SynchroPulse option Unit m min ipm Setting range 0 3 0 118 1 Factory setting 2 78 7 AL2 Arc length correction for upper SynchroPulse operating point Unit...

Страница 98: ...rms on the wire electrode Unit s Setting range AUt 0 0 3 Factory setting AUt IGC Ignition current Unit A Setting range 100 650 Factory setting 500 Ito Length of wire that is fed before the safety cut...

Страница 99: ...HotStart current HCU setup paramet ers are also reset HCU HotStart current Unit Setting range 100 200 Factory setting 150 Hti Hot current time Unit s Setting range 0 2 0 Factory setting 0 5 ASt Anti...

Страница 100: ...ing the 2nd level of the Setup menu MANUAL STD SYNERGIC PULSE SYNERGIC 1 Press the Process button to select the MIG MAG standard synergic welding process MANUAL STD SYNERGIC PULSE SYNERGIC 2T 4T 2 The...

Страница 101: ...ory setting Standard version EUr USA version US C C Cooler mode only when the cooling unit is connected Unit Setting range AUt On OFF Factory setting AUt AUt The cooling unit cuts out after a 2 minute...

Страница 102: ...e of values 1 kJ 99999 kJ cannot be displayed on the three digit display the following display format has been selected Value in kJ indicator on display 1 to 999 1 to 999 1000 to 9999 1 00 to 9 99 wit...

Страница 103: ...d with the same weld ing process It is not possible to switch during spot welding Function with MIG MAG Up Down key If an EasyJob is selected the EasyJob is changed otherwise the welding current is ch...

Страница 104: ...the no H2O service code is output For example if there are air bubbles in the cooling system the cooling unit will not cut out until the end of this preset time Unit s Setting range 5 25 Factory sett...

Страница 105: ...ction with MIG MAG Up Down key If an EasyJob is selected the EasyJob is changed otherwise the welding current is changed No welding taking place Toggles through all MIG MAG EasyJobs in sequence Weldin...

Страница 106: ...ng circuit resistance again Measure the welding circuit resistance for every welding process separately with the appropriate welding power leads Measuring the welding circuit resistance MIG MAG weld i...

Страница 107: ...hwei en welding process is selected 2 Establish a ground earth connection to the workpiece 3 Access the Setup menu 2nd level 2nd 4 Select parameter r NOTE Incorrect measurement of the welding circuit...

Страница 108: ...ctivity The setup parameter L is used to display the most recently calculated welding circuit inductivity The welding circuit inductivity is adjusted when the welding circuit resistance is measured De...

Страница 109: ...Troubleshooting and Maintenance 109...

Страница 110: ...110...

Страница 111: ...ect them from the grid Secure all devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electrically charged com...

Страница 112: ...ding do not make any impermissible change to the welding process reset error message by pressing any button Cause Remedy ELn 14 More than one robot interface is connected Only one robot interface may...

Страница 113: ...welding power leads and control lines are connec ted Switch off the power source Wait 10 seconds and switch the power source back on again If the error occurs again contact the After Sales Service te...

Страница 114: ...Allow power source to cool down check air filter and clean if neces sary check that fan is on Cause Remedy to2 xxx Note xxx stands for a temperature value Overtemperature in the secondary circuit of...

Страница 115: ...ource in a heated room and allow it to warm up Cause Remedy tu3 xxx Note xxx stands for a temperature value Undertemperature in the wirefeeder motor Place wirefeeder in a heated room and allow to warm...

Страница 116: ...ce of the workpiece if necessary set the Ito parameter in the Setup menu Cause Remedy EPG 17 The selected welding program is invalid Select a valid welding program Cause Remedy EPG 29 The required wir...

Страница 117: ...vel of the service menu see page 91 Cause Remedy Err doc Welding is not possible Error writing data Internal documentation error Communication error Turn power source off and on again Cause Remedy Err...

Страница 118: ...m incorrect operation and work that is not carried out properly This can result in serious personal injury and damage to property All the work and functions described in this document must only be car...

Страница 119: ...compressed air 2 Also clean the cooling air ducts if there is a large accumulation of dust WARNING An electric shock can be fatal Danger of electric shock due to grounding cable and device grounding p...

Страница 120: ...120...

Страница 121: ...Appendix 121...

