Operating
instructions
TransSteel 3000c Pulse
EN-US
Operating instructions
42,0426,0354,EA 007-04052022
Table of contents
Safety Instructions 7
Explanation of Safety Instructions 7
General 7
Intended Use 8
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 9
Personal Protection and Protection of Others 9
Danger from toxic gases and vapors 9
Danger from Flying Sparks 10
Risks from grid current and welding current 10
Stray welding currents 12
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Particular hazard areas 13
Requirement for the shielding gas 14
Danger from Shielding Gas Cylinders 14
Danger Posed by Shielding Gas Leak 15
Safety Measures at the Setup Location and During Transport 15
Safety Measures in Normal Operation 16
Maintenance and repair 16
Safety Inspection 17
Disposal 17
Safety symbols 17
Data backup 17
Copyright 17
EN-US
General information 19
General 21
Device concept 21
Operating principle 21
Application areas 21
Warning notices on the device 22
Description of the warnings on the device 23
Welding processes, procedures, and welding characteristics for MIG/MAG welding 25
General 25
Brief description of MIG/MAG standard synergic welding 25
Brief description of MIG/MAG pulsed synergic welding 25
Brief description of SynchroPulse welding 25
System components 26
General 26
Safety 26
Overview 26
Operating controls and connections 27
Control Panel 29
General 29
Safety 29
Control panel 30
Service parameters 35
Keylock 36
Connections, Switches, and Mechanical Components 37
Front and back 37
Side view 38
Installation and Startup 39
3
Minimum equipment for welding operations 41
General 41
Gas-cooled MIG/MAG welding 41
Water-cooled MIG/MAG welding 41
Manual metal arc welding 41
TIG DC Welding 41
Before installation and initial operation 42
Safety 42
Intended Use 42
Setup regulations 42
Grid Connection 43
Connecting the Mains Cable 44
Stipulated mains cables and strain-relief devices 44
Safety 44
Connecting the mains cable 44
Fitting the strain-relief device 45
Fitting the strain-relief device for Canada / US 46
Generator-Powered Operation 47
Generator-powered operation 47
Commissioning 48
Safety 48
General 48
Information on system components 48
Assembling system components 49
Establishing a ground earth connection 49
Inserting/changing feed rollers 50
Inserting the wirespool 51
Installing the basket-type spool 52
Feed in the wire electrode 53
Setting the contact pressure 55
Adjust the brake 56
Design of the brake 56
Setting the date and time when starting for the first time 57
MIG/MAG welding 59
Power Limitation 61
Safety function 61
MIG/MAG Operating Modes 62
General 62
Symbols and explanations 62
2-step mode 63
4-step mode 63
Special 2-step mode 64
Special 4-step mode 64
Spot welding 65
2-step stitch welding 65
4-step stitch welding 66
MIG/MAG welding 67
Safety 67
Preparation 67
Overview 67
MIG/MAG synergic welding 68
MIG/MAG synergic welding 68
Corrections during welding 70
SynchroPulse welding 70
MIG/MAG Standard Manual Welding 72
General 72
Available parameters 72
MIG/MAG standard manual welding 72
Corrections during welding 73
Spot welding and stitch welding 74
4
General 74
Spot welding 74
Stitch welding 75
EasyJob mode 77
General 77
Saving EasyJob operating points 77
Retrieving EasyJob operating points 77
Deleting EasyJob operating points 77
Retrieving EasyJob operating points on the Up/Down welding torch 78
TIG welding 79
TIG welding 81
Safety 81
Preparation 81
TIG welding 82
Igniting the arc 83
Ending the welding process 83
Pulse welding 84
Applications 84
Operating principle 84
Activating pulse welding 85
Manual Metal Arc Welding 87
Manual Metal Arc Welding 89
Safety 89
Preparation 89
Manual metal arc welding 90
Corrections during welding 90
HotStart function 92
Anti-Stick function 92
EN-US
Easy Documentation 93
General 95
General 95
Documented welding data 95
New CSV file 96
PDF report / Fronius signature 96
Activating / deactivating Easy Documentation 97
Activating Easy Documentation 97
Set the date and time 97
Deactivating Easy Documentation 98
Setup Settings 99
Setup Menu 101
General 101
Operation 101
Setup parameters for MIG/MAG synergic welding 102
Setup parameters for MIG/MAG standard manual welding 104
Setup parameters for MMA welding 105
Parameters for TIG welding 105
Setup Menu 2nd Level 107
Limitations 107
Operation (Setup Menu 2nd Level) 107
Parameters for MIG/MAG synergic welding in Setup menu 2nd level 108
Parameters for MIG/MAG standard manual welding in Setup menu 2nd level 110
Parameters for manual metal arc welding in Setup menu 2nd level 112
Parameters for TIG welding (Setup menu 2nd level) 113
Measuring the Welding Circuit Resistance r 114
General 114
Measuring the welding circuit resistance (MIG/MAG welding) 114
5
Measuring the welding circuit resistance (MMA welding) 115
Displaying the welding circuit Inductivity L 116
General 116
Displaying the welding circuit inductivity 116
Laying the hosepacks correctly 116
Troubleshooting and Maintenance 117
Troubleshooting 119
General 119
Safety 119
Displayed Service Codes 119
Displayed service codes in connection with OPT Easy Documentation 124
Service, maintenance and disposal 125
General 125
Safety 125
At every start-up 125
Whenever required 125
Every 2 Months 125
Every 6 Months 126
Disposal 126
Appendix 127
Average consumption values during welding 129
Average wire electrode consumption during MIG/MAG welding 129
Average shielding gas consumption during MIG/MAG welding 129
Average shielding gas consumption during TIG welding 129
Technical data 130
Overview with critical raw materials, year of production of the device 130
Special Voltage 130
Explanation of the term duty cycle 130
TransSteel 3000c Pulse TransSteel 3000c Pulse nc 132
Welding program tables 134
Welding program label on the device 134
Welding program tables for TransSteel 3000c Pulse 135
Welding program tables for TransSteel 3000c Pulse - US 137
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 ac-
cording to recognized safety standards. If used incorrectly or misused, however,
it can cause
Injury or death to the operator or a third party
-
Damage to the device and other material assets belonging to the operating
-
company
Inefficient operation of the equipment
-
All persons involved in the commissioning, operation, maintenance, and servicing
of the device must
Be suitably qualified
-
Have knowledge of welding
-
Have completely read and followed these Operating Instructions
-
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, all applicable local rules and 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!
7
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating
plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be
"not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means
Completely reading and obeying all instructions in the Operating Instruc-
-
tions
Completely reading and obeying all safety instructions and danger notices
-
Carrying out all the specified inspection and servicing work
-
Never use the device for the following applications:
Thawing pipes
-
Charging batteries
-
Starting motors
-
The device is designed for operation in industry and business. The manufacture
shall not be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
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 regu-
-
lations and are trained in handling the device
Have read and understood these Operating Instructions, especially the sec-
-
tion "Safety Rules," and have confirmed this with their signature
Are trained according to the requirements for the work results
-
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
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.
Grid Connection Devices with a high output can influence the energy quality of the grid due to
their current consumption.
This may affect a number of device types in terms of:
connection restrictions
-
-
criteria regarding maximum permissible grid impedance
-
criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or
not the device is allowed to be connected, where appropriate through discussion
with the power supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
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.
9
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
Do not breathe them in.
-
Extract them from the work area using appropriate equipment.
-
Ensure that there is a sufficient supply of fresh air. Ensure that there is a 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 measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding
fumes are:
The metals used for the workpiece
-
Electrodes
-
Coatings
-
Cleaning agents, degreasers, and the like
-
The welding process used
-
Consult the corresponding material safety data sheets and manufacturer's instructions for the components listed above.
Danger from Flying Sparks
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.
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 protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through
small cracks and openings. Take appropriate measures to ensure that there is no
risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed
tanks, drums, or pipes if these have not been prepared in accordance with corresponding national and international standards.
Risks from grid
current and
welding current
10
Do not undertake welding on containers in which gases, fuels, mineral oils, and
the like are/were stored. Residues pose a risk of explosion.
