FRO­NIUS TransSteel 4000 Pulse User manual

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
Copyright 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 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
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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
MIG/MAG synergic welding 68
Corrections during welding 70
SynchroPulse welding 70
MIG/MAG Standard Manual Welding 72
General 72
Available parameters 72
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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
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
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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
6

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!
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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.
8

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.
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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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