42,0426,0021, en PDF

/ Perfect Charging / Perfect Welding / Solar Energy
Operating Instructions
RCU 5000i EN Spare parts list
Remote control
42,0426,0021,EN 004-03112017
2
Dear reader,
EN
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with 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 results.
3
4
Contents
EN
Safety rules ................................................................................................................................................ 11
Explanation of safety symbols .............................................................................................................. 11
General ................................................................................................................................................. 11
Proper use ............................................................................................................................................ 12
Environmental conditions...................................................................................................................... 12
Obligations of the operator.................................................................................................................... 12
Obligations of personnel ....................................................................................................................... 12
EMC Device Classifications .................................................................................................................. 13
EMC measures ..................................................................................................................................... 13
EMF measures...................................................................................................................................... 13
Safety measures at the installation location and during transport ........................................................ 14
Commissioning, maintenance and repair.............................................................................................. 14
Safety symbols...................................................................................................................................... 15
Data protection...................................................................................................................................... 15
Copyright............................................................................................................................................... 15
General ...................................................................................................................................................... 16
Device concept ..................................................................................................................................... 16
Application areas .................................................................................................................................. 16
Advantages ........................................................................................................................................... 16
Standard equipment.............................................................................................................................. 16
Options.................................................................................................................................................. 16
Technical data....................................................................................................................................... 17
Information on radio certification........................................................................................................... 17
FCC Compliance................................................................................................................................... 17
Functions not described........................................................................................................................ 17
Control elements and connections............................................................................................................. 18
Control panel......................................................................................................................................... 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
Starting sequence - language setting ................................................................................................... 29
Error "073 (no Host)" - No connection to the power source.................................................................. 30
Locking and unlocking the RCU 5000i with a keycard ............................................................................... 31
Requirement ......................................................................................................................................... 31
User management, profiles, keys ......................................................................................................... 31
Locking the RCU 5000i ......................................................................................................................... 31
Unlocking the RCU 5000i...................................................................................................................... 32
Unlock RCU 5000i using Unlock function ............................................................................................. 33
MIG/MAG synergic welding ....................................................................................................................... 34
General ................................................................................................................................................. 34
Call up "MIG/MAG synergic welding" menu item.................................................................................. 34
Overview ............................................................................................................................................... 34
Retrieving a welding program .................................................................................................................... 35
Retrieving a welding program ............................................................................................................... 35
5
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
Trigger modes....................................................................................................................................... 48
Switching to extra-large display ................................................................................................................. 49
General ................................................................................................................................................. 49
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
TIG welding................................................................................................................................................ 63
Call up "TIG welding" menu item .......................................................................................................... 63
CC/CV mode.............................................................................................................................................. 65
General ................................................................................................................................................. 65
Call up "CC/CV mode" .......................................................................................................................... 65
Job welding ................................................................................................................................................ 67
Call up the "Job welding" menu item .................................................................................................... 67
Setting working parameters for a job .................................................................................................... 67
6
Changing the welding process during CMT Advanced welding............................................................ 68
Saving settings as a job ............................................................................................................................. 69
EN
General ................................................................................................................................................. 69
Instructions on storing jobs ................................................................................................................... 69
Store as job........................................................................................................................................... 69
Internal/external adjustment of selected parameters ................................................................................. 72
General ................................................................................................................................................. 72
Setting parameters internally/externally................................................................................................ 72
Optimizing and managing jobs................................................................................................................... 74
General ................................................................................................................................................. 74
Calling up "Optimizing & managing jobs" menu item............................................................................ 74
Overview ............................................................................................................................................... 75
Manage jobs .............................................................................................................................................. 76
Managing jobs....................................................................................................................................... 76
Deleting groups and jobs ...................................................................................................................... 78
Retrieving administration data for a selected job ....................................................................................... 80
Retrieving administration data for a job ................................................................................................ 80
Different administration data displays, depending on job type.............................................................. 80
Retrieving and changing a welding program for a selected job ................................................................. 81
General ................................................................................................................................................. 81
Retrieving a job welding program ......................................................................................................... 81
Changing a job welding program .......................................................................................................... 81
Retrieving and changing working parameters for a selected job ............................................................... 84
General ................................................................................................................................................. 84
Retrieving and changing job working parameters................................................................................. 84
Instructions on changing the wire feed speed value ............................................................................. 84
Retrieving and changing process settings for a selected job ..................................................................... 85
General ................................................................................................................................................. 85
Retrieving and changing job process settings ...................................................................................... 85
Retrieving and changing special 2-step parameters for a selected 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 boundaries for a selected job................................................................................ 89
General ................................................................................................................................................. 89
Purpose of correction boundaries ......................................................................................................... 89
Establishing correction boundaries for a job ......................................................................................... 89
Explanation of correction boundaries.................................................................................................... 90
Job-specific documentation ....................................................................................................................... 91
General ................................................................................................................................................. 91
Purpose of the "Job-specific doc." function........................................................................................... 91
Requirement for "Job-specific doc."...................................................................................................... 91
Establishing job-specific documentation ............................................................................................... 91
Explanation of job-specific documentation............................................................................................ 92
Retrieving and changing SynchroPuls parameters for a selected job ....................................................... 93
General ................................................................................................................................................. 93
Retrieving and changing SynchroPuls parameters for a job................................................................. 93
Establishing QMaster values for a selected job ......................................................................................... 94
General ................................................................................................................................................. 94
Purpose of QMaster values .................................................................................................................. 94
Establishing Q-Master values for a job ................................................................................................. 94
Explanation of QMaster values ............................................................................................................. 95
Determining QMaster wirefeed speed values for a selected job................................................................ 96
General ................................................................................................................................................. 96
Determining Q-Master wire feed speed values for a job....................................................................... 96
Explanation of Q-Master wire feed speed values ................................................................................. 97
Optimizing and managing characteristics .................................................................................................. 98
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General ................................................................................................................................................. 98
Calling up the "Optimizing & managing characteristics" menu item ..................................................... 98
Overview ............................................................................................................................................... 99
Manage characteristics .............................................................................................................................. 100
Select characteristics ............................................................................................................................ 100
Naming and renaming characteristics................................................................................................... 101
Deleting characteristic........................................................................................................................... 102
Managing characteristic points .................................................................................................................. 104
Select characteristic points ................................................................................................................... 104
Inserting characteristic points ............................................................................................................... 104
Deleting characteristic points ................................................................................................................ 107
Parameters of standard characteristics ..................................................................................................... 109
Ignition .................................................................................................................................................. 109
Arc (static)............................................................................................................................................. 109
Arc (dynamic)........................................................................................................................................ 110
End of welding ...................................................................................................................................... 111
Guideline values ................................................................................................................................... 111
Accepting voltage and current guideline values.................................................................................... 112
Parameters of pulse characteristics ........................................................................................................... 113
Ignition .................................................................................................................................................. 113
Pulsing parameters ............................................................................................................................... 113
Arc (static)............................................................................................................................................. 115
Short circuit ........................................................................................................................................... 117
End of welding ...................................................................................................................................... 117
Parameters of CMT characteristics............................................................................................................ 118
General ................................................................................................................................................. 118
Ignition .................................................................................................................................................. 118
CMT parameters ................................................................................................................................... 119
End of welding ...................................................................................................................................... 120
Parameters of CMT / pulse characteristics ................................................................................................ 122
General ................................................................................................................................................. 122
Ignition .................................................................................................................................................. 122
Overview: CMT parameters, pulse parameters .................................................................................... 123
CMT parameters ................................................................................................................................... 123
CMT/Pulsed .......................................................................................................................................... 124
End of welding ...................................................................................................................................... 125
Parameters of CMT Advanced characteristics........................................................................................... 126
General ................................................................................................................................................. 126
Ignition .................................................................................................................................................. 126
Hotstart ................................................................................................................................................. 126
Weld start.............................................................................................................................................. 127
CMT parameters and EN-CMT parameters.......................................................................................... 127
EN/EP CMT .......................................................................................................................................... 129
End of welding ...................................................................................................................................... 129
Parameters of CMT/Pulsed Advanced characteristics............................................................................... 131
General ................................................................................................................................................. 131
Ignition .................................................................................................................................................. 131
Hotstart ................................................................................................................................................. 131
Overview: CMT parameters, pulse parameters .................................................................................... 132
CMT parameters ................................................................................................................................... 132
Pulsed/CMT cycles ............................................................................................................................... 135
End of welding ...................................................................................................................................... 135
Changing characteristic parameters .......................................................................................................... 137
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The process controller .......................................................................................................................... 137
Screens displayed for different characteristics ..................................................................................... 137
Changing characteristic parameters ..................................................................................................... 138
EN
Documentation........................................................................................................................................... 139
General ................................................................................................................................................. 139
Evaluating welding data ........................................................................................................................ 139
Call up the "Documentation" menu item ............................................................................................... 140
Overview ............................................................................................................................................... 140
Establishing basic settings for the documentation ..................................................................................... 141
Establishing basic settings for the documentation ................................................................................ 141
Basic documentation settings when storing jobs .................................................................................. 141
Explanation of the parameters in the "Basic settings" screen............................................................... 141
Documentation on memory card........................................................................................................... 142
Memory requirements for documentation on memory card .................................................................. 142
Establishing QMaster values ..................................................................................................................... 144
Establishing QMaster values ................................................................................................................ 144
Explanation of QMaster values ............................................................................................................. 144
Setting maximum motor current ................................................................................................................. 146
General ................................................................................................................................................. 146
Setting maximum motor current............................................................................................................ 146
Component counter ................................................................................................................................... 147
General ................................................................................................................................................. 147
Activating the component counter......................................................................................................... 147
Defining the component number........................................................................................................... 147
Incrementing the component number ................................................................................................... 149
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 machine pre-sets for "Rod electrode (MMA) welding" .............................................................. 157
Setting machine pre-sets for "Job"........................................................................................................ 157
Ethernet setting.......................................................................................................................................... 158
General ................................................................................................................................................. 158
Changing Ethernet setting .................................................................................................................... 158
Ethernet parameters ............................................................................................................................. 159
Setting date and time ................................................................................................................................. 160
Setting date and time ............................................................................................................................ 160
Robot interface - robot welding .................................................................................................................. 161
General ................................................................................................................................................. 161
Internal parameter control in robot welding........................................................................................... 161
External parameter control in robot welding ......................................................................................... 162
Selective external/internal switching of selected parameters with external parameter control ............. 163
Other functions in robot welding ........................................................................................................... 164
Profiles/keys............................................................................................................................................... 166
General ................................................................................................................................................. 166
Explanation of terms used .................................................................................................................... 167
Predefined profiles ................................................................................................................................ 167
"Administrator" profile ........................................................................................................................... 168
"Locked" profile ..................................................................................................................................... 168
Recommendation for creating profiles and keys ........................................................................................ 169
Requirement ......................................................................................................................................... 169
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Procedure ............................................................................................................................................. 169
Creating and editing profiles ...................................................................................................................... 170
Requirement ......................................................................................................................................... 170
Create administrator key....................................................................................................................... 170
Creating profiles.................................................................................................................................... 172
Opening/closing profiles........................................................................................................................ 175
Editing profile ........................................................................................................................................ 176
Deleting profile ...................................................................................................................................... 180
Example profiles ........................................................................................................................................ 181
General ................................................................................................................................................. 181
Locked .................................................................................................................................................. 181
MIG/MAG welding specialist ................................................................................................................. 182
Robot programmer................................................................................................................................ 183
Welder/worker....................................................................................................................................... 184
Creating and editing keys .......................................................................................................................... 185
Assigning key cards to profiles (key setup)........................................................................................... 185
Editing users/keys................................................................................................................................. 187
Deleting users/keys............................................................................................................................... 189
Logging registered users on and off at the remote control unit.................................................................. 191
General ................................................................................................................................................. 191
Logging on a user ................................................................................................................................. 191
Displaying logged on users................................................................................................................... 192
Logging out a user ................................................................................................................................ 193
Displaying "Locked" profile ................................................................................................................... 193
RCU 5000i - Unlock function...................................................................................................................... 194
General ................................................................................................................................................. 194
Activating the "Profile / Keys" screen using the Unlock function........................................................... 194
Further actions ...................................................................................................................................... 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/R alignment - aligning welding circuit inductivity and welding circuit resistance ..................................... 208
General ................................................................................................................................................. 208
L/R alignment........................................................................................................................................ 208
RCU 5000i - Resetting to factory settings .................................................................................................. 211
General ................................................................................................................................................. 211
Resetting RCU 5000i to factory settings ............................................................................................... 211
RCU 5000i - Updating software ................................................................................................................. 212
Requirements........................................................................................................................................ 212
Before first update - installing LocalNet USB driver.............................................................................. 212
Before first update - installing BASICLoad software ............................................................................. 217
RCU 5000i - Updating software ............................................................................................................ 221
Alphabetical overview of settable parameters ........................................................................................... 223
Explanation ........................................................................................................................................... 223
Parameters A - Z................................................................................................................................... 223
Appendix 243
Spare parts list: RCU 5000i ....................................................................................................................... 244
10
Safety rules
EN
Explanation of
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
safety symbols
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury

may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not

avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
General
The device is manufactured using state-of-the-art technology and according
to recognised 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 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 carefully.
The operating instructions must always be at hand wherever the device is be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safe-
ty.
This is for your personal safety!
11
Proper use
The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufac-
turer shall not be held liable for any damage arising from such usage.
Proper use includes:

- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
The device is intended exclusively for operation with the intended power
sources.
The device is designed for use in industry and the workshop. The manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
Environmental
Operation or storage of the device outside the stipulated area will be deemed
conditions
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10°C to + 50°C (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)
Obligations of the
The operator must only allow persons to work with the device who:
operator
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the
section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
Before using the device, all persons instructed to do so undertake:
personnel
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
12
EMC Device Clas-
EN
Devices in emission class A:
sifications
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices 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 sup-
plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EMC measures
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rec-
tify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may 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 leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
EMF measures
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
13
Safety measures
A device toppling over could easily kill someone. Place the device on a solid,
at the installation
level surface such that it remains stable
location and dur-
- The maximum permissible tilt angle is 10°.
ing transport
Special regulations apply in rooms at risk of fire or explosion

- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment
is always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protec-
tion shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1
ft. 7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guide-
lines and accident prevention regulations. This applies especially to guidelines
regarding the risks arising during transport.
Do not 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 commissioning the device.
Commissioning,
It is impossible to guarantee that bought-in parts are designed and manufac-
maintenance and
tured to meet the demands made of them, or that they satisfy safety require-
repair
ments.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without
the manufacturer's consent.
- Components that are not in perfect condition must be replaced immedi-
ately.
- When ordering, please give the exact designation and part number as
shown in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the
specified torque.
14
Safety symbols
EN
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards
of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can
be found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the rele-
vant standards for Canada and the USA.
Data protection
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
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 changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
15
General
Device concept The RCU 5000i remote control is intended

for the operation of all power sources in the
TransSynergic/TransPuls Synergic series.
All functions available on the power source
can be retrieved using the RCU 5000i. In
addition, further functions are available
such as optimisation of welding characteri-
stics.
Connection to the power source takes pla-
ce via a LocalNet plug.
The RCU 5000i remote control unit is
equipped with an LCD. In conjunction with
a clearly laid-out menu, this makes for a
user-friendly device.
RCU 5000i remote control
Application areas The RCU 5000i remote control unit is used

- for operating and programming the power sources, making pre-settings,
- in robot applications,
- for manual 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 for software updates
Standard equip- The RCU 5000i remote control unit is equipped with the following as standard:
ment - Connected to the remote control: 1x remote control cable, 6-pin, 5 m (16 ft. 5 in.), incl.
LocalNet plug, 10-pin
- 1x USB cable, approx. 1.8 m (5 ft. 11 in.), incl. USB adapter
- 1x memory card, 3.3 V
- 1x transponder card ("key card")
- 1x CD-ROM "software tools"
Options RCU 5000i bracket

The RCU 5000i bracket is intended for mounting on a wall or a remote power source. The
remote control unit can be hung onto the RCU 5000i bracket.
16
Technical data
EN
Supply voltage 24 V DC
Current input 170 mA
Degree of protection IP 23
Mark of conformity CE, FCC
Frequency band 134,2 kHz
Max. transmission power < 65dBμA/m @10m
Dimensions l / w / h 258 / 180 / 48 mm
10.16 / 7.09 / 1.89 in.
Weight 1.5 kg
3.31 lb
Information on ra- The RCU 5000i remote control is fitted with an RFID module (Radio Frequency Identifica-
dio certification tion). The RFID module is for wireless and non-contact data transmission using the key-
card (transponder card). Data transmission takes place via a magnetic field.
In the USA, RFID modules are subject to FCC certification:

FCC ID: QKWRF5000I
FCC Compliance
FCC
This equipment has been tested and found to comply with the limits for a
Class A digital device, pursuant to part 15 of the FCC Rules.
These limits are designed to provide reasonable 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 case the user will be required to correct the interfer-
ence at his own expense.
Industry Canada RSS
This device complies with Industry Canada licence-exempt RSS stand-

ard(s). Operation is subject to the following two conditions: (1) this device
may not cause interference, and (2) this device must accept any interfer-
ence, including interference that may cause undesired operation of the de-
vice.
Functions not de- NOTE! Owing to software updates, you may find that your machine has certain
scribed functions that are not described in these operating instructions.
Moreover, illustrations in these instructions may differ slightly from the actual data
displayed on the LCD.
17
Control elements and connections
Control panel
(9) (15) (8)
(16) (3)
(1) (7)
(2) (6)
(5) (10) (11) (12) (13) (14) (4)

RCU 5000i control panel
Action keys
(1) Menu key ... for calling up the main menu
(2) Info key ... for displaying context-specific information
(3) OK key ... for confirming menu dialogs, precautionary queries, etc.
(4) Feeder inching button ... for feeding the filler wire with no accompanying flow of gas
or current
(5) Gas test 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
IMPORTANT! The current function is displayed on the LCD directly above the relevant
function key.
18
Miscellaneous
(15) Display ... black/white LCD
EN
(16) Keycard reader ... for identifying different access rights granted by means of a key-
card
Information on The OK key (3) aids the user in selecting the various function key functions.
OK key If there is a border around a function key function, this function can be selected by pressing
OK (3).
(1)
(2)
Example: border around F1 "Store as job" Example: border around F2 "Forward"
(1) Frame
19
Other controls,
connections, me-
chanical compo- (17)
nents
(18)
(21) (20) (19)
RCU 5000i front view - controls, connections
(17) Receptor for bracket ... for hanging onto the wall bracket or the power source
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
(22) Bracket ... 0-95° hinged holder and

(23) stand
(23) M5 threaded insert ... e.g. for fix-
ing to the wall
(23) (23) (22) (23)
RCU 5000i rear view - controls, mechanical compo-

nents
20
(24) Memory card slot
(25) USB port... for connecting to a PC,
EN
e.g. for software updates
(25) (24)
RCU 5000i side view - connections
21
Operating concept
Activities - orien- Operation instructions for the RCU 5000i remote control unit are divided according to ac-
tation tivities.
A distinction is made between the following activities:
- Welding (MIG/MAG Synergic, MIG/MAG manual, MMA, TIG and Job)
- Creating jobs
- Creating one's own characteristics and characteristic points
- Optimising and managing jobs
- Optimising and managing available characteristics
- Making presettings for the welding process
- Language and units of measurement - definitions
Main menu The individual activities 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.
Main menu display
"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 first data record appears. If navigating in the opposite
direction, the last data record appears after the first.
- The number of data records varies. Due to certain parameters or special functions on
the power source, data records may be added to the clothesline.
MIG/MAG synergic welding

(9) (8)
Example of "clothesline" with 5 data records (A - E) - "Working parameters" open
22
The RCU 5000i remote control uses the "clothesline" principle as follows:
- -All parameters, displays and functions required for a selected activity are sorted ac-
cording to the order in the "clothesline".
EN
- Every data record in a "clothesline" is displayed in its own screen.
Throughout the rest of the operating instructions the data records are shown as in the
example below:
Screen "Working parameters"

