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

+ 114 hidden pages

Fronius TransSteel 3500 / 5000 Syn Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual