Fronius TransSteel 3500 / 5000 Syn Operating Instruction [EN]

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Operating instructions

TransSteel 3500 Syn TransSteel 5000 Syn

Operating instructions

42,0426,0258,EN 017-02052022

Contents

Safety rules 7

Explanation of safety notices 7 General 7 Proper use 8 Environmental conditions 8 Obligations of the operator 8 Obligations of personnel 8 Mains connection 9 Protecting yourself and others 9 Danger from toxic gases and vapours 10 Danger from ﬂying sparks 10 Risks from mains current and welding current 11 Meandering welding currents 12 EMC Device Classifications 12 EMC measures 12 EMF measures 13 Specific hazards 13 Requirement for the shielding gas 14 Danger from shielding gas cylinders 14 Danger from escaping shielding gas 15 Safety measures at the installation location and during transport 15 Safety measures in normal operation 16 Commissioning, maintenance and repair 16 Safety inspection 17 Disposal 17 Safety symbols 17 Data protection 17 Copyright 17

General information 19

General 21

Device concept 21 Functional principle 21 Application areas 21 Warning notices on the device 21

Welding processes, procedures and welding characteristics for MIG/MAG welding 23

General 23 Welding characteristics 23 Summary of MIG/MAG standard synergic welding 23 Short description of arc air gouging 23

System components 24

General 24 Safety 24 Overview 24

Options 26

General 26 Machine interface 26 Gas preheater CO2 connection 26 Keylock switch 27 VRD: safety function 27 VRD: safety principle 28

Control elements and connections 29

Synergic control panel 31

General 31 Safety 31 Synergic control panel 32 Service parameters 35

Keylock 36

Connections, switches and mechanical components 37

TSt 3500/5000 Syn power source 37

Installation and commissioning 39

Minimum equipment needed for welding task 41

General 41 Gas-cooled MIG/MAG welding 41 MIG/MAG welding, water-cooled 41 MMA welding 41

Before installation and commissioning 42

Safety 42 Utilisation for intended purpose only 42 Setup regulations 42 Mains connection 43

Connecting the mains cable 44

Safety 44 General 44 Stipulated mains cables and strain-relief devices 44 Connecting the mains cable 45 Fitting the Europe strain-relief device 45 Fitting the Canada/US strain-relief device 46

Generator-powered operation 48

Start-up 49

General 49 Information on system components 49 Assembling the system components (overview) 49 Placing the wirefeeder on the power source 50 Fitting the interconnecting hosepack strain-relief device 51 Connecting the interconnecting hosepack 51 Connecting the gas cylinder 52 Establishing a ground earth connection 53 Connecting MIG/MAG welding torches 54 Inserting/replacing feed rollers 54 Inserting the wirespool 55 Inserting the basket-type spool 56 Feeding in the wire electrode 57 Setting the contact pressure 59 Adjusting the brake 59 Design of the brake 60

Welding 61

Power limitation 63

Safety function 63

MIG/MAG modes 64

General 64 Symbols and their explanations 64 2-step mode 65 4-step mode 65 Special 4-step mode 66 Spot welding 66 2-step stitch welding 67 4-step stitch welding 67

MIG/MAG welding 68

Safety 68 Preparatory work 68 Overview 68

MIG/MAG standard synergic welding 69

MIG/MAG standard synergic welding 69 Corrections during welding 70

MIG/MAG standard manual welding 71

General 71 Available parameters 71 MIG/MAG standard manual welding 71 Corrections during welding 72

Spot and stitch welding 73

General 73 Spot welding 73 Stitch welding 74

EasyJob mode 76

General 76 Storing EasyJob operating points 76 Retrieving EasyJob operating points 76 Deleting EasyJob operating points 76 Retrieving EasyJob operating points on the Up/Down welding torch 76

MMA welding 78

Safety 78 Preparation 78 MMA welding 78 Corrections during welding 79 HotStart function 80 Anti-stick function 80

Arc Air Gauging (TSt 5000 Syn) 81

Safety 81 Preparation 81 Arc air gouging 82

Easy Documentation 85

General 87

General 87 Documented welding data 87 New CSV file 88 PDF report / Fronius signature 88

Activating / deactivating Easy Documentation 89

Setting the date and time 89 Deactivating Easy Documentation 89

Setup settings 91

Setup menu 93

General remarks 93 Operation 93 Setup parameters for MIG/MAG standard manual welding 93 Setup parameters for MIG/MAG standard synergic welding 95 Setup parameters for MMA welding 96

Setup menu - Level 2 98

Operation (level 2 Setup menu) 98 Parameters for MIG/MAG welding in the Setup menu level 2 99 Parameters for manual metal arc (MMA) welding in the Setup menu level 2 101

Measuring welding circuit resistance r 102

General 102 Measuring welding circuit resistance (MIG/MAG welding) 102

Retrieving the welding circuit inductivity L 104

General 104 Displaying welding circuit inductivity 104 Laying the hosepacks correctly 104

Troubleshooting and maintenance 105

Troubleshooting 107

General 107 Safety 107 Fault diagnosis 107

Displayed service codes 110 Displayed service codes in connection with OPT Easy Documentation 115

Care, maintenance and disposal 117

General 117 Safety 117 At every start-up 117 Every 2 months 117 Every 6 months 118 Disposal 118

Appendix 119

Average consumption values during welding 121

Average wire electrode consumption during MIG/MAG welding 121 Average shielding gas consumption during MIG/MAG welding 121 Average shielding gas consumption during TIG welding 121

Technical data 122

Special voltages 122 Explanation of the term "duty cycle" 122 TSt 3500 Syn 123 TSt 3500 MV Syn 124 TSt 5000 Syn 125 TSt 5000 MV Syn 126 Overview with critical raw materials, year of production of the device 127

Welding program tables 128

TransSteel 3500 Syn - Euro welding program tables 128 TransSteel 5000 Syn - Euro welding program tables 130 TransSteel 3500 Syn - US welding program tables 132 TransSteel 5000 Syn - US welding program tables 134 TransSteel 3500 Yard welding program tables 136 TransSteel 5000 Yard welding program tables 137

Standard value tables for MIG/MAG standard manual welding 138

Settings tables 138

Safety rules

Explanation of safety notices

DANGER!

Indicates immediate danger.

If not avoided, death or serious injury will result.

▶

WARNING!

Indicates a potentially hazardous situation.

If not avoided, death or serious injury may result.

▶

CAUTION!

Indicates a situation where damage or injury could occur.

If not avoided, minor injury and/or damage to property may result.

▶

NOTE!

Indicates a risk of ﬂawed results and possible damage to the equipment.

General The device is manufactured using state-of-the-art technology and according to

recognised safety standards. If used incorrectly or misused, however, it can cause:

injury or death to the operator or a third party,

damage to the device and other material assets belonging to the operating

company, inefficient operation of the device.

All persons involved in commissioning, operating, maintaining and servicing the device must:

be suitably qualified,

have sufficient knowledge of welding and

read and follow these operating instructions carefully.

The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.

All safety and danger notices on the device

must be in a legible state,

must not be damaged,

must not be removed,

must not be covered, pasted or painted over.

For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device. Before switching on the device, rectify any faults that could compromise safety.

This is for your personal safety!

Proper use The device is to be used exclusively for its intended purpose.

The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.

Proper use includes:

carefully reading and following all the instructions given in the operating in-

structions studying and obeying all safety and danger notices carefully

performing all stipulated inspection and maintenance work.

Never use the device for the following purposes:

Thawing out pipes

Charging batteries

Starting engines

The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic setting.

The manufacturer likewise accepts no liability for inadequate or incorrect results.

Environmental conditions

Obligations of the operator

Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.

Ambient temperature range:

during operation: -10 °C to + 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)

The surrounding air must be free from dust, acids, corrosive gases or substances, etc. Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)

The operator must only allow persons to work with the device who:

are familiar with the fundamental instructions regarding safety at work and

accident prevention and have been instructed in how to use the device have read and understood these operating instructions, especially the sec-

tion "safety rules", and have confirmed as much with their signatures are trained to produce the required results.

Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner.

Obligations of personnel

Before using the device, all persons instructed to do so undertake:

to observe the basic instructions regarding safety at work and accident pre-

vention to read these operating instructions, especially the "Safety rules" section and

sign to confirm that they have understood them and will follow them.

Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

Mains connection

Protecting yourself and others

Devices with a higher rating may affect the energy quality of the mains due to their current consumption.

This may affect a number device types in terms of:

Connection restrictions

Criteria with regard to the maximum permissible mains impedance

Criteria with regard to the minimum short-circuit power requirement

at the interface with the public grid

see "Technical data"

In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company.

IMPORTANT! Ensure that the mains connection is earthed properly

Anyone working with the device exposes themselves to numerous risks, e.g.

ﬂying sparks and hot pieces of metal

Arc radiation, which can damage eyes and skin

Hazardous electromagnetic fields, which can endanger the lives of those us-

ing cardiac pacemakers Risk of electrocution from mains current and welding current

Greater noise pollution

Harmful welding fumes and gases

Suitable protective clothing must be worn when working with the device. The protective clothing must have the following properties:

Flame-resistant

Insulating and dry

Covers the whole body, is undamaged and in good condition

Safety helmet

Trousers with no turn-ups

Protective clothing refers to a variety of different items. Operators should:

Protect eyes and face from UV rays, heat and sparks using a protective visor

and regulation filter Wear regulation protective goggles with side protection behind the protect-

ive visor Wear stout footwear that provides insulation even in wet conditions

Protect the hands with suitable gloves (electrically insulated and providing

protection against heat) Wear ear protection to reduce the harmful effects of noise and to prevent in-

jury

Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:

Make them aware of all the dangers (risk of dazzling by the arc, injury from

ﬂying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.) Provide suitable protective equipment

Alternatively, erect suitable safety screens/curtains.

