FRONIUS TransSteel 4000 Pulse Manual de usuario

Operating

instructions

TransSteel 4000 Pulse

TransSteel 5000 Pulse

42,0426,0353,EA 007-04052022

EN-US Operating instructions

Table of contents

Safety Instructions 7

Explanation of Safety Instructions 7

General 7

Intended Use 8

Environmental Conditions 8

Obligations of the Operating Company 8

Obligations of Personnel 8

Grid Connection 9

Personal Protection and Protection of Others 9

Danger from toxic gases and vapors 9

Danger from Flying Sparks 10

Risks from grid current and welding current 10

Stray welding currents 12

EMC Device Classifications 12

EMC measures 12

EMF measures 13

Particular hazard areas 13

Requirement for the shielding gas 14

Danger from Shielding Gas Cylinders 14

Danger Posed by Shielding Gas Leak 15

Safety Measures at the Setup Location and During Transport 15

Safety Measures in Normal Operation 16

Maintenance and repair 16

Safety Inspection 17

Disposal 17

Safety symbols 17

Data backup 17

General information 19

General 21

Device concept 21

Operating principle 21

Application areas 21

Warning notices on the device 22

Welding processes, procedures, and welding characteristics for MIG/MAG welding 23

General 23

Brief description of MIG/MAG standard synergic welding 23

Brief description of MIG/MAG pulsed synergic welding 23

Brief description of SynchroPulse welding 23

Brief description of the gouging (Arc Air Gouging) 24

System components 25

General 25

Safety 25

Overview 26

VRD: Safety function 27

VRD: Safety principle 27

Operating controls and connections 29

Control Panel 31

General 31

Safety 31

Control panel 32

Service parameters 37

Keylock 38

Connections, Switches, and Mechanical Components 39

TransSteel 4000/5000 Pulse connections 39

EN-US

Installation and Startup 41

Minimum equipment for welding operations 43

General 43

Gas-cooled MIG/MAG welding 43

Water-cooled MIG/MAG welding 43

Manual metal arc welding 43

Minimum equipment for arc air gouging 43

Before installation and initial operation 44

Safety 44

Intended use 44

Setup regulations 44

Grid Connection 45

Connecting the Mains Cable 46

General 46

Stipulated mains cables and strain-relief devices 46

Safety 47

Connecting the mains cable 47

Fitting the strain-relief device for Europe 48

Fitting the strain-relief device for Canada / US 49

Generator-Powered Operation 50

Generator-powered operation 50

Commissioning 51

Safety 51

General 51

Information on system components 51

Assembling system components (overview) 52

Place the wirefeeder on the power source 53

Fit the strain-relief device of the interconnecting hosepack 53

Connecting the interconnecting hosepack 54

Correct routing of the interconnecting hosepack 55

Connecting the gas cylinder 56

Establishing a ground earth connection 57

Connecting a MIG/MAG welding torch 58

Other activities 58

Setting the date and time when starting for the first time 58

MIG/MAG welding 59

Power Limitation 61

Safety function 61

MIG/MAG Operating Modes 62

General 62

Symbols and explanations 62

2-step mode 63

4-step mode 63

Special 2-step mode 64

Special 4-step mode 64

Spot welding 65

2-step stitch welding 65

4-step stitch welding 66

MIG/MAG welding 67

Safety 67

Preparation 67

Overview 67

MIG/MAG synergic welding 68

Corrections during welding 70

SynchroPulse welding 70

MIG/MAG Standard Manual Welding 72

General 72

Available parameters 72

MIG/MAG standard manual welding 72

Corrections during welding 73

Spot welding and stitch welding 74

General 74

Spot welding 74

Stitch welding 75

EasyJob mode 77

General 77

Saving EasyJob operating points 77

Retrieving EasyJob operating points 77

Deleting EasyJob operating points 77

Retrieving EasyJob operating points on the Up/Down welding torch 78

MMA welding, arc air gouging 79

Manual Metal Arc Welding 81

Safety 81

Preparation 81

Manual metal arc welding 82

Corrections during welding 83

HotStart function 84

Anti-Stick function 84

Arc Air Gauging 85

Safety 85

Preparation 85

Arc air gouging 85

Easy Documentation 87

General 89

Documented welding data 89

New CSV file 90

PDF report / Fronius signature 90

Activating / deactivating Easy Documentation 91

Activating Easy Documentation 91

Set the date and time 91

Deactivating Easy Documentation 92

Setup Settings 93

Setup Menu 95

General 95

Operation 95

Setup parameters for MIG/MAG synergic welding 96

Setup parameters for MIG/MAG standard manual welding 98

Setup parameters for MMA welding 99

Setup Menu 2nd Level 100

Limitations 100

Operation (Setup Menu 2nd Level) 100

Parameters for MIG/MAG synergic welding in Setup menu 2nd level 101

Parameters for MIG/MAG standard manual welding in Setup menu 2nd level 103

Parameters for manual metal arc welding in Setup menu 2nd level 105

Measuring the Welding Circuit Resistance r 106

General 106

Measuring the welding circuit resistance (MIG/MAG welding) 106

Measuring the welding circuit resistance (MMA welding) 107

Displaying the welding circuit Inductivity L 108

General 108

Displaying the welding circuit inductivity 108

Laying the hosepacks correctly 108

Troubleshooting and Maintenance 109

EN-US

Troubleshooting 111

General 111

Safety 111

Displayed Service Codes 111

Displayed service codes in connection with OPT Easy Documentation 116

Service, maintenance and disposal 118

General 118

Safety 118

At every start-up 118

Every 2 Months 118

Every 6 Months 119

Disposal 119

Appendix 121

Average consumption values during welding 123

Average wire electrode consumption during MIG/MAG welding 123

Average shielding gas consumption during MIG/MAG welding 123

Average shielding gas consumption during TIG welding 123

Technical data 124

Overview with critical raw materials, year of production of the device 124

Special Voltage 124

Explanation of the term duty cycle 124

TransSteel 4000 Pulse TransSteel 4000 Pulse nc 126

TransSteel 4000 Pulse MV nc 128

TransSteel 5000 Pulse TransSteel 5000 Pulse nc 130

TransSteel 5000 Pulse MV nc 132

Welding program tables 134

Welding program label on the device 134

Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse 135

Welding program tables for TransSteel 4000 Pulse, TransSteel 5000 Pulse US 137

Safety Instructions

Explanation of

Safety Instruc-

tions

DANGER!

Indicates an immediate danger.

▶Death or serious injury may result if appropriate precautions are not taken.

WARNING!

Indicates a possibly dangerous situation.

▶Death or serious injury may result if appropriate precautions are not taken.

CAUTION!

Indicates a situation where damage or injury could occur.

▶Minor injury or damage to property may result if appropriate precautions are

not taken.

NOTE!

Indicates the possibility of ﬂawed results and damage to the equipment.

General The device has been manufactured using state-of-the-art technology and ac-

cording to recognized safety standards. If used incorrectly or misused, 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 operating

company

-Inefficient operation of the equipment

All persons involved in the commissioning, operation, maintenance, and servicing

of the device must

-Be suitably qualified

-Have knowledge of welding

-Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being

used. In addition to the Operating Instructions, all applicable local rules and reg-

ulations regarding accident prevention and environmental protection must also

be followed.

All safety and danger notices on the device must

-Be kept in a legible state

-Not be damaged/marked

-Not be removed

-Not be covered, pasted, or painted over

For the location of the safety and danger notices on the device, refer to the sec-

tion headed "General" in the Operating Instructions for the device.

Before switching on the device, remove any faults that could compromise safety.

Your personal safety is at stake!

EN-US

Intended Use The device is to be used exclusively for its intended purpose.

The device is intended exclusively for the welding process specified on the rating

plate.

Utilization for any other purpose, or in any other manner, shall be deemed to be

"not in accordance with the intended purpose." The manufacturer is not respons-

ible for any damage resulting from improper use.

Proper use also means

-Completely reading and obeying all instructions in the Operating Instruc-

tions

-Completely reading and obeying all safety instructions and danger notices

-Carrying out all the specified inspection and servicing work

Never use the device for the following applications:

-Thawing pipes

-Charging batteries

-Starting motors

The device is designed for operation in industry and business. The manufacture

shall not be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work results.

