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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)
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Operating controls and connections
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