Screen title (data record)
Screen (for data record)
- 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.
23
Description of the displays
General The RCU 5000i remote control unit uses various displays while operating. These so-called
screens are called up using the menu, and serve as dialog with the user.
"Menu" screen The "Menu" screen shows the main menu. To call up the "Menu" screen, press the Menu
key (1).
NOTE! Once the Menu key (1) is pressed, all open dialogs are cancelled without
asking for confirmation, with the exception of wizards.
(1) Menu items

(2) MIG/MAG synergic welding menu
(2)
item selected
(3) F3 "Select"
(1)
(3)
"Menu" screen
"Data" screen - A "Data" screen appears if a menu item 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 the down and up navigation keys (6) and (7).
Parameter values are set using the adjusting dial (18)
24
(2) (4) (5) (6)(7) (8) (9) (10)
EN
(11)
(1)
(12)
(3)
(13)
(14)
(15)
Example: "Data" screen
(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
point"
- F3 "Optimize characteristic"
- F4 "Filler metal"
- F5 "Internal/External"
"Wizard" screen Wizard refers to a guided input sequence. The user can move forwards or backwards with-
in the sequence. Various screens appear within a wizard.
(1) Dark border

(2) Processing step
(3)(4) (5)
(1) (2) (3) Completed steps
(4) Current step
(5) Step still live
(6) F1 "Back" (in grey in the first
screen)
(7) F2 "Forward" (or "Done" in the final
screen)
(8) F5 "Cancel"
(6) (7) (8)

Example: "Wizard" screen
25
"Dialogue" The "Dialogue" screen is used for showing subdialogues.
screen The "Dialogue" screen may contain hierarchical structures, pick lists, etc.
(1) Dark border

(2) F1 "Accept"
(3) F5 "Cancel"
(1)
(2) (3)
Example: "Dialogue" screen with "Accept" and "Can-
cel"
"Message" The "Message" screen displays certain statuses. The message must be acknowledged, or
screen a decision must be taken.
The "Message" screen appears in front of part of the current screen. This makes the cur-
rent screen turn grey.
(1) (2) (3) (4) (1) Current screen, shown in grey

(2) Symbol
(3) Message type
(4) Dark border
(5) F2 "Yes"
(6) F3 "No"
(7) F4 "Cancel"
(5) (6) (7)

Example: "Message" screen - Precautionary query
"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 minutes for as long as the error
persists. "Error" screens appear in front of part of the current screen. This makes the cur-
rent screen turn grey.
26
(1) (2) (3) (4) (5) (1) Current screen, shown in grey
(2) Symbol
EN
(3) Error code
(4) Error description
(5) Dark border
(6) F3 "OK"
(6)
Example: "Error" screen
(1) (2) (3) (4) (1) Current screen, shown in grey

(2) Symbol
(3) Error description
(4) Dark border
(5) F2 "Reset"
(6) F3 "Ignore"
(5) (6)
Example: "Error" screen with function keys "Reset"
and "Ignore"
27
Start-up
Before commis-
WARNING! Operating the equipment incorrectly can cause serious injury and
sioning
damage. Do not use the functions described until you have thoroughly read and
understood the following operating instructions:
- Remote control unit,
- Power source,
- Wirefeeders.
System require- The following firmware is required on the power source to be able to operate the RCU
ments 5000i remote control unit:
OFFICIAL UST V 3.20.1
Connecting RCU The RCU 5000i remote control unit can be connected to any LocalNet socket on the weld-
5000i ing machine, e.g.:
VR 4000 VR 7000 TPS 2700
TS/TPS 4000-5000
VR 1500
LocalNet connection socket on VR 4000, VR 7000 and LocalNet connection socket on TPS 2700 and TS/TPS
VR 1500 4000-5000
Procedure:
1 Switch the power source mains switch to the “0” position
2 Plug the remote control unit LocalNet plug into the LocalNet connection socket
3 Tighten the union nut on the plug
4 Move the power source mains switch to the "I" position - the remote control is ready,
the starting sequence appears
28
Starting se- The following appear on the display during the starting sequence:
EN
quence - lan- - Fronius logo (centre)
guage setting - Software version (bottom left)
- www.fronius.com (bottom right)
- language (F3 key)
The starting sequence lasts approx. 2 seconds. The language and units (metric or imperial)
can be preset during this time. To do this, press F3.
1 To preset the language and measure-

ment units, press F3 "Language"
– Machine pre-sets "Language and
units" screen appears
Starting sequence, F3 "Language"
2 Select the corresponding parameters

using down (6) or up (7) keys
3 Alter the parameter value with the ad-
justing dial (18)
4 Press the "Menu" button (1)
Machine pre-sets: "Language and units" screen, lan-

guage selected
29
Main menu appears in the selected langua-
ge
Main menu in the selected language
Error "073 (no The non-resettable error "073 (no Host)"

Host)" - No con- appears if the remote control cannot
nection to the connect to the power source during com-
power source 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.
"Error 073 (no Host)" screen
30
Locking and unlocking the RCU 5000i with a keycard
EN
Requirement 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 pre-sets" menu item.
User manage- More information about user management, profiles or keys can be found in the "Machine
ment, profiles, pre-sets" chapter, "Profiles / Keys" section.
keys
Locking the RCU Hold the keycard up to the keycard

1
5000i reader (16)
(16)
Holding the keycard up to the keycard reader
The "Info Key - The remote control unit is

now locked " screen appears
"Info Key - The remote control unit is now locked"

screen
31
The "Locked" profile is called up.
IMPORTANT! The properties in the
"Locked" profile can be altered in the "Ma-
chine pre-sets" menu item, in the "Profiles /
Keys" screen.
Main menu in the "Locked" profile
Various menu items and functions can be

selected, depending on which presettings
are saved in the "Locked" profile.
E.g.:
In the main menu, the factory 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).
"MIG/MAG synergic welding" menu item in locked re-

mote control, "Working parameters" screen
Unlocking the Hold the keycard up to the keycard

1
RCU 5000i reader (16)
(16)
32
The "Info Key - The remote control is now
unlocked" screen appears.
EN
The last screen called up prior to locking
appears. All menu items can now be acces-
sed without restrictions.
"Info Key - The remote control is now unlocked" screen
Unlock RCU 5000i An Unlock function has been added to the RCU 5000i remote control unit from software
using Unlock version OFFICIAL RCU V1.14.12.
function 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 pre-sets" chap-
ter, "RCU 5000i - Unlock function" section.
33
MIG/MAG synergic welding
General MIG/MAG synergic welding relates to synergic mode on the power source. Once the wire-
feed speed parameter is set, the welding current and sheet thickness parameters are ad-
justed accordingly.
The current welding amperage and sheet thickness values appear in the display area.
Call up "MIG/MAG Press the "Menu" button (1):

1
synergic weld-
– Main menu appears
ing" menu item
2 Select "MIG/MAG synergic welding"
menu item using the adjusting dial (18)
3 Press OK (3):
– The last "Data" screen called up
appears.
Main menu: "MIG/MAG synergic welding" menu item

selected
Overview "MIG/MAG synergic welding" is composed of the following sections:

- Retrieving a welding program
- Setting working parameters
- Switching to extra-large display
- Setting process settings parameters
- Setting additional parameters: special 2-step, special 4-step, spot welding
- Setting SynchroPuls parameters
34
Retrieving a welding program
EN
Retrieving a weld- Call up "MIG/MAG synergic welding"
1
ing program menu item
2 Select "Welding program" screen by
pressing the right arrow key (8)
– "Welding program" screen appe-
ars
MIG/MAG synergic welding: "Welding program"

screen
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
35
Setting working parameters
Setting working Call up "MIG/MAG synergic welding"

1
parameters menu item
2 Select "Working parameters" screen
by pressing the right arrow key (8):
– "Working parameters" screen ap-
pears.
3 Select the corresponding working pa-
rameters using down (6) or up (7) keys
4 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.
MIG/MAG synergic welding: "Working parameters"
screen, arc length correction selected
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-step
- Special 4-step
- Spot welding
Process The following processes can be set:

- Pulse (MIG/MAG pulse synergic welding)
- Standard (MIG/MAG standard synergic welding)
- CMT (Cold Metal Transfer)
36
If the set welding program and the selected
EN
process do not correspond, or if there is no
welding program for the selected process,
"no program" appears in the display area.
The "Wirefeed speed" parameter cannot be
altered.

screen, "no program" for "CMT" process
Individual parameters are displayed differently depending on the selected process and
welding program:
Process Parameter
Pulse Pulse correction
Standard Dynamic correction
in the CMT process HotStart time
Pulse correction
HotStart pulse cycles
Boost correction
Dynamic correction
"Pulse correction" parameter in the pulse process "Dynamic correction" parameter in the standard pro-
cess
37
"Hotstart time" parameter 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
38
"CMT" process The "CMT" process is only possible when combined with the following components:
EN
- 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.
39
Switching to extra-large display
General The wirefeed speed, welding current and welding voltage parameters can be displayed in
extra-large format. The wire feed unit and push-pull unit motor current is also shown in the
"Extra-large display" screen as an actual value.
Switching to ex- Call up "MIG/MAG synergic welding"

1
tra-large display menu item
2 Select "Extra-large display" screen by
pressing the right arrow key (8):
– "Extra-large display" screen appe-
ars
(1) (2) – The value for wire feed speed can
be altered in the "Extra-large dis-
play" screen using the adjusting
0.6 A 0.35 A dial (18).
If the "Wirefeed speed" parameter is alte-

red, the values for welding current and wel-
ding voltage also change accordingly.
MIG/MAG synergic welding: "Extra-large display"

screen
(1) Wire-feed unit motor current
(2) Push-pull unit motor current
40
Setting process settings parameters
EN
Setting process Call up "MIG/MAG synergic welding"
1
settings parame- menu item
ters
2 Select "Process settings" screen by
pressing the right arrow key (8).
– "Process settings" screen appears
3 Select the process settings parameters
using the down (6) or up (7) keys
4 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.
MIG/MAG synergic welding: "Process settings"
screen, gas pre-flow selected
41
Setting additional parameters: special 2-step, spe-
cial 4-step, spot welding
Setting addition- If trigger mode S2-step is selected in the "Working parameters" screen, the corresponding
al special 2-step screen is hung on the clothesline.
parameters The following additional parameters can be set:
- Starting current Is
- Starting-current dur. ts
- Slope 1 Sl1
- Slope 2 Sl2
- Final-current duration te
- Final current
1 Call up "MIG/MAG synergic welding"

menu item
by pressing the right arrow key (8)
pears
3 Select the "trigger mode" parameter
4 Set to S2-step using adjusting dial (18)
5 Select "Special 2-step" screen by pres-
sing the right arrow key (8)
– "Special 2-step" screen appears
"Working parameters" screen: S2-step trigger mode
6 Select further parameters using down

(6) or up (7) keys
7 Change the value of the further para-
meters using the adjusting dial (18)
– The value of the further parame-
ters can only be altered within the
defined setting range. The setting
range is highlighted.
MIG/MAG synergic welding: "Special 2-step" screen,

starting current Is selected
42
Setting addition- If S4-step trigger mode is selected in the "Working parameters" screen, the corresponding
EN
al special 4-step screen is hung on the clothesline.
parameters The following additional parameters can be set:
- Starting current Is
- Slope 1 Sl1
- Final current
- Slope 2 Sl2

menu item
pears
4 Set to S4-step using adjusting dial (18)
5 Select "Special 4-step" screen by pres-
"Working parameters" screen: S4-step trigger mode
6 Select further parameters using down

(6) or up (7) keys
7 Change the value of further parame-
ters using the adjusting dial (18)
– The value of the further parame-
ters can only be altered within the
defined setting range. The setting
range is highlighted.
MIG/MAG synergic welding: "Special 4-step" screen,

starting current Is selected
43
Setting addition- If spot welding is selected as the trigger mode in the "Working parameters" screen, the cor-
al spot welding responding screen is hung on the clothesline.
parameters The following parameters can be set:
- Wire feed speed
- Arc length correction
- Spot welding time

menu item
pears
4 Set spot welding using adjusting dial
(18)
5 Select "Spot welding" screen by pres-
– "Spot welding" screen appears
"Working parameters" screen: spot welding trigger

mode
6 Select parameters using the down (6)

or up (7) keys
7 Change the value of the parameters
using the adjusting dial (18)
– The value of the parameters can
only be altered within the defined
setting range. The setting range is
highlighted.
MIG/MAG synergic welding: "Spot welding" screen,

wirefeed speed selected
44
Setting SynchroPuls parameters
EN
General If the SynchroPuls software option is installed on the power source, the screen for the Syn-
chroPuls parameters is also available. The screen is added to the clothesline.
Setting Synchro- Call up "MIG/MAG synergic welding"

1
Puls parameters menu item
(software option)
2 Select "SynchroPuls" screen by pres-
sing the right arrow key (8).
– "SynchroPuls" screen appears
3 Select SynchroPuls parameters using
down (6) or up (7) keys
4 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 setting range. The
MIG/MAG synergic welding: "SynchroPuls" screen
45
MIG/MAG standard manual welding
General Unlike MIG/MAG synergic welding, in MIG/MAG manual welding the welding parameters
are set individually.
Call up "MIG/MAG Press the "Menu" button (1):

1
standard manual
welding" menu
item 2 Select "MIG/MAG standard manual
welding" menu item using the adjusting
dial (18)
3 Press OK (3):
appears.
Main menu: "MIG/MAG standard manual welding"

menu item selected
Overview "MIG/MAG standard manual welding" is composed of the following sections:

- Retrieving a welding program
- Switching to extra-large display
- Setting process settings parameters
- Setting additional spot welding parameters
46
Retrieving a welding program
EN
Select welding Call up "MIG/MAG standard manual
1
program welding" menu item
2 Select "Welding program" screen by
ars
MIG/MAG standard manual welding: "Welding pro-

gram" screen
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
47
Setting working parameters
Setting working Call up "MIG/MAG standard manual

1
parameters welding" menu item
pears
parameter value
– The parameter value can only be
altered within the defined setting
lighted.
MIG/MAG standard manual welding: "Working para-
meters" screen, wire feed speed selected
Trigger modes The following trigger modes can be set:

- 2-step
- 4-step
- Spot welding
48
Switching to extra-large display
EN
General The wirefeed speed, welding current and welding voltage parameters can be displayed in
extra-large format. The wire feed unit and push-pull unit motor current is also shown in the
"Extra-large display" screen as an actual value.
Switching to ex- Call up "MIG/MAG standard manual

1
tra-large display welding" menu item
ars
(1) (2)
– The values for wire feed speed
and welding voltage can be alte-
red in the "Extra-large display"
0.6 A 0.35 A screen using the adjusting dial
(18).
– Welding current is a display value:
- during welding
... actual value
- following welding
MIG/MAG standard manual welding: "Extra-large dis- ... hold value
play" screen
49
Setting process settings parameters
Setting process Call up "MIG/MAG standard manual

1
settings parame- welding" menu item
ters
tings parameters using the adjusting
dial (18).
MIG/MAG standard manual welding: "Process set-
tings" screen, gas pre-flow selected
50
Setting additional spot welding parameters
EN
Setting addition- If spot welding is selected as the trigger mode in the "Working parameters" screen, the cor-
al spot welding responding screen is hung on the clothesline.
parameters The following parameters can be set:
- Wire feed speed
- Arc length correction
- Spot welding time
1 Call up "MIG/MAG standard manual

welding" menu item
pears
4 Set spot welding using adjusting dial
(18)
5 Select "Spot welding" screen by pres-
"Working parameters" screen: spot welding trigger

mode
6 Select parameters using the down (6)

or up (7) keys
7 Change the value of the parameters
– The value of the parameters can
only be altered within the defined
setting range. The setting range is
highlighted.
MIG/MAG synergic welding: "Spot welding" screen,

wirefeed speed selected
51
Setting welding program and filler metal
General The welding program and filler metal can be set in the following menu items:
- MIG/MAG synergic welding
- MIG/MAG standard manual welding
- Optimising & managing jobs (only for saved MIG/MAG jobs)
Setting welding In the relevant "Data" screen, press F4

1
program and filler "Filler metal"
metal
– The 1st screen in the wizard appe-
ars ("Select a filler metal")
2 Select required filler metal using the
adjusting dial (18)
3 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 filler metal" screen: Al99.5 selected
4 Select corresponding wire diameter

– 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 wire diameter" screen: 1.2 mm selected
52
6 Select corresponding gas using the ad-
justing dial (18)
EN
– The "Select a reference" screen
only appears if there are several
characteristics for the selected fil-
ler metal, wire diameter and shiel-
ding gas.
– The value given in brackets after
the process indicates how many
characteristics there are for this
process.
"Select a shielding gas" screen: I1 100% Ar selected
8 Select the corresponding process

9 Select the corresponding characteri-
stic reference number using the adjus-
ting dial (18)
– E.g.:
Characteristic C0876 is only suita-
ble for CMT.
10 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 already per-
formed can be displayed again.
Example: AlSi 5 / 1.2 mm / I1 100% Ar screen "Select Changes can be made.
a reference": Characteristic S0016 selected
11 Press F2 "Done"
– The set welding program is accep-
ted, the last "Data" screen display-
ed appears
"Welding program" screen: Confirmation
53
Plotting user characteristics - optimising a charac-
teristic
General "Creating new user characteristics - Optimize characteristics" can only be carried out in the
MIG/MAG synergic welding menu item.
The basics of Every welding program is based on a welding characteristic. The characteristics of select-
plotting user ed welding programs can be altered to suit a specific user. These alterations are stored in
characteristics so-called user characteristics.
The programming of a user characteristic is necessary

- if filler metals (shielding gas, welding wire diameter) not contained in the welding da-
tabase are used.
- for optimising the welding process (e.g.: increasing welding speed, changing the weld
penetration ratios, changing the weld appearance).
NOTE! Reprogramming a characteristic requires a knowledge of arc and welding

technology.
To efficiently create a new characteristic, we recommend that the user proceed as follows:
- Select similar characteristic
- 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.
IMPORTANT! At least two characteristic points are needed to create a user characteristic.
To optimise all power ranges, however, 6-10 characteristic points should be programmed
(one point per material strength). A maximum of 19 characteristic points can be pro-
grammed.
Plotting user 1 In each "Data" screen, set a similar welding program or the welding program to be
characteristics - changed
optimising a char- Press F3 "Optimize characteristic":
2
acteristic
If it is not possible to edit a characteristic,
the message "Characteristic cannot be mo-
dified" is displayed.
The first The 1st screen in the wizard appe-