Страница 122: ...122...

Страница 123: ...tion at a wire speed of 10 m min 1 0 mm wire electrode dia meter 1 2 mm wire electrode dia meter 1 6 mm wire electrode dia meter Steel wire electrode 3 7 kg h 5 3 kg h 9 5 kg h Aluminum wire electrode...

Страница 124: ...production 2017 Special Voltage For devices designed for special voltages the technical data on the rating plate applies The following applies for all devices with a permitted grid voltage of up to 46...

Страница 125: ...device without interruptions 1 Search for a 100 ED value in the technical data which corresponds to the existing ambient temperature 2 Reduce the power or amperage value correspondingly so that the d...

Страница 126: ...eaker Type B Welding current range I2 MIG MAG 10 400 A MMA 10 400 A Welding current at 10 min 40 C 104 F 40 400 A 60 370 A 100 340 A Output voltage range according to standard characteristic U2 MIG MA...

Страница 127: ...to a 230 400 V and 50 Hz public grid 2 ED Duty cycle 3 A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low voltage grid The elec...

Страница 128: ...ecommended residual current cir cuit breaker Type B Welding current range I2 MIG MAG 10 400 A MMA 10 400 A Welding current at 10 min 40 C 104 F U1 200 460 V 40 400 A 60 370 A 100 340 A Output voltage...

Страница 129: ...7 W Power source efficiency at 400 A 36 V 90 1 Interface to a 230 400 V and 50 Hz public grid 2 ED Duty cycle 3 A device in emissions class A is not intended for use in residential areas in which the...

Страница 130: ...reaker Type B Welding current range I2 MIG MAG 10 500 A MMA 10 500 A Welding current at 10 min 40 C 104 F 40 500 A 60 420 A 100 360 A Output voltage range according to standard characteristic U2 MIG M...

Страница 131: ...to a 230 400 V and 50 Hz public grid 2 ED Duty cycle 3 A device in emissions class A is not intended for use in residential areas in which the power is supplied via a public low voltage grid The elec...

Страница 132: ...tolerance 10 15 Mains frequency 50 60 Hz Cos phi 1 0 99 Max permitted grid impedance Zmax on PCC1 52 2 mOhm Recommended residual current cir cuit breaker Type B Welding current range I2 MIG MAG 10 50...

Страница 133: ...43 6 kg 96 1 lb Max noise emission LWA 75 dB A Idle state power consumption at 400 V 82 7 W Power source efficiency at 500 A 40 V 90 1 Interface to a 230 400 V and 50 Hz public grid 2 ED Duty cycle 3...

Страница 134: ...Welding program tables Welding program label on the device A label with the most common welding programs is affixed to the power source Welding program label on the power source 134...

Страница 135: ...9 S2332 P4002 S2394 P4003 1 Steel ER70 120 Ar 2 12 CO C S2485 P4006 S2486 P3990 S2487 P3958 S2488 P3987 S2489 P4005 S2490 P4004 1 Steel ER70 120 Ar 13 25 CO D S2285 S2297 S2307 S2323 S2331 S2395 1 Ste...

Страница 136: ...F S2292 S2302 S2312 S2326 S2336 1 Steel dyn ER70 120 Ar 8 CO SP F S2293 S2303 S2313 S2327 S2337 2 Steel dyn ER70 120 Ar 18 CO SP F S2291 S2301 S2311 S2325 S2335 3 Steel dyn ER70 120 Ar 4 CO SP F S250...

Страница 137: ...P3977 S2377 P3979 S2409 P4002 S2394 P4003 1 Steel ER70 120 Ar 2 12 CO C S2419 P4006 S2369 P3990 S2309 P3958 S2376 P3987 S2333 P4005 S2490 P4004 1 Steel ER70 120 Ar 13 25 CO D S2285 S2297 S2307 S2331 S...

Страница 138: ...F S2374 S2367 S2312 S2380 S2336 1 Steel dyn ER70 120 Ar 8 10 CO SP F S2375 S2366 S2313 S2379 S2337 2 Steel dyn ER70 120 Ar 15 25 CO SP F S2291 S2301 S2311 S2325 S2335 3 Steel dyn ER70 120 Ar 4 O SP F...

Страница 139: ...139 EN US...

Страница 140: ......

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