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TransSteel 2700c MultiProzess
TransSteel 2700c MV MultiProzess
TransSteel 3500c MultiProzess
Operating Instructions
MIG/MAG Power source
EN-US
[
42,0426,0322,EA 007-22062020
2
Table of contents
Safety Instructions ..................................................................................................................................... 7
Explanation of Safety Instructions......................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 7
Environmental Conditions..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 8
Grid Connection.................................................................................................................................... 8
Personal Protection and Protection of Others....................................................................................... 9
Danger from toxic gases and vapors .................................................................................................... 9
Danger from Flying Sparks ................................................................................................................... 10
Risks from grid current and welding current ......................................................................................... 10
Stray welding currents .......................................................................................................................... 11
EMC Device Classifications.................................................................................................................. 12
EMC Measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 13
Particular Hazard Areas........................................................................................................................ 13
Requirement for the shielding gas ........................................................................................................ 14
Danger from Shielding Gas Cylinders................................................................................................... 14
Danger Posed by Shielding Gas Leak.................................................................................................. 14
Safety Measures at the Setup Location and During Transport............................................................. 15
Safety Measures in Normal Operation.................................................................................................. 15
Maintenance and repair ........................................................................................................................ 16
Safety Inspection .................................................................................................................................. 16
Disposal ................................................................................................................................................ 16
Safety Symbols..................................................................................................................................... 17
Data backup.......................................................................................................................................... 17
Copyright............................................................................................................................................... 17
EN-US
General information 19
General ...................................................................................................................................................... 21
Device Concept..................................................................................................................................... 21
Available welding processes................................................................................................................. 21
Operating Principle ............................................................................................................................... 22
Applications........................................................................................................................................... 23
Warning notices on the device.............................................................................................................. 23
Description of Warning Notices on the Device...................................................................................... 25
System components .................................................................................................................................. 27
General ................................................................................................................................................. 27
Safety.................................................................................................................................................... 27
Overview............................................................................................................................................... 27
Operating controls and connections 29
Control Panel ............................................................................................................................................. 31
General ................................................................................................................................................. 31
Safety.................................................................................................................................................... 31
Synergic control panel .......................................................................................................................... 32
Service parameters............................................................................................................................... 35
Keylock ................................................................................................................................................. 36
Connections, Switches, and Mechanical Components .............................................................................. 37
TSt 2700c MP ....................................................................................................................................... 37
TSt 3500c MP ....................................................................................................................................... 38
Installation 41
Minimum equipment for welding operations .............................................................................................. 43
General ................................................................................................................................................. 43
Gas-cooled MIG/MAG welding ............................................................................................................. 43
3
Water-cooled MIG/MAG welding .......................................................................................................... 43
Manual metal arc welding ..................................................................................................................... 43
TIG DC Welding.................................................................................................................................... 43
Before installation and initial operation ...................................................................................................... 44
Safety.................................................................................................................................................... 44
Intended Use......................................................................................................................................... 44
Setup regulations.................................................................................................................................. 44
Grid Connection.................................................................................................................................... 45
Generator-Powered Operation................................................................................................................... 46
Generator-Powered Operation.............................................................................................................. 46
TSt 2700c MV MP - Single-Phase Operation ............................................................................................ 47
Single-phase operation......................................................................................................................... 47
Explanation of the Term "Duty Cycle" in Single-Phase Operation........................................................ 49
Welding time in single-phase operation................................................................................................ 50
Connecting the Mains Cable...................................................................................................................... 51
General ................................................................................................................................................. 51
Stipulated Grid Cables and Strain-Relief Devices ................................................................................ 51
Connecting the Grid Cable, TSt 2700c MV, Single-Phase Operation................................................... 51
Connecting the Grid Cable, TSt 2700c MP MV .................................................................................... 53
Connecting the Grid Cable, TSt 3500c nc MP...................................................................................... 54
Fitting/Connecting the System Components.............................................................................................. 56
Information on System Components..................................................................................................... 56
Mounting on the Trolley ........................................................................................................................ 56
Connecting the Gas Cylinder................................................................................................................ 57
MIG/MAG 59
Commissioning .......................................................................................................................................... 61
General ................................................................................................................................................. 61
Connecting MIG/MAG Welding Torches............................................................................................... 61
Inserting/Changing Feed Rollers .......................................................................................................... 62
Inserting the Wirespool/Basket-Type Spool.......................................................................................... 63
Connecting the Gas Cylinder................................................................................................................ 64
Connecting the Polarity Reverser and Establishing a Ground Earth Connection ................................ 65
Feeding in the wire electrode................................................................................................................ 66
Setting the contact pressure ................................................................................................................. 68
Adjusting the Brake............................................................................................................................... 69
Design of the Brake .............................................................................................................................. 69
Power Limitation ........................................................................................................................................ 70
Safety function ...................................................................................................................................... 70
MIG/MAG Operating Modes ...................................................................................................................... 71
General ................................................................................................................................................. 71
Symbols and explanations.................................................................................................................... 71
2-step mode.......................................................................................................................................... 72
4-step mode.......................................................................................................................................... 72
Special 4-step mode ............................................................................................................................. 73
Spot welding ......................................................................................................................................... 73
2-step stitch welding ............................................................................................................................. 74
4-step stitch welding ............................................................................................................................. 74
MIG/MAG Standard Synergic Welding ...................................................................................................... 75
MIG/MAG Standard Synergic Welding ................................................................................................. 75
Corrections During Welding.................................................................................................................. 76
MIG/MAG Standard Manual Welding......................................................................................................... 77
General ................................................................................................................................................. 77
Available parameters ............................................................................................................................ 77
MIG/MAG Standard Manual Welding.................................................................................................... 77
Corrections During Welding.................................................................................................................. 78
Spot and Stitch Welding............................................................................................................................. 79
General ................................................................................................................................................. 79
Spot Welding......................................................................................................................................... 79
Stitch Welding....................................................................................................................................... 80
Rod Electrode 81
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Commissioning .......................................................................................................................................... 83
Safety.................................................................................................................................................... 83
Preparation ........................................................................................................................................... 83
Manual Metal Arc Welding ......................................................................................................................... 85
Manual Metal Arc Welding.................................................................................................................... 85
Functions for Optimizing the Welding Process .......................................................................................... 86
Arc-Force Dynamic ............................................................................................................................... 86
HotStart (Hti) function ........................................................................................................................... 86
Anti-stick (Ast) function ......................................................................................................................... 86
TIG 87
Commissioning .......................................................................................................................................... 89
Start-up ................................................................................................................................................. 89
TIG Welding ............................................................................................................................................... 91
TIG Welding.......................................................................................................................................... 91
Pulse welding............................................................................................................................................. 92
Applications........................................................................................................................................... 92
Operating principle................................................................................................................................ 92
Activating pulse welding........................................................................................................................ 93
EasyJobs 95
Saving and Retrieving EasyJobs ............................................................................................................... 97
General ................................................................................................................................................. 97
Saving an EasyJob ............................................................................................................................... 97
Retrieving an EasyJob.......................................................................................................................... 97
Deleting an EasyJob............................................................................................................................. 97
Retrieving operating points on the Up/Down welding torch .................................................................. 98
EN-US
Setup Settings 99
Setup Menu................................................................................................................................................ 101
General ................................................................................................................................................. 101
Operation .............................................................................................................................................. 101
Parameters for MIG/MAG Standard Synergic Welding......................................................................... 102
Parameters for MIG/MAG Standard Manual Welding........................................................................... 104
Parameters for MMA Welding............................................................................................................... 105
Parameters for TIG welding.................................................................................................................. 106
Setup Menu 2nd Level ............................................................................................................................... 107
Limitations............................................................................................................................................. 107
Operation (Setup Menu 2nd Level)....................................................................................................... 107
Parameters for MIG/MAG Standard Synergic Welding (Setup Menu 2nd Level) ................................. 109
Parameters for MIG/MAG Standard Manual Welding (Setup Menu 2nd Level) ................................... 111
Parameters for stick welding (SMAW) .................................................................................................. 113
Parameters for TIG Welding (Setup Menu 2nd Level).......................................................................... 114
Measuring the Welding Circuit Resistance r .............................................................................................. 116
General ................................................................................................................................................. 116
Measuring the welding circuit resistance (MIG/MAG welding).............................................................. 116
Displaying the Welding Circuit Inductivity L ............................................................................................... 118
General ................................................................................................................................................. 118
Displaying the welding circuit inductivity............................................................................................... 118
Laying the Hosepacks Correctly ........................................................................................................... 118
Troubleshooting and Maintenance 119
Troubleshooting ......................................................................................................................................... 121
General ................................................................................................................................................. 121
Safety.................................................................................................................................................... 121
Troubleshooting .................................................................................................................................... 121
Displayed Service Codes...................................................................................................................... 124
Service, maintenance and disposal ........................................................................................................... 130
General ................................................................................................................................................. 130
Safety.................................................................................................................................................... 130
5
At every start-up.................................................................................................................................... 130
Whenever Required.............................................................................................................................. 130
Every 2 Months..................................................................................................................................... 130
Every 6 Months..................................................................................................................................... 131
Disposal ................................................................................................................................................ 131
Appendix 133
Technical data............................................................................................................................................ 135
Special Voltage..................................................................................................................................... 135
Explanation of the Term Duty Cycle ..................................................................................................... 135
TSt 2700c MP ....................................................................................................................................... 136
TSt 2700c MV MP................................................................................................................................. 138
TSt 3500c MP ....................................................................................................................................... 140
Welding program tables ............................................................................................................................. 142
TSt 2700c MP welding program table................................................................................................... 142
TSt 2700c MP USA welding program table .......................................................................................... 143
TSt 3500c MP welding program table................................................................................................... 144
TSt 3500c MP USA welding program table .......................................................................................... 145
6
Safety Instructions
EN-US
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized safety standards. If used incorrectly or misused, however, it can cause
- Injury or death to the operator or a third party
- Damage to the device and other material assets belonging to the operating company
- Inefficient operation of the equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the Operating Instructions for the device.
