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RCU 5000i
Operating Instructions
Spare parts list
EN
Remote control
42,0426,0021,EN 004-03112017
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Dear reader,
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.
EN
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Contents
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
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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
Setting working parameters .................................................................................................................. 48
Trigger modes....................................................................................................................................... 48
Switching to extra-large display ................................................................................................................. 49
General ................................................................................................................................................. 49
Switching to extra-large display ............................................................................................................ 49
Setting process settings parameters.......................................................................................................... 50
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
Setting working parameters .................................................................................................................. 61
Switching to extra-large display ............................................................................................................ 62
Setting process settings parameters..................................................................................................... 62
TIG welding................................................................................................................................................ 63
Call up "TIG welding" menu item .......................................................................................................... 63
Setting working parameters .................................................................................................................. 63
Switching to extra-large display ............................................................................................................ 64
CC/CV mode.............................................................................................................................................. 65
General ................................................................................................................................................. 65
Call up "CC/CV mode" .......................................................................................................................... 65
Setting working parameters .................................................................................................................. 65
Switching to extra-large display ............................................................................................................ 66
Setting process settings parameters..................................................................................................... 66
Job welding ................................................................................................................................................ 67
Call up the "Job welding" menu item .................................................................................................... 67
Setting working parameters for a job .................................................................................................... 67
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Switching to extra-large display ............................................................................................................ 68
Changing the welding process during CMT Advanced welding............................................................ 68
Saving settings as a job ............................................................................................................................. 69
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
General ................................................................................................................................................. 96
Purpose of QMaster values .................................................................................................................. 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
................................................................ 96
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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
Guideline values ................................................................................................................................... 117
Accepting voltage and current guideline values.................................................................................... 117
Parameters of CMT characteristics............................................................................................................ 118
General ................................................................................................................................................. 118
Ignition .................................................................................................................................................. 118
CMT parameters ................................................................................................................................... 119
End of welding ...................................................................................................................................... 120
Guideline values ................................................................................................................................... 120
Accepting voltage and current guideline values.................................................................................... 121
Parameters of CMT / pulse characteristics ................................................................................................ 122
General ................................................................................................................................................. 122
Ignition .................................................................................................................................................. 122
Overview: CMT parameters, pulse parameters .................................................................................... 123
CMT parameters ................................................................................................................................... 123
Pulsing parameters ............................................................................................................................... 124
CMT/Pulsed .......................................................................................................................................... 124
End of welding ...................................................................................................................................... 125
Guideline values ................................................................................................................................... 125
Accepting voltage and current guideline values.................................................................................... 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
Guideline values ................................................................................................................................... 129
Accepting voltage and current guideline values.................................................................................... 130
Parameters of CMT/Pulsed Advanced characteristics............................................................................... 131
General ................................................................................................................................................. 131
Ignition .................................................................................................................................................. 131
Hotstart ................................................................................................................................................. 131
Overview: CMT parameters, pulse parameters .................................................................................... 132
CMT parameters ................................................................................................................................... 132
Pulsing parameters ............................................................................................................................... 133
Pulsed/CMT cycles ............................................................................................................................... 135
End of welding ...................................................................................................................................... 135
Guideline values ................................................................................................................................... 135
Changing characteristic parameters .......................................................................................................... 137
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The process controller .......................................................................................................................... 137
Screens displayed for different characteristics ..................................................................................... 137
Changing characteristic parameters ..................................................................................................... 138
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
Purpose of 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 .........................................................................................
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
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Safety rules
EN
Explanation of
safety symbols
General
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
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 required.
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 operating 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 being used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident prevention 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 safety.
This is for your personal safety!
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Proper use
The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer 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 manufacturer accepts no responsibility for any damage caused through use in a domestic
setting.
Environmental
conditions
Obligations of the
operator
Operation or storage of the device outside the stipulated area will be deemed
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 substances, etc.
Can be used at altitudes of up to 2000 m (6500 ft)
The operator must only allow persons to work with the device who:
- 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
personnel
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Before using the device, all persons instructed to do so undertake:
- 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.
EMC Device Classifications
Devices in emission class A:
- 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 supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
EN
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 rectify 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 connection, additional measures are necessary (e.g. use a suitable line filter).
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 approaching 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
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Safety measures
at the installation
location and during transport
A device toppling over could easily kill someone. Place the device on a solid,
level surface such that it remains stable
- The maximum permissible tilt angle is 10°.
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 protection 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 guidelines 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 damage before commissioning. Any damage must be repaired by trained service
technicians before commissioning the device.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
- 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 immediately.
- 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.
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Safety symbols
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 relevant standards for Canada and the USA.
EN
Data protection
Copyright
The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal
settings.
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 purchaser. 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.
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General
Device concept
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.
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 characteristics.
Connection to the power source takes place 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.
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 equipment
Options RCU 5000i bracket
The RCU 5000i remote control unit is equipped with the following as standard:
- 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"
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
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 < 65dBA/m @10m
Dimensions l / w / h 258 / 180 / 48 mm
10.16 / 7.09 / 1.89 in.
Weight 1.5 kg
3.31 lb
EN
Information on radio certification
FCC Compliance
The RCU 5000i remote control is fitted with an RFID module (Radio Frequency Identification). The RFID module is for wireless and non-contact data transmission using the keycard (transponder card). Data transmission takes place via a magnetic field.
In the USA, RFID modules are subject to FCC certification:
FCC ID: QKWRF5000I
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 interference at his own expense.
Functions not described
Industry Canada RSS
This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device
may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device.
NOTE! Owing to software updates, you may find that your machine has certain
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
(15)
)8()9(
(16)
(1)
(2)
(14)(13)(12)(11)(10)
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
)4()5(
(3)
(7)
(6)
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
(12) F3 key ... function key
(13) F4 key ... function key
(14) F5 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
(16) Keycard reader ... for identifying different access rights granted by means of a key-
card
EN
Information on
OK key
The OK key (3) aids the user in selecting the various function key functions.
If there is a border around a function key function, this function can be selected by pressing
OK (3).
(1)
Example: border around F1 "Store as job" Example: border around F2 "Forward"
(2)
(1) Frame
19
Other controls,
connections, mechanical components
(17)
(18)
(21)
RCU 5000i front view - controls, connections
)91()02(
(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
20
(23) (22) (23)(23)
RCU 5000i rear view - controls, mechanical components
(25) (24)
RCU 5000i side view - connections
(24) Memory card slot
(25) USB port... for connecting to a PC,
e.g. for software updates
EN
21
Operating concept
Activities - orientation
Main menu
Operation instructions for the RCU 5000i remote control unit are divided according to activities.
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
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)
Example of "clothesline" with 5 data records (A - E) - "Working parameters" open
(8)
22
The RCU 5000i remote control uses the "clothesline" principle as follows:
- -All parameters, displays and functions required for a selected activity are sorted according to the order in the "clothesline".
- 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.
EN
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)
(3) F3 "Select"
(1)
item selected
(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 represented 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)
(1)
(3)
Example: "Data" screen
(11)
(12)
(13)
(14)
(15)
(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"
EN
"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) Completed steps
(1)
(3)(4)
(2)
(5)
(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"
screen
The "Dialogue" screen is used for showing subdialogues.
The "Dialogue" screen may contain hierarchical structures, pick lists, etc.
(1) Dark border
(2) F1 "Accept"
(1)
(2) (3)
Example: "Dialogue" screen with "Accept" and "Cancel"
(3) F5 "Cancel"
"Message"
screen
The "Message" screen displays certain statuses. The message must be acknowledged, or
a decision must be taken.
The "Message" screen appears in front of part of the current screen. This makes the current 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 current screen turn grey.
26
(1) (2) (3) (4) (5)
(6)
Example: "Error" screen
(1) Current screen, shown in grey
(2) Symbol
(3) Error code
(4) Error description
(5) Dark border
(6) F3 "OK"
EN
(2) (3)
(5) (6)
Example: "Error" screen with function keys "Reset"
and "Ignore"
(4)(1)
(1) Current screen, shown in grey
(2) Symbol
(3) Error description
(4) Dark border
(5) F2 "Reset"
(6) F3 "Ignore"
27
Start-up
Before commissioning
System requirements
Connecting RCU
5000i
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following operating instructions:
- Remote control unit,
- Power source,
- Wirefeeders.
The following firmware is required on the power source to be able to operate the RCU
5000i remote control unit:
OFFICIAL UST V 3.20.1
The RCU 5000i remote control unit can be connected to any LocalNet socket on the welding machine, e.g.:
VR 4000 VR 7000
TPS 2700
TS/TPS 4000-5000
VR 1500
LocalNet connection socket on VR 4000, VR 7000 and
VR 1500
LocalNet connection socket on TPS 2700 and TS/TPS
4000-5000
Procedure:
Switch the power source mains switch to the “0” position
1
Plug the remote control unit LocalNet plug into the LocalNet connection socket
2
Tighten the union nut on the plug
3
Move the power source mains switch to the "I" position - the remote control is ready,
4
the starting sequence appears
28
Starting sequence - language setting
The following appear on the display during the starting sequence:
- Fronius logo (centre)
- 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.
To preset the language and measure-
1
ment units, press F3 "Language"
– Machine pre-sets "Language and
units" screen appears
EN
Starting sequence, F3 "Language"
Machine pre-sets: "Language and units" screen, language selected
Select the corresponding parameters
2
using down (6) or up (7) keys
Alter the parameter value with the ad-
3
justing dial (18)
Press the "Menu" button (1)
4
29
Main menu in the selected language
Main menu appears in the selected language
Error "073 (no
Host)" - No connection to the
power source
The non-resettable error "073 (no Host)"
appears if the remote control cannot
connect to the power source during commissioning.
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
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