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 rollers, 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.
EN-US
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.
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.
11
Stray welding
currents
If the following instructions are not observed, stray welding currents may occur,
which pose a risk of the following:
Fire
-
Overheating of parts connected to the workpiece
-
Irreparable damage to ground conductors
-
Damage to the device and other electrical equipment
-
Ensure that the workpiece clamp is securely connected to the workpiece.
Secure the workpiece clamp as close to the spot to be welded as possible.
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 power distribution boards, twin-head mounts,
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
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 lowvoltage grid.
EMC device classification as per the rating plate or technical data.
emissions, it may affect the application area for which it was designed (e.g., when
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
If this is the case, then the 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 interferenceprone equipment that could be affected by the device:
Safety devices
-
Grid power lines, signal lines, and data transfer lines
-
IT and telecommunications equipment
-
Devices for measuring and calibrating
-
12
Supporting measures to avoid EMC problems:
Grid power supply
1.
If electromagnetic interference occurs despite a grid connection that
-
complies with regulations, take additional measures (e.g., use a suitable
grid filter).
Welding power-leads
2.
Keep them as short as possible
-
Route them close together (also to avoid EMF problems)
-
Route them far from other lines
-
Equipotential bonding
3.
Workpiece grounding
4.
If necessary, establish grounding using suitable capacitors.
-
Shield, if necessary
5.
Shield other devices in the vicinity
-
Shield the entire welding installation
-
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 power-leads and the head/torso of the
-
welder as great as possible for safety reasons
Do not carry welding power-leads and hosepacks over your shoulder or wrap
-
them around your 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 panels 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 prop-
-
erly.
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 – risk of burns.
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.
13
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 to transport
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).
-
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.
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.
EN-US
Danger Posed by
Shielding Gas
Leak
Safety Measures
at the Setup
Location and
During Transport
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.
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
-
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.
15
Safety Measures
in Normal Operation
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.
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.
Maintenance and
repair
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
manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flam-
mable in certain 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.
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.
16
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.
Safety Inspection
Disposal To comply with European directives and national law, waste electrical and elec-
The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.
The manufacturer recommends calibrating power sources within the same 12month interval.
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.
tronic equipment must be collected separately and sent for environmentallyfriendly recycling. Used devices must be returned to a distributor or an approved
collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.
EN-US
Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the
volume of cardboard.
Safety symbols Devices with the CE label satisfy the essential requirements of the low-voltage
and electromagnetic 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 manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these Operating Instructions remains with the manufacturer.
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
19
20
General
Device concept The TransSteel (TSt) 3000c Pulse
power source is a fully digitized, microprocessor-controlled inverter power
source.
A modular design and ability to easily
extend the system guarantee a high
degree of flexibility. The device is de-
signed for the following welding processes:
MIG/MAG pulse welding
-
MIG/MAG standard synergic weld-
-
ing
TIG welding
-
Manual metal arc welding
-
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.
For details, refer to the "Welding operations" chapter.
EN-US
Operating principle
Application
areas
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 target state is maintained.
This results in:
A precise welding process
-
A high degree of reproducibility on all results
-
Excellent weld properties.
-
The TransSteel 3000c Pulse is used in trade and industry for manual applications
with classical steel and galvanized sheet metal.
The power source is designed for:
Mechanical and equipment engineering
-
Steel construction
-
Plant and container construction
-
Metal and portal construction
-
Rail vehicle construction
-
Metalworking trades
-
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Warning notices
40,0006,3035
inside
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.
22
Welding is dangerous. The following basic requirements must be met:
Adequate welding qualifications
-
Appropriate protective equipment
-
Exclusion of unauthorized persons
-
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
-
Description of
A B
the warnings on
the device
Warning notices are attached to the device for certain device versions.
The arrangement of the symbols may vary.
! Warning! Caution!
The symbols represent possible dangers.
A Drive rollers can injure fingers.
B The welding wire and drive parts are under welding voltage during opera-
tion.
Keep hands and metal objects away!
EN-US
1. An electric shock can be fatal.
1.1 Wear dry, insulating gloves. Do not touch the wire electrode with bare
hands. Do not wear wet or damaged gloves.
1.2 Use a base that is insulated from the floor and work area to protect
against electric shock.
1.3 Before working on the device, switch off the device and remove the mains
plug or disconnect the power supply.
2. Inhalation of welding fumes can be harmful to health.
2.1 Keep your face away from any welding fumes.
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2.2 Use forced-air ventilation or local extraction to remove welding fumes.
xx,xxxx,xxxx *
2.3 Remove welding fumes with a fan.
3. Welding sparks can cause an explosion or fire.
3.1 Keep flammable materials away from the welding process. Do not perform
welding near flammable materials.
3.2 Welding sparks can cause a fire. Have fire extinguishers ready. If neces-
sary, have a supervisor ready who can operate the fire extinguisher.
3.3 Do not weld on drums or closed containers.
4. Arc rays can burn the eyes and injure the skin.
4.1 Wear headgear and protective goggles. Use ear protection and wear a
shirt collar with button. Use a welding helmet with the correct tinting.
Wear suitable protective clothing over the entire body.
5. Before working on the machine or welding:
undertake training on the device and read the instructions!
6. Do not remove or paint over the sticker with the warnings.
* Manufacturer order number of the sticker
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Welding processes, procedures, and welding characteristics for MIG/MAG welding
General In order to process a wide range of materials effectively, various welding pro-
cesses, procedures, and welding characteristics are available on the power
source.
Brief description
of MIG/MAG
standard synergic welding
MIG/MAG standard synergic
MIG/MAG standard synergic welding is a MIG/MAG welding process covering the
entire power range of the power source with the following arc types:
Dip transfer arc
Droplet transfer occurs in the lower power range during the short circuit.
Intermediate arc
The droplet increases in size at the end of the wire electrode and is transferred in
the mid power range during the short circuit.
Spray arc
A short circuit-free transfer of material in the high power range.
EN-US
Brief description
of MIG/MAG
pulsed synergic
welding
Brief description
of SynchroPulse
welding
MIG/MAG pulsed synergic
MIG/MAG pulsed synergic welding is a pulsed arc process with a controlled material transfer.
In the base current phase, the energy input is reduced to such an extent that the
arc barely burns steadily and the surface of the workpiece is preheated. In the
pulsing current phase, an accurately timed current pulse guarantees a precise
detachment of the weld material droplet.
This principle guarantees low-spatter welding and precise operation throughout
the entire power range.
SynchroPulse is available for the standard synergic and pulsed synergic processes.
The cyclic change of the welding power between two operating points with SynchroPulse achieves a finely rippled weld appearance and a non-continuous heat
input.
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System components
(1)
(2)
(3)
(4)
(5)
(6)
(7)
General The power sources can be operated with various system components and op-
tions. This makes it possible to optimize procedures and to simplify machine
handling and operation, depending on the field of application for the power
source.
Safety
Overview
WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equip-
▶
ment and all system components.
(1) MIG/MAG welding torch
(2) Stabilization of the gas cylinder holder
(3) Power source
(4) Cooling unit
(5) Trolley with gas cylinder holder
(6) Grounding and electrode cable
(7) TIG welding torch
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Operating controls and connec-
tions
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Control Panel
General The functions are all arranged in a logical way on the control panel. The individual
parameters required for welding can be
Selected by means of buttons
-
Changed using buttons or the selection dial
-
Shown on the digital display during welding.
-
Due to the synergic function, all other parameters are also adjusted if a single
parameter is changed.
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.
This can result in serious personal injury and damage to property.
All the work and functions described in this document must only be carried
▶
out by technically trained and qualified personnel.
Read and understand this document in full.
▶
Read and understand all safety rules and user documentation for this equip-
▶
ment and all system components.
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Control panel
(1)
(2)
(3)
(4)
(5)
(6)(7)
(14)(13) (17)
(12)
(11)
(10) (8)
(9)
(15)(16)
No. Function
(1) "Parameter selection" button (right)
a) for selecting the following parameters
Arc length correction
For correcting the arc length
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.
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