Before switching on the device, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
7
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage
resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Obligations of the
Operating Company
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current
8
All persons who are assigned to work with the device must do the following before beginning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
consumption.
This may affect a number of device types in terms of:
- connection restrictions
- criteria regarding maximum permissible grid impedance
- criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
EN-US
Personal Protection and Protection of Others
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Danger from toxic
gases and vapors
Keep persons, especially children, away during the operation of the devices and during the
welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from
the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
9
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow
rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the mea-
sured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
Danger from Flying Sparks
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-
tected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums,
or pipes if these have not been prepared in accordance with corresponding national and
international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/
were stored. Residues pose a risk of explosion.
Risks from grid
current and welding current
10
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed roll-
ers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180°
around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- Never immerse it in liquids to cool it
- Never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same time
may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Protection class I devices require a grid with a ground conductor and a connector system
with ground conductor contact for proper operation.
EN-US
Stray welding
currents
Operation of the device on a grid without a ground conductor and on a socket without a
ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for
any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched on again by
applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply.
If work is needed on voltage-carrying parts, bring in a second person who will switch off the
main switch at the correct time.
If the following instructions are not observed, stray welding currents may occur, which pose
a risk of the following:
- Fire
- Overheating of components connected to the workpiece
- Destruction of ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece terminal is securely connected to the workpiece.
Secure the workpiece terminal as close to the spot to be welded as possible.
11
Position the device with sufficient insulation against electrically conductive environments,
e.g., insulation against electrically conductive floors or electrically conductive mounts.
Observe the following when using electrical distributors, double-headed retainers, etc.:
Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire
drum, large spool or wirespool to the wirefeeder with insulation.
EMC Device Classifications
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
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 grid.
EMC device classification as per the rating plate or technical data.
sions, 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 operating company is obliged to take appropriate action to rectify
the situation.
Test and assess the immunity of equipment in the vicinity of the device in accordance with
national and international provisions. Examples of interference-prone equipment that could
be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
12
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
EN-US
Particular Hazard
Areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- fans
- gears
- rollers
- shafts
- wirespools and welding wires.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury (cuts
to the hand, facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder) and
use suitable protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective
equipment when reworking workpieces and ensure that other persons are sufficiently protected.
Leave the welding torch and other parts with a high operating temperature to cool before
working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting
connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting devices by crane.
- Attach chains or ropes to all designated attachments of the suitable load-carrying
equipment.
- Chains or ropes must be the smallest angle possible from vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
13
In the event of crane attachment of the wirefeeder during welding, always use a suitable,
insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane, counterbalanced lift
truck or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g. for mechanical damage, corrosion,
or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is
used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the
shielding gas connection adapter on the device side before installation.
Requirement for
the shielding gas
Danger from
Shielding Gas
Cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment and
reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding
gas cylinders are an integral part of the welding equipment, so they must be handled very
carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.
Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Danger Posed by
Shielding Gas
Leak
14
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct
matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders
and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.
Follow the manufacturer's instructions and applicable national and international provisions
for shielding gas cylinders and accessories.
Risk of asphyxiation due to uncontrolled shielding gas leak
Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in
the event of leakage.
- Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least
20 m³ per hour.
- Please observe the safety and maintenance information for the shielding gas cylinder
or the main gas supply.
- When no welding is taking place, close the valve of the shielding gas cylinder or the
main gas supply.
- Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.
EN-US
Safety Measures
at the Setup Location and During
Transport
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
Only set up and operate the device in accordance with the protection class shown on the
rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Before transporting the device, completely drain the coolant and dismantle the following
components:
- wirefeeder
- wirespool
- shielding gas cylinder
Safety Measures
in Normal Operation
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before commissioning. Have any damage repaired by trained service
technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- 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
Safety devices that are not fully functional must be repaired before the device is switched
on.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by crane.
15
Only the original coolant from the manufacturer is suitable for use in our devices due to its
properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manufac-
turer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in cer-
tain conditions. Only transport the coolant in closed original containers and keep away from
sources of ignition.
Properly dispose of used coolant according to national and international regulations. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
Maintenance and
repair
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
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.
every 12 months.
The manufacturer recommends calibrating power sources within the same 12-month inter-
val.
A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
16
be returned to your dealer, or you must locate the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Safety Symbols Devices with the CE label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards of the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive 2014/53/EU.
The full text of the EU Declaration of Conformity is available on the following website: http:/
/www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
EN-US
Text and illustrations were accurate at the time of printing. Fronius reserves 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 Operating Instructions, we will be most grateful for your comments.
17
18
General information
General
EN-US
Device Concept
Available welding processes
The TransSteel (TSt) 2700c MP and TSt
3500c MP power sources are fully digitized,
microprocessor-controlled inverter power
sources.
A modular design and easy ability to extend
the system guarantee a high degree of flexibility. The devices are designed for the
welding of steel.
The following welding processes are available on the power sources:
MIG/MAG welding
TSt 2700c MP TSt 3500c MP
21
Manual metal arc welding
TSt 2700c MP TSt 3500c MP
TIG welding with touchdown ignition
Operating Principle
TSt 2700c MP TSt 3500c MP
The central control and regulation unit of the power sources is coupled with a digital signal
processor. The central control and regulation unit and signal processor control the entire
welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired status is
maintained.
The device has a "Power limitation" safety feature. This means that the power source can
be operated at the power limit without compromising process safety.
This results in:
- A precise welding process,
- A high degree of reproducibility on all results
- Excellent weld properties.
22
Applications The devices are used in trade and industry for manual applications with classical steel and
galvanized sheets.
The TSt 2700c MP is primarily used in light-gage steel sheet (light steelwork) applications.
Repair, maintenance, and assembly work in shipyards, automotive suppliers, workshops
or the furniture construction industry are among the typical application areas. The TSt
2700c MP power source thus positions itself in its power category between the trade/workshop and the industry sector.