The characteristic ars ("Optimize characteristics")
can not be modified!
Information screen - "Characteristics cannot be modi-

fied!"
54
3 Select the lower and upper power li-
mits using down (6) or up (7) keys
EN
4 Set lower and upper power limit using
the adjusting dial (18)
lighted.
– The values displayed in the dis-
play area for current, voltage and
sheet thickness depend directly
on the power values entered.
"Optimize characteristic" screen: setting power values
pears ("Optimize characteristic")
6 Select corresponding characteristic
– If an existing characteristic is to be
overwritten, a precautionary query
appears.
"Optimize characteristic" screen: Selecting the syner-

gic line
7 Press F3 "Name characteristic" to

name the characteristic:
– "Name characteristic" screen ap-
pears
Precautionary query for overwriting the characteristic
55
8 Select corresponding characters using
9 Press F4 ">" to enter the next charac-
ter
– Corrections can be carried out
using F3 "<" or F2 "< Delete"
10 Press F1 "Accept" when finished:
– The new name is accepted, "Opti-
mize characteristics" screen ap-
pears
"Name characteristic" screen
pears as confirmation ("Optimize
characteristic")
Changes can be made.
"Optimize characteristic" screen: Selecting the syner-

gic line
12 Press F2 "Done":
– The last "Data" screen displayed
appears.
"Optimize characteristic" wizard: confirmation of opti-

mised characteristic
56
Creating new characteristic points for user charac-
teristics
EN
General The "Create new characteristic point" function can be performed in the following menu
items:
- MIG/MAG standard manual welding
The basics of Various parameter settings can be saved in the user characteristics as characteristic
plotting new char- points.
acteristic points
The following are required to create a new characteristic point:
- Welding program (filler metal, wire diameter, shielding gas), for which a characteristic
point is to be created
- Value for the wirefeed speed (e.g. reference values corresponding to previous welding
attempts, past experience or material strength)
NOTE! Creating new characteristic points requires a knowledge of arc and weld-
ing technology.
grammed.
Creating a new Procedure for when certain parameter settings are to be saved as a characteristic point:
characteristic
point Call up the welding program for which
1
a characteristic point is to be created
2 Set the wirefeed speed for which the
characteristic point is to be created
3 In the relevant "Data" screen, press F2
"Create new characteristic point"
ars ("Create new characteristic
point")
4 Select corresponding characteristic
– If the characteristic point to be cre-
ated is to be added to a characte-
ristic that does not correspond to
the currently set characteristic
"Create new characteristic point" screen: No.6 -
(e.g. adding an aluminium charac-
"Al99.5 1.2 I1 mod selected"
teristic point to a CuSi characteri-
stic), a precautionary query
appears
57
5 Press F2 "Yes" or F3 "No" or F4 "Can-
cel"
– If a standard characteristic point is
to be added to a pulse characteri-
stic or vice versa, an error messa-
ge appears.
Precautionary query: characteristic point does not

match
6 Press F3 "OK"
ars ("Create new characteristic
point")
Error message: characteristic point cannot be saved
7 Select another characteristic using the

adjusting dial (18)
8 Press F3 "Name characteristic" to
name the characteristic:
pears
"Create new characteristic point" screen: No. 7 - <

Empty characteristic > selected
58
EN
ter
using F3 "<" or F2 "< Delete".
– The new name is accepted, "Cre-
ate new characteristic point"
screen appears
pears as confirmation ("Create
new characteristic point")
"Create new characteristic point" screen
13 Press F2 "Done":
– The characteristic point is saved,
the corresponding "Data" screen
appears.
"Create new characteristic point" screen: confirmation

of the saved characteristic point
59
Selecting user characteristics
Selecting user In the corresponding "Data" screen,

1
characteristics press F4 "Filler metal":
2 Select "User characteristic" using the
adjusting dial (18)
pears ("Select a user characteri-
stic")
"Select a filler metal" screen: User characteristic selec-

ted
4 Select corresponding user characteri-

stic using the adjusting dial (18)
– The 3rd screen in the wizard
confirmation
"Select a user characteristic" screen: no.2 "CuSi3 10

I1 mod" selected
6 Press F2 "Done":
– The set user characteristic is ac-
cepted, the last "Data" screen dis-
played appears
"Welding program" screen: confirmation of user cha-

racteristic
60
MMA welding
EN
Call up "Rod elec- Press the "Menu" button (1)
1
trode (MMA)
welding" menu
item 2 Select "Rod electrode (MMA) welding"
3 Press OK (3)
appears
Main menu: "Rod electrode (MMA) welding" menu

item selected
Setting working Call up "Rod electrode (MMA) welding"

1
parameters menu item
pears.
parameter value
lighted.
Rod electrode (MMA) welding: "Working parameters"
screen, welding current selected
61
Switching to ex- The welding current and welding voltage parameters can be displayed in extra-large for-
tra-large display mat:
1 Call up "Rod electrode (MMA) welding"

menu item
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
Rod electrode (MMA) welding: "Extra-large display"
screen
Setting process Call up "Rod electrode (MMA) welding"

1
settings parame- menu item
ters
ting using the adjusting dial (18)
Rod electrode (MMA) welding: "Process settings"

screen, hotstart current HCU selected
62
TIG welding
EN
Call up "TIG weld- Press the "Menu" button (1)
1
ing" menu item
2 Select "TIG welding" menu item using
3 Press OK (3)
appears
Main menu: "TIG welding" menu item selected
Setting working Call up "TIG welding" menu item

1
parameters
pears.
parameter value
lighted.
TIG welding: "Working parameters" screen, main cur-

rent selected
63
Switching to ex- The welding current and welding voltage parameters can be displayed in extra-large for-
tra-large display mat:
1 Call up "TIG welding" menu item

ars
– The value for the welding ampera-
ge can be altered in the "Extra-lar-
ge display" screen by using the
adjusting dial (18).
- during welding
... actual value
- following welding
... hold value
TIG welding: "Extra-large display" screen
64
CC/CV mode
EN
General If the "CC/CV mode" software option is installed on the power source, the "CC/CV mode"
menu item appears in the main menu.
The CC/CV mode menu item allows the user to operate the power source with either con-
stant welding voltage or constant welding current.
Parameter changes in the "CC/CV mode" menu item can be made via a robot control or
the RCU 5000i remote control.
"CC/CV mode" is used in hot wire applications, for example.
Call up "CC/CV Press the "Menu" button (1)

1
mode"
2 Select "CC/CV mode" menu item using
3 Press OK (3)
appears
Main menu: "CC/CV mode" menu item selected
Setting working Call up "CC/CV mode"

1
parameters
pears.
parameter value
lighted.
CC/CV mode: "Working parameters" screen, current

command value selected
65
Switching to ex- The wirefeed speed, voltage command value and current command value parameters can
tra-large display be displayed in extra-large format:
1 Call up "CC/CV mode"

ars
– The values for wirefeed speed,
(1) (2)
voltage command value and cur-
rent command value can be alte-
red in the "Extra-large display"
0.6 A 0.35 A screen using the adjusting dial
(18).
- during welding
... actual value
- following welding
CC/CV mode: "Extra-large display" screen ... hold value
Setting process Call up "CC/CV mode"

1
settings parame-
ters 2 Select "Process settings" screen by
parameter value
lighted.
CC/CV mode: "Process settings" screen
66
Job welding
EN
Call up the "Job Press the "Menu" button (1)
1
welding" menu
item
2 Select "Job welding" menu item using
3 Press OK (3)
appears
Main menu: "Job welding" menu item selected
Setting working If correction boundaries for a selected job are defined in the "Optimizing & managing jobs"
parameters for a menu item, the following working parameters for this job can be set in the "Job welding"
job menu item in the "Working parameters" screen:
- Actual power correction
- actual arc-length correction
1 Call up the "Job welding" menu item

pears.
3 Select "group no." parameter using the
4 Select desired group (0 - 99) using the
adjusting dial (18)
5 Select "Job n°" parameter using the
6 Select desired job (0 - 999) using the
adjusting dial (18)
– If a job is selected from the next
Job welding: "Working parameters" screen, actual po- group, the group displayed also
wer correction for job no. 22 from group 2 selected (ex- changes accordingly.
ample for a MIG/MAG job)
7 Select the corresponding working parameters using down (6) or up (7) keys
8 Use the adjusting dial (18) to alter the parameter value
– The parameter value can only be altered within the defined setting range. The set-
ting range is highlighted.
67
Switching to ex- For a selected job, the wirefeed speed, welding current and welding voltage parameters
tra-large display can be displayed in extra-large format.
1 Call up the "Job welding" menu item

ars
– The parameters "group no." and
"job no." can be selected using the
down (6) or up (7) keys, and alte-
red using the adjusting dial (18).
0. 6 A 0. 35 A
(1) (2) – The wirefeed speed 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
Job welding: "Extra-large display" screen
Changing the NOTE! Neither the welding process nor the currently selected characteristic can
welding process be changed during CMT Advanced welding.
during CMT Ad-
vanced welding To change the welding process or characteristic:
- first, end the CMT Advanced process
- wait 300 - 600 ms
Another welding process or characteristic cannot be selected during this

time.
- Resume the welding process with another welding process or characteristic
68
Saving settings as a job
EN
General The "Store as job" function can be performed in the following menu items:
- CC/CV mode
- Job welding
- Optimizing & managing jobs
Instructions on 1 Set all parameters in all screens displayed

storing jobs – Set parameters in screen A
– Set parameters in screen B
– Set parameters in Screen C, etc.
2 Press F1 "Store as job" and follow the menu
Store as job Procedure for when certain parameter settings are to be stored as a job:
1 In the corresponding "Data" screen,

press F1 "Store as job"
ars ("Store as job - Group")
2 Select corresponding group using the
adjusting dial (18)
3 Press F3 "Name group" to name the
group:
– "Name group" screen appears
"Store as job - Group" screen: no. 6 <Empty group>

selected

ter
– Corrections can be carried out by
pressing F3 "<" or F2 "< Delete".
– The new name is accepted, "Store
as job - Group" screen appears
"Name group" screen
69
pears ("Store as job - Memory
location")
"Store as job - Group" screen: no. 6 SR 71 selected
8 Select corresponding job using the ad-

justing dial (18)
9 Press F3 "Name job" to name the job:
– "Name job" screen appears
"Store as job - Memory location" screen: Job 61 <Emp-

ty job> selected

ter
as job - Memory location" screen
appears
"Name job" screen
70
EN
pears as confirmation ("Store as
job").
"Store as job - Memory location" screen: Job 61 Test

selected
14 Press F2 "Done":
– The last selected "Data" screen
appears.
"Store as job" screen as confirmation
71
Internal/external adjustment of selected parameters
General Using the RCU 5000i remote control unit, the selected parameters can be set as follows:
- internally on the remote control
- externally, e.g. on the wire-feed unit, power source, other remote controls, robot con-
trol, etc.
If the system has an external operating facility, the relevant parameters are automatically
set to external parameter entry, e.g.:
in the case of a connected wire-feed unit, the value for the "Wirefeed speed" parameter
must be set on the wire-feed unit. If the parameter value is to be set on the RCU 5000i re-
mote control unit, the "wirefeed speed" parameter must be converted to internal 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
Setting parame- 1 In the corresponding "Data" screen, press F5 "Int/Ext"

ters internally/ex- – The remote control unit converts to the desired parameter entry:
ternally
Internal parameter entry (Int): External parameter entry (Ext):
The parameters to be set are entered and The parameters to be set are entered and
altered on the RCU 5000i remote control altered at the power source, wirefeeder or
unit. via a robot control.
The selected parameter is shown with a The selected parameter is shown with a
black bar with a "window" for the parameter continuous black bar on the remote control
value. The parameter value in the "window" unit display. With external parameter entry,
can be changed. the parameter value cannot be altered on
the remote control unit.
Example of internal parameter entry: black bar with Example of external parameter entry: continuous black
"window" - Arc length correction selected bar - Arc length correction selected
72
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:
EN
Example of an unconnected remote control unit: F5
"Int/Ext" greyed out
73
Optimizing and managing jobs
General For selected jobs, the following functions can be performed in the "Optimizing & managing
jobs" menu item:
- Retrieving administration data
- Setting job-specific parameters
Depending on the type of the selected job, many different screens are displayed on the
"clothesline".
The sequence of displayed screens also depends on the type of job.
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)
- Job-specific doc.
1) Only displayed if the SynchroPulse option is installed on the power source

2) Only displayed if the trigger mode is set to S2-step for the selected job
3) Only displayed if the trigger mode is set to S4-step for the selected job
4) Only displayed if the trigger mode is set to spot welding for the selected job
Calling up "Opti- Press the "Menu" button (1)

1
mizing & manag-
ing jobs" menu
item 2 Select "Optimizing & managing jobs"
3 Press OK (3)
– Precautionary query "Do you want
to edit the jobs online?" appears
Main menu: "Optimizing & managing jobs" menu item

selected
74
4 Press F2 "Yes" or F3 "No"
– Online editing - F2 "Yes"
EN
The power source changes to the
job correction menu, independent
of the current power source set-
tings. Data changed on the remote
control unit also appear on the po-
wer source.
– 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.
appears
Precautionary query: Do you want to edit the jobs on-
line?
Overview "Optimizing and managing jobs" is composed 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 for a selected job
- Retrieving and changing spot welding parameters for a selected job
- Establishing correction boundaries for a selected job
- Job-specific documentation
- Retrieving and changing SynchroPuls parameters for a selected job
- Establishing QMaster values for a selected job
- Creating a new characteristic point
75
Manage jobs
Managing jobs Call up the "Optimizing & managing

1
jobs" menu item
2 Whatever screen is showing, press F1
"Manage jobs":
ars ("Manage jobs - Group")
adjusting dial (18)
4 Press F3 "Name group" to name a
group
– "Name group" screen appears
Optimizing and managing jobs: "Manage jobs - Group"

screen

ter
– The new name is accepted, "Ma-
nage jobs - Group" screen appe-
ars
"Name group" screen
pears ("Manage jobs - Memory
location")

screen
76
9 Select desired memory location using
EN
10 Press F3 "Name job" to name the job:
– "Name job" screen appears
"Manage jobs - Memory location" screen

ter
as job - Memory location" screen
appears
"Name job" screen
14 Press F2 "Done":
appears.
"Store as job - Memory location" screen: Job 3 Left

side up selected
77
Deleting groups Call up the "Optimizing & managing
1
and jobs jobs" menu item
"Manage jobs":
ars ("Manage jobs - Group")
3 When deleting groups, select groups to
be deleted (0 - 99) using the adjusting
dial (18)
4 Press F4 "Delete group"
– Precautionary query "Do you real-

ly want to delete the complete
group 0?" appears

screen IMPORTANT! When deleting a group, all
the jobs in that group are also deleted.
5 Press F2 "Yes"
– The selected group is deleted, the
1st screen in the wizard appears
("Manage jobs - Group")
"Delete group" precautionary query
pears ("Manage jobs - Memory
location")
"Manage jobs - Group" screen with deleted group
78
7 When deleting jobs, select relevant
memory location using adjusting dial
EN
(18)
8 Press F4 "Delete job":
ly want to delete job 3?" appears
9 Press F2 "Yes"
– The selected job is deleted, the
2nd screen in the wizard appears
("Manage jobs - Memory locati-
on")
"Delete job" precautionary query
10 Press F2 "Done":
appears.
79
Retrieving administration data for a selected job
Retrieving admin- Call up the "Optimizing & managing

1
istration data for jobs" menu item
a job
2 Select "Administration data" screen by
– "Administration data" screen ap-
pears
3 Select "group no." parameter using the
adjusting dial (18)
adjusting dial (18)
Optimizing and managing jobs: "Administration data" – If a job is selected from the next
screen group, the group displayed also
changes accordingly.
Different adminis- Depending on the type of job selected, the administration data display differs, e.g.:
tration data dis-
plays, depending
The following are displayed for MIG/MAG The following are displayed for CC/CV
on job type
synergic jobs: mode jobs:
- Welding current, welding voltage and - Welding current, welding voltage
material strength - each depending on - Creation date
the wire feed speed set
- Welding program F4 "Filler metal" is not active, the function
- Creation date key is shown as greyed out.
"Administration data" screen for a MIG/MAG synergic "Administration data" screen for a CC/CV mode job
job
80
Retrieving and changing a welding program for a se-
lected job
EN
General The sequence of screens shown on the "clothesline" depends on the type of job selected.
The "Welding program" screen only appears with MIG/MAG synergic jobs.
Retrieving a job Call up the "Optimizing & managing

1
welding program jobs" menu item
2 Whatever screen is showing, select
"Group n°" parameter using the down
(6) or up (7) keys
adjusting dial (18)
adjusting dial (18)
– If a job is selected from the next
group, the group displayed also
changes accordingly.
Optimizing and managing jobs: "Welding program" 6 Select "Welding program" screen by
screen pressing the right arrow key (8)
ars
Changing a job Call up a job welding program

1
welding program
2 Press F4 "Filler metal" to change the
welding program:
Optimizing and managing jobs: "Welding program"

screen
81
3 Select required filler metal using the
adjusting dial (18)
pears ("Select a wire diameter")
– Only the wire diameters available
for the filler metal selected in the
1st screen are shown.
"Select a filler metal" screen: AlMg5 selected
5 Select corresponding wire diameter

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 wire diameter" screen: 1.0 mm selected
7 Select corresponding gas using the ad-

justing dial (18)
– The "Select a reference" screen
only appears if there are several
characteristics for the selected fil-
ler metal, wire diameter and shiel-
ding gas.
– The value given in brackets after
the process indicates how many
characteristics there are for this
process.
"Select a shielding gas" screen: I1 100% Ar selected
82
9 Select the corresponding process
EN
10 Select the corresponding characteri-
stic reference number using the adjus-
ting dial (18)
– E.g.:
Characteristic C0876 is only suita-
ble for CMT.
– The 4th screen in the wizard
confirmation
Example: AlSi 5 / 1.2 mm / I1 100% Ar screen "Select Changes can be made.
a reference": Characteristic S0016 selected
12 Press F2 "Done"
Optimizing & managing jobs: "Welding program"

screen
The set welding program is accepted, "Wel-

ding program" screen appears
Optimizing & managing jobs: "Welding program"

screen
83
Retrieving and changing working parameters for a
selected job
Retrieving and 1 Call up the "Optimizing & managing jobs" menu item
changing job Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
working parame- keys
ters
3 Select desired group (0 - 99) using the adjusting dial (18)
4 Select "Job n°" parameter using the down (6) or up (7) keys
5 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.
6 Select "Working parameters" screen by pressing the right arrow key (8)
– "Working parameters" screen appears

parameter value
lighted.
Optimizing and managing jobs: "Working parameters"

screen
Instructions on If the wirefeed speed value is changed in

changing the wire MIG/MAG synergic jobs in the "Working pa-
feed speed value rameters" screen, the values for welding
current and welding voltage also change
accordingly, due to the synergic function.
Changes to welding current and welding
voltage must be reflected in the "QMaster"
screen in the "current command value" and
"voltage command value" parameters.
"Working parameters" screen - changing the wirefeed

speed value
84
Retrieving and changing process settings for a se-
lected job
EN
changing job pro- Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
cess settings keys
ingly.

parameter value
lighted.
Optimizing and managing jobs: "Process settings"

screen
85
Retrieving and changing special 2-step parameters
for a selected job
"Special 2-step" screen only appears:

- if the trigger mode is set to S2-step for the job selected
- for MIG/MAG synergic jobs
changing special Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
2-step parame- keys
ters for a job
ingly.
6 Select "Special 2-step" screen by pressing the right arrow key (8)

parameter value
lighted.
Optimizing and managing jobs: "Special 2-step"

screen
86
Retrieving and changing special 4-step parameters
for a selected job
EN
The "Special 4-step" screen only appears:

changing special Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
4-step parame- keys
ters for a job
ingly.
6 Select "Special 4-step" screen by pressing the right arrow key (8)

parameter value
lighted.
Optimizing and managing jobs: "Special 4-step"

screen
87
Retrieving and changing spot welding parameters
for a selected job
The "Spot welding" screen only appears:

changing spot Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
welding parame- keys
ters for a job
ingly.
6 Select "Spot welding" screen by pressing the right arrow key (8)

parameter value
lighted.
Optimizing and managing jobs: "Spot welding" screen
88
Establishing correction boundaries for a selected
job
EN
The "Correction boundaries" screen only appears with MIG/MAG synergic jobs.
Purpose of cor- Correction boundaries can be entered individually for each job.
rection bounda- If correction boundaries are set for a job, welding power and arc length of the job con-
ries cerned can be corrected within the boundaries defined (in job welding).
Establishing cor- 1 Call up the "Optimizing & managing jobs" menu item
rection bounda- Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
ries for a job keys
ingly.
6 Select "Correction boundaries" screen by pressing the right arrow key (8)
– "Correction boundaries" screen appears

parameter value
lighted.
Optimizing and managing jobs: "Correction boundari-

es" screen
89
Explanation of
The correction range for welding power is made up as follows:
correction bound-
aries set wirefeed speed E.g.: 15.0 m/min
+ 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
In job welding, the welding power can therefore be corrected between 14.6 m/min and 15.8
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- + 20.0 %
ries
= upper limit for arc length = 30.0 %
set arc length correction value E.g.: + 10.0 %

- value as % for arc length correction bounda- - 20.0 %
ries
= lower limit for arc length = -10.0 %
In job welding, the arc length can therefore be corrected within the range of - 10.0% to +
30%.
90
Job-specific documentation
EN
Purpose of the "Job-specific doc." is for documenting the current welding values of a selected job.
"Job-specific "Job-specific doc." can be set individually for each job.
doc." function
Requirement for The "Job documentation" parameter in the "Basic settings" screen of the "Documentation"
"Job-specific menu item must be set as follows:
doc." - Parameter "Job documentation" ..... Job-specific
Establishing job- 1 Call up the "Optimizing & managing jobs" menu item
specific docu- Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
mentation keys
ingly.
6 Select "Job-specific doc." screen by pressing the right arrow key (8)
– "Job-specific doc." screen appears

parameter value
lighted.
Optimizing and managing jobs: "Job-specific doc."

screen
91
Explanation of
Parameter Setting Result
job-specific docu-
mentation Documentation On In job welding, the present welding values in the
selected job are documented according to the
"Every n-th seam" and "Every n seconds" param-
eters
Off The present welding values in the selected job are
not documented in job welding
Every n-th seam 1 In job welding, the present welding values in the
selected job are documented at every (weld)
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 every 0.1 seconds.
documented in job welding every 0.2 seconds.
...
documented in job welding every 9.9 seconds (=
maximum)
92
Retrieving and changing SynchroPuls parameters
for a selected job
EN
The "SynchroPuls" screen only appears:

- if the SynchroPulse option is installed on the power source
changing Syn- Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
chroPuls parame- keys
ters for a job
ingly.
6 Select "SynchroPuls" screen by pressing the right arrow key (8)
– "SynchroPuls" screen appears

parameter value
lighted.
Optimizing and managing jobs: "SynchroPuls" screen
93
Establishing QMaster values for a selected job
Purpose of QMas- QMaster values can be entered individually for each job. If set QMaster values are exceed-
ter values ed or not reached over a specific period, one of the following reactions takes place:
- Power source switches off immediately
- A warning signal is given
- No reaction
Establishing Q- 1 Call up the "Optimizing & managing jobs" menu item

Master values for Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
a job keys
ingly.
6 Select "QMaster" screen by pressing the right arrow key (8)
– "QMaster" screen appears

parameter value
lighted.
Optimizing and managing jobs: "QMaster" screen
NOTE! If the wirefeed speed value in the "Working parameters" screen is

changed, the values for welding current and welding voltage also change accord-
ingly, due to the synergic function.
Changes to welding current and welding voltage must be reflected in the "QMas-
ter" screen in the "current command value" and "voltage command value" param-
eters.
IMPORTANT! If the "Max. duration of voltage-deviation" and "Max. duration of current-de-

viation" parameter values are entered as "Off" in a selected job, the Q-Master function for
this job is deactivated.
94
Explanation of
EN
Current set value E.g.: 338.0 A
QMaster values
+ 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
If the actual welding current during job welding is greater than 344 A or less than 332 A for
more than 0.3 sec, a reaction occurs in the form of a 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 command value E.g.: 28.6 A

- value in V for lower voltage limit - 0.2 A
= lower voltage limit = 28.4 A
Reaction E.g.: Warning
If the actual welding voltage while job welding is greater than 28.8 V or less than 28.4 V for
more than 0.3 sec, a reaction occurs in the form of a warning.
95
Determining QMaster wirefeed speed values for a
selected job
Purpose of QMas- QMaster values can be entered individually for each job. If set QMaster values are exceed-
ter values ed or not reached over a specific period, one of the following reactions takes place:
- No reaction
The reactions specified in the "QMaster" screen also apply to the Q-Master wire feed
speed values.
Determining Q- 1 Call up the "Optimizing & managing jobs" menu item

Master wire feed Whatever screen is showing, select "Group n°" parameter using the down (6) or up (7)
2
speed values for keys
a job
ingly.
6 Select "QMaster vD" screen by pressing the right arrow key (8)
– "QMaster vD" screen appears

parameter value
lighted.
Optimizing and managing jobs: "QMaster vD" screen
IMPORTANT! Whenever you change the wire feed speed in the "Working parameters"
screen, also think about the welding speed command value in the "QMaster vD" screen in
order to obtain a constant weld seam cross-section.
IMPORTANT! If the "Max. duration of wirefeed speed-dev." and "Max. duration of welding
speed dev." parameter values are "Off" for a particular job, the Q-Master wire feed function
for this job is deactivated.
96
Explanation of Q-
Wire feed speed command value 1)
EN
E.g.: 15.0 m/min
Master wire feed
speed values - 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
Reaction 2) E.g.: Warning
If the actual wire feed speed while job welding is greater than 15.5 m/min or less than 14.5
m/min for more than 0.3 sec, a reaction occurs in the form of a warning.
1) According to "Working parameters" screen

2) According to "QMaster" screen
97
Optimizing and managing characteristics
General In the "Optimizing & managing characteristics" menu item, user characteristics can be
managed, renamed or optimized.
NOTE! Optimizing user characteristics requires knowledge of arc and welding

technology.
grammed.
Calling up the Press the "Menu" button (1)

1
"Optimizing &
managing charac-
teristics" menu 2 Select the "Optimizing & managing
item characteristics" menu item using the
adjusting dial (18)
3 Press OK (3)
– Precautionary query "Do you want
to edit the characteristics online?"
appears
Main menu: "Optimizing and managing characteri-

stics" menu item selected
4 Press F2 "Yes" or 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.
Precautionary query: Do you want to edit the charac-
appears
teristics online?
98
Overview "Optimizing & managing characteristics" is composed of the following sections:
EN
- Managing characteristics
- 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
99
Manage characteristics
Select character- Call up "Optimizing & managing cha-

1
istics racteristics" menu item
appears.
"Managing characteristics":
ars ("Managing characteristics")
Example of a "Data" screen for characteristic XYZ
3 Select the desired characteristic using

4 Press F1 "Select characteristic"
"Managing characteristics" screen
The last "Data" screen called up for the

selected characteristic appears.
100
Naming and re- Call up "Optimizing & managing cha-
EN
1
naming charac- racteristics" menu item
teristics
appears.

4 Press F1 "Select characteristic"
pears

ter
– The new name is accepted, "Ma-
naging characteristics" screen ap-
pears
101
8 Press F5 "Cancel"
The last "Data" screen called up appears.
Deleting charac- Call up "Optimizing & managing cha-

1
teristic racteristics" menu item
appears.
102
EN
4 Press F2 "Delete characteristic"
ly want to delete Synergic ...?" ap-
pears
5 Press F2 "Yes"
– The characteristic is deleted, "Ma-
naging characteristics" screen ap-
pears
Precautionary query "Do you really want to delete Sy-

nergic ...?"
6 To go back to the previous "Data"

screen, press F4 "Cancel"
"Managing characteristics" screen with deleted cha-

racteristic
103
Managing characteristic points
Select character- Call up "Optimizing & managing cha-

1
istic points racteristics" menu item
appears.
2 Press F1 "Managing characteristics"
and select the corresponding characte-
ristic
3 Whatever screen is showing, select the
characteristic point to be altered by
pressing F2 or F5:
– F2 "Previous point" ... the charac-
teristic point before the current
one appears. The first point in the
characteristic, F2 "Previous point"
is greyed out.
Example of a "Data" screen for characteristic XYZ – 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- Call up "Optimizing & managing cha-

1
teristic points racteristics" menu item
appears.
and select the corresponding characte-
ristic
"Insert point":
ars ("Insert characteristic point")
104
4 Using the adjusting dial (18), choose
whether to calculate or to copy the cha-
EN
racteristic point
Calculating a characteristic point:

pears ("Calculate characteristic
point")
"Insert characteristic point" screen - "Calculate" selec-

ted
6 using the adjusting dial (18), enter wi-

refeed speed for which the new cha-
racteristic point is to be calculated
pears as confirmation ("Calculate
characteristic point")
"Calculate characteristic point" screen - entering wire

feed speed
8 Press F2 "Done"
"Calculate characteristic point" screen - confirmation
105
The new characteristic point is inserted into
the characteristic, according to its wirefeed
speed. The corresponding "Data" screen
appears
Example of a "Data" screen with new characteristic

point (Point 1)
Copying a characteristic point:

pears as confirmation ("Characte-
ristic point now copied")
"Insert characteristic point" screen - "Copy" selected
6 Press F2 "Done"
"Characteristic point now copied" screen
106
The currently selected characteristic point
is copied into the characteristic, the corres-
EN
ponding "Data" screen appears.
Example of a "Data" screen with copied characteristic

point (Point 3)
Deleting charac- Call up "Optimizing & managing cha-

1
teristic points racteristics" menu item
appears.
and select the characteristic from
which a characteristic point is to be de-
leted
3 Whatever screen is showing, select the
characteristic point to be deleted using
F2 "Previous point" or F5 "Next point"
4 Press F4 "Delete point":
ly want to delete Point ... ?" appe-
ars
5 Press F2 "Yes":
Precautionary query "Do you really want to delete

Point ...?"
107
The selected characteristic point is deleted,
the corresponding "Data" screen appears.
108
Parameters of standard characteristics
EN
Ignition 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] that the set ignition current is active when welding begins
0 = no ignition current
40 = max. duration for ignition current
Ignition current
Strength of ignition current [A] set when welding begins. The ignition current depends on
the filler metal and wire diameter.
- In the case of low ignition current, the welding wire is not sufficiently preheated or
burned
- In the case of high ignition current, the filler wire is excessively preheated or burned
Arc (static) Wire feed speed

The wire feed speed [m/min] regulated via a pulse generator guarantees a controlled
speed value on the feed rollers.
Effects of an excessively high wire feed speed:

- arc too short
- The wire electrode is not sufficiently melted - heavy spatter due 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 form
Effects of an excessively low base current:

- ionisation of the arc section too low
- arc breaks in the base current phase
Voltage command value

This parameter gives the voltage command value in [V] for the arc.
Effects of excessively high voltage:

- arc too long
- wire electrode may weld fast to the contact tube
- low short-circuit frequency
109
Effects of excessively low voltage:
- arc too short - unstable arc
Characteristic slope
Resistance value [μOhm] with which a drooping or neutral characteristic can be set.
32767 = drooping characteristic
0 = neutral characteristic
Arc (dynamic)
I (A)
(1) (2)
(3)
(13) (4)
(5)
(6) (7)
(8)
(12)
(11)
(10)
(9)
t (s)
Characteristic parameters for dynamic standard arcs
(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 welding
current for the duration of the short circuit.
0 = no special dynamic (soft arc, tending towards instability)
65535 = maximum special dynamic (hard, stable arc)
110
Current drop
The current drop parameter determines the speed at which the short circuit current con-
EN
trol changes to voltage control.
0 = flat drop (soft arc, tending towards instability)
65535 = steep drop (hard, stable arc)
Current rise
The current rise parameter determines the speed at which the welding current increases
for the duration of the short circuit.
0 = steep rise (hard, stable arc)
65535 = flat rise (soft arc, tending towards instability)
End of welding
Burn-back time
The burn-back time [s] can be saved for each characteristic point.
0.00 = minimum burn back time (risk of wire sticking to weld pool)
0.40 = maximum burn back time (risk of wire sticking to contact tube)
Burn-back pulsing current

Strength of current pulse [A], set at end of welding. The current pulse when welding stops
produces a defined detachment of the last drop (a wire end with small drop is a precon-
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
Guideline values
Guideline value for material
The guideline value for the material strength [mm] is normally determined by trial and er-
ror or by performing a test weld
Voltage guideline value

The voltage guideline value [V] is normally determined by trial and error or by performing
a test weld. On power sources TS 4000/5000 and TPS 2700/4000/5000, the voltage
guideline value corresponds to the voltage on the contact tube.
Current guideline value

In MIG/MAG manual welding the current guideline value [A] is normally determined by tri-
al and error or by performing a test weld.
Type of arc
For the best characteristic, keep the arc type that occurs during the test weld (short, glob-
ular, long or spray arc).
111
Accepting volt- Voltage and current guideline values are accepted by the remote control unit directly from
age and current the test weld:
guideline values
1 Set welding voltage and welding cur-
rent at the power source
2 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.
3 At the end of welding, the last active
hold values for welding voltage and
welding current are accepted as volta-
ge and current guideline values. Volta-
Voltage and current guideline values during test weld, ge and current guideline values can be
continuous black selection bar kept or reset.
112
Parameters of pulse characteristics
EN
Ignition
Feeder creep speed
Wire feed speed [m/min] before welding begins (0 - currently set wire feed speed)

The length of time [ms] the ignition current set when welding begins is active.
0 = no ignition current
40 = max. duration for ignition current
Ignition current
Strength of ignition current [A] set when welding begins. The ignition current depends on
the filler metal and wire diameter.
- In the case of low ignition current, the welding wire is not sufficiently preheated or
burned
- In the case of high ignition current, the filler wire is excessively preheated or burned
Pulsing parame-
ters I (A)
(1) (2)
(3
)
(5)
(4)
(5)
(9)
(7)
(6)
(8)
t (s)
Overview of the pulsing parameters
(1) Pulsing current time (6) Droplet detachment current

(2) Droplet-detachment time (7) Current rise when pulsing begins
(3) Current-rise (tau) (8) Ground current
(4) Current drop when pulsing ends (9) Pulse current
(5) Tau current drop
113
Ground current
The function of the base current [A] is to maintain the arc during the pause between the
pulses (= base current phase).
Effects of an excessively high base current:

- wire electrode welded on too hard
- large drops form
Effects of an excessively low base current:

- ionisation of the arc section too low
- Arc breaks in the base current phase
Current rise when pulsing begins

The parameter [A/ms] describes the linear rise of the current when pulsing begins, e.g.
0 = no current rise
100 = soft arc
1000 = max. rise in current (hard arc)
Current-rise (tau)
Time of transition [ms] from a linear slope to the pulsing current (0 - 5)
0 = hard transition, loud arc noise
5 = soft transition, softer arc noise
Pulsing current
The height of the pulsing current [A] depends in the first instance on the material and di-
ameter of the wire electrode, as well as the shielding gas used. A certain energy limit (=
critical limit) must be reached for droplet detachment to occur, and thereby ensure material
transfer without a short circuit. The pulsing current must remain above the critical limit.
Effects of an excessively high pulsing current:

- Droplet detachment energy too high
- Spatter with small droplets
Effects of an excessively low pulsing current:

- Droplet detachment energy too low
- Spatter with large droplets
Pulsing current time

The duration of the pulse phase [ms] depends essentially 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 droplet detachment, and therefore heavy spatter
Current drop when pulsing ends

The parameter [A/ms] describes the linear current drop when pulsing ends, e.g.
0 = no current decrease
100 = soft arc
1000 = maximum current drop (hard arc)
114
Tau current drop
Time of transition [ms] from a linear slope to the droplet detachment current (0 - 5)
EN
0 = hard transition, loud arc noise
5 = soft transition, softer arc noise
Droplet detachment current

The droplet detachment current [A] is effective in the decreasing steep edge of a pulse,
and serves to produce the best droplet detachment. The droplet detachment current must
be greater than the base current, otherwise there is a risk of an arc breakNô kein Strom-
abfall
- A high droplet detachment current raises the pulsing or droplet detachment energy
- A low droplet detachment current decreases the pulsing or droplet detachment energy
Droplet-detachment time
Length of time [ms] that the droplet detachment current is active (0 - 50)
0 = no droplet detachment current
Pulse frequency
The pulsing frequency [Hz] is determined by the droplet size and is proportional to the
wirefeed speed.
Arc (static) Wire feed speed

The wire feed speed [m/min] regulated via a pulse generator guarantees a controlled
speed value on the feed rollers.
Effects of an excessively high wire feed speed:

- arc too short
Effects of an excessively low wirefeed speed:

- arc too long
Voltage command value

This parameter gives the voltage command value in [V] for controlling the arc length.

- arc too long

- arc too short
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)
115
Fact-f-control (p)
Effect of deviations [%] on the frequency (0 - 50)
Fact-I_b-correction
Effect of arc length correction [%] on the base current (0 - 50)
Fact-I_p1-correction
Effect of arc length correction [%] on 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.
I (A)
(1)
(2)
I (A) t (s)
(3)
I (A) t (s)
(4)
I (A)
(5) t (s)
(6)
t (s)
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)
116
Short circuit Current-rise (short circuit)
EN
The parameter [A/ms] describes how the current is ramped up in the event of a short circuit.
End of welding
Burn-back time
The burn-back time [s] can be saved for each characteristic point.
0.00 = minimum burn back time (risk of wire sticking to weld pool)
0.40 = maximum burn back time (risk of wire sticking to contact tube)
Guideline values Guideline value for material

The guideline value for the material strength [mm] is normally determined by trial and error
or by performing a test weld

a test weld. On power sources TS 4000/5000 and TPS 2700/4000/5000, the voltage guide-
line value corresponds to the voltage on the contact tube.

In MIG/MAG standard manual welding, the current guideline value [A] is normally deter-
mined by trial and error or by performing a test weld.
guideline values
2 Perform test weld
black.
117
Parameters of CMT characteristics
General NOTE! The creation and editing of CMT characteristics is a complex task and
therefore a core skill of Research & Development. Special measurement technol-
ogy (e.g. a high-speed camera, oscilloscope) as well as extensive background
knowledge is required for the creation and editing of CMT characteristics.
The modification of CMT characteristics on-site simply optimizes the application
in question.
Ignition In CMT processes, the ignition process is generally initiated with SFI (Spatter-Free Igni-
tion). Regardless of the CMT characteristic, subsequent ignition behaviour in the CMT pro-
cess is controlled by the following parameters:
- vd_ignition or - slaghammer On_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 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
Parameter [V] for changing the arc length when welding starts
10 = short arc
40 = long arc
t_hotstart
The length of time [ms] that the change in the arc length is active when welding begins.
0 = no change in the arc length
654.98 = max. duration for the change in arc length
118
slaghammer On_1/Off_0
Function for removing slag at the end of the wire electrode. The wire electrode carries out
EN
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.
CMT parameters The CMT parameters are displayed in the screens "CMT - Param1" and "CMT - Param2".
(1)
(2) (3)
(4) (5)
VD (m/s)
(7)
0
t (s)
I (A) (11)
(10)
(13)
(9)
(6)
(8)
(14)
U (V) t (s)
(12) t (s)
Overview of the CMT characteristic parameters
(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 elec-
trode into the weld pool
(8) I_sc2
Current command value with short circuit [A]
119
(9) d_boostup
Linear current rise rate [A/ms] at the start of the boost phase
0 = no current rise
1000 = maximum rise in current
(10) tau_boostup
Non-linear current rise rate [ms] at the start of the boost phase (0.08 - 5.00)
(11) I_boost
(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 decrease [A/ms] following the boost phase
1000 = maximum decrease in current
(14) tau_boostdown
Non-linear current decrease rate [ms] following the boost phase (0.08 - 20)
The parameter is not displayed for all CMT characteristics.
End of welding
I_drop_melt
Current command value [A] for globule formation at the end of welding (t=10 ms)
3 = no globule formation
500 = maximum globule formation
t_burnback
Duration of the currentless wire withdraw [ms] after the welding current has been
switched off (vD = -6 m/min)
Guideline values Current guideline value

The current guideline value [A] is normally determined by trial and error or by performing
a test weld.


a test weld. On the TS 4000/5000 and TPS 2700/4000/5000 power sources, the voltage
120
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.
EN
guideline values
2 Perform test weld
black.
121
Parameters of CMT / pulse characteristics
General NOTE! The creation and editing of CMT/pulse characteristics (CMT+P) is a com-
plex task and therefore a core skill of Research & Development. Special meas-
urement technology (e.g. a high-speed camera, oscilloscope, etc.) as well as
extensive background knowledge is required for the creation and editing of
CMT+P characteristics.
The modification of CMT+P characteristics on-site simply optimizes the applica-
tion in question.
tion). The subsequent ignition behaviour in the CMT process is controlled by the following
parameters:
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
t_ignition
ing begins.
U_hotstart
Parameter [V] for changing the arc length when welding starts
10 = short arc
40 = long arc
t_hotstart
The length of time [ms] that the change in the arc length is active when welding begins.
654.98 = max. duration for the change in arc length
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 parameter is not displayed for all CMT characteristics.
122
Overview: CMT
EN
parameters, pulse (1) (2)
parameters KSP (3) KSP
VD (m/s) BoP BrP
(5)
(12)
0
t (s)
(10) (11)
I (A) (7) (13)

(9)
(4) (14) (15)
(6)
t (s)
U (V)
(8) (17) (16) t (s)
Overview of the CMT+P characteristic parameters
KSP Short-circuit phase (1) CMT cycle

BoP Boost phase (2) Pulse cycles
BrP Burn phase (3) Plasma phase
CMT parameters
(4) I_sc_wait
(5) vd_sc_wait
(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
0 = no boost phase
99.98 = maximum duration of the boost phase
123
Pulsing parame-
(9) d_pulsup
ters
Linear rate of rise in the pulsing current [A/ms]
0 = no pulsing current rise
1000 = maximum pulsing current rise
(10) tau_pulsup
Non-linear rate of rise in the pulsing current [ms] (0.08 - 5)
(11) I_p1
Current command value [A] during the pulse phase
(12) vd_pulscycle
Wire feed speed [m/min] during the pulse cycle (0 - 45)
(13) d_pulsdown
Linear pulsing current 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! The pulsing frequency is calculated as follows:

1
f=
(t_base + t_p1)
(17) t_p1
Duration of the pulsing current phase [ms] from the start of the current rise until the
start of the current decrease
0 = no pulsing current phase
50.02 = maximum duration of the pulsing current phase
CMT/Pulsed CMT_cycles
Number of CMT cycles (0 - 500)
Puls_cycles
Number of pulse cycles (0 - 500)
124
End of welding
EN
t_burnback

a test weld.


Wirefeed speed
guideline values
2 Perform test weld
black.
125
Parameters of CMT Advanced characteristics
The modification of CMT Advanced characteristics on-site simply optimizes the
application in question.
parameters:
I_ignition
t_ignition
ing begins.
Hotstart
t_hotstart
The length of time [ms] that the change in arc power is active when welding begins.
650 = max. duration for the change in arc power
126
Weld start Positive_weldstart_cycles
EN
Number of positive weld start cycles
Negative_weldstart_cycles
Number of negative weld start cycles
Summary_weldstart_cycles
Total number of weld start cycles
"Weld start" screen for CMT Advanced characteristics
CMT parameters The CMT parameters are displayed in the screens "CMT - Param1" and "CMT - Param2".
and EN-CMT pa- The EN-CMT parameters in the negative cycle are displayed on the "CMT - Param1" and
rameters "CMT - Param2" screens.
EN ...... "Electrode Negative"
(1) (2)
(3) (4)
VD (m/s)
(6) / (-6)
t (s)
I (A) (9) (10)

(8) (12)
(7) (5) t (s)
0 (13)
(-13)
(-7) (-5)
(-8) (-12)
(-9) (-10)
U (V)
t (s)
0
(11)
(-11)
Overview of the CMT Advanced characteristic parameters
(1) Short-circuit phase (3) Boost phase

(2) Plasma phase (4) Burn phase
Negative cycle
(5) I_sc_wait
(-5) EN_I_sc_wait
127
(6) vd_sc_wait
(-6) EN_vd_sc_wait
(7) I_sc2
(-7) EN_I_sc2
Current command value with short circuit [A]
(8) d_boostup
(-8) EN_d_boostup
0 = no current rise
(9) tau_boostup
(-9) EN_tau_boostup
(10) I_boost
(-10) EN_I_boost
Current command value during the boost phase
(11) t_I_boost
(-11) EN_t_I_boost
0 = no boost phase
99.98 = maximum duration of the boost phase [ms]
(12) d_boostdown
(-12) EN_d_boostdown
(13) tau_boostdown
(-13) EN_tau_boostdown
128
EN/EP CMT Positive_cycles
EN
Positive CMT cycles
Negative_cycles
Negative CMT cycles
End of welding
I_drop_melt
EN_I_drop_melt
Current command value [A] for globule formation at the end of welding (t=10 ms)
3 = no globule formation
500 = maximum globule formation
t_burnback

a test weld.


Wirefeed speed
129
guideline values
2 Perform test weld
black.
130
Parameters of CMT/Pulsed Advanced characteris-
tics
EN
The modification of CMT+P ADV characteristics on-site simply optimizes the ap-
plication in question.
parameters:
I_ignition
t_ignition
ing begins.
I_sc_wait
Current command value [A] following the boost phase until the dipping of the wire elec-
Hotstart
t_hotstart
The length of time [ms] that the change in arc power is active when welding begins.
650 = max. duration for the change in arc power
131
Overview: CMT The CMT parameters are displayed in the screens "CMT - Param1" and "CMT - Param2".
parameters, pulse The pulsing parameters are displayed on the "Pulsing parameter 1" and "Pulsing parame-
parameters ter 2" screens.
(1) (2)
KSP (3) KSP
VD (m/s) BoP BrP
(4)
(19)
0
t (s)
(14)
(13)
I (A) (16)
(12)
(17) (18)
0 (11) t (s)
(6) (5)
(10)
(7)
(8)
U (V)
0
t (s)
(9) (15)
Overview of the CMT+P Advanced characteristic parameters
KSP Short-circuit phase (1) CMT cycle

BoP Boost phase (2) Pulse cycles
BrP Burn phase (3) Plasma phase
Negative cycle
CMT parameters
(4) vd_sc_wait
(5) I_sc2
Current command value [A] with short circuit
(6) d_boostup
0 = no current rise
132
(7) tau_boostup
EN
(8) I_boost
Current command value [A] during the boost phase
(9) t_I_boost
0 = no boost phase
99.98 = maximum duration of the boost phase
(10) d_boostdown
(11) tau_boostdown
Pulsing parame-
(12) d_Ip1
ters
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 phase
(15) t_p1
Duration of the pulsing current phase [ms] from the start of the current rise until the
start of the current decrease
0 = no pulsing current phase
79.50 = maximum duration of the pulsing current phase
133
(16) d_Ip2
Linear pulsing current decrease rate t_p2
[A/ms]
(14) I_p1
0.1 = no decrease in puls-
ing current
2200 = maximum pulsing
(16) d_Ip2
current drop
(17) tau_Ip2
Non-linear pulsing current decrease
rate [ms] (17) tau_Ip2 I_p2
I (A) d_I_Base
I_p2 (18) I_base

tau_I_base
Droplet-detachment current [A] t (s)
(must be greater than I_base, other- Parameters on the falling edge of the pulse
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-detachment current decrease rate [ms]
(18) I_base
Current command value [A] during the base current phase
(19) vd_pulscycle
Wire feed speed [m/min] during the pulse cycle (0 - 45)
U_set_puls
This parameter specifies the voltage command value [V] for controlling the arc
length.

- arc too long

- arc too short
134
k_I_p1_reg_gain
Effect of deviations [%] on the pulsing current
EN
k_Vd_reg_gain
Effect of deviations [%] on the wirefeed speed
k_I_b_reg_gain
Effect of arc length correction [%] on the base current
I_p1_reg_delta_min
Lower control limit for the pulsing current Ip1 [A]
I_p1_reg_delta_max
Upper control limit for the pulsing current Ip1 [A]
Pulsed/CMT cy- N_CMT_Cycles

cles Number of CMT cycles
N_Puls_Cycles
Number of pulse cycles
"Pulsed/CMT cycles" screen for CMT + P ADV charac-

teristics
End of welding
t_burnback

a test weld.


135
Wirefeed speed
136
Changing characteristic parameters
EN
The process con- The process controller appears in each screen of the "Optimizing & managing character-
troller istics" menu item. This process controller supports optimization of pulse characteristics by
means of the control parameters Fact-I_b control (pi), Fact-I_p1 control (pi) and Fact-f con-
trol (p)
(1)
(2)
Process controller with setting ranges
(1) optimum range (2) actual value
The value set for a regulator parameter should ideally lie within the optimum 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-
Screen Pulse Standard CMT CMT+P CMT ADV CMT+P ADV
played for differ-
ent Ignition X X X X X X
characteristics Hotstart - - - - X X
Weld start - - - - X -
CMT - Param1 - - X X X X
CMT - Param2 - - X - X X
EN CMT - Param1 - - - - X -
EN CMT - Param2 - - - - X -
EN/EP CMT - - - - X -
Pulsing parameters X - - X - -
Pulsing parameter 1 - - - - - X
Pulsing parameter 2 - - - - - X
Pulsed/CMT cycles - - - - - X
Arc (static) X X - - - -
Arc (dynamic) - X - - - -
Short circuit X - - - - -
CMT/Pulsed - - - X - -
End of welding X X X X X X
Guideline values X X X X X X
137
Changing charac- 1 Call up "Optimizing & managing characteristics" menu item
teristic parame- – The last "Data" screen called up appears.
ters
2 Press F1 "Managing characteristics" and select the corresponding characteristic
3 Whatever screen is showing, use the right arrow key (8) to select the "Data" screen in
which the characteristic parameter to be changed is located
4 Using F2 or F5, select the characteristic point whose characteristic parameter is to be
changed:
– F2 "Previous point" ... the 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.
5 Select the characteristic parameter to be changed using the down (6) or up (7) key
6 Use the adjusting dial (18) to alter the parameter value
A parameter value can only be altered within the defined setting range. The setting range
is highlighted.
Example:
The characteristic parameter "Droplet-detachment

time" will be changed for point 2 of the characteristic
CrNi188 08 M21 mod in the "Pulsing parameters"
screen
138
Documentation
EN
General The "Documentation" menu item serves to capture actual welding data during the welding
process.
The following welding data are documented:
- Welding current, welding voltage
- Exceeding or falling short of defined limit values (QMaster)
- Motor current of wire feeder and push-pull unit
- Component counter
- Errors arising during the welding process
- Events
For welding mode, the documentation of welding data is possible in the following menu
items:
- "MIG/MAG synergic welding"
- "MIG/MAG standard manual welding"
- "CC/CV mode" (if the "CC/CV mode" software option is installed on the power source)
- "Job welding"
Evaluating weld- The documented welding data can be evaluated in two ways:
ing data
RCU 5000i RCU 5000i
(1) (1)
(5)
(3)
(4)
(2) (2)
Direct evaluation of welding data Storing welding data on a memory card, subsequent
evaluation
(1) Power source (4) Card reader

(2) PC/laptop + RCU Data Receiver (5) Memory card
(3) LocalNet/RS 232 interface
Requirements: Requirements:
- PC or laptop with Microsoft® Excel - PC or laptop with Microsoft® Excel
- "RCU Data Receiver" software in- - "RCU Data Receiver" software in-
stalled on PC/laptop stalled on PC/laptop
- Data connection between PC/laptop - Regular card reader for reading data
and the power source (e.g. via Local- from the memory card
Net/RS 232 interface or "Ethernet"
option on the power source)
139
- RCU 5000i remote control - RCU 5000i remote control
- If there is no LocalNet connection - If there is no LocalNet connection
free on the power source: LocalNet free on the power source: LocalNet
passive distributor passive distributor
Welding data which is evaluated directly can also be stored on the memory card.
Call up the "Docu- Press the "Menu" button (1)

1
mentation" menu
item
2 Select "Documentation" menu item
3 Press OK (3):
appears.
Main menu: "Documentation" menu item selected
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
140
Establishing basic settings for the documentation
EN
Establishing ba- Call up the "Documentation" menu
1
sic settings for item
the documenta-
tion 2 Select "Basic settings" screen by pres-
– "Basic settings" screen appears
3 Select the corresponding parameter
4 Alter the parameter using the adjusting
dial (18)
lighted.
Documentation: "Basic settings" screen
Basic documen- The parameters "Every n-th seam" and "Every n seconds" are accepted as basic settings
tation settings when jobs are saved. In the "Optimizing and managing jobs" menu item the parameters
when storing jobs "Every n-th seam" and "Every n seconds" can be set individually for each job.
Explanation of
Documentation
the parameters in
for activating/deactivating the documentation function
the "Basic set-
tings" screen 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
for setting the number of weld seams after which documentation is to occur Used for ran-
dom documentation for example
Range 1 - 100
1 The actual welding values are documented after every (weld) seam
2 The actual welding values are documented after every 2nd (weld) seam
... ...
100 The actual welding values are documented after every 100 (weld) seams
(= maximum)
Every n seconds
for setting the period of time after which documentation is to occur
Range Off/0.1 - 9.9
Off Actual welding values are not documented; an average value for welding
current and welding voltage is given across the entire weld; errors and
over/undershooting are documented
0.1 The actual welding values are documented every 0.1 seconds
141
0.2 The actual welding values are documented every 0.2 seconds
... ...
9.9 The 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, the actual welding values are documented according to
the parameters in the "Basic settings" screen
Job-specific In job welding, the actual welding values are documented according to
the documentation parameters stored in the job concerned
Doc. on SD card
for activating/deactivating whether welding data are stored on the memory card
Range Off/On
Off The actual welding values are not stored on the remote control unit mem-
ory card.
On The actual welding values are buffered in the cache memory and stored
on the memory card.
Documentation If the "Doc. on SD card" parameter is set to "On", the actual welding values are buffered in
on memory card the cache memory and stored on the remote control memory card.
IMPORTANT! The memory card must not

be write-protected.
Please insert a memory If there is no memory card in the memory
card card slot (24), the "Warning - Please insert
a memory card" screen appears.
A regular card reader is required for reading

data from the memory card.
"Warning - Please insert a memory card" screen
Memory require- The memory requirements for documentation on the memory card depend on the param-
ments for docu- eters "Every n-th seam" and "Every n seconds" as well as the power source's duty cycle.
mentation on
memory card The following table shows guideline values for the amount of time it takes to fill a 32 MB
memory card.
142
Example 1 Example 2 Example 3
Welding and weld-off 1h 1h 1h
EN
times
Duty cycle 100 % 100 % 100 %
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 650 kB/h 150 kB/h 5 kB/h
Change memory card after approx. 49 h after approx. 213 h after approx. 6400
h
Example 4 Example 5 Example 6

Welding and weld-off 1h 1h 1h
times
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 = 1, Every n seconds =

0.1, duty cycle 100%) change a full memory card within a maximum of 4 minutes, otherwise
the data buffered on the RCU 5000i remote control unit will be lost.
The RCU 5000i remote control unit supports 32MB - 1GB memory cards.
143
Establishing QMaster values
Purpose of QMas- Q-Master values can be established in the "Documentation" menu item. When storing jobs
ter values these QMaster values are accepted as pre-sets. If during job welding set QMaster value
limits are exceeded over a specific period, one of the following reactions results:
- No reaction
Establishing Call up the "Documentation" menu

1
QMaster values item
2 Select "QMaster" screen by pressing
the right arrow key (8)
– "QMaster" screen appears
parameter value
lighted
Establishing QMaster values
IMPORTANT! If the "Max. duration of current-deviation" and "Max. duration of voltage-de-

viation" are entered as "Off" in the "QMaster" screen, the Q-Master function is deactivated.
Explanation of Example:
QMaster values 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:
Welding current according to job E.g.: 250.0 A

+ value in A for upper current limit + 25.0 A
= upper welding current limit value = 275.0 A
Welding current according to job E.g.: 250.0 A

- value in A for lower current limit - 14.0 A
= lower welding current limit value = 236.0 A
Reaction E.g.: Shutdown
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 source switches off.
144
Welding voltage according to job E.g.: 35.0 V
+ value in V for upper voltage limit + 2.1 V
EN
= 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
Reaction E.g.: Shutdown
If the actual welding voltage during job welding is greater than 37.1 V or less than 31.4 V
for more than 0.8 sec, the power source switches off.
145
Setting maximum motor current
General In the "Documentation" menu item, the maximum motor current can be defined for the wire-
feed motor and the motor of a push-pull unit. When storing jobs, these maximum motor cur-
rent values are used as pre-sets. If the defined motor current values are exceeded for a
certain period during welding, then one of the following will occur:
- No reaction
Setting maximum Call up the "Documentation" menu

1
motor current item
2 Select "Motor current" screen by pres-
– "Motor current" screen appears
parameter value
lighted
Documentation: "Motor current" screen
IMPORTANT! If the "Maximum duration of current exceed" and "Maximum duration of cur-
rent exceed (PPU)" parameters are entered as "Off" in the "Motor current" screen, then the
motor current watchdog function is deactivated.
146
Component counter
EN
General A component counter function is provided in the "Documentation" menu item. Using the
part counter, consecutive numbers can be assigned to any desired parts or workpieces.
Each part can be precisely identified through the assigned number, e.g. when an error oc-
curs.
Activating the Call up the "Documentation" menu

1
component coun- item
ter
2 Select "Component counter" screen by
– "Component counter" screen ap-
pears
3 Select "Component counter" parame-
ter using the down (6) or up (7) keys
parameter value
lighted
Documentation: "Component counter" screen, "Com-
ponent counter" parameter = "On"
IMPORTANT! If the component counter function is not required, set the "Component coun-
ter" parameter to "Off"!
Defining the com- The component number can be any alphanumeric expression with a maximum length of
ponent number 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 characters entered after a separator. If 3 characters
are entered, the component number will have 3 digits, i.e. from 0 to max. 999.
1 Call up the "Documentation" menu

item
pears
3 Select "Component number" parame-
ter using the down (6) or up (7) keys
4 Press F3 "Name"
– The "Component number" screen
is displayed.
Documentation: "Component counter" screen, "Com-

ponent number" parameter selected
147
ter
"Enter component number" screen
The new component number is accepted,

the "Component counter" screen appears.
"Component counter" screen with new component

number
Example of a part number with separator:
K10-0002
4-digit final number (will be increased up to max. 9999)
Separator
Characters before the separator remain unchanged
This gives a range of possible component numbers from K10-0002 to K10-9999.
148
Incrementing the Incrementing the part number can be performed manually using F1 and F2 or by job.
EN
component num-
ber Call up the "Documentation" menu
1
item
pears
3 Select the "Increment" parameter
"Part number counter" screen, parameter "Increment"

set to "Manual"
Manual incrementing
4 Set "Increment" parameter to "Manual"
–
IMPORTANT! If the "Increment" pa-

rameter is set to "Manual", the value
of the "Job trigger" parameter has no
effect on incrementing the part num-
ber.
5 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 manually incremen-

ted component number
Incrementing by job
4 Set "Increment" parameter to "Job"
5 Enter the number of the job whose
component number is to be incremen-
ted using the "Job trigger" parameter.
– The part number is incremented
each time the job specified in the
"Job trigger" parameter is selec-
ted.
"Component counter" screen with incrementing of

component number by job no. 5
149
Welding log
General The welding data of all MIG/MAG welding operations (Synergic, manual, job) from welding
start-up through the sections up to the end of welding are recorded in the welding log.
Displaying weld- Call up the "Documentation" menu

1
ing data from the item
welding log
2 Select "Welding log" screen by pres-
– The "Welding log" screen appears
3 Select the desired welding operation
– The entry contains information on:
- Welding process
- Date, time, duration of the
weld
- Welding current, Welding
voltage
- Wire feed speed
- Job
"Welding log" screen - Violating upper/lower
limit values
4 Press F1 "Open"
– The selected welding operation is
displayed in detail with all availab-
le sections in the "Welding infor-
mation" screen.
5 Select the desired section using the

adjusting dial (18)
6 To call up the welding data for an indi-
vidual section, press F2 "Open".
"Welding information" screen for seam 2 comprising 5

sections
150
The welding data of the respective section
is displayed.
EN
"Welding information" screen for seam 2, section 1
151
Event log
General The following data are recorded in the event log:

- User logons/logoffs
- Changes to jobs
- Faults and their rectification
- Updates to RCU 5000i software
The event log holds approx. 400 entries.
Event log Call up the "Documentation" menu

1
item
2 Select "Event log" screen by pressing
– The "Event log" screen appears
3 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.
4 Press F1 "Open" to display detailed in-
formation
– The detailed information for the
selected entry is displayed.
"Event log" screen
152
Removing a memory card
EN
General The memory card must be removed from the remote control unit (e.g. during weld-off
times) in order to evaluate the data.
The memory card can be removed at any time.
Removing a mem- NOTE! When documenting to a memory card, always press F5 "Remove SD
ory card card" before removing the card.
1 In the corresponding "Data" screen,

press F5 "Remove SD card"
– The remote control unit checks
whether any welding data remains
in the cache memory.
No data available. – If there is no data in the cache me-
Remove SD card. mory, the "Information - No data
available" screen appears.
– If data remains in the cache me-
mory, the "Save data" precautio-
nary query appears.
"Information - No data available" screen
2 To save the data, press F2 "Yes"

– "Information - Save complete"
screen appears
Some documentation data

still remains in the buffer.
Do you want to save it now?
"Save data" precautionary query
153
2 Removing a memory card
Save complete.
The memory card can now
be removed.
"Information - Save complete" screen
154
Machine pre-sets
EN
General The following functions can be carried out in the "Machine pre-sets" menu item:
- Setting machine pre-sets for MIG/MAG, TIG, MMA and job welding
- Setting date and time
- User management - setting up profiles and keys
- Setting language and units of measurement
- Displaying the version data
Call up the "Ma- Press the "Menu" button (1)

1
chine pre-sets"
menu item
2 Select "Machine pre-sets" menu item
3 Press OK (3):
appears.
Main menu: "Machine pre-sets" menu item selected
Overview
"Machine pre-sets" is composed of the following sections:
- Setting machine pre-sets for weld- - RCU 5000i - Unlock function
ing - 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- - Aligning wirefeeder or push-pull unit
files and keys
- Creating and editing profiles - L/R alignment - aligning welding cir-
- Example profiles cuit inductivity and welding circuit
resistance
- Creating and editing keys
- Logging registered users on and off - RCU 5000i - Resetting to factory
at the remote control unit settings
155
Setting machine pre-sets for welding
Setting machine Call up the "Machine pre-sets" menu

1
pre-sets for "MIG/ item
MAG"
2 Select "MIG/MAG" screen by pressing
– "MIG/MAG" screen appears
3 Select the corresponding pre-set using
4 Alter the value of the pre-sets using the
adjusting dial (18)
– A pre-set value can only be alte-
red within the defined setting ran-
ge. The setting range is
highlighted.
Machine pre-sets: "MIG/MAG" screen

1
pre-sets for "TIG" item
2 Select "TIG" screen by pressing the
right arrow key (8)
– "TIG" screen appears
adjusting dial (18)
– The "Comfort Stop sensitivity" pre-
set only appears if the "TCS - TIG
Comfort Stop" option is installed
on the power source.
Machine pre-sets: "TIG" screen
highlighted.
156
EN
1
pre-sets for "Rod item
electrode (MMA)
welding" 2 Select "Rod electrode (MMA) welding"
screen by pressing the right arrow key
(8)
– The "Rod electrode (MMA) wel-
ding" screen appears
adjusting dial (18)
highlighted.
Machine pre-sets: "Rod electrode (MMA) welding"
screen
Setting machine The values entered in the "Job" screen serve as pre-sets for all jobs, e.g.:
pre-sets for "Job" If no other values for the parameters "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.
1 Call up the "Machine pre-sets" menu

item
2 Select "Job" screen by pressing the
right arrow key (8)
– "Job" screen appears
adjusting dial (18)
highlighted.
Machine pre-sets: "Job" screen
IMPORTANT! If the "Power-corr. limit: High", "Power-corr. limit: Low" and "Arc-length corr.
boundary" parameter values in the "Job" screen are entered as 0, no correction boundaries
are set for job mode.
157
Ethernet setting
General Ethernet is a way of including a power source in a local network. If the Ethernet option
(UBST PCB with Ethernet connection) is installed on the power source, then the screen for
setting the Ethernet parameters will be available on the RCU 5000i. The screen is added
to the clothesline.
As an alternative to a PC or laptop, Ethernet settings for the respective power source can
be made from the RCU 5000i.
Software version V1.03.18 and higher of the RCU 5000i remote control unit supports the
UBST PCB.
More information about Ethernet can be found in the "Ethernet field bus" operating instruc-
tions.
Changing Ether- NOTE! The setting of Ethernet parameters assumes a prior knowledge of net-
net setting work technology.

item
2 Select "Ethernet setting" screen by
– The "Ethernet setting" screen is
displayed
3 Press F3 "Change"
– The "Modify Ethernet setting"
screen is displayed
To reset the UBST setting to the factory set-

tings:
1 Press F5 "UBST factory"
Machine pre-sets: "Ethernet setting" screen
4 Select the desired Ethernet parameter

5 Select the desired parameter by pres-
sing F3 "<" or F4 ">"
6 Adjust the parameter using the adjus-
ting dial (18)
7 After setting the Ethernet parameter,
press F2 "Done"
– The "Ethernet settings" screen will

be displayed with the changed
Ethernet parameters.
IMPORTANT! The changed data will not be

transmitted to the UBST PCB until the wiz-
Machine pre-sets: "Ethernet setting" screen
ard has finished.
158
Ethernet parame-
EN
IP address
ters
Each power source in a local network is assigned its own IP address. The respective pow-
er source can be identified and addressed via this IP address.
Subnet mask
Subnet mask is a network-specific parameter of the local network. Setting the "Subnet
mask" parameter is carried out on-site by 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.
If, for instance, the "Firewall IP" parameter is set to 0. 0. 0. 0, all computers on the network
will have access to the power source.
159
Setting date and time
Setting date and Call up the "Machine pre-sets" menu

1
time item
2 Select "Time/date" screen by pressing
– "Time/date" screen appears
4 Alter the parameter using the adjusting
dial (18)
lighted.
Machine pre-sets: "Time/date" screen
160
Robot interface - robot welding
EN
General The RCU 5000i remote control unit automatically recognises when the welding machine is
connected to a robot control via a robot interface (robot welding).
In the "Robot interface" screen, the user can switch between internal and external param-
eter control, especially for robot welding:
- For internal parameter control, the parameters are entered and altered on the RCU
5000i remote control
- For external parameter control, the parameters are entered and altered via the robot
control.
External parameter control is the standard setting for robot welding. When restarting and
locking, the RCU 5000i remote control changes automatically to 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- Call up the "Machine pre-sets" menu

1
ter control in ro- item
bot welding
2 Select "Robot interface" screen by
– "Robot interface" screen appears
3 Set "general parameter control" para-
meter to "Internal" using the adjusting
dial (18)
Machine pre-sets: "Robot interface" screen - general

parameter control = internal
4 Press F3 "OK"
– The RCU 5000i remote control
unit changes to internal parameter
control.
– The "Info parameter internal"
screen appears every two minu-
tes, as long as the remote control
unit is in internal parameter cont-
rol.
– All parameters to be set are ente-
red and altered on the RCU 5000i
remote control.
"Info parameter internal" screen
161
Selected parameters are shown with a
black bar with a "window" for the parameter
value.
In the "window", the value of the selected
parameter can be altered using the adjus-
ting dial (18).
Example of internal parameter entry: black bar with

"window" - arc length correction selected
External parame- Call up the "Machine pre-sets" menu

1
ter control in ro- item
bot welding
2 Select "Robot interface" screen by
– "Robot interface" screen appears
3 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.
Machine pre-sets: "Robot interface" screen - general

parameter control = external
Selected parameters are shown with a con-

tinuous black bar on the remote control unit
display.
With external parameter control, the para-
meter value cannot be altered on the remo-
te control unit.
Example of external parameter entry: continuous

black bar - arc length correction selected
162
Selective exter- With external parameter control, the user can select and switch between external/internal
EN
nal/internal for selected parameters using F5 "Int/Ext". The external parameters can therefore be al-
switching of se- tered and set internally on the remote control unit.
lected parameters The function key F5 "Int/Ext" is available in the following menu items:
with external pa- - MIG/MAG synergic welding
rameter control - MIG/MAG standard manual welding
- MMA welding
- TIG welding
- Job welding
1 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
– The parameter is displayed with a
continuous black bar.
2 Press F5 "Int/Ext":
– The selected parameter is conver-
ted to internal parameter control
(black bar with "window")
Example of external parameter entry: continuous

black bar - arc length correction selected

parameter value
Example of internal parameter entry: black bar with

"window" - arc length correction selected
IMPORTANT! In robot welding, the F5 function key "Int/Ext" is disabled for safety reasons
if the parameter "Trigger mode" is selected in the "MIG/MAG synergic welding" menu item,
"Working parameters" screen.
F5 "Int/Ext" is greyed out:
163
screen, trigger mode selected - F5 "Int/Ext" disabled
Other functions in Selecting menu items

robot welding In robot welding, the following menu items can be selected:
- Welding process currently selected by the robot
- Optimizing & managing characteristics
- Documentation
- Default machine settings
Selectable menu items and the welding process currently selected by the robot are shown
as black, other welding processes are shown as grey, e.g.:
Example 1: "Menu" screen in robot welding, "Job wel- Example 2: "Menu" screen in robot welding, "MIG/
ding" currently selected by robot (shown as black), MAG synergic welding" currently selected by robot
"Machine pre-sets" menu item selected by the user (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.
Changing displayed "Data" screens (only for welding processes)

If the welding process currently highlighted by the robot is selected by the user, the corre-
sponding "Data" screens appear. If the robot changes the welding process, the "Data"
screen display also changes according to the new welding process.
164
E.g.:
- Robot working in "MIG/MAG synergic welding" process
- "MIG/MAG synergic welding" menu item has been opened by the user, "Process set-
EN
tings" screen is selected
- Robot changes to "Job welding"
- The remote control display automatically changes to the last "Data" screen displayed
in the "Job welding" menu item
"External robot" signal

On a robot connection using field-bus systems, the "external robot" signal is transmitted by
the remote control to 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 active" screen appears on the remote control. To hide the screen, press F3 "Ignore".
The "Information - Touchsensing is active" screen appears every two minutes, as long as
the "Touchsensing" robot signal is active.
"Information - Touchsensing is active" screen
165
Profiles/keys
General Users can be managed in the "Profiles / Keys" screen. User management is advisable if
several users work with the same remote control unit. User management operates on a
profile principle, using a system of key cards (item 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.
(1)
(2)
(3)
1 2 3 4 5 6 7
(4)
... ... ...
(5) (6) (7)

...
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 users/keys
166
Explanation of Profiles
EN
terms used Profiles are used for managing registered users (= user management). Users' access
rights and permitted activities are defined in profiles.
Two profiles have been predefined in the factory:
- "Administrator" profile, with full rights and options
- "Locked" profile, preset with access to welding processes in the factory, but not func-
tion keys
Key
A "key" is a key card assigned to a specific user and registered on the remote control. Each
user should be assigned his/her own key card.
Key card (= transponder, transponder key, transponder card)

Data is stored on each key card to identify that key card alone. This data is transmitted via
a magnetic field to the remote control when the key card is held near the remote control's
key card reader.
Administrator
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 level of training or qualifications.
Predefined pro- Call up the "Machine pre-sets" menu

1
files item
2 Select "Profiles / Keys" screen by pres-
– The "Profiles / Keys" screen appe-
ars with the predefined profiles
"Administrator" and "Locked".
Machine pre-sets: "Profiles / Keys" screen - predefined

profiles
If no other keys or profiles apart from "Administrator" and "Locked" are defined, any key
card can lock and unlock the remote control.
When the remote control is locked, the "Locked" profile is activated (see also section
"Locking and unlocking the RCU 5000i with a key card").
167
"Administrator" The "Administrator" profile cannot be deleted, renamed or edited.
profile
"Locked" profile - The "Locked" profile cannot be 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
168
Recommendation for creating profiles and keys
EN
Requirement Please proceed systematically when creating profiles and keys.
NOTE! Incorrectly created profiles and keys can have serious consequences. In-
correctly created profiles and keys can lead to key cards not being recognised or
granted access, in which case the RCU 5000i remote control unit locks.
Please read the following points carefully and keep to this recommendation when creating
profiles and keys.
Procedure NOTE! Losing an administrator key card can lead to the remote control becoming
unusable, depending on the settings. Keep one of the two administrator key cards
in a safe place.
1 Create two equal keys in the "Administrator" profile

– This ensures continued access to the administrator function even in the event of
loss of one of the administrator key cards.
2 Preparing for the creation of additional profiles:
– How many profiles 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.
3 Create profiles
4 Assign key cards/users to the profiles
5 Check that the set key cards have access to the relevant profiles.
169
Creating and editing profiles
Requirement An administrator key must first be created before profiles can be created.
Create adminis- Call up the "Machine pre-sets" menu

1
trator key item
2 Call up "Profiles / Keys" screen by
– "Profiles / Keys" screen appears
3 Select "Administrator" profile using the
adjusting dial (18)
4 Press F1 "New key"
ars ("Enter name")
Machine pre-sets: "Profiles / Keys" screen - "Adminis-

trator" profile selected
5 Press F3 "Name key"

– "Name key" screen appears
"Enter name" screen
170
EN
ter
– When creating the 1st key, the
2nd screen in the wizard ("Regis-
ter transponder") appears immedi-
ately.
– From the 2nd key onwards, once
the new name has been accepted,
the "Enter name" screen appears
once more. In this case press F2
"Name key" screen "Forward"
pears ("Register transponder")
9 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
"Register transponder" screen
10 Press F3 "OK"
11 Register other key cards
– Otherwise, the last screen in the
wizard appears ("Confirmation")
"Error - key already exists" screen
171
12 Press F2 "Done"
"Confirmation" screen
Creating profiles Call up the "Machine pre-sets" menu

1
item
2 Call up "Profiles / Keys" screen by
3 Press F3 "New profile"
– The "Information - Administrator
key setup" screen only appears if
no administrator key has been
created
Machine pre-sets: "Profiles / Keys" screen - "Adminis-

4 Press F3 "OK"
5 Create administrator key
– Otherwise, the 1st screen appears
("Enter the profile name")
"Information - Administrator key setup" screen
172
6 Press F3 "Name profile"
– "Name profile" screen appears
EN
"Enter the profile name" screen

ter
– The new name is accepted, the
2nd screen in the wizard appears
("Menus and screens")
"Name profile" screen
10 Select menu items and screens permit-

ted for the profile in question using the
adjusting dial (18)
11 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 of menu items that

have not been activated, their
screens are greyed out.
IMPORTANT! The higher-level menu item

"Menus and screens" screen:
"Working parameters" screen and "Optimizing & ma-
must also be activated in order to activate
naging jobs" menu item activated; screens.
"Optimizing & managing characteristics", "Documen-
tation" and "Machine pre-sets" menu items not activa- 12 Press F2 "Forward"
ted; – The 3rd screen in the wizard ap-
"Machine pre-sets" menu item with greyed out screens pears ("More settings")
173
13 Select function keys to be activated for
the profile in question using the adjus-
ting dial (18)
14 To activate the functions, press F4
"Select"
– An activated function key function
box.
"More settings" screen:

"Create jobs" function keys activated;
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 characteristic MIG/MAG synergic welding, MIG/MAG manual
point 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, optimizing and
managing jobs
Parameter access -
Backup Default machine settings
Restore Default machine settings
VR/LR calibration Default machine settings
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
If the "Parameter access" function is activated, the user can alter the values of the selected
parameter using the adjusting dial (18).
174
– The last screen in the wizard ap-
EN
pears ("Confirmation").
16 Press F2 "Done"
The "Profiles / Keys" screen appears with

the new profile.
Machine pre-sets - "Profiles / Keys" screen with new

profile
Opening/closing Select desired profile using the adjus-

1
profiles ting dial (18)
2 Press F2 "Open profile"
– The profile is opened, the keys as-
signed to the profile appear.
Machine pre-sets - "Profiles / Keys" screen - "Adminis-

175
3 To close the profile, press F2 "Close
profile"

trator" profile opened
The profile is closed.

Editing profile Select desired profile using the adjus-

1
ting dial (18)
2 Press F4 "Edit profile"
ars ("Change profile name").
Machine pre-sets - "Profiles / Keys" screen - "Welders"

profile selected
176
3 Press F3 "Change profile name" to ch-
ange the profile name
EN
– "Name profile" screen appears.
"Change profile name" screen

ter
– The new name is accepted, "Ch-
ange profile name" screen appe-
ars
"Name profile" screen
pears ("Menus and screens")
"Change profile name" screen
177
8 Select menu items and screens that
are to be changed using adjusting dial
(18)
IMPORTANT! The higher-level menu item

must also be activated in order to activate
screens.
9 Press F4 "Select" to activate a menu

item or screen
– An activated menu item or screen
box.
– In the case of menu items that
have not been activated, their
screens are greyed out.
"Menus and screens" screen
pears ("More settings")
11 Select function key functions that are

to be changed using adjusting dial (18)
12 To activate the functions, press F4
"Select"
– An activated function key function
box.
"More settings" screen
IMPORTANT! To activate function key functions, at least one higher-level menu item must
be activated:

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 characteristic MIG/MAG synergic welding, MIG/MAG manual
point 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, optimizing and
managing jobs
Parameter access -
Backup Default machine settings
Restore Default machine settings
VR/LR calibration Default machine settings
178
Factory Default machine settings
EN
Modify (UBST-IP) Default machine settings
Managing jobs Optimizing & managing jobs
Managing characteristics Optimizing & managing characteristics
Manage keys/profiles Default machine settings
If the "Parameter access" function is activated, the user can alter the values of the selected
parameter using the adjusting dial (18).
– The last screen in the wizard ap-
pears ("Confirmation").
14 Press F2 "Done"
The "Profiles / Keys" screen appears with

the new profile.
Machine pre-sets - "Profiles / Keys" screen with new

profile
179
Deleting profile Select desired profile using the adjus-
1
ting dial (18)
2 Press F5 "Delete profile"
ly want to delete the profile ... in-
cluding all associated keys?"
appears.
Machine pre-sets - "Profiles / Keys" screen - "TIG Wel-

ders" profile selected
3 Press F2 "Yes"
Precautionary query "Do you really want to delete the

profile ... including all associated keys?"
The selected profile is deleted, the "Profiles

/ Keys" screen appears.
Machine pre-sets - "Profiles / Keys" screen
180
Example profiles
EN
General For ease of reference, the lists in the following example profiles have been 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:

Main menu in the "Locked" profile
181
MIG/MAG welding Tasks:
specialist - Determining parameters for weld seams
- Create jobs
- Optimizing and managing jobs

Main menu in "MIG/MAG welding specialist" profile
182
Robot program- Tasks:
EN
mer - Establishing communication between robot control and welding machine
- Control function

Main menu in the "Robot programmer" profile
183
Welder/worker Tasks:
- Welding jobs
- Performing backups
- Simple maintenance, e.g. replacing welding torch wearing parts (gas nozzle, contact
tube, etc.), replacing feed rollers, wirespool

Main menu in the "Welder/worker" profile
184
Creating and editing keys
EN
Assigning key Using the adjusting dial (18), select the
1
cards to profiles profile to which a key card is to be as-
(key setup) signed
2 Press F1 "New key"
ars ("Enter name")
Machine pre-sets - "Profiles / Keys" screen - "MIG/

MAG Welders" profile selected
3 Press F3 "Name key"

"Enter name" screen

ter
– The new name is accepted, "Enter
name" screen appears
"Name key" screen
185

IMPORTANT! Do not duplicate any keys.

Assign one key card to each user.
"Enter name" screen
8 Hold the keycard to be registered up to

– Only when a key card has already
been registered does the "Error -
key already exists" screen appear
"Register transponder" screen
9 Press F3 "OK"
186
11 Press F2 "Done"
EN
Editing users/ Open profile to which the key to be al-

1
keys tered is assigned
2 Select corresponding key using the ad-
justing dial (18)
3 Press F2 "Edit key":
ars ("Change name")
"Profiles / Keys" screen - "Mr. Y" key selected
4 Press F3 "Name key" to change the

name:
"Change name" screen
187
ter
– The new name is accepted, "Ch-
ange name" screen appears
"Name key" screen

IMPORTANT! Do not duplicate any keys.

Assign one key card to each user.
"Change name" screen
9 Hold the keycard to be registered up to

– Only when a key card has already
been registered does the "Error -
key already exists" screen appear
"Change transponder" screen
188
10 Press F3 "OK"
EN
12 Press F2 "Done"
Deleting users/ Open profile to which the key to be al-

1
keys tered is assigned
2 Select corresponding key using the ad-
justing dial (18)
3 Press F4 "Delete key":
ly want to delete key ... ?" appears
"Profiles / Keys" screen - "Mr. Y" key selected
189
4 Press F2 "Yes"
Precautionary query "Do you really want to delete key

... ?"
The selected key is deleted, the "Profiles /

Keys" screen appears.
Machine pre-sets, "Profiles / Keys" screen
190
Logging registered users on and off at the remote
control unit
EN
General Using the key cards, users can log on and off at the RCU 5000i remote control unit.
Requirements:
The user's key card must be registered on the RCU 5000i remote control unit and assigned
to a profile.
If a user tries to log 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.
1 Hold the keycard up to the keycard

reader (16)
– The "Info Key - user logged in"
screen appears.
(16)
191
The last "Data" screen called up by the user
appears.
"Info Key - user logged in" screen
Displaying On the RCU 5000i remote control, logged-on users are shown in the information bar in the
logged on users "Data" screens, e.g.:
Machine pre-sets - "Profiles / Keys" screen - user "A2" Job welding, "Working parameters" screen, user "Mr.
logged on X" logged on;
"Working parameters" screen, function keys with no
function
192
Logging out a Hold the keycard up to the keycard
EN
1
user reader (16)
– The "Info Key - user logged in"
screen appears.
(16)
The "Locked" profile is activated.
"Info Key - user logged out" screen
Displaying If the "Locked" profile is activated on the RCU 5000i remote control, this is shown in the
"Locked" profile information bar in the "Data" screens, e.g.:
MIG/MAG synergic welding, "Welding program"

screen, "Locked" profile activated
193
RCU 5000i - Unlock function
General 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.
Activating the Disconnect the RCU 5000i from the

1
"Profile / Keys" welding system or switch off the wel-
screen using the ding system
Unlock function
2 Insert memory card in the RCU 5000i
3 Connect the RCU 5000i to the welding
system or switch on the welding sys-
tem
– The starting sequence is display-
ed for about 2 seconds.
4 Press the Info key during the starting
sequence
Starting sequence – The information "The unlock file

for your RCU 5000i has been cre-
ated on the SD card." is displayed.
5 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
The unlock file for your 5000i.
RCU 5000i has been
created on the SD card. 6 Take the memory card out of the RCU
5000i and transfer "UREQUEST.TXT"
to a PC or laptop (e.g. using a standard
card reader)
"Information - File has been created" screen
7 E-mail "UREQUEST.TXT" to the following address:

– welding.techsupport@fronius.com
– Fronius will reply by sending you an e-mail containing the text file "UAC-
CESS.TXT". This file also contains a number/letter code.
IMPORTANT! The "UACCESS.TXT" file can only be used once to unlock the "Profile /
Keys" screen in the machine pre-sets.
8 Copy "UACCESS.TXT" to the memory card
194
IMPORTANT! The name of the text file used to activate the "Profile / Keys" screen must
be "UACCESS.TXT".
EN
9 Disconnect the RCU 5000i from the
welding system or switch off the wel-
ding system
10 Insert memory card in the RCU 5000i
Your RCU 5000i has been
unlocked. 11 Connect the RCU 5000i to the welding
Please create a new system or switch on the welding sys-
Administrator key tem
– The RCU 5000i will recognise the
"UACCESS.TXT" text file and ch-
anges the "Locked" profile.
– The information message "Your
RCU 5000i has been unlocked ..."
is displayed.
"Information - RCU 5000i unlocked" screen
In the "Machine pre-sets" menu item...
Main menu in "Locked" profile - after being changed

using the Unlock function
the "Profile / Keys" screen can be selected.
"Profile / Keys" screen - after changing the "Locked"

profile using the Unlock function
195
If the "Locked" profile is selected, the chan-
ges can be displayed by pressing the F4
key "Change profile" and then pressing F2
"Forward":
"More settings" screen in the "Locked" profile after

"Menus and screens" screen in the "Locked" profile af- being changed using the Unlock function
ter being changed using the Unlock function
Further actions 1 Add new administrator key (see "Recommendation for creating profiles and keys" and
"Creating and editing keys")
2 Reset the "Locked" profile to the factory setting as described in "Example profiles"
(see "Creating profiles and keys")
196
Setting the language and units of measurement
EN
General In machine pre-sets, the following user languages are currently available for setting in the
"Language and units" screen:
German Dutch
English Chinese
French Japanese
Italian Korean
Spanish Slovenian
Czech Polish
Swedish Finnish
Portuguese (Brazil) Russian
In addition, the user can choose between metric (mm, kg, m/min, l, etc.) and imperial units
(in, lb, ipm, gal, etc.)
Setting the lan- Call up the "Machine pre-sets" menu

1
guage and units item
of measurement
2 Select "Language and units" screen by
pressing right arrow key (8)
– "Language and units" screen ap-
pears
parameter value
lighted.
Machine pre-sets: "Language and units" screen
197
Displaying version data
General As long as the RCU 5000i remote control is connected to a power source, the version data
for power source (UST), digital signal processor (DSP) and wire-feed unit (SR 41) as well
as for the remote control are shown in the "Version" screen.
Displaying ver- Call up the "Machine pre-sets" menu

1
sion data item
2 Select "Version" screen by pressing
– "Version" screen appears
– The version data are for display
V3.21.004 only and cannot be altered.
V4.0.123
V1.70.21
V1.03.18
Machine pre-sets: "Version" screen
198
Creating backup
EN
General With the "Backup" function, all data for the remote control can be saved:
- Current parameter settings
- Jobs
- User characteristics
- Set welding programs
- Default machine settings
- Documentation settings
- Set welding data, etc.
The backup is saved on the memory card. The file format used here "*.FBC" is not normally
visible.
Creating backup IMPORTANT! The memory card must not

be write-protected.
1 Insert the memory card into the memo-

ry card slot (24)
item
(24) 3 Using the right key (8) select a screen
that has "Backup" and "Restore" on
keys F1 and F2
"Backup"
– "Name backup" screen appears
Inserting the memory card
– The current date and time are pro-
posed as the backup name, e.g.:
03021116
Hour
Day
Month
Year

ter
"Name backup" screen
199
All data from the remote control unit are sa-
ved onto the memory card
"Backup" screen
200
Restoring data
EN
General With the "Restore" function, existing backups can be spooled back into the remote control:
The backup is transferred from the memory card to the remote control.
Restoring data Insert the memory card containing the

1
backup that is to be restored into the
memory card slot (24)
item
3 Using the right key (8) select a screen
that has "Backup" and "Restore" on
(24) keys F1 and F2
"Restore"
– The 1st screen in the wizard
("Restore from memory card") ap-
Inserting the memory card pears
5 Select corresponding backup using the

adjusting dial (18)
– The 2nd screen in the wizard
("Restore from memory card") ap-
pears
"Restore from memory card" screen
7 Select data that are to be restored

8 Press F4 "Select" to select the approp-
riate data (X in check box = selected)
– If "Complete" is selected, the
"User characteristics", "Jobs" and
"Profile / Keys" data are greyed
out and cannot be selected.
9 Press F2 "Done"
– The selected backup is transfer-
red to the remote control, the
"Restore" screen appears.
"Restore from memory card" screen
201
The last "Data" screen called up appears
"Restore" screen
202
Aligning wirefeeder or push-pull unit
EN
Aligning wire- Each time changes are made to the wirefeeder (e.g. replacing wire-guide liners), it must
feeder (VR align- be aligned.
ment)
item
3 Press F3 "VR alignment"
ars ("Disengage the wire")
4 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".
– The VR alignment is started, the
2nd in the wizard appears ("No-
load alignment")
"Disengage the wire" screen
Once VR alignment is complete, the 3rd

screen in the wizard appears "Confirmati-
on".
"No-load alignment" screen
203
6 Press F2 "Done":
"MIG/MAG" screen appears.
Aligning the The push-pull unit must be aligned prior to each initial start-up and each time the wirefeed-
push-pull unit 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.

item
3 Press F3 "VR alignment"
ars ("Select the push-pull motor")
204
4 Select corresponding push-pull motor
EN
pears ("Disengage the wire")
"Select the push-pull motor" screen
6 Follow the instructions given in the "Di-

sengage the wire" screen
– The VR alignment is started, the
3rd in the wizard appears ("No-
load alignment")
Once no-load alignment is complete, the

4th screen in the wizard appears "Engage
the wire".
205
8 Follow the instructions given in the
"Engage the wire" screen
CAUTION! Risk of injury from wire

electrode emerging at speed. Hold
the welding torch so that it points
away from your face and body.
9 Press F2 "Done":
– VR alignment is restarted, the 5th
screen in the wizard appears
("Alignment under load")
"Engage the wire" screen
Once VR alignment is complete, the 6th

screen in the wizard appears "Confirmati-
on".
"Alignment under load" screen
10 Press F2 "Done":
206
"MIG/MAG" screen appears.
EN
207
L/R alignment - aligning welding circuit inductivity
and welding circuit resistance
General If the following components on the welding machine are altered, welding circuit inductivity
(L) and resistance (R) must be aligned:
- Torch hosepacks
- Interconnecting hosepacks
- Grounding (earthing) cables, welding cables
- Wire-feed units
- Welding torches, electrode holders
- Push-pull units
NOTE! L/R alignment must be carried out separately for each welding process.
L/R alignment Call up the "Machine pre-sets" menu

1
item
– "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
3 Press F4 "L/R alignment"
Machine pre-sets: e.g. "MIG/MAG" screen – The 1st screen in the wizard appe-
ars ("Actual values")
pears ("Preparations")
"Actual values" screen
208
IMPORTANT! Contact between the earth-
ing clamp and workpiece must be estab-
EN
lished on a cleaned area of the workpiece.
5 Follow the instructions given in the

"Preparations" screen
– If TIG welding, place the tungsten
electrode instead of the contact
tube firmly in place.
– If rod electrode (MMA) welding,
place the electrode holder instead
of the contact tube firmly in place.
– L/R alignment is started, the 3rd
screen in the wizard appears
"Preparations" screen
("More settings")
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").
"L/R alignment" screen
7 Press F2 "Done":
209
The last "Data" screen called up appears
Machine pre-sets: e.g. "MIG/MAG" screen
210
RCU 5000i - Resetting to factory settings
EN
General The machine pre-sets for the remote control unit can be reset to the factory settings at any
time. This deletes all data.
It is recommended to create a backup of this data before resetting the remote control unit.
Resetting RCU Call up the "Machine pre-sets" menu

1
5000i to factory item
settings
appears
2 Press F5 "Factory":
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.
For example: "Version" screen with "Factory" button
3 Press F2 "Yes":
– The machine pre-sets on the re-
mote control unit are reset to the
factory settings.
Precautionary query: "Do you really want to reset all

user data?"
211
RCU 5000i - Updating software
Requirements The following programs are required for updating the RCU 5000i software:
- LocalNetUSB driver (on the "Software Tools" CD-ROM)
- BASICLoad software V2.83.2 or higher (on the "Software Tools" CD-ROM)
- Current RCU 5000i firmware (for registered TechGuide users, TechGuide Online:
http://www.fronius.com/techguide, or via Fronius customer service)
Before first up- 1 Insert the "Software Tools" CD-ROM into your computer's CD drive
date - installing If the CD-ROM does not open automatically, open CD-ROM
2
LocalNet USB
driver
Start page appears
"Software Tools" CD-ROM - start page
3 Select language
"Download Information" page appears
"Software Tools" CD-ROM - "Download Information" page
4 Select "Firmware RCU 5000i"
212
"Firmware RCU 5000i" page appears
EN
"Software Tools" CD-ROM - "Firmware RCU 5000i" page
5 Download "LocalNetUSB", save file to your PC's local drive

6 Run "LocalNetUSB.exe"
"WinZip Self Extractor - LocalNetUSB.exe" window appears
"WinZip Self Extractor - LocalNetUSB.exe" window
7 Select desired saving location using the "Browse" button

8 Click "Unzip"
"WinZip Self Extractor" confirmation appears, the LocalNetUSB driver is installed on

the PC
213
"WinZip Self Extractor" confirmation
9 Plug USB cable supplied into PC

10 Plug USB cable into USB 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
11 Click "Next>"
"Found New Hardware Wizard - Install Hardware Device Drivers" window appears
214
EN
"Found New Hardware Wizard - Install Hardware
Device Drivers" window
12 Select "Search for a suitable driver for my device (recommended)"

13 Click "Next>"
"Found New Hardware Wizard - Locate Driver Files" window appears
"Found New Hardware Wizard - Locate Driver

Files" window
14 Select "Specify a location"

15 Click "Next>"
"Found New Hardware Wizard - Insert ..." window appears
215
"Found New Hardware Wizard - Insert ..." window
16 Click "Browse" to select the location entered in point 7

17 Click the "OK" button
"Found New Hardware Wizard - Driver Files Search Results" window appears
"Found New Hardware Wizard - Driver Files

Search Results" window
18 Click "Next>"
"Completing the Found New Hardware Wizard" window appears
"Completing the Found New

Hardware Wizard" window
216
19 Click "Finish"
EN
The installation of the LocalNetUSB driver is complete
Before first up- 1 Select "BSL tool"

date - installing
BASICLoad soft-
ware
"Software Tools" CD-ROM - "Firmware RCU 5000i" page
"BSL Tool" page appears
"BSL Tool" CD-ROM
2 Download the latest version of "BASICLoad", save the file locally on your PC
3 Run "BASICLoad_V ... .exe"
"InstallShield Self-extracting EXE" window appears
"InstallShield Self-extracting EXE" window
217
4 Click "Yes"
Setup is prepared, "Setup" window appears
"Setup" window
After setup preparations are complete, the "BASICLoad V2.83.2" page and "Wel-
come" window appear
"BASICLoad V2.83.2" page, "Welcome" window
5 Click the "Next >" button
"Software License Agreement" window appears
"BASICLoad V2.83.2" page, "Software License Agreement" window
6 Read the contents of the "Software License Agreement" and accept
218
"User Information" window appears
EN
"BASICLoad V2.83.2" page, "User Information" window
7 Enter name and company

"Choose Destination Location" window appears
"BASICLoad V2.83.2" page, "Choose Destination Location" window
9 Select desired saving location using the "Browse" button

"Select Program Folder" window appears
219
"BASICLoad V2.83.2" page, "Select Program Folder" window
11 Enter desired folder name (existing folders are displayed)

Setup process runs, "Setup Complete" window appears
"BASICLoad V2.83.2" page, "Setup Complete" window
13 Click the "Finish" button
"BASICLoad-Setup V2.83.2 (c) FRONIUS ..." window appears
220
EN
"BASICLoad-Setup V2.83.2 (c) FRONIUS ..." window
14 Click OK, the installation is complete
RCU 5000i - Up- 1 Save current RCU 5000i software on your PC's local drive
dating software
IMPORTANT! Keep to the relevant version of the welding program database.
2 Plug USB cable supplied into PC

3 Plug USB cable into USB connection (25) on the remote control unit
NOTE! When updating software, saved jobs may become unusable due to
changed characteristics. It is recommended to create a backup of the data before
the update.
4 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
221
During the update procedure, the remote control unit LCD stays dark.
5 Unplug 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:
1.03.47
V3.21.004
V4.0.123
V1.70.21
Machine pre-sets: "Version" screen
222
Alphabetical overview of settable parameters
EN
Explanation
Adjustable parameters (Displayed on the power source)
Explanation or function of the parameter
Unit [Parameter unit, e.g.: m/min]
Range Setting range of the parameter, e.g. 0.5 - max.
"Minimum" and "maximum" are used for setting ranges that differ according to power
source, wire-feed unit, welding program, etc.
Parameters A - Z
Actual arc-length correction
for correcting the set arc length
Unit [%]
Range Depends on the "Arc-length corr. boundary" parameter in the "Correction
boundaries" screen, and the "Arc length correction" parameter in the "Work-
ing parameters" screen
Actual power correction (P)
Time during which the droplet detachment current is active
Unit [m/min]
Range depends on the parameters "Power corr. limit: High" and "Power corr. limit:
Low" in the "Correction boundaries" screen
Anti-Stick (ASt)
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)
Unit -
Range On/Off
Arc length correction (AL.1)
for correcting the arc length; as a SynchroPulse parameter it corrects
the arc length in the lower operating point (= mean wire feed speed
minus wire feed speed deviation)
Unit [%]
Range -30 - +30
Arc-break watchdog (Arc)
for presetting whether the arc-break watchdog is activated, or for pre-
setting the maximum duration of the arc break.
Unit [s]
Range Off/0.01 -2.00
Arc-length corr. boundary (AL.c)
for presetting the boundaries for correcting the arc length
Unit [%]
Range ± 0 - 30
Arc-length correction 2 (AL.2)
for correcting the arc length for SynchroPulse in the upper operating
point (= mean wire feed speed plus wire feed speed deviation)
Unit [%]
Range -30 - +30
223
Boost correction
for setting the boost value in the case of CMT characteristic C0878
Unit -
Range -5.0 - +5.0
Burn-back correction (bbc)
for setting burn-back time (= time between wire-feed unit stop and
current stop at end of welding)
Unit [s]
Range -0.2 - +0.2
Burn-back pulse current
Strength of current pulse set at end of welding. The current pulse when at the end of weld-
ing produces a defined detachment of the last drop (a wire end with a small droplet is a
precondition for good ignition). The parameter value must be greater than 0, otherwise
there will be no current pulse.
Unit [A]
Range 0 - max.
Burn-back time (bbc)
characteristic parameter for setting burn-back time (= time between
wire-feed unit stop and current stop at end of welding)
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 (Uco)
for presetting the burning voltage limit during MMA welding
Unit [V]
Range Off/5 - max.
Characteristic (Eln)
for setting the characteristic for electrode welding
Unit -
Range Constant current/0.1 - 20.0/constant power
Resistance value with which a drooping or neutral characteristic can be set.
Unit [μOhm]
Range 0 - 32767
CMT cycles
for setting the CMT cycles for a CMT/pulse characteristic
Unit -
Range 1 - 500
Comfort Stop sensitivity (CSS)
for presetting the comfort stop sensitivity
Unit [V]
Range Off / 0.5 -5
Cooling unit (C-C)
for presetting whether a cooling unit is to be switched on or off, or op-
erated automatically
Unit -
Range Off/On/Auto
224
Boost correction
for setting the boost value in the case of CMT characteristic C0878
EN
Unit -
Range -5.0 - +5.0
Burn-back correction (bbc)
for setting burn-back time (= time between wire-feed unit stop and
current stop at end of welding)
Unit [s]
Range -0.2 - +0.2
Burn-back pulse current
Strength of current pulse set at end of welding. The current pulse when at the end of weld-
ing produces a defined detachment of the last drop (a wire end with a small droplet is a
precondition for good ignition). The parameter value must be greater than 0, otherwise
there will be no current pulse.
Unit [A]
Range 0 - max.
Burn-back time (bbc)
characteristic parameter for setting burn-back time (= time between
wire-feed unit stop and current stop at end of welding)
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 (Uco)
for presetting the burning voltage limit during MMA welding
Unit [V]
Range Off/5 - max.
Characteristic (Eln)
for setting the characteristic for electrode welding
Unit -
Range Constant current/0.1 - 20.0/constant power
Resistance value with which a drooping or neutral characteristic can be set.
Unit [μOhm]
Range 0 - 32767
CMT cycles
for setting the CMT cycles for a CMT/pulse characteristic
Unit -
Range 1 - 500
Comfort Stop sensitivity (CSS)
for presetting the comfort stop sensitivity
Unit [V]
Range Off / 0.5 -5
Cooling unit (C-C)
for presetting whether a cooling unit is to be switched on or off, or op-
erated automatically
Unit -
Range Off/On/Auto
225
Current command value
a) reference current value for Q-Master values
b) current command value for operating the power source with constant welding current
in CC/CV mode
Unit [A]
Range min. - max.
Current decrease
With a standard arc, the current decrease parameter determines the speed at which the
short circuit current control changes to voltage control.
Unit -
Range 0 - 65535
Current decrease when pulse ends
The parameter describes the linear decrease of the current when pulsing ends.
Unit [A/ms]
Range 0 - 1000
in MIG/MAG standard manual welding, the current guideline value is normally determined
by trial and error or by performing a test weld; it has no 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 circuit)
The parameter describes how the current is ramped up in the case of a short circuit.
Unit [A/ms]
Range 0 - 1000
Current-rise (tau)
time of transition from a linear slope to the pulse current
Unit [ms]
Range 0-5
d_boostdown
for setting the linear current decrease rate following the boost phase for CMT character-
istics
Unit [A/ms]
Range 0 - 1000
d_boostup
for setting the linear current rise rate at the start of the boost phase for CMT characteris-
tics
Unit [A/ms]
Range 0 - 1000
226
d_I_base
linear droplet-detachment current decrease rate with CMT Advanced Pulse characteris-
EN
tics
Unit [A/ms]
Range 0 - max.
d_Ip1
linear pulse current rise rate [A/ms] with CMT Advanced Pulse characteristics
0.1 = no pulse current rise
2200 = maximum pulse current rise
d_Ip2
linear pulse current decrease rate [A/ms] with CMT Advanced Pulse
characteristics
0.1 = no decrease in pulse current
2200 = maximum pulse current drop
d_pulsdown
for setting the linear rate of decrease in the boost current for CMT/Pulse characteristics
Unit [A/ms]
Range 0 - 1000
d_pulsup
for setting the linear rate of rise in the boost current for CMT/Pulse characteristics
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 on the memory card
Unit -
Range On/Off
Droplet detachment current
The droplet detachment current is effective in the decreasing steep edge of a pulse, and
serves to produce the best droplet detachment. The droplet detachment current must be
greater than the base current, otherwise there is a risk of an arc break.
Unit [A]
Range 0 - max.
Droplet-detachment time
Time during which the droplet-detachment current is active
Unit [ms]
Range 0 - 50
227
Dynamic (dYn)
for dynamic correction in the case of standard arc (MIG/MAG manual
welding) or MMA welding
Unit -
Range 0 - 10
Dynamic correction (dYn)
for correcting the dynamic range in the case of a standard arc
Unit -
Range -0.5 - +5
EN_d_boostdown
for setting the linear current decrease rate following the boost phase for CMT Advanced
characteristics
Unit [A/ms]
Range 0 - 1000
EN_d_boostup
For setting the linear current rise rate at the start of the boost phase for CMT Advanced
characteristics
Unit [A/ms]
Range 0 - 1000
EN_I_boost
negative current set value during the boost phase for CMT 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 short circuit (CMT Advanced characteristics and CMT Ad-
vanced Pulse characteristics)
Unit [A]
Range 5.0 - 300.0
EN_t_I_boost
for setting the duration of the boost phase (how long the current set value is active in the
boost phase)
Unit [ms]
Range 0.00 - 99.98
EN_tau_boostdown
for setting the non-linear current decrease rate following the boost phase for CMT char-
acteristics
Unit [ms]
Range
228
EN_tau_boostup
for setting the non-linear current rise rate at the start of the boost phase for CMT charac-
EN
teristics
Unit [ms]
Range 0.08 - 5.00
EN_vd_sc_wait
for setting the wire feed speed following the boost phase until the dip-
ping of the wire electrode into the weld pool
Unit [m/min] [ipm]
Range 0.00 - 80.00 0 - 3,150
Every n seconds
for setting the period of time after which documentation is to occur
Unit [s]
Range Off/0.1 - 9.9
Every n-th seam
for setting the number of weld seams 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 (pi)
effect of deviations on the pulse current
Unit [%]
Range 0 - 50
Fact-I_p1 correction
effect of arc length correction on the pulse current
Unit [%]
Range 0 - 50
Feeder creep (Fdc)
for setting whether parameters will be entered internally or externally
Unit [m/min]
Range SFI/Auto/Off/0.5 - maximum
229
Feeder creep speed
for setting the speed of the wire feeder creep (characteristic parameters)
Unit [m/min]
Range 0.5 - max.
Final current Ie (I-E)
for setting the final current so that
a) heat build-up towards the end of welding is prevented and
b) the end-crater is filled (in the case of aluminium)
Unit [%]
Range 0 - 200
Final-current duration te (t-E)
for setting the linear current decrease rate following the boost phase
for CMT Advanced characteristics
Unit [s]
Range Off/0.1 - 9.9
Firewall IP
for assigning access rights to a specific power source for all comput-
ers on a local network
Unit -
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 (F)
for setting the frequency for SynchroPulse
Unit [Hz]
Range Off/0.5 -10
Gas factor (Cor)
for setting the correction factor when a different shielding gas is used
for the selected filler metal than the one programmed at the factory
(only where "Digital Gas Control" option is available)
Unit -
Range Auto/1 - 10
Gas post-flow (GPo)
for setting the gas post-flow time after the arc has extinguished
Unit [s]
Range 0 - 9.9
Gas pre-flow (GPr)
for setting the gas flow time before the arc is ignited
Unit [s]
Range 0 - 9.9
Gas set value (GAS)
for setting the set value for gas flow
Unit [l/min]
Range OFF/5 - 30
230
Gen. Parameter control
for setting whether parameters will be entered internally or externally
EN
Unit -
Range Internal/External
Ground current
characteristic parameters for setting the base current value, which is
maintained independently of the voltage
Unit [A]
Range min. - max.
Group number
various jobs are grouped together
Unit -
Range 0 - 99
The guideline value for material strength is normally established by trial and error or by
means of a test weld; it has no influence on the welding parameters
Unit [mm]
Range 0 - max.
Hot-current time Hti (Hti)
for setting the length of time the HotStart current is active
Unit [s]
Range 0-2
HotStart ALS
Arc Length Start - for setting an increased arc length for welding start-
up, for MIG/MAG synergic welding, standard welding process.
Unit [%]
Range 0 - 100
HotStart current HCU (HCU)
HotStart current - for setting the HotStart current for MMA welding
(e.g. for improved ignition properties)
Unit [%]
Range 0 - 100
HotStart pulse cycles
for setting the HotStart pulse cycles in the case of CMT characteristic C0875
Unit -
Range -5.0 - +5.0
HotStart time (a) ALt
Arc Length time - for preliminary setting of the time, during which for
MIG/MAG Synergic welding, standard welding process, the increased
arc length will be continually reduced to the currently set value of the
arc length.
Unit [s]
Range Off/0.05 -5.00
HotStart time (b) ALt
for setting the value for the HotStart time in the case of CMT charac-
teristics C0873, C0876 and C0877
Unit -
Range -5.0 - +5.0
231
I_base
current set value during the base current phase for CMT/Pulse and CMT Advanced Pulse
characteristics
Unit [A]
Range 5.0 - 300.0
I_boost
current set value during the boost phase for CMT characteristics
Unit [A]
Range 5.0 - 600.0
I_drop_melt
current set value for globule formation at the end of welding for CMT characteristics
Unit [A]
Range 3.0 - 500.0
I_ignition
set value for the ignition current set when welding begins (CMT char-
acteristics and CMT/pulse characteristics)
Unit [A]
Range 5.0 - 500.0
I_p1_
current set value during the pulse phase for CMT/pulse and CMT Advanced Pulse char-
acteristics
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
current set value with short circuit (CMT characteristics and CMT/pulse characteristics)
Unit [A]
Range 5.0 - 300.0
Ignition current
for setting the ignition current
Unit [A]
Range min. - max.
for setting the time during which the ignition current is active
Unit [ms]
Range 0 - 40
Ignition time-out (Ito)
for presetting the wire length at which safety cut-out occurs
Unit [mm]
Range Off/5 -100
232
Increment
to specify whether the part number will be incremented manually or by job
EN
Unit -
Range manual / job
IP address
for setting the IP address for a specific power source in the local network. The IP address
provides for unique identification of the power source
Unit -
Job documentation
for activating/deactivating the documentation function for a selected job
Unit -
Range On/off/per job
Job number (Job)
to distinguish between individual jobs, they are saved with a number
Unit -
Range 0 - 999
Job trigger
for setting the job number that will cause the part number to be incremented when that
job is selected.
Unit -
Range 0 - 999
JobMaster special display (Gun)
for presetting whether the special display for JobMaster is to be
switched on or off
Unit -
Range Off/1
Jobslope (JSL)
defines the time between the job that is currently selected and the
next job
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-
acteristics
Unit [%]
Range 0 - 100
k_I_p1_reg_delta_max
upper control limit for the pulse current Ip1 with CMT Advanced Pulse characteristics
Unit [A]
Range 0 - max.
k_I_p1_reg_delta_min
lower control limit for the pulse current Ip1 with CMT Advanced Pulse characteristics
Unit [A]
Range 0 - max.
k_I_p1_reg_gain
the effect of the control deviation on the pulse current with CMT Ad-
vanced Pulse characteristics
Unit [%]
Range 0 - 100
233
k_Vd_reg_gain
the effect of the deviation on the wire feed speed with CMT Advanced Pulse characteris-
tics
Unit [%]
Range 0 - 100
Language
for presetting the language used by the remote control
Unit -
Range Deutsch/English/Francais/Italiano/Espanol/Cesky/Svenska/Portugues
Limit output
for activating/deactivating the transmission of a limit signal by the remote control to the
robot control
Unit -
Range Off/On
Lower current limit
for setting the lower current limit with reference to the set value
Unit [A]
Range 0 - -100
Lower voltage limit
for setting the lower 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 voltage deviation)
for setting the maximum duration of a voltage deviation
Unit [s]
Range Off/0.1 - 9.9
(maximum duration of current deviation)
for setting the maximum duration of a current deviation
Unit [s]
Range Off/0.1 - 9.9
Maximum duration of current exceed
for setting the maximum duration of a current exceed on the main wire-feed unit
Unit [s]
Range Off/0.1 - 9.9
234
Maximum duration of wire feed speed deviation
for setting the maximum duration of a wire feed speed deviation
EN
Unit [s]
Range Off/0.1 - 9.9
Maximum main motor current
for setting the maximum permitted motor current on the main wire-feed unit
Unit [A]
Range 0.0 - 9.9
Maximum PPU motor current
for setting the maximum permitted motor current on a push-pull unit
Unit [A]
Range 0.0 - 9.9
Mean wire feed speed
refers to the specified value for wire feed speed (see also wire feed speed)
Unit [m/min]
Range min. - max.
Month
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 expression with a maximum length of 20 characters
Part number counter
for activating the part counter function
Unit -
Range Off/On
Polarity
for setting the polarity for MMA welding
Unit -
Range Plus/minus
Positive_weldstart_cycles
Number of positive weld start cycles with CMT Advanced characteristics
Unit -
Range -
235
Power-corr. limit: High (PcH)
for presetting the upper power correction limit
Unit [%]
Range -20 - +20
Power-corr. limit: Low (PcL)
for setting the lower power correction limit
Unit [%]
Range 0 - -20
Power-sharing control (P-C)
for presetting whether the power-sharing control is to be switched on
or off
Unit -
Range Off/On
Process
for selecting the welding process for the arc
Unit -
Range Standard/pulse/CMT
Puls_cycles
for setting the pulse cycles for a CMT/pulse characteristic
Unit -
Range 0 - 500
Pulse correction (dYn)
for correcting the pulsing range of a pulsed arc
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 setting the fre-
quency of the pulsed arc
Unit [Hz]
Range 1.2 - 500
Pulse frequency
characteristic parameter for setting the frequency of the pulsed arc
Unit [Hz]
Range 2 - 1000
Reaction
for setting the reaction, when Q-Master values are exceeded
Unit -
Range none/warning/switch-off
236
Function for removing slag at the end of the wire electrode for CMT characteristics
EN
Unit -
Range -
Slope 1 Sl1 (SL)
for setting the time during which the starting current is decreased to
the welding current
Unit [s]
Range 0.1 - 9.9
Slope 2 Sl2 (SL)
for setting the time during which the welding current is decreased to
the final current
Unit [s]
Range 0.1 - 9.9
Special 2-step mode (S2t)
for presetting the special 2-step mode (= selecting jobs and groups
via the welding torch trigger)
Unit -
Range normal/1
Special 4-step mode (S4t)
for presetting the special 4-step mode (= switching from one job to the
next using the "JobMaster" welding torch)
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 (SPt)
duration of the spot-welding process
Unit [s]
Range 0.1 - 5
Standard (SEt)
for presetting the units standard used by the remote control
Unit -
Range metric/inch/lb/gallon
Starting current ls (I-S)
for setting the starting current for MIG/MAG welding (e.g. aluminium
welding start-up)
Unit [%]
Range 0 - 200
Starting-current dur. ts (t-S)
for setting the length of time the starting current is active
Unit [s]
Range Off/0.1 - 9.9
237
Subnet mask
Network-specific parameter of a local network; allocated on-site by the relevant network
administrator
Unit -
Summary_weldstart_cycles
Total number of weld start cycles
Unit -
Range -
t_base
for setting the length of time that the current command value is active in the base current
phase for CMT/pulse characteristics
Unit [ms]
Range 0.00 - 99.98
t_burnback
for setting the duration of the currentless wire retract after the welding current has been
switched off
Unit [ms]
Range 0.00 -200.02
t_hotstart
for setting the 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 setting the pulse current phase for CMT/pulse and CMT Advanced Pulse characteris-
tics
Unit [ms]
Range 0.00 - 50.02
t_p2
the length of time the droplet-detachment current is active with CMT Advanced Pulse
characteristics
Unit [ms]
Range 0 - 50
Current-drop (tau)
Time of transition from a linear slope to the droplet-detachment current.
Unit [ms]
Range 0-5
238
tau_boostdown
for setting the non-linear current decrease rate following the boost phase for CMT char-
EN
acteristics
Unit [ms]
Range
tau_boostup
for setting the non-linear current rise rate at the start of the boost phase for CMT charac-
teristics
Unit [ms]
Range 0.08 - 5.00
tau_I_base
Time of transition from a linear ramp to the base current.
Unit [ms]
Range 0-5
tau_Ip1
non-linear pulse current rise rate [ms] with CMT Advanced Pulse characteristics
Unit -
Range -
tau_Ip2
non-linear pulse current decrease rate [ms] with CMT Advanced Pulse characteristics
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 (Fdi)
for setting the wire feed speed at which the welding wire is fed into the
torch hosepack
Unit [m/min]
Range min. - max.
Time
for presetting the time in the date display
Unit -
Range hh:mm:ss (the time can only be set in its entirety)
Trigger mode
for setting the welding torch operating mode
Unit -
Range 2-step, special 2-step, 4-step, special 4-step, spot welding (MIG/MAG syn-
ergic welding)
2-step, 4-step, spot welding (MIG/MAG manual welding)
239
Twin-Control (t-C)
defines the lead power source in the "TimeTwin Digital" process; only
shown when there is an active LHSB link and when Twin software en-
abling is available on both power sources
Unit -
Range Off/On
Type of arc
when optimising characteristics, documents the arc type determined during the test weld:
dip transfer arc, spray arc, long arc, intermediate arc; has no influence on the welding pa-
rameters
Unit -
Range Short/long/spray/globular
U_hotstart
for setting the change in the arc length when welding starts
Unit [V]
Range 10.00 - 40.00
U_set_puls
voltage set value for the arc length control with characteristic optimisation 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 setting the wire feed speed before the start of welding for CMT characteristics
Unit [m/min] [ipm]
Range -30.00 - +30.00 -1,180 - +1,180
Vd_pulscycle
for setting the wire feed speed during the duration of the CMT/pulse characteristics
Unit [m/min] [ipm]
Range 0.00 - 45.00 0 - 1,770
Vd_sc_wait
for setting the wire feed speed following the boost phase until the dipping of the wire elec-
Unit [m/min] [ipm]
Range 0.00 - 80.00 0 - 3,150
240
The voltage guideline value is normally determined by trial and error or by performing a
EN
test weld. On power sources TS 4000/5000 and TPS 2700/4000/5000, the voltage guide-
line value corresponds to the voltage on the contact tip; it has no influence on the welding
parameters
Unit [V]
Range 0 - max.
Voltage set value
a) reference voltage for Q-Master values
b) voltage set value for the standard arc when optimising characteristics
c) voltage set value for operating the power source with constant welding voltage in CC/
CV mode
Unit [V]
Range min. - max.
Welding current
for MMA welding
Unit [A]
Range 0 - max.
Welding voltage
For MIG/MAG standard manual welding
Unit [V]
Range 0 - max.
Wire feed speed deviation (dFd)
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.
Unit [m/min]
Range min. - max.
Wire feed speed
for setting the wire feed speed for MIG/MAG synergic welding, MIG/MAG standard man-
ual welding and in CC/CV mode
Unit [m/min]
Range min. - max.
Wire-end cut-out (FCO)
for pre-setting whether the wire end will stop immediately at the end
of a seam, or not at all
Unit -
Range none/end of seam/immediately
Wire-stick control (Stc)
for presetting whether the wire-stick control is to be switched on or off
(wire stick control checks whether the welding wire sticks after weld-
ing)
Unit -
Range Off/On
Year
for presetting the year in the date display
Unit -
Range 1996 - 2095
241
242
Appendix
Spare parts list: RCU 5000i
244
245
246
247
FRONIUS INTERNATIONAL GMBH
Froniusplatz 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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Spare parts list: RCU 5000i ....................................................................................................................... 244

WARNING! Indicates a potentially dangerous situation. Death or serious injury

CAUTION! Indicates a situation where damage or injury could occur. If it is not

Proper use includes:

Special regulations apply in rooms at risk of fire or explosion

Device concept The RCU 5000i remote control is intended

RCU 5000i remote control

Application areas The RCU 5000i remote control unit is used

Advantages - Clear layout thanks to LCD

Options RCU 5000i bracket

In the USA, RFID modules are subject to FCC certification:

Industry Canada RSS

This device complies with Industry Canada licence-exempt RSS stand-

(5) (10) (11) (12) (13) (14) (4)

Function keys with varying functions

Example: border around F1 "Store as job" Example: border around F2 "Forward"

(21) (20) (19)

RCU 5000i front view - controls, connections

(22) Bracket ... 0-95° hinged holder and

(23) (23) (22) (23)

RCU 5000i rear view - controls, mechanical compo-

Main menu The individual activities are highlighted in

A "clothesline" is assigned to every menu

Main menu display

"Clothesline" The "clothesline" principle:

MIG/MAG synergic welding

Example of "clothesline" with 5 data records (A - E) - "Working parameters" open

Screen "Working parameters"

(1) Menu items

Example: "Data" screen

(1) Screen identifying character (9) Time

(1) Dark border

(6) (7) (8)

(1) Dark border

(1) (2) (3) (4) (1) Current screen, shown in grey

(5) (6) (7)

(1) (2) (3) (4) (1) Current screen, shown in grey

VR 4000 VR 7000 TPS 2700

1 To preset the language and measure-

Starting sequence, F3 "Language"

2 Select the corresponding parameters

Machine pre-sets: "Language and units" screen, lan-

Main menu in the selected language

Error "073 (no The non-resettable error "073 (no Host)"

Possible causes are, for example, poor

Once an active link is established, error

The error "073 (no Host)" can be ignored.

"Error 073 (no Host)" screen

Locking the RCU Hold the keycard up to the keycard

Holding the keycard up to the keycard reader

The "Info Key - The remote control unit is

"Info Key - The remote control unit is now locked"

Main menu in the "Locked" profile

Various menu items and functions can be

"MIG/MAG synergic welding" menu item in locked re-

Unlocking the Hold the keycard up to the keycard

Holding the keycard up to the keycard reader

"Info Key - The remote control is now unlocked" screen

Call up "MIG/MAG Press the "Menu" button (1):

Main menu: "MIG/MAG synergic welding" menu item

Overview "MIG/MAG synergic welding" is composed of the following sections:

MIG/MAG synergic welding: "Welding program"