Environmental

Conditions

Operation or storage of the device outside the stipulated area will be deemed as

not in accordance with the intended purpose. The manufacturer accepts no liab-

ility 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 to 50% at 40°C (104°F)

-Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc.

Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

Obligations of

the Operating

Company

The operating company must only allow persons to work with the device if they

-Are familiar with the basic occupational safety and accident prevention regu-

lations and are trained in handling the device

-Have read and understood these Operating Instructions, especially the sec-

tion "Safety Rules," and have confirmed this with their signature

-Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

Obligations of

Personnel

All persons who are assigned to work with the device must do the following be-

fore beginning the work:

-Follow the basic regulations for occupational safety and accident prevention

-Read these Operating Instructions, especially the section "Safety Rules," and

confirm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage

can occur in one's absence.

Grid Connection Devices with a high output can inﬂuence the energy quality of the grid due to

their current consumption.

This may affect a number of device types in terms of:

-connection restrictions

-criteria regarding maximum permissible grid impedance *)

-criteria regarding the minimum required short-circuit power *)

*) both at the interface with the public grid

See technical data

In this case, the operator or the person using the device should check whether or

not the device is allowed to be connected, where appropriate through discussion

with the power supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

Personal Protec-

tion and Protec-

tion of Others

You are exposed to numerous hazards while handling the device, for example:

-Flying sparks and pieces of hot metal

-Arc radiation that poses a risk of injury to the eyes and skin

-Hazardous electromagnetic fields that pose a risk of death for individuals

with pacemakers

-Electrical risks from grid current and welding current

-Increased noise exposure

-Harmful welding fumes and gases

Wear suitable protective clothing when dealing with the device. The protective

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 involves the following:

-Protecting the face and eyes from UV radiation, heat and ﬂying sparks with a

face guard featuring a regulation-compliant filter

-Wearing regulation-compliant protective goggles with side protection behind

the face guard

-Wearing rigid, wet-insulating footwear

-Protecting hands with appropriate gloves (featuring electrical insulation and

thermal protection)

-Wearing ear protection to reduce noise exposure and protect against injury

Keep persons, especially children, away during the operation of the devices and

during the welding process. If persons are in the vicinity, however:

-Instruct them about all hazards (blinding hazard due to arcs, risk of injury

from ﬂying sparks, welding fumes hazardous to health, noise exposure, pos-

sible hazard due to grid current or welding current, etc.)

-Provide suitable protective equipment or

-Construct suitable protective walls and curtains.

Danger from tox-

ic gases and va-

pors

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph

118 from the International Agency for Research on Cancer.

EN-US

Use at-source extraction source and a room extraction system.

If possible, use a welding torch with an integrated extraction device.

Keep your head out of the welding fumes and gases.

Take the following precautionary measures for fumes and harmful gases:

-Do not breathe them in.

-Extract them from the work area using appropriate equipment.

Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventila-

tion ﬂow rate of at least 20 m³ per hour.

Use a welding helmet with air supply if there is insufficient ventilation.

If there is uncertainty as to whether the extraction capacity is sufficient, com-

pare the measured toxic emission values against the permissible limit values.

The following components are factors that determine how toxic the welding

fumes are:

-The metals used for the workpiece

-Electrodes

-Coatings

-Cleaning agents, degreasers, and the like

-The welding process used

Consult the corresponding material safety data sheets and manufacturer's in-

structions for the components listed above.

Recommendations for exposure scenarios, risk management 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 the arc radiation range.

When no welding is taking place, close the valve of the shielding gas cylinder or

the main gas supply.

Danger from Fly-

ing Sparks

Flying sparks can cause fires and explosions.

Never undertake welding near ﬂammable materials.

Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the

arc or protected with a certified cover.

Keep suitable, tested fire extinguishers on hand.

Sparks and pieces of hot metal may also get into surrounding areas through

small cracks and openings. Take appropriate measures to ensure that there is no

risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed

tanks, drums, or pipes if these have not been prepared in accordance with cor-

responding national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, and

the like are/were stored. Residues pose a risk of explosion.

Risks from grid

current and

welding current

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

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