The TSt 3500c MP power source is designed for:
- Mechanical and equipment engineering
- Steel construction
- Plant and container construction
- Metal and portal construction
- Rail vehicle construction
EN-US
Warning notices
on the device
There are warning notices and safety symbols on the power sources. These warning notices and safety symbols must not be removed or painted over. They warn against incorrect
operation, as this may result in serious injury and property damage.
Safety symbols on the rating plate:
40,0006,3035
TSt 3500c MP
inside
TSt 2700c MP
23
Welding is dangerous. The following basic requirements must be met:
- Adequate welding qualifications
- Appropriate protective equipment
- Exclusion of unauthorized people
Do not use the functions described here until you have fully read and understood the following documents:
- These Operating Instructions
- All system component Operating Instructions, especially the safety rules
24
Description of
AB
Warning Notices
on the Device
On certain device versions, warning notices are attached to the device.
The arrangement of the symbols may vary.
Warning! Watch Out!
There are possible hazards as shown by the symbols.
A Drive rolls can injure fingers.
B Welding wire and drive parts are at welding voltage during operation
Keep hands and metal objects away.
EN-US
1. Electric shock can kill.
1.1 Wear dry insulating gloves. Do not touch electrode with bare hand. Do not wear
wet or damaged gloves.
1.2 Protect yourself from electric shock by insulating yourself from work and ground.
1.3 Disconnect input plug or power before working on machine
2. Breathing welding fumes can be hazardous to your health.
2.1 Keep your head out of the fumes.
2.2 Use forced ventilation or local exhaust to remove the fumes.
2.3 Use ventilating fan to remove fumes.
25
3 Welding sparks can cause explosion or fire.
xx,xxxx,xxxx *
3.1 Keep flammables away from welding. Don’t weld near flammables.
3.2 Welding sparks can cause fires.Have a fire extinguisher nearby and have a watch-
person ready to use it.
3.3 Do not weld on drums or any closed containers.
4. Arc rays can burn eyes and injure skin.
4.1 Wear hat and safety glasses. Use ear protection and button shirt collar. Use weld-
ing helmet with correct shade of filter. Wear complete body protection.
26
5. Become trained and read the instructions before working on the machine or weld-
ing.
6. Do not remove or paint over (cover) the label.
* identifying number to order label from manufacturer
System components
General The power sources can be operated with various system components and options. This
makes it possible to optimize procedures and to simplify machine handling and operation,
depending on the field of application for the power source.
EN-US
Safety
Overview
WARNING!
Danger due to incorrect operation.
This can result in severe personal injury and damage to property.
► Do not use the functions described here until you have fully read and understood the
Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions of the system components, especially the safety rules.
(1)
(2)
(3)
(6)
(4)
TSt 2700c MP
No. Function
(1) MIG/MAG welding torch
(2) Stabilization of the gas cylinder holder
(3) Power source
(4) Trolley and gas cylinder holder
(5) Grounding and electrode cable
(6) TIG welding torch
(5)
27
(1)
(2)
(3)
(7)
(6)
TSt 3500c MP
No. Function
(1) MIG/MAG welding torch
(2) Stabilization of the gas cylinder holder
(3) Power source
(4) Cooling unit
only TSt 3500c
(5) Trolley and gas cylinder holder
(6) Grounding and electrode cable
(7) TIG welding torch
(4)
(5)
28
Operating controls and connections
Control Panel
General The functions are all arranged in a logical way on the control panel. The individual param-
eters required for welding can be
- easily selected using buttons
- changed using buttons or the selection dial
- shown on the digital display during welding
The power source uses the Synergic control panel and certain general items of data such
as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored expert knowledge is available at all times. All the parameters can be corrected manually. The Synergic control panel also allows entirely
manual configuration of parameters.
NOTE!
Because of software updates, certain functions may be available for your device but
not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your
device. However, the function of these operating elements is identical.
EN-US
Safety
WARNING!
Danger from incorrect operation and work that is not carried out properly.
Serious personal injury and damage to property may result.
► Read and understand this document.
► Read and understand all the Operating Instructions for the system components, espe-
cially the safety rules.
31
Synergic control
(1) (2) (3) (4)(5) (6) (7)
(17)
(16)
(15) (14) (13) (12) (11)
(10)
(8)
(9)
panel
No. Function
(1) "Parameter selection" button (left)
For selecting the following welding parameters and for changing parameters in the
Setup menu
The relevant symbol lights up when a welding parameter is selected.
Sheet thickness in mm or in.
If the welding current to be selected is not known, it is sufficient to enter the
sheet thickness. The required welding current and any other parameters
marked with *) will then be adjusted automatically.
Welding current in A *)
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Wire speed in m/min or ipm
*)
32
(2) SF - spot/stitch welding indicator
lights up if a value has been entered for the spot/interval welding time Setup parameter (SPt) (spot or stitch welding operating mode is enabled)
(3) Left digital display
(4) HOLD indicator
At the end of each welding operation, the actual values for welding current and
welding voltage are stored - the "HOLD" indicator lights up.
(5) Intermediate arc indicator
A spatter-prone "intermediate arc" occurs between the dip transfer arc and the
spray arc. The intermediate arc indicator lights up to alert you to this critical area.
(6) Right digital display
(7) "Parameter selection" button (right)
For selecting the following welding parameters and for changing parameters in the
Setup menu
The relevant symbol lights up when a welding parameter is selected.
Arc length correction
For correcting the arc length
EN-US
Welding voltage in V *)
Before welding begins, the device automatically displays a standard value
based on the programmed parameters. The actual value is displayed during
welding.
Arc-force dynamic
For influencing the short-circuiting dynamic at the moment of droplet transfer
- ... Harder and more stable arc
0 ... Neutral arc
+ ... Soft and low-spatter arc
Real Energy Input
For displaying the energy applied during the welding operation. **)
(8) Selection dial (left)
For changing the sheet thickness, welding current and wire speed parameters and
for changing parameters in the Setup menu
(9) Selection dial (right)
For changing the arc length correction, welding voltage and arc-force dynamic parameters and for changing parameters in the Setup menu
(10) "Save" buttons (Easy Job)
For saving up to 5 operating points
(11) "Process" button
For selecting the welding process
MANUAL - MIG/MAG standard manual welding
SYNERGIC - MIG/MAG standard synergic welding
Manual metal arc welding
TIG welding
33
(12) "Mode" button
For selecting the operating mode
2 T - 2-step mode
4 T - 4-step mode
Special 4-step mode
Spot welding/stitch welding
(13) "Shielding gas" button
For selecting the shielding gas used. The SP parameter is reserved for additional
shielding gases.
The LED next to the selected shielding gas lights up.
(14) "Wire diameter" button
For selecting the wire diameter used. The SP parameter is reserved for additional
wire diameters.
The LED next to the selected wire diameter lights up.
(15) "Material" button
For selecting the filler metal used. The SP parameter is reserved for additional materials.
The LED next to the selected filler metal lights up.
(16) "Wire threading" button
Press and hold the button:
gasless wire threading into the torch hosepack
While the button is being held, the wire drive operates at feeder inching speed.
(17) Gas-test button
For setting the required gas volume on the gas pressure regulator.
Tap button once: shielding gas flows out
Tap button again: shielding gas flow stops
If the Gas-test button is not tapped again, the shielding gas flow will stop after 30 s.
*) In the MIG/MAG standard synergic welding process, if one of these parameters is
selected, then the synergic function ensures that all other parameters, including
the welding voltage parameter, are adjusted automatically.
**) The Real Energy Input indicator must be activated in level 2 of the Setup menu –
EnE parameter. The value continuously rises during welding in line with the permanently increasing energy input. The final value is stored after welding ends until
welding starts again or the power source is switched back on - the HOLD indicator
lights up.
34
Service parame-
231
ters
Various service parameters can be retrieved by pressing the "Parameter selection" buttons
at the same time.
Opening the display
Press and hold the "Parameter selection" button (left)
1
Press the "Parameter selection" button (right)
Release the "Parameter selection" buttons
The first parameter "Firmware version" will be displayed, e.g., "1.00 | 4.21"
Selecting parameters
Use the "Mode" and "Process" buttons or the left-hand selection dial to select the required setup parameter
EN-US
/
Available parameters
Example: 1.00 | 4.21
Firmware version
Example: 2 | 491
Welding program configuration
Example: r 2 | 290
Number of the currently selected welding program
Example: iFd | 0.0
Motor current for wire drive in A
The value changes as soon as the motor is running.
Example: 654 | 32.1 = 65 432.1 h = 65 432 h 6 min
Indicates the actual arc time since first use
Note: The arc time indicator is not suitable as a basis for calculating hiring fees or for warranty purposes, etc.
2nd
2nd menu level for service technicians
35
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the
control panel. As long as the keylock is active
- settings cannot be adjusted on the control panel
- only parameter settings can be retrieved
- any assigned "Save" button can be retrieved provided that an assigned "Save" button
was selected when the keylock was enabled
Activate/deactivate the keylock as follows:
Press and hold the "Mode" button
1
Press the "Parameter selection" button (right)
2
Release the "Mode" and "Parameter selection" buttons
3
Keylock activated:
The message "CLO | SEd" appears on the displays.
Keylock deactivated:
The message "OP | En" appears on the displays.
36
Connections, Switches, and Mechanical Compo-
nents
TSt 2700c MP
(11)
*
EN-US
(6)
(5)
(4)
(7)
(1) (2) (3)
* Side panel not shown
(1) LocalNet connection
Standardized connection for remote control
(2) Welding torch connection
For connecting the welding torch
(3) TIG Multi Connector
For connecting the TIG welding torch
(4) (+) Current socket with bayonet latch
Used for
- Connecting the polarity reverser or grounding cable for MIG/MAG welding (de-
pending on the wire electrode used)
- Connecting the electrode cable or grounding cable for MMA welding (depending
on the type of electrode used)
- Connecting the grounding cable for TIG welding
(8)
(10)
(9)
(13)(12)
(5) (-) Current socket with bayonet latch
Used for
- Connecting the grounding cable or polarity reverser for MIG/MAG welding (de-
pending on the wire electrode used)
- Connecting the electrode cable or grounding cable for MMA welding (depending
on the type of electrode used)
- Connecting the TIG welding torch
(6) Polarity reverser
For selecting the welding potential on the MIG/MAG welding torch
(7) MIG/MAG shielding gas connection socket
For the shielding gas supply to the welding torch connection (2)
(8) TIG shielding gas connection socket
For the shielding gas supply for the (-) current socket (5)
(9) Grid cable with strain relief device
Not prefitted on all models
37
TSt 3500c MP
(10) Power switch
For switching the power source on and off
(11) LED wirespool interior lighting
with the setup parameter LED the turn-off time is adjustable
(12) Wirespool holder with brake
For holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a
max. weight of 19 kg (41.89 lbs.)
(13) 4-roller drive
(7)
*
(6)
(5)
(10)
(11)
(4)
(3)
(1) (2)
* Side panel not shown
(8) (9)
(13)(12)
(1) (-) Current socket with bayonet latch
Used for
- Connecting the grounding cable or polarity reverser for MIG/MAG welding (de-
pending on the wire electrode used)
- Connecting the electrode cable or grounding cable for MMA welding (depending
on the type of electrode used)
- Connecting the TIG welding torch
38
(2) Welding torch connection
For connecting the welding torch
(3) TIG Multi Connector
For connecting the TIG welding torch
(4) Power switch
For switching the power source on and off
(5) LocalNet connection
Standardized connection for remote control
(6) (+) Current socket with bayonet latch
Used for
- Connecting the polarity reverser or grounding cable for MIG/MAG welding (de-
pending on the wire electrode used)
- Connecting the electrode cable or grounding cable for MMA welding (depending
on the type of electrode used)
- Connecting the grounding cable for TIG welding
(7) Polarity reverser
For selecting the welding potential on the MIG/MAG welding torch
(8) MIG/MAG shielding gas connection socket
For the shielding gas supply to the welding torch connection (2)
(9) TIG shielding gas connection socket
For the shielding gas supply for the (-) current socket (5)
(10) EASY DOCUMENTATION label
(11) Grid cable with strain relief device
Not prefitted on all models
(12) Wirespool holder with brake
For holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a
max. weight of 19 kg (41.89 lbs.)
(13) 4-roller drive
EN-US
39
40
Installation
Minimum equipment for welding operations
General Depending on the welding process, a minimum level of equipment is required to work with
the power source.
The following describes the welding processes and the corresponding minimum equipment for welding operations.
EN-US
Gas-cooled MIG/
MAG welding
Water-cooled
MIG/MAG welding
Manual metal arc
welding
- Power source
- Grounding cable
- Gas-cooled MIG/MAG welding torch
- Gas connection (shielding gas supply)
- Wire electrode
- Power source
- Cooling unit including coolant
- Grounding cable
- Water-cooled MIG/MAG welding torch
- Gas connection (shielding gas supply)
- Wire electrode
- Power source
- Grounding cable
- Electrode support
- Rod electrode
TIG DC Welding - Power source
- Grounding cable
- TIG welding torch with or without rocker switch
- Gas connection (shielding gas supply)
- Filler metal depending on application
43
Before installation and initial operation
Safety
Operating the device incorrectly can cause serious injury and damage to property.
► Do not use the functions described here until you have fully read and understood the
► Do not use the functions described here until you have fully read and understood all of
An electric shock can be fatal.
If the power source is connected to the grid during installation, there is a danger of serious
personal injury and property damage.
► Only carry out work on the device when the power source's power switch is in the - O
► Only carry out work on the device when the power source has been disconnected from
Intended Use The power source is only intended for MIG/MAG, MMA and TIG welding. Any other use is
deemed to be "not in accordance with the intended purpose." The manufacturer shall not
be liable for any damage resulting from such improper use.
WARNING!
Operating Instructions.
the Operating Instructions of the system components, especially the safety rules.
WARNING!
- position.
the grid.
Intended use also means:
- Following all instructions in the Operating Instructions
- Carrying out all the specified inspection and maintenance work
Setup regulations The device has been tested according to degree of protection IP 23. This means:
- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49
in.)
- Protection against spraywater at any angle up to 60° from the vertical
The device can be set up and operated outdoors in accordance with degree of protection
IP 23.
Direct moisture (e.g., from rain) must be avoided.
WARNING!
Toppling or falling devices can be deadly.
► Place devices on a solid, level surface so that they remain stable.
WARNING!
Danger of electrical current due to electrically conductive dust in the device.
This can result in severe personal injury and damage to property.
► Only operate the device if an air filter is fitted. The air filter is a very important safety
device for achieving IP 23 protection.
44
The ventilation channel is a very important safety device. When selecting the setup location, ensure that the cooling air can enter or exit unhindered through the vents on the front
and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed
to be sucked into the device.
Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the mains cable
or mains plug has not been attached to your version of the appliance, these must be installed according to national standards. Fuse protection for the grid lead can be found in
the technical data.
CAUTION!
An inadequately dimensioned electrical installation can lead to serious damage.
► The grid lead and its fuse protection should be designed to suit the existing power sup-
ply. The technical data on the rating plate should be followed.
EN-US
45
Generator-Powered Operation
Generator-Powered Operation
The power source is generator-compatible.
The maximum apparent power S
of the power source must be known in order to select
1max
the correct generator output.
The maximum apparent power S
Three-phase devices: S
Single-phase devices: S
I
and U1 according to the device rating plate and technical data
1max
1max
1max
= I
= I
The generator apparent power S
of the power source is calculated as follows:
1max
x U1 x √3
1max
x U
1max
GEN
1
needed is calculated using the following rule of
thumb:
S
GEN
= S
1max
x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power S
apparent power S
of the power source!
1max
must not be less than the maximum
GEN
When single phase devices are being operated with a 3-phase generator, note that the
stated apparent power of the generator is often just the total that can be present across all
three phases of the generator. If necessary, obtain further information about the singlephase power of the generator from the generator manufacturer.
NOTE!
The voltage delivered by the generator must never fall outside of the mains voltage
tolerance range.
The mains voltage tolerance is specified in the "Technical Data" section.
46
TSt 2700c MV MP - Single-Phase Operation
EN-US
Single-phase operation
As an alternative to three-phase operation, the multivoltage variant (MV) of the power
source enables a welding operation with limited power or duration from just a single-phase
supply. The maximum possible welding power is limited by the dimensioning of the mains
fuse protection, which determines the safety cut-out of the power source.
If the grid lead has a 20 A or 30 A fuse, the FUS parameter may be changed to 20 A or 30
A. Welding with a higher maximum power or for longer periods is therefore possible. The
FUS welding parameter can be found in the Setup menu 2nd level and can be set when
the US setting is enabled or a single-phase supply is being used (SEt welding parameter
set to US).
In order to use the power source in single-phase operation, the following prerequisite must
be fulfilled:
- Correct single-phase power source supply in accordance with the chapter "Installation" section "Connecting the mains cable" from page 51.
The following table shows which grid voltages and fuse ratings limit the welding current in
single-phase operation:
47
Grid voltage
Fuse rating
230 V
10 A
230 V
13 A
230 V
16 A
240 V
15 A
240 V
20 A
240 V
30 A
D.C. = Duty cycle
Welding process D.C.
[%]
MIG/MAG
Rod electrode
TIG
MIG/MAG
Rod electrode
TIG
MIG/MAG
Rod electrode
TIG
MIG/MAG
Rod electrode
TIG
MIG/MAG
Rod electrode
TIG
MIG/MAG
Rod electrode
TIG
40
100 *
40
100 *
35
100 *
40
100 *
40
100 *
35
100 *
40
100 *
40
100 *
35
100 *
40
100 *
40
100 *40125
35
100 *
40
100 *
40
100 *
35
100 *
40
100 *
40
100 *
35
100 *
Welding current limitation [A]
160
100
140
100
180
120
170
120
140
120
210
150
180
145
150
130
220
170
180
145
220
170
200
160
180
140
260
180
220
170
180
140
260
180
48
* The 100% values relate to welding with no time limits and without cooling breaks.
The welding current data applies at an ambient temperature of 40 °C (104 °F).
At a grid voltage of 240 V and a fuse rating of 30 A, the maximum value of 220 A is possible
for MIG/MAG welding with a duty cycle of 40% for example.
In single-phase operation, a safety cut-out prevents the fuse from tripping at higher welding
powers. The safety cut-out is active at fuse ratings of 15 A, 16 A and 20 A and determines
the possible welding duration, without the fuse being tripped. If the precalculated weld time
is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immediately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again. After this time, the message
disappears, and the power source is ready for operation again.
At a fuse rating of 30 A, the temperature monitoring for the power source ensures the weld-
t (min:s)1:30 2:30 6:30 7:30 9 1045
I (A)
180 A
ing current is promptly switched off. A service code from "to1" to "to7" is displayed. Detailed
information on the service codes "to1" to "to7" can be found in the "Troubleshooting" chapter under "Displayed service codes". If there is no fault or the cooling components are not
dirty, then the device will be ready for welding again after an appropriate welding pause.
EN-US
Explanation of
the Term "Duty
Cycle" in SinglePhase Operation
For single-phase operation, the "Technical Data" chapter specifies duty cycle values as a
function of the fuse rating and the welding current. Although the percentages of these duty
cycle values are also based on the ten-minute cycle explained in the "Technical Data"
chapter for general duty cycles, the cooling phase of the fuse, however, is calculated at
approx. 60 s only. Afterwards, the power source is once again ready for use.
Due to technical standards, in single-phase operation, the duty cycle is only specified up
to the end (switch off) of the first welding cycle. If the relationship to the ten-minute cycle
normally used when specifying the duty cycle was also established with respect to the cooling phases, in practice there would be longer welding phases than those stated. The values are actually based on cooling phases of approx. 60 s only, after which the power
source is ready for further use.
The following example shows the welding and pause cycles as defined in the relevant standards, with a welding current of 180 A and a duty cycle of 15%.
49
Welding time in
single-phase operation
The following diagram shows the possible welding time in accordance with standards, depending on the fuse rating and welding current.
t (min)
11
10
9
8
7
6
5
4
3
2
1
(1) (2) (3) (4) (5)
130120 140 150 160 170 180 190 200 I2 (A)
(1) 10 A mains fuse protection (2) 13 A mains fuse protection (3) 15 A mains fuse protection
(4) 16 A mains fuse protection (5) 20 A mains fuse protection
50
Connecting the Mains Cable
General A strain-relief device for the following cable cross-sections is fitted to the power source:
Power source Cable cross-section
Canada / US Europe
TSt 2700c MP AWG 14 to AWG 6 *) 4G2.5
TSt 3500c MP AWG 12 *) 4G2.5
*) Canada / US cable type: Extra-hard usage
Strain-relief devices for other cable cross-sections must be designed accordingly.
EN-US
Stipulated Grid
Cables and
Strain-Relief Devices
Connecting the
Grid Cable, TSt
2700c MV, SinglePhase Operation
Power source Grid voltage Cable cross-sec-
tion
Canada / US
TSt 2700c MP 1 x 230 / 240 V AWG 14 (15 A) *) 3G2.5 (16 A)
TSt 2700c MP 1 x 240 V AWG 12 (20 A) *) TSt 2700c MP 1 x 240 V AWG 12 (30 A) *) TSt 2700c MP 3 x 200 V AWG 12 4G2.5
TSt 2700c MP 3 x 230 / 240 V AWG 14 4G2.5
TSt 2700c MP 3 x 380 / 400 V AWG 14 *) 4G2.5
3 x 460 V AWG 14 *) 4G2.5
TSt 3500c MP 3 x 380 / 400 V AWG 12 *) 4G2.5
3 x 460 V AWG 12 *) 4G2.5
*) Canada / US cable type: Extra-hard usage
The item numbers of the different cables can be found in the Spare Parts List.
American Wire Gauge
If no grid cable is connected, a grid cable that is suitable for the connection voltage must
be fitted before commissioning.
CAUTION!
Europe
If no ferrules are used, there is a risk of injury and damage from short circuits between the phase conductors or between the phase conductors and the ground conductor.
► Fit ferrules to all phase conductors and the ground conductor of the stripped grid cable.
The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase
conductors.
51
1 2
2
3
2
NL2
L1
4
1
3,5 Nm
TX25
1
1
1
1
1
3 4
1
5
5
IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.
TX25
2
2
1
2
2
2
2
52
Connecting the
2
4
Grid Cable, TSt
2700c MP MV
If no grid cable is connected, a grid cable that is suitable for the connection voltage must
be fitted before commissioning.
CAUTION!
If no ferrules are used, there is a risk of injury and damage from short circuits between the phase conductors or between the phase conductors and the ground conductor.
► Fit ferrules to all phase conductors and the ground conductor of the stripped grid cable.
The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase
conductors.
1 2
1
3,5 Nm
EN-US
TX25
1
1
1
1
1
3 4
1
3
53
5
2
5
Connecting the
Grid Cable, TSt
3500c nc MP
TX25
2
2
2
2
2
1
2
IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.
If no grid cable is connected, a grid cable that is suitable for the connection voltage must
be fitted before commissioning.
CAUTION!
If no ferrules are used, there is a risk of injury and damage from short circuits between the phase conductors or between the phase conductors and the ground conductor.
► Fit ferrules to all phase conductors and the ground conductor of the stripped grid cable.
The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase
conductors.
1 2
1
54
3 4
1,2 Nm
4
3
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
EN-US
55
Fitting/Connecting the System Components
Information on
System Components
Mounting on the
Trolley
The steps and activities described below include references to various system components, such as
- Trolley
- Cooling units (TSt 3500c only)
- Welding torches, etc.
For more detailed information about installing and connecting the system components,
please refer to the appropriate Operating Instructions for the system components.
WARNING!
Work performed incorrectly can cause serious injury and damage.
► The following activities must only be carried out by trained and qualified personnel.
► Please note the information in the "Safety instructions" chapter!
The following diagram shows an overview of how the individual system components are
put together.
For detailed information about the individual steps, please refer to the corresponding Operating Instructions for the system components.
56
TSt 2700c MP TSt 3500c MP
Connecting the
3
Gas Cylinder
WARNING!
Danger of severe injury and damage to property if gas cylinders fall over.
When using gas cylinders:
► Place them on a solid, level surface in such a way that they remain stable
► Secure the gas cylinders to prevent them from falling over
► Fit the optional wirefeeder holder
► Follow the gas cylinder manufacturer's safety rules.
EN-US
TSt 2700c MP TSt 3500c MP
Secure the gas cylinder with a strap
1
Briefly open the gas cylinder valve to remove any dust or dirt
2
Inspect the seal on the gas pressure regulator
NOTE!
US devices (TSt 3500c only) are supplied with an adapter for the gas hose:
► Seal the outside thread on the gas solenoid valve using suitable means before screw-
ing on the adapter.
► Test the adapter to ensure that it is gas-tight.
57
58
MIG/MAG
Commissioning
4
*
*
3
6
7
8
5
5
EN-US
General
Connecting MIG/
MAG Welding
Torches
WARNING!
Operating the device incorrectly can cause serious injury and damage to property.
► Do not use the functions described here until you have fully read and understood the
Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions of the system components, especially the safety rules.
The device is started up by pressing the torch trigger (for manual applications).
NOTE!
When connecting the welding torch, check that
► all connections are connected properly
► all cables, leads and hosepacks are undamaged and correctly insulated.
1
1
* The TSt 3500c MP can be optional-
ly equipped with a cooling unit.
Coolant hoses are only available on
water-cooled welding torches.
61
Inserting/Chang-
2
1
4
4
5
6
3
2
3
8
6
7
9
3
1
2
2
5
4
4
4
ing Feed Rollers
CAUTION!
Risk of injury due to feed roller holders shooting upwards.
► When unlocking the lever, keep fingers away from the area to the left and right of the
lever.
In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the
diameter and alloy of the wire being welded.
An overview of the available feed rollers can be found in the Spare Parts Lists.
1 2
1
4
5
31
2
3
6
7
3 4
3
3
2
4
1
5
5
6
62
Inserting the
Wirespool/Basket-Type Spool
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
► When inserting the wirespool/basket-type spool, hold the end of the wire electrode
firmly to avoid injuries caused by the wire electrode springing back.
CAUTION!
Risk of injury from falling wirespool/basket-type spool.
► Make sure that the wirespool or basket-type spool with basket-type spool adapter is
fitted securely to the wirespool holder.
CAUTION!
Danger of injury and material damage if the wirespool/basket-type spool topples
over because the locking ring has been placed the wrong way round.
► Always position the locking ring as shown in the diagram on the left.
EN-US
1
1
63
NOTE!
2
TSt 2700c MP
TSt 3500c MP
WIG
MIG/MAG
WIG
MIG/MAG
2
When working with basket-type spools, only use the basket-type spool adapter supplied with the device.
1 2
1
Connecting the
Gas Cylinder
WARNING!
Danger from falling gas cylinders.
Serious personal injury and damage to property may result.
► Place gas cylinders on a solid, level surface so that they remain stable.
► Secure the gas cylinders to prevent them from falling over
► Please observe the gas cylinder manufacturer's safety rules.
1 2
1
64
Connecting the
1
2
1
2
1
1
2
1
Polarity Reverser
and Establishing
a Ground Earth
Connection
Connecting the Polarity Reverser
EN-US
NOTE!
If the polarity reverser is incorrectly connected, it can result in poor-quality weld
properties.
► Connect the polarity reverser according to the wire electrode used.
Check the wire electrode packaging to determine whether the wire electrode is for (+)
or (-) welding.
1
1
1
TSt 2700c MP
TSt 3500c MP
Establishing a Ground Earth Connection
Connect grounding cable to the free current socket
1
1
1
2
1
1
2
2
TSt 2700c MP: Example of ground connection to the
(+) current socket
TSt 3500c MP: Example of ground connection to the
(-) current socket
1
65
2
2
2
Feeding in the
wire electrode
CAUTION!
Risk of injury due to springiness of spooled wire electrode.
► When inserting the wire electrode into the 4 roller drive, hold the end of the wire elec-
trode firmly to avoid injuries caused by the wire electrode springing back.
CAUTION!
Risk of damage to the welding torch from sharp end of wire electrode.
► Deburr the end of the wire electrode well before threading in.
1 2
1
CAUTION!
Risk of injury from emerging wire electrode.
► When pressing the "Wire threading" button or the torch trigger, keep the welding torch
away from your face and body, and wear suitable protective goggles.
IMPORTANT! To facilitate wire threading, the following procedure is possible when the
"Wire threading" button is pressed and held down.
66
- Hold the button for up to one second
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
... the wire speed stays at 1 m/min or
39.37 ipm for the first second.
- Hold the button for up to 2.5 seconds
... after one second, the wire speed increases over the next 1.5 seconds.
- Hold the button for more than 2.5 se-
conds ... after 2.5 seconds, the wire is
fed at a constant rate equal to the wire
speed set for the Fdi welding parameter.
If you release the "Wire threading" button and press it again before one second has
elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire speed of 1 m/min or 39.37 ipm where necessary.
If there is no "Wire threading" / "Gas-test" button, the torch trigger can be used in a similar
way. Before using the torch trigger for wire threading, proceed as follows:
Press the "Mode" button to select 2-step mode
1
Set the "Ito" parameter to "Off" in the Setup menu
2
EN-US
CAUTION!
Danger of injury and damage from electric shock and from the wire electrode emerging from the torch.
When you press the torch trigger:
► Keep the welding torch away from your face and body
► Wear suitable protective goggles
► Do not point the welding torch at people
► Make sure that the wire electrode does not touch any conductive or grounded parts
(e.g., housing, etc.)
IMPORTANT! If the torch trigger is pressed instead of the "Wire threading"/"Gas-test"
button, the welding wire runs at the feeder creep speed (depending on the welding program) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.
The welding system detects that the welding process should not start, but that the wire is
to be threaded in. At the same time, the gas solenoid valve closes, and the welding voltage
on the wire electrode is switched off.
If the torch trigger is kept pressed, wirefeeding restarts immediately without shielding gas
and welding voltage, and the process continues as described above.
67
1 2
2
4
5
3
1
4
1
3
Setting the contact pressure
NOTE!
Set the contact pressure in such a way that the wire electrode is not deformed but
nevertheless ensures proper wirefeeding.
Standard values for the U-groove rollers:
Steel: 4 - 5
CrNi: 4 - 5
Tubular covered electrodes: 2 - 3
68
Adjusting the
4
STOP
6
7
1
2
3
5
3
5
2
4
6
OK
STOP
3
5
Brake
NOTE!
After releasing the torch trigger the wirespool must stop unreeling.
If it continues unreeling, readjust the brake.
1 2
1
2
1
3
3
EN-US
Design of the
Brake
WARNING!
Danger from incorrect installation.
Serious personal injury and damage to property may result.
► Do not dismantle the brake.
► Maintenance and servicing of brakes is
to be carried out by trained, qualified
personnel only.
The brake is only available as a complete
unit.
This illustration is for information purposes
only.
69
Power Limitation
Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the power
source can be operated at the power limit whilst maintaining process safety.
Wire speed is a determining parameter for welding power. If it is too high, the arc gets
smaller and smaller and may be extinguished. In order to prevent this, the welding power
is lowered.
If the "MIG/MAG standard synergic welding" process is selected, the symbol for the "Wire
speed" parameter flashes as soon as the safety function trips. The flashing continues until
the next welding start-up, or until the next parameter change.
If the "Wire speed" parameter is selected, for example, the reduced value for wire speed
is displayed.
70
MIG/MAG Operating Modes
EN-US
General
Symbols and explanations
WARNING!
Operating the device incorrectly can cause serious injury and damage to property.
► Do not use the functions described here until you have fully read and understood the
Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions of the system components, especially the safety rules.
For details of the meaning, settings, setting range and units of the available welding parameters (e.g., gas pre-flow time), please refer to the "Setup parameters" chapter.
Press the torch trigger | Hold the torch trigger | Release the torch trigger
GPr Gas pre-flow time
I-S Starting current
Can be increased or decreased depending on the application
SL Slope
Starting current is continuously lowered as far as the welding current and the welding current as far as the final current
I Welding current phase
Even heat input into the parent material whose temperature is raised by the advancing heat
I-E Final current
To fill up end-craters
GPo Gas post-flow time
SPt Spot welding time / interval welding time
SPb Interval pause time
71
2-step mode
t
I
+
I
GPr GPo
t
I
+
I
GPr GPo
+
4-step mode
"2-step mode" is suitable for
- Tacking work
- Short weld seams
- Automatic and robot operation
"4-step mode" is suitable for longer weld seams.
72
Special 4-step
+ +
I
I-S I-E
GPr SL SL
GPo
mode
Spot welding
EN-US
Special 4-step mode allows the starting and final current to be configured in addition to the
advantages of 4-step mode.
+
I
I
< SPt
GPr GPoSPt
t
The "Spot welding" mode is suitable for welded joints on overlapped sheets.
Start by pressing and releasing the torch trigger - GPr gas pre-flow time - welding current
phase over the SPt spot welding time duration - GPo gas post-flow time.
If the torch trigger is pressed again before the end of the spot welding time (< SPt), the
process is canceled immediately.
73
2-step stitch
GPr SPt SPtSPb
GPo
II
+
welding
4-step stitch
welding
2-step stitch welding
The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets,
to prevent the weld seams from dropping through the parent material.
4-step stitch welding
+
I
GPr SPt SPtSPb
I
+
GPo
The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets,
to prevent the weld seams from dropping through the parent material.
74
MIG/MAG Standard Synergic Welding
1
4
7
EN-US
MIG/MAG Standard Synergic
Welding
Press the "Material" button to select the filler metal to be used.
Press the "Wire diameter" button to select the diameter of the wire electrode used.
2
Press the "Shielding gas" button to select the shielding gas to be used.
3
The assignment of the SP position is in the welding program tables in the appendix.
Press the "Process" button to select the "MIG/MAG standard synergic" welding pro-
cess:
Press the "Mode" button to select the desired MIG/MAG mode:
5
2-step mode
4-step mode
Special 4-step mode
NOTE!
Under certain circumstances, it may not be possible to change welding parameters
that have been set on the control panel of a system component (TR 2000 or TR 3000
remote control) on the control panel of the power source.
Use the "Parameter selection" buttons to select the welding parameters to be used to
6
specify the welding power in Synergic operation:
Sheet thickness
or
Welding current
or
Wire speed
or
Welding voltage
Use the appropriate selection dial to set the welding parameter
The welding parameter values are shown in the digital display located above.
All welding parameter set values remain stored until the next time they are changed. This
is still true if the power source has been turned off and on again in the meantime. To display
the actual welding current during welding, select the welding current parameter.
Open the gas cylinder valve
8
Adjust quantity of shielding gas:
9
- Tap the Gas-test button
- Turn the adjusting screw on the bottom of the gas pressure regulator until the ma-
nometer displays the desired quantity of gas
- Tap the Gas-test button again
75
CAUTION!
2
Danger of injury and damage from electric shock and from the wire electrode emerging from the torch.
When you press the torch trigger:
► Keep the welding torch away from your face and body
► Wear suitable protective goggles
► Do not point the welding torch at people
► Make sure that the wire electrode does not touch any conductive or grounded parts
(e.g., housing)
Press the torch trigger and start welding
10
Corrections
During Welding
To obtain the best possible welding results, the arc length correction and arc-force dynamic
welding parameters will sometimes need to be corrected.
Press the "Parameter selection" buttons to select the parameters you wish to correct.
1
Use the selection dials to set the selected welding parameters to the required values.
Welding parameter values are shown in the displays located above them.
76
MIG/MAG Standard Manual Welding
3
5
General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no
synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by
the welding process in question.
EN-US
Available parameters
The following parameters are available for MIG/MAG manual welding:
Wire speed
1 m/min (39.37 ipm.) - maximum wire speed, e.g., 25 m/min (984.25 ipm.)
Welding voltage
TSt 2700c MP: 14.4 - 34.9 V
TSt 3500c MP: 14.5 - 38.5 V
Arc-force dynamic:
For influencing the short-circuiting dynamic at the instant of droplet transfer
Welding current
Only the actual value is displayed
MIG/MAG Standard Manual
Welding
Press the "Material" button to select the filler metal to be used.
1
Press the "Wire diameter" button to select the diameter of the wire electrode used.
2
Press the "Shielding gas" button to select the shielding gas to be used.
The assignment of the SP position is in the welding program tables in the appendix.
Press the "Process" button to select the "MIG/MAG standard manual" welding pro-
4
cess:
Press the "Mode" button to select the desired MIG/MAG mode:
2-step mode
4-step mode
In MIG/MAG standard manual welding, special 4-step mode corresponds to conventional 4-step mode.
NOTE!
Under certain circumstances, it may not be possible to change welding parameters
that have been set on the control panel of a system component (TR 2000 or TR 3000
remote control) on the control panel of the power source.
77
Use the "Parameter selection" buttons to select the welding parameter (wire speed)
8
10
1
6
Use the appropriate selection dial to set the wire speed
7
Use the "Parameter selection" buttons to select the welding parameter (welding
voltage)
Use the appropriate selection dial to set the welding voltage
9
The welding parameter values are shown in the digital display located above
All welding parameter set values remain stored until the next time they are changed. This
is still true if the power source has been turned off and on again in the meantime. To display
the actual welding current during welding, select the welding current parameter.
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
Open the gas cylinder valve
Adjust quantity of shielding gas:
11
- Tap the Gas-test button
- Turn the adjusting screw on the bottom of the gas pressure regulator until the ma-
nometer displays the desired quantity of gas
- Tap the Gas-test button again
Corrections
During Welding
CAUTION!
Danger of injury and damage from electric shock and from the wire electrode emerging from the torch.
When you press the torch trigger:
► Keep the welding torch away from your face and body
► Wear suitable protective goggles
► Do not point the welding torch at people
► Make sure that the wire electrode does not touch any conductive or grounded parts
(e.g., housing)
Press the torch trigger and start welding
12
To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.
Press the "Parameter selection" button to select the arc-force dynamic parameter
Use the selection dial to set the desired arc-force dynamic value
2
The welding parameter value is shown in the digital display located above it.
78
Spot and Stitch Welding
2
8
General The spot and stitch welding modes are MIG/MAG welding processes.
Spot welding is used on welded joints on overlapping sheets that are only accessible on
one side.
Stitch welding is used for light-gage sheets.
As the wire electrode is not fed continuously, the weld pool can cool down during the intervals. Local overheating leading to the parent material being melted through is largely
avoided.
EN-US
Spot Welding Press the "Material" button to select the filler metal to be used.
1
Press the "Wire diameter" button to select the diameter of the wire electrode used.
Press the "Shielding gas" button to select the shielding gas to be used.
3
The assignment of the SP position is in the welding program tables in the appendix.
Press the "Process" button to select the desired welding process:
4
Press the "Mode" button to select the spot welding/stitch welding mode:
5
(spot welding/stitch welding)
Set the SPt parameter in the Setup menu (spot welding time/interval welding time) to
6
the desired value
Ensure that the ground earth connection has been established
7
Ensure that the shielding gas supply has been established
The power source is ready for welding.
79
Stitch Welding Press the "Material" button to select the filler metal to be used.
2
8
1
Press the "Wire diameter" button to select the diameter of the wire electrode used.
Press the "Shielding gas" button to select the shielding gas to be used.
3
The assignment of the SP position is in the welding program tables in the appendix.
Press the "Process" button to select the desired welding process:
4
Press the "Mode" button to select the spot welding/stitch welding mode:
5
(spot welding/stitch welding)
Set the SPt parameter in the Setup menu (spot welding time/interval welding time) to
6
the desired value
Set the SPb parameter in the Setup menu (spot welding/stitch pause time) to the de-
7
sired value
Set the Int parameter (interval) in the Setup menu to the desired value
Ensure that the ground earth connection has been established
9
Ensure that the shielding gas supply has been established
10
The power source is ready for welding.
80
Rod Electrode
Commissioning
1
2
TSt 2700c MP
TSt 3500c MP
3
4
1
2
3
4
2
EN-US
Safety
Preparation
WARNING!
Operating the device incorrectly can cause serious injury and damage to property.
► Do not use the functions described here until you have fully read and understood the
Operating Instructions.
► Do not use the functions described here until you have fully read and understood all of
the Operating Instructions of the system components, especially the safety rules.
WARNING!
An electric shock can be fatal.
If the unit is connected to the grid during installation, there is a danger of serious injury and
damage to property.
► Only carry out work on the device if the power switch is in the - O - position.
► Only carry out work on the device when it has been disconnected from the grid.
1
1
Check the rod electrode packaging to determine whether the rod electrode is for (+)
or (-) welding.
2
83
3
3
CAUTION!
Danger due to welding processes starting unintentionally.
Personal injury and damage to property may result.
► As soon as the power source is switched on, ensure that the rod electrode does not
unintentionally/accidentally touch electrically conductive or grounded parts (such as
housing).
Plug the grid cable into the grid
4
Switch on the power source
5
84
Manual Metal Arc Welding
1
EN-US
Manual Metal Arc
Welding
Press the "Process" button to select the MMA welding process:
The welding voltage is applied to the welding socket with a three second time lag.
NOTE!
Under certain circumstances, it may not be possible to change welding parameters
that have been set on the control panel of a system component (TR 2000 or TR 3000)
on the control panel of the power source.
Press the "Parameter selection" button to select the amperage parameter.
2
Use the selection dial to set the desired amperage.
3
The amperage value is displayed on the left-hand digital display.
All welding parameter set values remain stored until the next time they are changed.
This is still true if the power source has been turned off and on again in the meantime.
Initiate welding process
4
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
85
Functions for Optimizing the Welding Process
200
300
I (A)
Hti
HCU > I
H
t (s)
I
H
HCU
0,5 1 1,5
1
Arc-Force Dynamic
HotStart (Hti)
function
Arc-force dynamic:
For influencing the short-circuiting dynamic at the instant of droplet transfer
- = hard, stable arc
0 = neutral arc
+ = soft, low-spatter arc
This function is activated at the factory.
Advantages
- Improved ignition properties, even when using electrodes with poor ignition properties
- Better fusion of the parent material during the start-up phase, meaning fewer cold-shut
defects
- Slag inclusions largely avoided
Key
Hti Hot-current time,
0 - 2 s, factory setting 0.5 s
HCU HotStart current,
100 - 200%, factory setting 150%
I
H
Main current = set welding current
Anti-stick (Ast)
function
The Hti and HCU parameters can be set in
the Setup menu. For a parameter description see section HCU HotStart current from
page 105.
Function
During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (I
).
H
This function is activated at the factory.
As the arc becomes shorter, the welding voltage may also fall so that the rod electrode is
more likely to stick to the workpiece. This may also cause the rod electrode to burn out.
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. The welding
process can be resumed without problems once the rod electrode has been detached from
the workpiece.
Deactivating the function:
Set the Ast (anti-stick) setup parameter to OFF
For a parameter description see section Ast Anti-stick function from page 105.
86
TIG
Commissioning
TSt 2700c MP
TSt 3500c MP
WIG
MIG/MAG
WIG
MIG/MAG
3
4
Start-up
1
1
2
2
EN-US
TSt 2700c MP
1
2
3
4
3
1
2
4
TSt 3500c MP
TSt 2700c MP
1
3 4
2
1
2
TSt 3500c MP
89
5
5
CAUTION!
Danger due to welding processes starting unintentionally.
Personal injury and damage to property may result.
► As soon as the power source is switched on, ensure that the tungsten electrode does
not unintentionally/accidentally touch electrically conductive or grounded parts (such
as housing).
Plug the grid cable into the grid
6
Switch on the power source
7
90
TIG Welding
1
4
576
+
5
8
TIG Welding Press the "Process" button to select the TIG welding process:
Press the "Parameter selection" button to select the amperage parameter.
2
Use the selection dial to set the desired amperage.
3
The amperage value is shown on the left-hand digital display.
All the parameter set values are saved until the next time they are changed. This is
still true if the power source has been turned off and on again in the meantime.
When using a welding torch with a torch trigger and TIG Multi Connector plug (with
2-step mode factory setting):
EN-US
Position the gas nozzle at the ignition point so that there is a distance of approximately
4
2 to 3 mm (0.078 to 0.118 in.) between the tungsten electrode and the workpiece
Slowly straighten the welding torch until the tungsten electrode touches the workpiece
Pull back the torch trigger and hold it in this position
6
Shielding gas flows.
Raise the welding torch and tilt it into the normal position
7
The arc now ignites.
Carry out welding
91
Pulse welding
1/F-P
I-P
I-G
I
t
t
up
t
down
I-S
I-E
dcY
Applications Pulsed welding is welding with a pulsing welding current. It is used to weld steel pipes out-
of-position or to weld thin sheet metal.
In these applications, the welding current set at the start of welding is not always optimum
for the entire welding process:
- If the amperage is too low, the parent material will not be melted enough
- If overheating occurs, there is a danger that the liquid weld pool may drip.
Operating principle
- A low base current I-G rises steeply to the significantly higher pulse current I-P and
drops back to the base current I-G after the Duty cycle dcY time.
- This results in an average current that is lower than the set pulse current I-P.
- During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.
The power source controls the "Duty cycle dcY" and "Base current I-G" parameters according to the set pulse current (welding current) and pulse frequency.
92
Welding current progression curve
Adjustable parameters:
I-S Starting current
I-E Final current
F-P Pulse frequency (1/F-P = Time between two pulses)
I-P Pulse current (set welding current)
Fixed parameters:
t
up
t
down
UpSlope
DownSlope
dcY Duty cycle
I-G Base current
Activating pulse
welding
Set a value for the F-P setup parameter (pulse frequency)
1
- Setting range: 1 - 990 Hz
For a parameter description see section F-P Pulse frequency from page 106.
EN-US
93
94
EasyJobs
Saving and Retrieving EasyJobs
1
1
3
General The "Save" buttons allow five EasyJobs to be saved. The adjustable parameters on the
control panel are saved as EasyJobs.
NOTE!
Setup parameters are not saved as EasyJobs.
EN-US
Saving an EasyJob
Retrieving an
EasyJob
Press and hold one of the "Save" buttons to save the current settings on the control
1
panel, e.g., Number 1
- The left indicator displays "Pro"
- After a short time, the left indicator switches to the original value
Release the "Save" button
2
To retrieve saved settings, press the corresponding "Save" button briefly, e.g., Number 1
- The control panel will show the saved settings
Deleting an EasyJob
Press and hold the relevant "Save" button to delete the memory content of that "Save"
button, e.g., Number 1
- The left indicator displays "Pro"
- After a short time, the left indicator switches to the original value
Keep the "Save" button held down
2
- The left indicator displays "CLr"
- After a while, both indicators display "---"
Release the "Save" button
97
Retrieving operating points on the
Up/Down welding
torch
Press one of the "Save" buttons on the control panel to retrieve the saved settings using
the Up/Down welding torch.
Press one of the "Save" buttons on the control panel, e.g.:
1
- The control panel will show the saved settings
The "Save" buttons can now be selected using the buttons on the Up/Down welding torch.
Vacant "Save" buttons are skipped.
In addition to the "Save" button number lighting up, a number is displayed directly on the
Up/Down welding torch:
Number 1
Number 2
Number 3
Number 4
Number 5
98
Setup Settings
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