Danger from toxic gases and vapours

The fumes produced during welding contain harmful gases and vapours.

Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the International Agency for Research on Cancer.

Use at-source extraction and a room extraction system. If necessary, use a welding torch with an integrated extraction device.

Keep your face away from welding fumes and gases.

Fumes and hazardous gases

must not be breathed in

must be extracted from the working area using appropriate methods.

Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³ per hour at all times.

Otherwise, a welding helmet with an air supply must be worn.

If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values.

The following components are responsible, amongst other things, for the degree of toxicity of welding fumes:

Metals used for the workpiece

Electrodes

Coatings

Cleaners, degreasers, etc.

Welding process used

Danger from ﬂying sparks

The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.

Recommendations for trade fair scenarios, risk management measures and for identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.

Close the shielding gas cylinder valve or main gas supply if no welding is taking place.

Flying sparks may cause fires or explosions.

Never weld close to ﬂammable materials.

Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or alternatively covered with an approved cover.

A suitable, tested fire extinguisher must be available and ready for use.

Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.

Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.

Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. Residues pose an explosive hazard.

Risks from mains current and welding current

An electric shock is potentially life threatening and can be fatal.

Do not touch live parts either inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers and all pieces of metal that are in contact with the welding wire are live.

Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated wirefeeder holder.

Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area between the body and the earth or 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. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180° and pretension.

Do not wrap cables or leads around the body or parts of the body.

The electrode (rod electrode, tungsten electrode, welding wire, etc.) must

never be immersed in liquid for cooling

Never touch the electrode when the power source is switched on.

Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time may be fatal under certain circumstances.

Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly.

Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed. Otherwise, this is considered gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.

If necessary, provide adequate earthing for the workpiece.

Switch off unused devices.

Wear a safety harness if working at height.

Before working on the device, switch it off and pull out the mains plug.

Attach a clearly legible and easy-to-understand warning sign to the device to prevent anyone from plugging the mains plug back in and switching it on again.

After opening the device:

Discharge all live components

Ensure that all components in the device are de-energised.

If work on live parts is required, appoint a second person to switch off the main switch at the right moment.

Meandering welding currents

If the following instructions are ignored, meandering welding currents can develop with the following consequences:

Fire hazard

Overheating of parts connected to the workpiece

Damage to ground conductors

Damage to device and other electrical equipment

Ensure that the workpiece is held securely by the workpiece clamp.

Attach the workpiece clamp as close as possible to the area that is to be welded.

Position the device with sufficient insulation against electrically conductive environments, such as insulation against conductive ﬂoor or insulation to conductive racks.

If power distribution boards, twin-head mounts, etc., are being used, note the following: The electrode of the welding torch / electrode holder that is not used is also live. Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.

In the case of automated MIG/MAG applications, ensure that only an insulated wire electrode is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.

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 mains.

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 operator is obliged to take appropriate action to rectify the situation.

Check and evaluate the immunity to interference of nearby devices according to national and international regulations. Examples of equipment that may be susceptible to interference from the device include:

Safety devices

Network, signal and data transfer lines

IT and telecommunications devices

Measuring and calibrating devices

Supporting measures for avoidance of EMC problems:

Mains supply

1. If electromagnetic interference arises despite the correct mains connec-

tion, additional measures are necessary (e.g. use of a suitable line filter)

Welding power-leads

2. must be kept as short as possible

must be laid close together (to avoid EMF problems)

must be kept well apart from other leads

Equipotential bonding

Earthing of the workpiece

4. If necessary, establish an earth connection using suitable capacitors.

Shield, if necessary

5. Shield other devices nearby

Shield the entire welding installation

EMF measures Electromagnetic fields may pose as yet unknown risks to health:

Effects on the health of persons in the vicinity, e.g. those with pacemakers

and hearing aids Individuals with pacemakers must seek advice from their doctor before ap-

proaching the device or any welding that is in progress For safety reasons, maintain as large a distance as possible between the

welding power-leads and the head/torso of the welder Do not carry welding power-leads and hosepacks over the shoulders or wind

them around any part of the body

Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:

Fans

Cogs

Rollers

Shafts

Wirespools and welding wires

Do not reach into the rotating cogs of the wire drive or into rotating drive components.

Covers and side panels may only be opened/removed while maintenance or repair work is being carried out.

During operation

Ensure that all covers are closed and all side panels are fitted properly.

Keep all covers and side panels closed.

The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.).

Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles.

Never touch the workpiece during or after welding - risk of burns.

Slag can jump off cooling workpieces. The specified protective equipment must therefore also be worn when reworking workpieces, and steps must be taken to ensure that other people are also adequately protected.

Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.

Special provisions apply in areas at risk of fire or explosion

- observe relevant national and international regulations.

Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas.

Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant ﬂow or return lines.

Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Use only suitable load-carrying equipment supplied by the manufacturer when transporting devices by crane.

Hook chains or ropes onto all suspension points provided on the load-carry-

ing equipment. Chains and ropes must be at the smallest angle possible to the vertical.

Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

If the wirefeeder is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).

If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.

All lifting tackle (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors). The testing interval and scope of testing must comply with applicable national standards and directives as a minimum.

Requirement for the shielding gas

Danger from shielding gas cylinders

Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teﬂon tape.

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 gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they must be handled with the greatest of care.

Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked ﬂames, sparks and arcs.

Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.

Keep the shielding gas cylinders well away from any welding or other electrical circuits.

Never hang a welding torch on a shielding gas cylinder.

Never touch a shielding gas cylinder with an electrode.

Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.

Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylinders and accessories that are in good condition.

Turn your face to one side when opening the valve of a shielding gas cylinder.

Close the shielding gas cylinder valve if no welding is taking place.

If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder.

The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories.

Danger from escaping shielding gas

Safety measures at the installation location and during transport

Risk of suffocation from the uncontrolled escape of shielding gas

Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.

Ensure an adequate supply of fresh air with a ventilation rate of at least

20 m³/hour. Observe safety and maintenance instructions on the shielding gas cylinder or

the main gas supply. Close the shielding gas cylinder valve or main gas supply if no welding is tak-

ing place. Check the shielding gas cylinder or main gas supply for uncontrolled gas

leakage before every start-up.

A device toppling over could easily kill someone. Place the device on a solid, level surface such that it remains stable

The maximum permissible tilt angle is 10°.

Special regulations apply in rooms at risk of fire or explosion

Observe relevant national and international regulations.

Use internal directives and checks to ensure that the workplace environment is always clean and clearly laid out.

Only set up and operate the device in accordance with the degree of protection shown on the rating plate.

When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.

7.69 in.) to ensure that cooling air can ﬂow in and out freely.

When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.

Do not lift or transport operational devices. Switch off devices before transport or lifting.

Before transporting the device, allow coolant to drain completely and detach the following components:

Wirefeeder

Wirespool

Shielding gas cylinder

After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service technicians before commissioning the device.

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 risk of

injury or death to the operator or a third party

damage to the device and other material assets belonging to the operator

inefficient operation of the device

Any safety devices that are not functioning properly must be repaired before switching on the device.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one is likely to be endangered.

Check the device at least once a week for obvious damage and proper functioning of safety devices.

Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane.

Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, ﬂammability, etc.).

Only use suitable original coolant from the manufacturer.

Do not mix the manufacturer's original coolant with other coolants.

Commissioning, maintenance and repair

Only connect the manufacturer's system components to the cooling circuit.

The manufacturer accepts no liability for damage resulting from use of other system components or a different coolant. In addition, all warranty claims will be forfeited.

Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.

Used coolant must be disposed of properly in accordance with the relevant national and international regulations. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website.

Check the coolant level before starting to weld, while the system is still cool.

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.

Safety inspection

Disposal Waste electrical and electronic equipment must be collected separately and re-

The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.

The manufacturer recommends that the power source be calibrated during the same 12-month period.

A safety inspection should be carried out by a qualified electrician

after any changes are made

after any additional parts are installed, or after any conversions

after repair, care and maintenance has been carried out

at least every twelve months.

For safety inspections, follow the appropriate national and international standards and directives.

Further details on safety inspection and calibration can be obtained from your service centre. They will provide you on request with any documents you may require.

cycled in an environmentally-friendly way, in accordance with the European Directive and national legislation. Used equipment must be returned to the distributor or disposed of via an approved local collection and disposal facility. Correct disposal of used equipment promotes the sustainable recycling of material resources. Failing to dispose of used equipment correctly can lead to adverse health and/or environmental impacts.

Packaging materials

Separate collection according to material. Check your local authority regulations. Crush containers to reduce size.

Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage

and electromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).

Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

Data protection The user is responsible for the safekeeping of any changes made to the factory

settings. The manufacturer accepts no liability for any deleted personal settings.

The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your comments.

General information

General

Device concept

Functional principle

The TransSteel (TSt) 3500 Syn and TSt 5000 Syn power sources are fully digitised, microprocessor-controlled inverter power sources.

The modular design and potential for system add-ons ensure a high degree of ﬂexibility. The devices are designed for the welding of steel and the following welding processes:

MAG welding

MMA welding

The device has a "Power limitation" safety feature. This means that the

TransSteel 3500 / 5000 Syn

The central control and regulation unit of the power source 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 command values are kept.

power source can be operated at the power limit without compromising process safety. For more information, see the "Welding mode" section.

Application areas

Warning notices on the device

This results in:

a precise welding process,

a high degree of reproducibility of all results,

excellent weld properties.

The devices are used in the commercial sector for manual and automated applications with classical steel and galvanised sheets:

Machine and equipment construction

Steelwork

Plant and container construction

Shipyards and the offshore industry

Metal and gantry construction

Rail vehicle construction

Metalworking trades

Warning notices and safety symbols are affixed to the power source. 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 damage.

Warning notices affixed to the power source

Welding is dangerous. The following basic requirements must be met:

Welders must be sufficiently qualified

Suitable protective equipment must be used

All persons not involved in the welding process must be kept at a safe dis-

tance

Do not use the functions described here until you have fully read and understood the following documents:

These Operating Instructions

All the Operating Instructions for the system components, especially the

safety rules

Welding processes, procedures and welding characteristics for MIG/MAG welding

General Power sources offer a selection of welding processes, procedures and welding

characteristics that enable a wide range of materials to be processed in the most effective way.

Welding characteristics

When selecting the filler metal, various process-optimised welding characteristics are available depending on the welding process and shielding gas combination. The supplementary label for the welding process provides information about certain properties and the use of the welding characteristic:

Special welding characteristic properties:

Steel Characteristics for conventional welding tasks

Steel root Characteristics for root passes with powerful arc

Steel dynamic Characteristics for high welding speeds with concentrated

arc

Summary of MIG/MAG standard synergic welding

Short description of arc air gouging

MIG/MAG standard synergic

The MIG/MAG standard synergic welding process is a MIG/MAG welding process across the entire power range of the power source with the following arc types:

Dip transfer arc Droplet transfer takes place during a short circuit in the lower power range.

Intermediate arc The droplet increases in size on 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.

During arc air gouging, an arc is ignited between a carbon electrode and the workpiece, and the base material is melted and cleaned with compressed air. The operating parameters for arc air gouging are defined in a special characteristic.

Applications:

Removing shrink holes, pores, or slag inclusions from workpieces

Detaching sprue or finishing entire workpiece surfaces in casting operations

Edge preparation for heavy plates

Preparation and repair of weld seams

Working out root passes or defects

Production of air gaps

System components

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

General The power sources can be operated with various system components and op-

tions. This makes it possible to optimise procedures and to simplify machine handling and operation, as necessitated by the particular field of application in which the power source is to be used.

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 device

▶

and all system components.

(1) Welding torch (2) Wirefeeder (3) Wirefeeder holder (4) Interconnecting hosepacks (5) Power source (6) Cooling unit (7) Trolley and gas cylinder holders (8) Grounding cable and electrode cable

Options

General The options listed below are available with all power source variants.

Machine interface

The machine interface connects the power source to the machine control. The following signals can be transmitted across the machine interface:

Signal input: Start of welding / end of welding

Signal input for a ﬂoating contact (sensor, relay, etc.) between pin X1:1 and

pin X1:2 The machine control signal input is processed by the power source in the

same way as a welding torch signal input. Ensure that the correct mode is set (2-step or 4-step) Use gold-plated contacts for optimum signal transmission

Signal output: Current ﬂow signal

Floating contact between pin X1:3 and pin X1:4

NOTE!

The machine interface isolates the welding circuit up to a maximum of 500 V DC.

To ensure reliable isolation from the welding circuit, use a relay with an insulation voltage greater than 1500 V DC.

Technical data - start/end of welding signal input

maxAC

5 V

Gas preheater CO2 connection

max

4 mA

Technical data - current ﬂow signal output

max

24 V

20 mA

External gas preheaters for gas pressure regulators can be connected to the gas preheater CO2 connection. Gas preheaters have a 36 V supply.

NOTE!

Voltage is only supplied to gas preheaters during welding operations.

The power of the gas preheaters must not exceed 150 W. The gas preheater supply is protected against overloads and short-circuits.

Technical data

36 V

A, max

150 W

Keylock switch An optional keylock switch is available for the power source to prevent the set-

tings from being inadvertently changed on the control panel. If the keylock switch is in the horizontal position,

no settings can be set on the control panel,

only parameter settings can be retrieved,

any assigned "Save" button can be retrieved provided that an assigned "Save"

button was selected when the keylock was enabled.

Keylock activated:

"CLO | SEd" appears on the display

Keylock deactivated:

"OP | En" appears on the display

VRD: safety function

A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. It is recommended for environments in which the risk of an electric shock or electrical accident is increased considerably during arc welding:

Due to a low human body resistance of the welder

If the welder is exposed to a clear risk of touching the workpiece or other

parts of the welding circuit

A low human body resistance is possible when there is:

water in the area

humidity

heat, particularly ambient temperatures in excess of 32°C (89.6°F)

In wet, damp or hot locations, humidity or sweat can significantly reduce the skin resistance and the insulation resistance of protective equipment and clothing.

Such environments can include:

Temporary dams for draining certain areas of a site during construction work

(cofferdams) Trenches

Mines

Rain

Areas partly submerged by water

Spraywater areas

The VRD option reduces the voltage between the electrode and the workpiece. In safe conditions, the indicator for the currently selected welding process is permanently lit. A safe condition is defined as follows:

The output voltage in an open circuit is limited to 35 V.

For as long as the welding operation is active (welding circuit resistance < 200 Ohm), the indicator of the currently selected welding process ﬂashes and the output voltage may exceed 35 V.

VRD: safety principle

In MMA welding mode: Within 0.3 seconds of end of welding:

VRD is active again

The output voltage is limited to 35 V once more

The welding circuit resistance is greater than the minimum human body resistance (greater than or equal to 200 Ohm):

VRD is active

Open circuit voltage is limited to

35 V Unintentional contact with the

output voltage does not put the welder at risk

The welding circuit resistance is less than the minimum human body resistance (less than 200 Ohm):

VRD is inactive

Output voltage not restricted in

order to ensure sufficient welding power Example: Welding starts

Control elements and connections

Synergic control panel

General The functions on the control panel are all arranged in a logical way. The various

welding parameters can easily be selected using buttons and can just as easily be

altered using buttons or the adjusting dial

displayed on the digital display during welding

The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.

NOTE!

Due to software updates, you may find that your device has certain functions that are not described in these operating instructions or vice versa.

Individual illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters can be adjusted manually. The Synergic control panel also allows parameters to be set manually.

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 device

▶

and all system components.

Synergic control

(1) (2)

(3) (4)

(5)

(6)(7)

(14)(13)

(12)

(11)

(10) (8)

(9)

(15) (16)

panel

(1) "Parameter selection" button (right)

a) for selecting the following welding parameters

Arc length correction

for correcting the arc length

Welding voltage in V *)

Before the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Arc-force dynamic

for inﬂuencing the short-circuiting dynamic at the moment of droplet transfer

- ... harder, more stable arc 0 ... neutral arc + ... soft, low-spatter arc

b) for changing parameters in the Setup menu

(2) "Parameter selection" button (left)

a) for selecting the following welding parameters

Sheet thickness

Sheet thickness in mm or in. If the welding current to be selected is not known, it is sufficient to enter the sheet thickness. The required welding current and any other parameters marked with *) will then be adjusted automatically.

Welding current *)

Welding current in A Before the start of welding, the device automatically displays a standard value based on the programmed parameters. During welding, the actual value is displayed.

Wire speed *)

Wire speed in m/min or ipm.

b) for changing parameters in the Setup menu

(3) Adjusting dial (right)

for changing the arc length correction, welding voltage and arc-force dynamic parameters for changing welding parameters in the Setup menu

(4) Adjusting dial (left)

for changing the sheet thickness, welding current and wire speed parameters for selecting welding parameters in the Setup menu

(5) "Save" buttons (Easy Job)

zum Speichern von bis zu 5 Arbeitspunkten

(6) "Process" button **)

for saving up to 5 operating points

MANUAL - MIG/MAG standard manual welding

SYNERGIC - MIG/MAG standard synergic welding

STICK - Manual metal arc (MMA) welding

(7) "Mode" button

for selecting the operating mode

2 T - 2-step mode

4 T - 2-step mode

S 4 T - Special 4-step mode

(8) "Shielding gas" button

for selecting the shielding gas to be used. The SP parameter is reserved for additional shielding gases. When a shielding gas is selected, the LED behind the relevant shielding gas lights up.

(9) "Wire diameter" button

for selecting the wire diameter to be used. The SP parameter is reserved for additional wire diameters. When a wire diameter is selected, the LED behind the relevant wire diameter lights up.

(10) "Material" button

for selecting the filler metal to be used. The SP parameter is reserved for additional filler metals When a material is selected, the LED behind the relevant filler metal lights up.

(11) "Wire threading" button

Press and hold the button: gasless wire threading into the torch hosepack

While the button is being held, the wire drive operates at feeder inching speed.

(12) "Gas-test" button

For setting the necessary gas ﬂow rate on the pressure regulator. Press the button once: shielding gas ﬂows out Press the button again: shielding gas ﬂow stops

If the "Gas-test" button is not tapped again, the shielding gas ﬂow will stop after 30 s.

(13) SF - spot / stitch welding indicator

lights up if a value has been entered for the spot / stitch welding time Setup parameter (SPt) (spot or stitch welding operating mode is enabled)

(14) Intermediate arc indicator

A spatter-prone "intermediate arc" occurs between the dip transfer arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical range.

(15) HOLD indicator

At the end of each welding operation, the actual values for welding current and welding voltage are stored - the "HOLD" indicator lights up.

(16) Real Energy Input

for displaying the energy applied during the welding operation.

The Real Energy Input display must be activated in level 2 of the Setup menu - EnE parameter. The value continuously rises during welding in line with the permanently increasing energy yield. The final value at the end of welding remains stored until welding starts again or the power source is switched back on - the HOLD indicator lights up.

*) If one of these parameters is selected in the MIG/MAG standard synergic

welding process, then the synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically.

**) In conjunction with the VRD option, the currently selected welding pro-

cess indicator is simultaneously an additional indicator:

The indicator is permanently lit: The Voltage Reduction Device (VRD)

is active and is limiting the output voltage to less than 35 V. The indicator starts to ﬂash as soon as a welding action starts in

which the output voltage can exceed 35 V.

Service para-

meters

Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.

Opening the display

Selecting parameters

Available parameters

Example:

1.00 | 4.21

Example: 2 | 491

Example: r 2 | 290

The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"

Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the required Setup parameter

Explanation

Firmware version

Welding program configuration

Number of the currently selected welding program

Indicates the actual arc time since us654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins

ing for the first time

Note: The arc time indicator is not

suitable as a basis for calculating hir-

ing fees, warranty services, etc.

Example: iFd | 0.0

Motor current for wire drive in A

The value changes as soon as the mo-

tor is running.

2nd Second menu level for service techni-

cians

Keylock A keylock can be selected to prevent the settings from being inadvertently

changed on the control panel. As long as the keylock is active

No settings can be made on the control panel

Only parameter settings can be retrieved

Any assigned "Save" button can be retrieved provided that an assigned "Save"

button was selected when the keylock was enabled

To activate/deactivate the keylock:

Keylock activated: The message "CLO | SEd" appears on the displays.

Keylock deactivated: The message "OP | En" appears on the displays.

The keylock can be activated and deactivated using the keylock switch option.

Connections, switches and mechanical compon-

(1)

(2)

(3)

(4)

(6)

(7)

(9)

(8)

(5)

ents

TSt 3500/5000 Syn power source

(1) (-) - current socket with bayonet latch

Used for

Connecting the grounding cable during MIG/MAG welding

Connecting the electrode cable or grounding cable during manual

metal arc welding (depending on the type of electrode used)

(2) Mains switch

For switching the power source on and off

(3) (+) - current socket with bayonet latch

Used for

Connecting the current cable from the interconnecting hosepack dur-

ing MIG/MAG welding Connecting the electrode cable or grounding cable during manual

metal arc welding (depending on the type of electrode used)

(4) Gas preheater socket (option)

(5) Machine interface (optional)

(6) EASY DOCUMENTATION sticker

(7) Mains cable with strain relief device

(8) LocalNet port

Standardised connection socket for the wirefeeder (interconnecting hosepack)

(9) Air filter

Remove from the side for cleaning

Installation and commissioning

Minimum equipment needed for welding task

General Depending on which welding process you intend to use, a certain minimum equip-

ment level will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the welding task are then described.

Gas-cooled MIG/MAG welding

MIG/MAG welding, watercooled

MMA welding

Power source

Grounding cable

MIG/MAG welding torch, gas-cooled

Gas connection (shielding gas supply)

Wirefeeder (VR 5000 Remote)

Interconnecting hosepack, gas-cooled

Wire electrode

Power source

Cooling unit

Grounding cable

MIG/MAG welding torch, water-cooled

Gas connection (shielding gas supply)

Wirefeeder (VR 5000 Remote)

Water-cooling option (for VR 5000 Remote)

Interconnecting hosepack, water-cooled

Wire electrode

Power source

Grounding cable

Electrode holder

Rod electrodes

Before installation and commissioning

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 device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Utilisation for intended purpose only

Setup regulations

The power source may only be used for MIG/MAG and MMA welding. Any other form of usage is deemed "not in accordance with the intended purpose". The manufacturer shall not be held liable for any damages arising from such usage.

Utilisation in accordance with the "intended purpose" also comprises

following all the information in the operating instructions

carrying out all the specified inspection and servicing work

The device is tested to IP 23 protection, meaning:

Protection against penetration by solid foreign bodies with diameters > 12

mm (0.49 in.) Protection against spraywater at any angle up to 60° to the vertical

The device can be set up and operated outdoors in accordance with degree of protection IP 23. Avoid direct wetting (e.g. from rain).

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

WARNING!

Mains connection

Danger from electrical current due to electrically conductive dust in the device.

This can result in serious injury and damage to property.

Only operate the device with an air filter fitted. The air filter is a very import-

▶

ant safety device for achieving IP 23 protection.

The venting duct is a very important safety device. When choosing the installation location, ensure that the cooling air can enter and exit unhindered through the air ducts on the front and back of the device. Electroconductive metallic dust (e.g. from grinding work) must not be allowed to get sucked into the device.

The devices are designed for the mains voltage specified on the rating plate. If your version of the appliance does not come with mains cables and plugs readyfitted, these must be fitted in accordance with national regulations and standards. For details of fuse protection of the mains lead, please see the technical data.

CAUTION!

Danger due to insufficiently dimensioned electrical installations.

This can result in damage to property.

Dimension the mains lead and its fuse to suit the local power supply.

▶

The technical data shown on the rating plate applies.

Connecting the mains cable

Safety

Danger due to work that has been carried out incorrectly.

This can result in serious injury and damage to property.

▶ ▶

Danger due to improperly prepared mains cable.

This can cause short circuits and damage.

▶

General If no mains cable is connected, a mains cable that is suitable for the connection

voltage must be fitted before commissioning. A strain-relief device for the following cable cross-sections is fitted to the power source:

WARNING!

The work described below must only be carried out by trained and qualified personnel. Observe national standards and directives.

CAUTION!

Fit ferrules to all phase conductors and the ground conductor of the stripped mains cable.

Stipulated mains cables and strain-relief devices

Power source Cable cross-section

fitted strain-relief device for Canada / US

TSt 3500 Syn AWG 12 *) 4G2.5

TSt 5000 Syn AWG 10 *) 4G4

TSt 3500 MV Syn AWG 10 *) 4G4

TSt 5000 MV Syn AWG 6 *) 4G10

*) Canada / US cable type: Extra-hard usage

Strain-relief devices for other cable cross-sections must be designed accordingly.

Power source Mains voltage Cable cross-sec-

tion

Canada / US

TSt 3500 Syn 3 x 380 / 400 V AWG 12 *) 4G2.5

3 x 460 V AWG 12 *) 4G2.5

Europe

TSt 5000 Syn 3 x 380 / 400 V AWG 8 *) 4G4

3 x 460 V AWG 10 *) 4G4

TSt 3500 MV Syn

3 x 208 / 230 / 400 / 460VAWG 10 *) 4G4

TSt 5000 MV

100mm

(4inch)

3 x 208 / 230 / 400 / 460VAWG 6 *) 4G10

Syn

*) Canada / US cable type: Extra-hard usage

The item numbers of the different cables can be found in the Spare Parts List of the device.

AWG ... American Wire Gauge

Connecting the mains cable

Fitting the Europe strainrelief device

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning.

The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

An illustration of the mains cable connection can be found in the following sections: "Fitting the strain-relief device" or "Fitting the strain-relief device for Canada / US". To connect the mains cable, proceed as follows:

Remove the side panel from the device

Push the mains cable in far enough to make it possible to connect the ground

conductor and the phase conductors to the block terminal properly.

Fit ferrules to the ground conductor and phase conductors

Connect the ground conductor and phase conductors to the block terminal

Use the strain-relief device to secure the mains cable

Fit the side panel of the device

1,2 Nm

Fitting the Canada/US strain-relief device

IMPORTANT! Tie the phase conduct-

ors near the block terminals using cable ties.

1 2

3,5 Nm

IMPORTANT! Tie the phase conduct-

ors near the block terminals using cable ties.

Generator-powered operation

Generatorpowered operation

The power source is generator-compatible.

The maximum apparent power S

of the power source must be known in order

1max

to select the correct generator output. The maximum apparent power S

3-phase devices: S

Single-phase devices: S

1max

= I

1max

= I

x U1 x √3

See device rating plate or technical data for I

The generator apparent power S

of the power source is calculated as follows:

1max

x U

1max

GEN

and U1 values

1max

needed is calculated using the following rule

of thumb:

GEN

= S

1max

x 1.35

A smaller generator may be used when not welding at full power.

IMPORTANT! The generator apparent power S the maximum apparent power S

of the power source.

1max

must always be higher than

GEN

When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the singlephase power of the generator from the generator manufacturer.

NOTE!

The voltage delivered by the generator must never exceed the upper or lower limits of the mains voltage tolerance range.

Details of the mains voltage tolerance can be found in the "Technical data" section.

Start-up

General Commissioning a power source is described by reference to a manual water-

cooled MIG/MAG application.

Information on system components

Assembling the system components (overview)

The steps and activities described below include references to various system components, including:

trolley

upright console

cooling units

wire-feed units

interconnecting hosepacks

welding torches, etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.

WARNING!

Work that is carried out incorrectly can cause serious injury and damage.

The following activities must only be carried out by trained and qualified per-

▶

sonnel. All instructions in the section headed "Safety rules" must be observed.

▶

The diagram below is intended to show you how to fit the individual system components.

Placing the

wirefeeder on the power source

CAUTION!

Risk of injury and material damage from falling wirefeeder.

Make sure that the wirefeeeder is located securely on the swivel pin and that

▶

the devices, upright consoles and trolleys are stable.

Fitting the inter-

connecting hosepack strainrelief device

Connecting the interconnecting hosepack

Fitting the strain-relief device to the trolley

Fitting the strain-relief device to the wirefeeder

IMPORTANT! To prevent wear and tear, leave some slack when connecting the cables. A strain-relief device is not provided for 1.2 m (3 ft 11.24 in.) interconnecting hosepacks.

WARNING!

Fitting the equipment incorrectly can cause serious injury and damage.

Do not carry out the steps described here until you have read and completely

▶

understood all the Operating Instructions.

NOTE!

When connecting the interconnecting hosepack, check that

all connections are connected properly

▶

all cables, leads and hosepacks are undamaged and correctly insulated

▶

IMPORTANT! There is no cooling unit present in the case of gas-cooled systems. There is no need to attach the water connections in the case of gas-cooled systems.

Connecting the gas cylinder

WARNING!

There is a high risk of very serious injury and damage if a gas cylinder falls over.

When using gas cylinders:

Place them on a solid, level surface in such a way that they remain stable

▶

Secure the gas cylinders to prevent them from falling over

▶

Fit the VR holder option

▶

Observe the safety rules of the gas cylinder manufacturer

▶

Place the gas cylinder on the base

of the trolley

Secure the gas cylinder by fixing

the cylinder strap around the upper part of the cylinder (but not around the neck) to prevent it from toppling over

Take the protective cap off the gas

cylinder

Brieﬂy open the gas cylinder valve

to remove any dust or dirt

Inspect the seal on the gas pres-

sure regulator

Screw the pressure regulator onto

the gas cylinder and tighten it

Connect the shielding gas hose of

the interconnecting hosepack to the pressure regulator using the gas hose

NOTE!

US devices are supplied with an adapter for the gas hose:

Seal male thread spacers on the gas solenoid valve using suitable means be-

▶

fore screwing on the adapter. Test the adapter to ensure that it is gas-tight.

▶

Establishing a

ground earth connection

NOTE!

When establishing a ground earth connection, observe the following points:

Use a separate grounding cable for each power source

▶

Keep the plus cable and grounding cable together as long and as close as

▶

possible Physically separate the welding circuits of individual power sources

▶

Do not route several grounding cables in parallel;

▶

if parallel routing cannot be avoided, keep a minimum distance of 30 cm between the welding circuits Keep the grounding cable as short as possible, provide a large cable cross-

▶

section Do not cross grounding cables

▶

Avoid ferromagnetic materials between the grounding cable and the inter-

▶

connecting hosepack Do not wind up long grounding cables - coil effect!

▶

Lay long grounding cables in loops Do not route grounding cables in iron pipes, metal cable conduits or on steel

▶

rails, avoid cable ducts; (routing of plus cables and grounding cables together in an iron pipe does not cause any problems) If there are several grounding cables, separating the grounding points on the

▶

component so that they are as far away from one another as possible is recommended, as well as preventing crossed current paths from occurring underneath the individual arcs. Use compensated interconnecting hosepacks (interconnecting hosepacks

▶

with integrated grounding cable)

Connecting

31 2

4 5

MIG/MAG welding torches

* when the optional water connection and the water-cooled welding torch are fitted

Inserting/replacing feed rollers

CAUTION!

Danger from feed roller holders ﬂying upwards.

This can result in injuries.

When unlocking the clamping lever, keep fingers away from the area to the

▶

left and right of the lever.

CAUTION!

Danger from exposed feed rollers.

This can result in injuries.

Always fit the protective cover of the 4-roller drive after inserting or repla-

▶

cing a feed roller.

Inserting the wirespool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

While inserting the wirespool, hold the end of the wire electrode firmly to

▶

avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling wirespool.

Make sure the wirespool sits securely on the wirespool holder.

▶

CAUTION!

Risk of injury and material damage if the wirespool topples over because the locking ring has been placed the wrong way around.

Always position the locking ring as shown in the diagram on the left.

▶

Inserting the basket-type spool

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

When inserting the basket-type spool, hold the end of the wire electrode

▶

firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of injury from falling basket-type spool.

Make sure that the basket-type spool and basket-type spool adapter are fit-

▶

ted securely to the wirespool holder.

NOTE!

When working with basket-type spools, only use the basket-type spool adapter included in the scope of supply.

CAUTION!

Risk of injury and material damage if the basket-type spool topples over because the locking ring has been placed the wrong way round.

Always position the locking ring as shown in the diagram on the left.

▶

CAUTION!

Feeding in the wire electrode

Risk of injury and material damage from falling basket-type spool.

Place the basket-type spool on the adapter provided in such a way that the

▶

bars on the spool are inside the adapter guideways.

1 2

CAUTION!

Risk of injury due to springiness of spooled wire electrode.

When inserting the wire electrode into the 4-roller drive, hold the end of the

▶

wire electrode firmly to avoid injuries caused by the wire springing back.

CAUTION!

Risk of damage to the welding torch from sharp end of wire electrode.

Deburr the end of the wire electrode well before threading in.

▶

1 2

CAUTION!

Fdi

2 3

2,5

t (s)

(m/min, ipm)

Risk of injury from emerging wire electrode.

When pressing the wire threading button or the torch trigger, keep the weld-

▶

ing torch away from your face and body, and wear suitable protective goggles.

IMPORTANT! To facilitate the exact positioning of the wire electrode, the following sequences are possible when the wire threading button is pressed and held down.

Hold the button for up to one

second ... the wire speed stays at 1 m/min or 39.37 ipm for the first second. Hold the button for up to 2.5

seconds ... after one second has elapsed, the wire speed increases at a uniform rate over the next 1.5 seconds. Hold the button for more than 2.5

seconds ... after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the Fdi welding parameter.

If the "Wire threading" button is released and pressed again before one second has elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire speed of 1 m/min or 39.37 ipm where necessary.

If there is no "Wire threading" button, the torch trigger can be used in the same way. Before using the torch trigger for wire threading, proceed as follows:

Press the "Mode" button to select 2-step mode

Set the "Ito" parameter to "Off" in the Setup menu

CAUTION!

Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.

When pressing the torch trigger:

Keep the welding torch away from your face and body

▶

Wear suitable protective goggles

▶

Do not point the welding torch at people

▶

Make sure that the wire electrode does not touch any conductive or earthed

▶

parts (e.g. housing)

IMPORTANT! If the torch trigger is pressed instead of the "Wire threading" button, the welding wire runs at the feeder creep speed (depending on the welding program) for the first 3 seconds. After these 3 seconds, wirefeeding is brieﬂy interrupted.

The welding system detects that the welding process should not start, but that the wire is to be fed in. At the same time, the gas solenoid valve closes, and the welding voltage on the wire electrode is switched off.

If the torch trigger is held down, wirefeeding restarts immediately without shield-

ing gas and welding voltage, and the process continues as described above.

3 4

Setting the contact pressure

CAUTION!

Risk from excessive contact pressure.

This can result in severe damage to property and poor weld properties.

Set the contact pressure in such a way that the wire electrode is not de-

▶

formed but nevertheless ensures proper wirefeeding.

Contact pressure preferred values for U-groove rollers:

Steel: 4 - 5

CrNi: 4 - 5

Tubular cored electrodes: 2 - 3

Adjusting the brake

NOTE!

After releasing the "Wire threading" button, the wirespool should stop unreeling.

If it continues unreeling, readjust the brake.

▶

STOP

Design of the brake

WARNING!

Danger from incorrect installation.

This can result in severe personal injury and damage to property.

Do not dismantle the brake.

▶

Maintenance and servicing of

▶

brakes is to be carried out by trained, qualified personnel only.

The brake is only available as a complete unit. This illustration of the brake is for information purposes only.

Welding

Power limitation

Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the

power source can be operated at the power limit whilst maintaining process safety.

Wire speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. In order to prevent this, the welding power is lowered.

For the selected "MIG/MAG standard synergic welding" process, the symbol for the "Wire speed" parameter ﬂashes as soon as the safety function trips. The ﬂashing continues until the next welding start-up, or until the next parameter change.

For example, if the "Wire speed" parameter is selected, the reduced value for wire speed is displayed.

MIG/MAG modes

General

Symbols and their explanations

WARNING!

Operating the equipment incorrectly can cause serious injury and damage.

Do not use the functions described here until you have read and completely

▶

understood these Operating Instructions. Do not use the functions described here until you have fully read and under-

▶

stood all of the Operating Instructions for the system components, in particular the safety rules.

For details of the meaning, settings, setting range and units of the available welding parameters (e.g. gas pre-ﬂow time), please refer to the "Setup parameters" chapter.

Press the torch trigger | Hold the torch trigger | Release the torch trigger

GPr Gas pre-ﬂow time

I-S Starting current

Can be increased or decreased depending on the application

SL Slope

The starting current is continuously lowered as far as the welding current and the welding current as far as the final current

I Welding current phase

Uniform thermal input into the base material, whose temperature is raised by the advancing heat

I-E Final current

To fill the end-crater

GPo Gas post-ﬂow time

SPt Spot welding time / interval welding time

SPb Interval pause time

2-step mode

GPr

GPo

GPr GPo

"2-step mode" is suitable for

Tacking work

Short weld seams

Automated and robot welding

4-step mode

"4-step mode" is suitable for longer weld seams.

Special 4-step

+ +

I-S I-E

GPr SL SL

GPo

GPr GPoSPt

< SPt

mode

Spot welding

Special 4-step mode allows the starting and final current to be configured in addition to the advantages of 4-step mode.

The "Spot welding" mode is suitable for welded joints on overlapped sheets.

Start by pressing and releasing the torch trigger - GPr gas pre-ﬂow time - Welding current phase for the duration of the SPt spot welding time - GPo gas post-

ﬂow.

If the torch trigger is pressed again before the end of the spot welding time (< SPt), the process is cancelled immediately.

2-step stitch

GPr SPt SPtSPb

GPo

I I

GPr SPt SPtSPb

GPo

welding

4-step stitch welding

2-step stitch welding

The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the base material.

4-step stitch welding

The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the base material.

MIG/MAG welding

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 device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparatory work

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

Connect welding torch water hoses to the correct connections on the

wirefeeder (when using a cooling unit and water-cooled welding torch)

Plug in the mains plug

Move the mains switch to the "I" position:

all the indicators on the control panel light up brieﬂy

where applicable, the cooling unit starts to run

IMPORTANT! Follow the safety rules and note operating conditions in the cooling unit Operating Instructions.

MIG/MAG standard synergic welding

MIG/MAG standard manual welding

Spot and stitch welding

MIG/MAG standard synergic welding

Press the "Material" button to select the filler metal to be used.

Press the "Wire diameter" button to select the diameter of the wire elec-

trode used.

Press the "Shielding gas" button to select the shielding gas to be used.

The assignment of the SP position is in the welding program tables in the appendix.

Press the "Process" button to select the desired welding process:

MIG/MAG standard synergic welding

Press the "Mode" button to select the desired MIG/MAG mode:

2-step mode

4-step mode

Special 4-step mode

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000 remote control) on the control panel of the power source.

Use the "Parameter selection" buttons to select the welding parameters to

be used to specify the welding power:

Sheet thickness

Welding current

Wire speed

Welding voltage

Use the appropriate adjusting dial to set the relevant welding parameters.

The welding parameter values are shown in the digital display located above them. All welding parameter set values remain stored until the next time they are changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter.

Open the gas cylinder valve

Setting the shielding gas ﬂow rate:

Tap the "Gas-test" button

Turn the adjusting screw on the underside of the pressure regulator

until the pressure gauge shows the required gas ﬂow rate

Tap the "Gas-test" button again

CAUTION!

Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.

When pressing the torch trigger

keep the welding torch away from your face and body

▶

wear suitable protective goggles

▶

do not point the welding torch at people

▶

make sure that the wire electrode does not touch any conductive or earthed

▶

parts (e.g. housing)

Press the torch trigger and start welding

Corrections during welding

The arc length correction and arc-force dynamic parameters can be used to optimise the welding result.

Arc length correction:

- = shorter arc, reduced welding voltage 0 = neutral arc + = longer arc, increased welding voltage

Arc-force dynamic:

To inﬂuence the short-circuiting dynamic at the instant of droplet transfer

- = hard, stable arc 0 = neutral arc + = soft, low-spatter arc

MIG/MAG standard manual welding

General The MIG/MAG standard manual welding process is a MIG/MAG welding process

with no synergic function. Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

Available parameters

MIG/MAG standard manual welding

The following parameters are available in MIG/MAG manual welding:

Wire feed speed

1 m/min (39.37 ipm) - maximum wire feed speed, e.g. 25 m/min (984.25 ipm)

Welding voltage

TSt 3500: 15.5 - 31.5 V TSt 5000: 14.5 - 39 V

Dynamic

for inﬂuencing the short-circuiting dynamic at the moment of particle transfer

Welding current

only for displaying the actual value

Press the "Process" button to select the desired welding process:

MIG/MAG standard manual welding

Press the "Mode" button to select the desired MIG/MAG mode:

2-step mode

4-step mode

In MIG/MAG standard manual welding, special 4-step mode corres-

ponds to conventional 4-step mode.

Press the "Parameter selection" button to select the wire speed parameter

Use the adjusting dial to set the desired value for the wire speed

Press the "Parameter selection" button to select the welding voltage para-

meter

Use the adjusting dial to set the desired value for the welding voltage

The welding parameter values are shown in the digital display located

above them.

All welding parameter set values remain stored until the next time they are

changed. This applies even if the power source is switched off and on again. To display the actual welding current during welding, select the welding current parameter.

To display the actual welding current during welding:

Press the "Parameter selection" button to select the welding current

parameter

The actual welding current is shown on the digital display during weld-

ing.

Open the gas cylinder valve

Setting the shielding gas ﬂow rate:

Tap the "Gas-test" button

Turn the adjusting screw on the underside of the pressure regulator

until the pressure gauge shows the required gas ﬂow rate

Tap the "Gas-test" button again

CAUTION!

Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.

When pressing the torch trigger

keep the welding torch away from your face and body

▶

wear suitable protective goggles

▶

do not point the welding torch at people

▶

make sure that the wire electrode does not touch any conductive or earthed

▶

parts (e.g. housing)

Corrections during welding

Press the torch trigger and start welding

To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.

Press the "Parameter selection" button to select the arc-force dynamic para-

meter

Use the adjusting dial to set the desired arc-force dynamic value

The welding parameter value is shown in the digital display located above it.

Spot and stitch welding

General The spot and stitch welding modes are MIG/MAG welding processes. The spot

and stitch welding modes can be activated on the power source control panel.

Spot welding is used on welded joints on overlapped sheets that are only accessible on one side.

Stitch welding is used for light-gauge sheets. As the wire electrode is not fed continuously, the weld pool can cool down during the intervals. Local overheating leading to the base material being melted through is largely avoided.

Spot welding Activating spot welding mode:

For the SPt Setup parameter (spot / stitch welding time), enter a value >

OFF

As soon as a value is entered for the SPt Setup parameter, spot welding mode is activated. The spot / stitch welding indicator (SF) lights up on the control panel.

Preparations:

Set the spot / stitch welding time (SPt) in the Setup menu

Select the filler metal, wire diameter and shielding gas being used with the

relevant buttons

Select the desired welding process:

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

Select the desired MIG/MAG mode:

2-step mode

(For spot welding mode, only 2-step mode is available)

Depending on the selected welding process, select the desired welding para-

meters using the relevant adjusting dial

Open the gas cylinder valve

Set the shielding gas ﬂow rate

WARNING!

Danger due to emerging wire electrode.

This can result in serious personal injuries.

Hold the welding torch so that the tip of the welding torch points away from

▶

the face and body. Wear suitable protective goggles.

▶

Do not point the welding torch at people.

▶

Ensure that the wire electrode does not touch any electrically conductive ob-

▶

jects.

Spot welding

Procedure for producing a welding spot:

Hold the welding torch vertical

Press and release the torch trigger

Keep the welding torch in the same position

Wait for the gas post-ﬂow time

Raise the welding torch

Stitch welding Activating stitch welding mode:

For the SPt Setup parameter (spot / stitch welding time), enter a value >

OFF For the SPt Setup parameter (spot pause time), enter a value > OFF

As soon as a value is entered for the SPt Setup parameter, the spot / stitch welding indicator (SF) lights up.

Preparations:

Set the spot / stitch welding time (SPt) in the Setup menu

Set the spot pause time (SPb) in the Setup menu

Select the filler metal, wire diameter and shielding gas being used with the

relevant buttons

Select the desired welding process:

MIG/MAG standard manual welding

MIG/MAG standard synergic welding

Select the desired MIG/MAG mode for stitch welding mode:

2-step mode

4-step mode

Depending on the selected welding process, select the desired welding para-

meters using the relevant adjusting dial

Open the gas cylinder valve

Set the shielding gas ﬂow rate

CAUTION!

Risk of injury and damage from electric shock and from the wire electrode emerging from the torch.

When pressing the torch trigger

keep the welding torch away from your face and body

▶

wear suitable protective goggles

▶

do not point the welding torch at people

▶

make sure that the wire electrode does not touch any conductive or earthed

▶

parts (e.g. housing)

Stitch welding

Procedure for stitch welding:

Hold the welding torch vertical

Depending on the selected mode:

press and hold the torch trigger (2-step mode) press and release the torch trigger (4-step mode)

Keep the torch in the same position

Wait for the welding interval

Position the welding torch at the next point

To end stitch welding, depending on the selected mode:

release the torch trigger (2-step mode) press and release the torch trigger (4-step mode)

Wait for the gas post-ﬂow time

Lift the torch off the workpiece

EasyJob mode

General The "Save" buttons allow up to 5 EasyJob operating points to be saved. Every op-

erating point matches the settings on the control panel.

EasyJobs can be stored for each welding process.

IMPORTANT! Setup parameters are not saved at this time.

Storing EasyJob operating points

Retrieving EasyJob operating points

Deleting EasyJob operating points

Press and hold one of the "Save" buttons to save the current set-

tings on the control panel, e.g.:

The left indicator displays "Pro"

After a short time, the left indicator switches to the original

value

Release the "Save" button

To retrieve saved settings, press the corresponding "Save" button

brieﬂy, e.g.:

The control panel will show the saved settings

Press and hold the relevant "Save" button to delete the memory

content of that "Save" button, e.g.:

The left indicator displays "Pro".

After a short time, the left indicator switches to the original

value

Keep the "Save" button held down

The left display shows "CLr".

After a while, both displays show "---"

Retrieving EasyJob operating points on the Up/ Down welding torch

Release the "Save" button

One of the "Save" buttons on the control panel must be pressed in order to retrieve the saved settings using the Up/Down welding torch.

Press one of the "Save" buttons on the control panel, e.g.:

The control panel will show the saved settings.

The "Save" buttons can now be selected using the buttons on the Up/Down welding torch. Vacant "Save" buttons are skipped.

In addition to the "Save" button number lighting up, a number is displayed directly on the Up/Down welding torch:

Indicator on the Up/Down welding torch

EasyJob operating point on the con-

trol panel

MMA welding

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 device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation

MMA welding

Move the mains switch to the "O" position

Disconnect the mains plug

Detach all cables to the wirefeeder at the power source

IMPORTANT! Check the rod electrode packaging to determine whether the

rod electrodes are for (+) or (-) welding.

Plug the grounding cable into either the (-) or the (+) current socket, depend-

ing on the type of electrode, and lock in place

Use the other end of the grounding cable to establish a connection to the

workpiece

Plug the bayonet current plug of the electrode holder cable into the free cur-

rent socket with the opposite polarity, according to the type of electrode, and twist it clockwise to latch it in place

Plug in the mains plug

CAUTION!

Risk of injury and damage from electric shock.

As soon as the mains switch is in the "I" position, the rod electrode in the electrode holder is live.

Make sure that the rod electrode does not touch any persons or electrically

▶

conductive or earthed parts (e.g. the housing, etc.)

Move the mains switch to the "I" position: all the indicators on the control

panel will brieﬂy light up

Press the "Process" button to select the MMA welding process:

The welding voltage is applied to the welding socket with a three second time lag.

If the MMA welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

NOTE!

Under certain circumstances, it may not be possible to change welding parameters that have been set on a system component (such as remote control or wirefeeder) from the control panel of the power source.

Press the "Parameter selection" button to select the amperage parameter.

Use the adjusting dial to set the desired amperage.

The amperage value is displayed in the left-hand digital display.

Corrections during welding

All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed. This applies even if the power source was switched off and on again in the interim.

Start welding

To display the actual welding current during welding:

Press the "Parameter selection" button to select the welding current para-

meter The actual welding current is shown on the digital display during welding.

To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.

Press the "Parameter selection" button to select the arc-force dynamic para-

meter

Use the adjusting dial to set the desired arc-force dynamic value

The welding parameter value is shown in the digital display located above it.

Inﬂuence of the short-circuiting dynamic at the instant of droplet transfer:

- = hard, stable arc 0 = neutral arc + = soft, low-spatter arc

HotStart func-

I (A)

300

200

HCU

HCU > I

t (s)

0,5

1,5

Hti

tion

To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart function.

Advantages

Improved ignition properties, even when using electrodes with poor ignition

properties Better fusion of the base material during the start-up phase, meaning fewer

cold-shut defects Largely prevents slag inclusions

For details on setting the available welding parameters, please refer to "Setup parameters", "Setup menu - level 2".

Legend

Hti Hot-current time,

0 - 2 s, factory setting: 0.5 s

HCU HotStart current,

100 - 200 %, factory setting 150 %

Anti-stick function

Main current = set welding cur-

rent

Function

During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (IH).

As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to stick. This may also cause the rod electrode to burn out.

Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. After the rod electrode has been detached from the workpiece, the welding process can be continued without any problems.

The anti-stick function (Ast) can be activated and deactivated in the Setup menu with the Setup parameters for manual metal arc welding.

Arc Air Gauging (TSt 5000 Syn)

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 device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Preparation IMPORTANT! A grounding cable with a cable cross-section of 120 mm² is re-

quired for arc air gouging.

Move the mains switch to the "O" position

Disconnect the mains plug

Remove the MIG/MAG welding torch

Plug the grounding cable into the (-) current socket and twist to fasten it

Use the other end of the grounding cable to establish a connection to the

workpiece

Plug the bayonet current plug of the arc air gouging torch into the (+) current

socket and twist it clockwise to fasten it

Connect the compressed air connection of the arc air gouging torch to the

compressed air supply Working pressure: 5 - 7 bar (constant)

Clamp the carbon electrode so that the electrode tip protrudes approxim-

ately 100 mm out of the arc air gouging torch; the air outlet openings of the arc air gouging torch must be located at the bottom

Plug in the mains plug

Arc air gouging

CAUTION!

Risk of injury and damage from electric shock.

As soon as the mains switch is in the "I" position, the electrode in the arc air gouging torch is live.

Make sure the electrode does not touch any persons or electrically conduct-

▶

ing or earthed parts (e.g. the housing, etc.).

CAUTION!

Risk of personal injury due to loud operating noise.

Use suitable ear protection during arc air gouging!

▶

Move the mains switch to the "I" position: all the indicators on the control

panel will brieﬂy light up

Press the "Process" button to select the MMA welding process:

The welding voltage is applied to the welding socket with a three second time lag.

If the MMA welding process is selected, any cooling unit present is automatically deactivated. It is not possible to switch it on.

IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on a control panel of a system component (such as remote control or wirefeeder) from the control panel of the power source.

In the setup menu for MMA welding, set the AAG parameter to "on";

To enter the setup menu, see page 93.

NOTE!

Settings for the break voltage and the starting current time are ignored.

Exit the setup menu for MMA welding

Press the "Parameter selection" button to select the amperage parameter.

Using the adjusting dial, adjust the main current according to the electrode

diameter as indicated on the electrode packaging

The amperage value is displayed in the left-hand digital display.

NOTE!

At higher amperages, guide the arc air gouging torch with both hands!

Use a suitable welding helmet.

▶

Open the compressed air valve on the handle of the arc air gouging torch

Initiate processing

The tilt angle of the carbon electrode and the gouging speed determine the depth of an air gap.

The arc air gouging parameters are the same as the welding parameters for MMA welding, see page 96.

Easy Documentation

General

General If the Easy Documentation option is available on the power source, the most im-

portant welding data for each weld can be documented and saved as a CSV file on a USB ﬂash drive. A Fronius signature is stored with the welding data which can be used to check and guarantee the authenticity of the data.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB ﬂash drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

Documented welding data

The following data is also documented:

Device type File name Item number Serial number Firmware version of power source Firmware of PC board DOCMAG (Easy Documentation) Docu version https://www.easydocu.weldcube.com (a PFDF report of selected welding data can be created under this link)

Nr. Counter

Start by plugging in the USB ﬂash drive; When switching the power source off and on, the counter continues at the last weld seam number. A new CSV file is created after 1000 welds.

Date Date yyyy-mm-dd

Time Time hh:mm:ss

at start of current ﬂow

Duration Duration in [s]

from start of current ﬂow to end of current (current ﬂow signal)

I Welding current * in [A]

U Welding voltage * in [V]

vd Wire speed * in [m/min]

wfs Wire speed * in [ipm]

IP Power * from instantaneous values in [W]

IE Energy from instantaneous values in [kJ]

across the entire weld

I-Mot Motor current * in [A]

Synid Characteristic number

per weld

Job EasyJob number

per weld seam

Process Welding process

Mode Operating mode

Status PASS: regular welding

IGN: Welding interrupted during the ignition phase Err | xxx: Welding interrupted due to a fault; the corresponding service code is documented

Interval Weld seam number for "Interval" operating mode

Signature

* In each case from the main process phase;

The welding data is documented as average values in the main process phase and per weld.

New CSV file A new CSV file is generated:

if the USB ﬂash drive is disconnected and reconnected while the power

source is on If the date and time are changed

From 1000 welds

During a firmware update

if the USB ﬂash drive is disconnected and reconnected to another power

source (= change of serial number).

Signature per weld seam number

In the event of termination in the ignition phase, the average value in the ignition phase is stored and a identifier is output to indicate that the main process phase has been reached

PDF report / Fronius signature

By scanning the link on the left

A PDF report of the selected welding data can be created

The authenticity of the data can be checked and guaran-

teed via the Fronius signature read out with the welding data.

https://easydocu.weldcube.com

Activating / deactivating Easy Documentation

...

Setting the date and time

The date and time are set in the 2nd level of the service menu.

The first parameter in the service menu is displayed.

Select the "2nd" setup parameter using the left-hand adjusting dial

The first parameter in the 2nd level of the service menu is displayed.

Select the "yEA" (= year) setup parameter using the left-hand adjusting dial

Deactivating Easy Documentation

NOTE!

If the power source is reset to factory settings via setup parameter FAC, the date and time remain stored.

CAUTION!

Risk of data loss or data damage due to premature disconnection of the USB ﬂash drive

Do not disconnect the USB ﬂash drive until approx. 10 seconds after the end

▶

of the last weld to ensure correct data transfer.

To set the date and time:

Left-hand adjusting dial:

Select parameter Right-hand adjusting dial:

Change values

Setting ranges:

yEA Year (20yy; 0 - 99) Mon Month (mm; 1 -1 12) dAY Day (dd; 1 - 31) Hou Hour (hh; 0 - 24) Min Minute (mm; 0 - 59)

Unplug the USB ﬂash drive from the power source

The following appears on the power source display:

Easy Documentation is deactivated.

Confirm the display by pressing the arrow key

Setup settings

Setup menu

General remarks The Setup menu provides simple access to expert knowledge in the power source

and to additional functions. The Setup menu can be used to make simple adjustments of the parameters to suit the various job settings.

Operation Access to the setup menu is described based on the MIG/MAG standard synergic

welding process. Access is the same for the other welding processes.

Accessing the Setup menu

Changing welding parameters

Exiting the Setup menu

Use the "Process" button to select the "MIG/MAG standard synergic welding" process

The control panel is now in the Setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.

Select the desired setup parameter using the left-hand adjusting dial

Alter the setup parameter value using the right-hand adjusting dial

Setup parameters for MIG/MAG standard manual welding

"Min." and "max." are used for setting ranges that differ according to power source, welding program, etc.

GPr Gas pre-ﬂow time

Unit: s Setting range: 0 - 9.9 Factory setting: 0.1

GPo Gas post-ﬂow time

Unit: s Setting range: 0 - 9.9 Factory setting: 0.5

Fdi Feeder inching speed

Unit: m/min (ipm)

Setting range: 1 - max. (39.37 - max.) Factory setting: 10 (393.7)

bbc Burn-back time correction

Burn-back time effect due to a delayed switch-off of the welding current after the wire electrode stops being fed forward. A ball forms on the wire electrode.

Unit: s Setting range: AUt, 0 - 0.3 Factory setting: AUt

IGC Ignition current

Unit: A Setting range: 100 - 650 Factory setting: 500

Ito Length of wire that is fed before the safety cut-out trips

Unit: mm (in.) Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94) Factory setting: OFF

NOTE!

The Ito function (wire length up to safety cut-out) is a safety function.

The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire speeds.

SPt Spot welding time / interval welding time

Unit: s Setting range: 0.3 - 5 Factory setting: 0.3

SPb Interval pause time

Unit: s Setting range: OFF, 0.3 - 10 (in 0.1 s increments) Factory setting: OFF

Int Interval

Displayed only if a value has been set for SPb Unit: Setting range: 2T (2-step), 4T (4-step) Factory setting: 2T (2-step)

FAC Reset power source to factory settings

Press and hold down one of the "Parameter selection" buttons for 2 s to restore the factory settings

- when "PrG" appears on the digital display, the power source has been reset IMPORTANT! When the power source is reset, all personal settings in the Setup menu are lost. Operating points that were saved using the "Save" buttons are retained when the power source is reset. The functions in the second level of the

Setup menu (2nd) are also not deleted. Exception: Ignition time-out function parameter (ito).

2nd Second level of the Setup menu (see "Setup menu - level 2")

Setup parameters for MIG/MAG standard synergic welding

"Min." and "max." are used for setting ranges that differ according to power source, welding program, etc.

GPr Gas pre-ﬂow time

Unit: s Setting range: 0 - 9.9 Factory setting: 0.1

GPo Gas post-ﬂow time

Unit: s Setting range: 0 - 9.9 Factory setting: 0.5

SL Slope (special 4-step mode only)

Unit: s Setting range: 0 - 9.9 Factory setting: 0.1

I-S I (current) - Starting - Starting current (special 4-step mode only)

Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 100

I-E I (current) - End: Final current (special 4-step mode only)

Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 50

t-S t (time) - Starting - Starting current duration (special 4-step mode only)

Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF

t-E t (time) - End: Final current duration (special 4-step mode only)

Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF

Fdi Feeder inching - feeder inching speed

Unit: m/min (ipm) Setting range: 1 - max. (39.37 - max.) Factory setting: 10 (393.7)

bbc Burn-back time correction - burn-back effect

Wire burn-back effect through wire withdrawal at end of welding, regardless of the selected characteristic Unit: s Setting range: Aut, 0 - 0.3 Factory setting: Aut

Ito Ignition time-out function - length of wire that is fed before the safety

cut-out trips

Unit: mm (in.) Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94) Factory setting: OFF

NOTE!

The "Ignition time-out" function (ito) is a safety function.

The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire speeds.

SPt Spot time - spot / stitch welding time

Unit: s Setting range: OFF, 0.1 - 5 Factory setting: OFF

SPb Spot break - stitch pause time

Unit: s Setting range: OFF, 0.1 - 10 (in 0.1 s increments) Factory setting: OFF

FAC Reset power source to factory setting

Press and hold down one of the "Parameter selection" buttons for 2 s to restore the factory settings

- when "PrG" appears on the digital display, the power source has been reset.

Setup parameters for MMA welding

IMPORTANT! When the power source is reset, all personal settings in the

Setup menu are lost. When the power source is reset, operating points that were saved using the "Save" buttons are not deleted, but are retained in the memory. The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ignition time-out function parameter (ito).

2nd Second level of the set-up menu (see "Set-up menu - Level 2")

IMPORTANT! If you reset the power source using the FAC factory setup parameter, the hot-current time (Hti) and HotStart current (HCU) setup parameters are also reset.

HCU HotStart current

Unit: % Setting range: 100 - 200 Factory setting: 150

Hti Hot current time

Unit: s Setting range: 0 - 2.0 Factory setting: 0.5

ASt Anti-stick

Unit: Setting range: On, OFF

Factory setting: OFF

AAG Gouging (Arc Air Gauging)

Arc air gouging with a carbon electrode, e.g., for joint preparation Unit: Setting range: on / oFF Factory setting: oFF

FAC Reset power source to factory settings

Press and hold down one of the "Parameter selection" buttons for 2 s to restore the factory settings - when "PrG" appears on the digital display, the power source has been reset. IMPORTANT! When the power source is reset, all personal settings are lost. When the power source is reset, operating points that were saved using the "Save" buttons are not deleted, but are retained in the memory. The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ignition time-out function parameter (ito).

2nd Second level of the set-up menu (see "Set-up menu - Level 2")

Setup menu - Level 2

Operation (level 2 Setup menu)

To access the Level 2 Setup menu:

Changing welding parameters

Use the "Process" button to select the "MIG/MAG standard synergic welding" process

The control panel is now in the Setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.

Select the "2nd" setup parameter using the left-hand adjusting dial

The control panel is now in the second level of the setup menu for the "MIG/MAG standard synergic welding" process - the last setup parameter that was selected is displayed.

Exiting the Setup menu

Select the desired setup parameter using the left-hand adjusting dial

Alter the setup parameter value using the right-hand adjusting dial

A parameter is displayed in the first level of the Setup menu.

Parameters for MIG/MAG welding in the Setup menu level 2

C-C Cooling unit Control

(only with connected cooling unit)

Unit: Setting range: Aut, On, OFF Factory setting: Aut

Aut: The cooling unit cuts out after a 2-minute welding off-time.

IMPORTANT! If the coolant temperature and ﬂow monitoring options have been installed in the cooling unit, the cooling unit cuts out as soon as the return-ﬂow temperature drops below 50 °C, but at the earliest after a 2-minute welding off-time.

On: The cooling unit is always ON OFF: The cooling unit is always OFF

IMPORTANT! If the FAC welding parameter is used, the C-C parameter is not reset to the factory setting. If the MMA welding process is selected, the cooling unit is always switched off, even if the switch is in the "On" position.

C-t Cooling Time

(only with connected cooling unit) Time from when ﬂow monitoring is triggered until the "no | H2O" service code is output. For example, if there are air bubbles in the cooling system, the cooling unit will not cut out until the end of this preset time.

Unit: s Setting range: 5 - 25 Factory setting: 10

IMPORTANT! Every time the power source is switched on, the cooling unit carries out a test run for 180 seconds.

SEt Setting - country-specific setting (Standard/USA), etc. Std/US

Unit: Setting range: Std, US (Standard/USA) Factory setting: Standard version: Std (measurements: cm/mm) USA version: US (measurements: inches)

r r (resistance) - welding circuit resistance (in mOhm)

see "Measuring welding circuit resistance r"

L L (inductivity) - welding circuit inductivity (in microhenry)

see "Displaying welding circuit inductivity L"

EnE Real Energy Input – electrical energy of the arc relative to the welding

speed

Unit: kJ Setting range: ON / OFF Factory setting: OFF

Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three-digit display, the following display format has been selected:

Value in kJ / indicator on display: 1 to 999 / 1 to 999 1000 to 9999 / 1.00 to 9.99 (without "ones" digit, e.g. 5270 kJ -> 5.27) 10000 to 99999 / 10.0 to 99.9 (without "ones" and "tens" digits, e.g. 23580 kJ -> 23.6)

ALC Arc Length Correction - correction of the arc length via the welding

voltage

Setting range: ON / OFF Factory setting: OFF

The arc length depends on the welding voltage. The welding voltage can be adjusted to suit individual needs in Synergic operation.

If the ALC parameter is set to "OFF", the welding voltage cannot be adjusted. The welding voltage is automatically determined by the selected welding current or wire speed. If the arc length correction is adjusted, the voltage changes, but the welding current and wire speed remain the same. When setting the arc length correction using the adjusting dial, the left display is used for the correction value of the arc length. The welding voltage value on the right display changes simultaneously. Afterwards the left display shows the original value, e.g. welding current.

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Fronius TransSteel 3500 / 5000 Syn Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual