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TransSteel 3500c

Fronius TransSteel 2500c, TransSteel 2500c MV, TransSteel 3500c Operating Instructions Manual

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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0107,EN 013-05082014
TransSteel 2500c TransSteel 2500c MV TransSteel 3500c
Operating Instructions
MIG/MAG Power source
EN
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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful handling of the product will repay you with years of safe and reliable operation. These are essential prerequisites for excellent results.
Explanation of safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re­quired.
DANGER! Indicates immediate and real danger. If it is not avoided, death or se­rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
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Contents
Safety rules ................................................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection .................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 9
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks ..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications .................................................................................................................. 12
EMC measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 12
Specific hazards.................................................................................................................................... 13
Factors affecting welding results........................................................................................................... 14
Danger from shielding gas cylinders..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 15
Maintenance and repair ........................................................................................................................ 16
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
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.............................................................................................................. 22
Options....................................................................................................................................................... 23
VRD: safety function ............................................................................................................................. 23
VRD: safety principle ............................................................................................................................ 23
System components .................................................................................................................................. 25
General ................................................................................................................................................. 25
Safety.................................................................................................................................................... 25
Overview ............................................................................................................................................... 25
Control elements and connections 27
Synergic Central control panel................................................................................................................... 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Synergic control panel .......................................................................................................................... 29
Service parameters............................................................................................................................... 32
Keylock ................................................................................................................................................. 33
Connections, switches and mechanical components ................................................................................ 34
Front and rear sides, TSt 2500c ........................................................................................................... 34
Front and rear sides, TSt 3500c ........................................................................................................... 35
Page...................................................................................................................................................... 36
Installation and commissioning 37
Minimum equipment needed for welding task............................................................................................ 39
General ................................................................................................................................................. 39
MIG/MAG welding, gas-cooled ............................................................................................................. 39
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MIG/MAG welding, water-cooled .......................................................................................................... 39
Manual metal arc welding ..................................................................................................................... 39
Before installation and commissioning....................................................................................................... 40
Safety.................................................................................................................................................... 40
Utilisation for intended purpose only..................................................................................................... 40
Setup regulations .................................................................................................................................. 40
Mains connection .................................................................................................................................. 40
Connecting the mains cable....................................................................................................................... 42
General ................................................................................................................................................. 42
Stipulated mains cables and strain-relief devices ................................................................................. 42
Connecting the mains cable.................................................................................................................. 42
Fitting the strain-relief device, TSt 2500c MV, single-phase operation................................................. 43
Fitting the strain-relief device, TSt 2500c.............................................................................................. 44
Fitting the strain-relief device, TSt 2500c MV ....................................................................................... 45
Fitting the strain-relief device, TSt 3500c.............................................................................................. 46
Fitting the Canada / U S strain-relief device, TSt 3500c ....................................................................... 46
Generator-powered operation.................................................................................................................... 48
Generator-powered operation............................................................................................................... 48
Single-phase operation .............................................................................................................................. 49
Single-phase operation ......................................................................................................................... 49
Fitting/connecting the system components................................................................................................ 50
Information on system components ...................................................................................................... 50
Mounting on the trolley.......................................................................................................................... 50
Connecting the gas cylinder.................................................................................................................. 50
Connecting a MIG/MAG welding torch.................................................................................................. 51
Establishing a ground (earth) connection ............................................................................................ 52
Inserting/replacing feed rollers.............................................................................................................. 52
Inserting the wirespool/basket-type spool............................................................................................. 53
Feeding in the wire electrode................................................................................................................ 54
Setting the contact pressure ................................................................................................................. 56
Adjusting the brake ............................................................................................................................... 56
Design of the brake............................................................................................................................... 57
Start-up ...................................................................................................................................................... 58
General ................................................................................................................................................. 58
Prerequisites ......................................................................................................................................... 58
Commissioning ..................................................................................................................................... 58
Welding 59
Power limitation.......................................................................................................................................... 61
Safety function ...................................................................................................................................... 61
MIG/MAG modes ....................................................................................................................................... 62
General ................................................................................................................................................. 62
Symbols ................................................................................................................................................ 62
2-step mode .......................................................................................................................................... 62
4-step mode .......................................................................................................................................... 62
Special 2-step mode ............................................................................................................................. 63
Special 4-step mode ............................................................................................................................. 63
MIG/MAG welding...................................................................................................................................... 64
Safety.................................................................................................................................................... 64
Overview ............................................................................................................................................... 64
MIG/MAG standard synergic welding ........................................................................................................ 65
MIG/MAG standard synergic welding ................................................................................................... 65
Corrections during welding ................................................................................................................... 65
MIG/MAG standard manual welding .......................................................................................................... 66
General ................................................................................................................................................. 66
Available parameters ............................................................................................................................ 66
MIG/MAG standard manual welding ..................................................................................................... 66
Corrections during welding ................................................................................................................... 67
MMA welding ............................................................................................................................................. 68
Safety.................................................................................................................................................... 68
Preparation ........................................................................................................................................... 68
MMA welding ........................................................................................................................................ 68
Corrections during welding ................................................................................................................... 69
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HotStart function ................................................................................................................................... 69
Anti-stick function.................................................................................................................................. 69
Saving and retrieving operating points....................................................................................................... 70
General ................................................................................................................................................. 70
Saving operating points ........................................................................................................................ 70
Retrieving operating points ................................................................................................................... 70
Deleting operating points ...................................................................................................................... 70
Retrieving operating points on the Up/Down welding torch .................................................................. 70
Setup settings 73
Setup menu................................................................................................................................................ 75
General remarks ................................................................................................................................... 75
Configuring the setup parameters......................................................................................................... 75
Setup parameters for MIG/MAG standard manual welding .................................................................. 76
Setup parameters for MIG/MAG standard synergic welding................................................................. 77
Setup parameters for MMA welding...................................................................................................... 78
Setup menu - Level 2................................................................................................................................. 79
Restrictions ........................................................................................................................................... 79
Configuring the setup parameters......................................................................................................... 79
Welding parameters for MIG/MAG welding in the Level 2 setup menu ................................................ 81
Parameters for manual metal arc (MMA) welding in the Setup menu level 2 ....................................... 82
Measuring welding circuit resistance r ....................................................................................................... 83
General ................................................................................................................................................. 83
Measure the welding circuit resistance r............................................................................................... 83
Displaying welding circuit inductivity L ....................................................................................................... 84
General ................................................................................................................................................. 84
Displaying welding circuit inductivity L .................................................................................................. 84
Laying the hosepacks correctly............................................................................................................. 84
Troubleshooting and maintenance 85
Troubleshooting ......................................................................................................................................... 87
General ................................................................................................................................................. 87
Safety.................................................................................................................................................... 87
Fault diagnosis...................................................................................................................................... 87
Displayed service codes ....................................................................................................................... 90
Care, maintenance and disposal ............................................................................................................... 96
General ................................................................................................................................................. 96
Safety.................................................................................................................................................... 96
At every start-up.................................................................................................................................... 96
If necessary........................................................................................................................................... 96
Every 2 months ..................................................................................................................................... 96
Every 6 months ..................................................................................................................................... 96
Disposal ................................................................................................................................................ 97
Technical data............................................................................................................................................ 98
Special voltages.................................................................................................................................... 98
TSt 2500c.............................................................................................................................................. 98
TSt 2500c MV ....................................................................................................................................... 100
TSt 3500c.............................................................................................................................................. 102
Appendix .................................................................................................................................................... 104
Quick reference..................................................................................................................................... 104
TransSteel 2500 welding program table .............................................................................................. 106
TransSteel 2500 USA welding program table ...................................................................................... 107
TransSteel 3500 Euro welding program tables .................................................................................... 108
TransSteel 3500 US welding program tables ...................................................................................... 109
Spare parts list: TransSteel 2500c............................................................................................................. 110
Spare parts list: TransSteel 3500c............................................................................................................. 111
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Safety rules
General
Proper use
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!
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 instructions
- 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.
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Environmental conditions
Obligations of the operator
Obligations of personnel
Mains connection
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 section "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.
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- 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.
Devices with a higher rating may affect the energy quality of the mains due to their current input.
This may affect a number of 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.
NOTE! Ensure that the mains connection is earthed properly
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Protecting your­self and others
Danger from toxic gases and va­pours
Persons involved with welding expose 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 using cardiac pacemakers
- risk of electrocution from mains current and welding current
- greater noise pollution
- harmful welding fumes and gases
Anyone working on the workpiece while welding is in progress must wear suit­able protective clothing with 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 protec­tive 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 injury.
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 or
- erect suitable safety screens/curtains.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that may, under certain circumstances, cause birth defects or cancer.
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.
Otherwise, a protective mask with an air supply must be worn.
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Danger from fly­ing sparks
Risks from mains current and weld­ing current
Close the shielding gas cylinder valve or main gas supply if no welding is tak­ing place.
If there is any doubt about whether the extraction system is powerful enough, then 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.
The relevant material safety data sheets and manufacturer's specifications for the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
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.
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 wire-feed unit 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 temporary backing or cover for the earth or ground potential. This temporary backing 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. Loose connections, scorched, damaged or inadequately dimen­sioned cables and leads must be repaired/replaced immediately.
Do not sling cables or leads around the body or parts of the body.
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Meandering weld­ing currents
The electrode (rod electrode, tungsten electrode, welding wire, etc) must
- never be immersed in liquid for cooling
- never be touched 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.
The device must only be operated on a mains supply with a ground conductor and a socket with a ground conductor contact.
If the device is operated on a mains supply without a ground conductor and using a socket without a ground conductor contact, this will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection 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.
If the following instructions are ignored, meandering welding currents can de­velop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable 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.
If the floor is electrically conductive, the device must be set up with sufficient insulating material to insulate it from the floor.
If 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 wire-feed unit.
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EMC Device Clas­sifications
EMC measures
EMF measures
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is sup­plied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
In certain cases, even though a device complies with the standard limit values for 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
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connec­tion, additional measures are necessary (e.g. use a suitable line fil­ter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids
- wearers of pacemakers must seek advice from their doctor before ap­proaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind them around any part of the body
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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 wire-feed unit) 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 and/or ropes onto all suspension points provided on the load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG de­vices).
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Factors affecting welding results
Danger from shielding gas cyl­inders
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 accessories (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.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device­side thread of the adapter for the shielding gas connection using suitable Tef­lon tape.
The following requirements with regard to shielding gas quality must be met if the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being used
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.
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Safety measures at the installation location and dur­ing transport
Safety measures in normal opera­tion
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 escape unhindered.
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.
Before transporting the device, allow coolant to drain completely and detach the following components:
- Wire-feed unit
- 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.
Only operate the device if 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.
The manufacturer accepts no liability for damage resulting from use of a dif­ferent coolant. In addition, all warranty claims will be forfeited.
The coolant can ignite under certain conditions. Transport the coolant only in its original, sealed containers and keep well away from any sources of ignition.
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Maintenance and repair
Safety inspection
Disposal
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 and 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 replacement and wearing parts (also applies to standard parts). Do not make any modifications, alterations, etc. to the device without the man­ufacturer's consent. Parts that are not in perfect condition must be replaced immediately. When ordering, please give the precise designation and part number as shown in the spare parts list, as well as the serial number of your device.
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.
Do not dispose of this device with normal domestic waste! To comply with the European Directive 2002/96/EC on Waste Electrical and Electronic Equip­ment and its implementation as national law, electrical equipment that has reached the end of its life must be collected separately and returned to an ap­proved recycling facility. Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on the environment and your health!
Page 19
17
EN
Safety symbols
Data protection
Copyright
Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directive (e.g. relevant product norms from the EN 60 974 series).
Devices with the CSA test mark satisfy the requirements of the relevant stand­ards in Canada and the USA.
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.
Copyright of these operating instructions remains with the manufacturer.
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.
Page 20
18
Page 21
General information
Page 22
Page 23
21
EN
General
Device concept
The TransSteel (TSt) 2500c and 3500c po­wer sources are completely 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.
All devices are suitable for:
- MIG/MAG welding
- MMA welding
Functional princi­ple
The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and signal processor control the entire welding process. During the welding process, the actual data is measured continuously and the device re­sponds immediately to any changes. Control algorithms ensure that the desired target state is maintained.
The device has a "Power limitation" safety feature. This means that the power source can be operated at the power limit without compromising process safety.
This results in:
- a precise welding process
- a high degree of reproducibility of all results
- excellent weld properties.
Application areas The devices are used in workshops and industry for manual applications with classical
steel and galvanised sheets.
The TSt 2500c power sources are primarily used in light-gauge steel sheet (light steelwork) applications. Repair, maintenance, and assembly work in shipyards, automotive suppliers, workshops or the furniture construction industry are among the typical application areas. The TSt 2500c power sources thus position themselves in their power category between the trade/workshop sector and the industry sector.
The TSt 3500c power sources are designed for:
- Machine and equipment construction
- Steelwork
- Plant and container construction
- Metal and gantry construction
- Rail vehicle construction
Page 24
22
Warning notices on the device
Warning notices and safety symbols are affixed to the power sources. These warning no­tices and safety symbols must not be removed or painted over. They warn against operat­ing the device incorrectly, as this may result in serious injury and damage.
Safety symbols on the rating plate
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 distance
Do not use the functions described here until you have thoroughly read and un­derstood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
40,0006,3035
inside
Page 25
23
EN
Options
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
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
Page 26
24
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
Page 27
25
EN
System components
General The power sources can be operated with various system components and options. 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
TSt 2500c
No. Function
(1) Welding torch
(2) Gas cylinder holder stabiliser
(3) Power source
(4) Trolley and gas cylinder holder
(5) Grounding (earthing) cable and electrode cable
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
(1)
(2)
(3)
(4)
(5)
Page 28
26
TSt 3500c
No. Function
(1) Welding torch
(2) Gas cylinder holder stabiliser
(3) Power source
(4) Cooling unit
TSt 3500c only
(5) Trolley and gas cylinder holder
(6) Grounding (earthing) cable and electrode cable
(1)
(2)
(3)
(4)
(5)
(6)
Page 29
Control elements and connections
Page 30
Page 31
29
EN
Synergic Central control panel
General The functions on the control panel are all arranged in a logical way. The individual param-
eters required for welding can be
- selected easily using buttons
- altered using buttons or the adjusting dial
- displayed on the digital display during welding
The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best weld­ing parameters. As a result, stored 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
Synergic control panel
NOTE! Due to software updates, you may find that your device has certain func-
tions 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.
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
(13)
(14)
(4)
(7)
(10) (9) (8) (6)
(3)
(2)
(1)
(5)
*
* TSt 2500c
(11)
(12)
Page 32
30
No. Function
(1) "Parameter selection" button (right)
for selecting the following welding parameters and for changing parameters in the Setup menu
The relevant symbol lights up when a welding parameter is selected.
Arc length correction
for correcting the arc length
Welding voltage in V *)
Before the start of welding, the system automatically displays a standard val­ue based on the programmed parameters. During welding, the actual value is displayed.
Dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer
- ... harder, more stable arc 0 ... neutral arc + ... soft, low-spatter arc
Real Energy Input
for displaying the energy applied during the welding operation. **)
(2) "Parameter selection" button (left)
for selecting the following welding parameters and for changing parameters in the Setup menu
The relevant symbol lights up when a welding parameter is selected.
Sheet thickness in mm or in.
If the welding current to be selected is not known it is sufficient to enter the sheet thickness. The required welding current and any other parameters marked with *) will then be adjusted automatically.
Welding current in A *) Before the start of welding, the device automatically displays a standard value
based on the programmed parameters. During welding, the actual value is displayed.
Wire feed speed in m/min or ipm
*)
(3) Adjusting dial (right)
for changing the arc length correction, welding voltage and arc-force dynamic pa­rameters as well as changing parameters in the Setup menu
(4) Adjusting dial (left)
for changing the sheet thickness, welding current and wire feed speed parameters as well as changing parameters in the Setup menu
(5) "Save" buttons (Easy Job)
for saving up to 5 operating points
Page 33
31
EN
(6) "Process" button
***)
for selecting the welding process
MANUAL - MIG/MAG standard manual welding SYNERGIC - MIG/MAG standard synergic welding STICK - manual metal arc welding
(7) "Mode" button
for selecting the operating mode
2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode
(8) "Shielding gas" button
for selecting the shielding gas to be used. Parameter SP is reserved for additional shielding gases.
The LED lights up next to the selected shielding gas.
(9) "Wire diameter" button
for selecting the wire diameter to be used. Parameter SP is reserved for additional wire diameters.
The LED lights up next to the selected wire diameter.
(10) "Material" button
for selecting the filler metal to be used. Parameter SP is reserved for additional filler metals.
The LED lights up next to the selected filler metal.
(11) '"Gas-test" button (TSt 2500c)
to set the required gas flow rate at the pressure regulator. Tap button once: shielding gas flows out Tap button again: shielding gas flow stops If the "Gas-test" button is not tapped again, the shielding gas flow will stop after 30
s.
(12) '"Wire threading" button (TSt 2500c)
Press and hold the button: Thread the wire into the torch hosepack with no accompanying flow of gas While the button is being held down, the wire drive runs at feeder inching speed.
(13) Intermediate arc indicator
A spatter-prone "intermediate arc" occurs between the dip transfer arc and the spray arc. To alert you to this critical area - and help you avoid it - the intermediate arc indicator lights up.
(14) HOLD indicator
At the end of each welding operation, the actual values for welding current and welding voltage are stored, and 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.
Page 34
32
Service parame­ters
Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.
Opening the display
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Available parameters
**) 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.
***) In conjunction with the VRD option, the currently selected welding process indica-
tor 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.
Press and hold the "Parameter selection" button (left)
Press the "Parameter selection" button (right)
Release the "Parameter selection" buttons
Select the required setup parameter using the "Mode" and "Pro­cess" buttons or the left-hand adjusting dial
1
2
3
1
Example:
1.00 | 4.21
Firmware version
Example: 2 | 491
Welding program configuration
Example: r 2 | 290
Number of the currently selected welding program
Example: iFd | 0.0
Motor current for wire drive in A The value changes as soon as the motor is running.
654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins
Indicates the actual arc time since using for the first time Note: The arc time indicator is not suitable as a basis for calcu­lating hiring fees, for warranty purposes, etc.
2nd 2nd menu level for service engineers
Page 35
33
EN
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
Activate/deactivate the keylock as follows:
Keylock activated: The message "CLO | SEd" appears on the displays.
Keylock deactivated: The message "OP | En" appears on the displays.
Press and hold the "Mode" button
Press the "Parameter selection" button (right)
Release the "Mode" and "Parameter Selection" buttons
1
2
3
Page 36
34
Connections, switches and mechanical components
Front and rear sides, TSt 2500c
TSt 2500c
No. Function
(1) Welding torch connection
for connecting the welding torch
(2) (-) - Current socket with bayonet latch
used for
- connecting the grounding (earthing) cable during MIG/MAG welding
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(3) LocalNet connection
Standardised connection for remote control
(4) (+) - Current socket with bayonet latch
used for
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(5) Shielding gas connection
(6) Mains switch
for switching the power source on and off
(7) Mains cable with strain relief device
(8) Air filter
(1) (7)(8)
(2) (3) (4) (5) (6)
Page 37
35
EN
Front and rear sides, TSt 3500c
TSt 3500c
No. Function
(1) Welding torch connection
for connecting the welding torch
(2) (-) - Current socket with bayonet latch
used for
- connecting the grounding (earthing) cable during MIG/MAG welding
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(3) (+) - Current socket with bayonet latch
used for
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(4) LocalNet connection
Standardised connection for remote control
(5) Mains switch
for switching the power source on and off
(6) Mains cable with strain relief device
(1) (9) (8)
(2) (3) (4) (5) (7)(6)
Page 38
36
(7) "Wire threading" / "Gas-test" button
Push button down and hold: for threading the wire electrode into the torch hosepack with no accompanying flow
of gas. While the button is being held down, the wire drive runs at feeder inching speed.
Push button upwards: to set the required gas flow rate at the pressure regulator. Tap button once: shielding gas flows out Tap button again: shielding gas flow stops
If the "Gas-test" button is not tapped again, the shielding gas flow will stop after 30 s.
(8) Air filter
(9) Shielding gas connection
Page
No. Function
(1) Wirespool holder with brake
for holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a max. weight of up to 19 kg (41.89 lbs.)
(2) 4-roller drive
(1) (2)
Page 39
Installation and commissioning
Page 40
Page 41
39
EN
Minimum equipment needed for welding task
General Depending on which welding process you intend to use, a certain minimum equipment lev-
el 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.
MIG/MAG weld­ing, gas-cooled
- Power source
- Grounding (earthing) cable
- MIG/MAG welding torch, gas-cooled
- Gas connection (shielding gas supply)
- Wire electrode
MIG/MAG weld­ing, water-cooled
- Power source
- Cooling unit including coolant
- Grounding (earthing) cable
- MIG/MAG welding torch, water-cooled
- Gas connection (shielding gas supply)
- Wire electrode
Manual metal arc welding
- Power source
- Grounding (earthing) cable
- Electrode holder
- Rod electrode
Page 42
40
Before installation and commissioning
Safety
Utilisation for in­tended purpose only
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
Setup regulations The device is tested to IP 23, meaning:
- protection against penetration by solid foreign bodies with diameters > 12 mm (0.49 in.)
- protection against water sprayed directly at any angle up to 60° from the vertical
The device can be set up and operated outdoors in accordance with degree of protection IP 23. Avoid direct wetting (e.g. from rain).
The venting duct is a very important safety feature. 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.
Mains connection The devices are designed to run on the mains voltage shown on the respective rating
plates. If your version of the device does not come with mains cables and plugs ready-fit­ted, 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.
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! An electric shock can be fatal. If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
WARNING! If one of these machines topples over or falls it could cause serious or even fatal injury. Place device on a solid, level surface in such a way that it re­mains stable.
CAUTION! Electroconductive metallic dust may damage the device. The air filter is a very important safety feature for achieving IP 23. Always fit the air filter when operating the device.
Page 43
41
EN
NOTE! Inadequately dimensioned electrical installations can cause serious dam-
age. The incoming mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.
Page 44
42
Connecting the mains cable
General A strain-relief device for the following cable cross-sections is fitted to the power source:
*) Canada / US cable type: Extra-hard usage
Strain-relief devices for other cable cross-sections must be designed accordingly.
Stipulated mains cables and strain­relief devices
*) Canada / US cable type: Extra-hard usage
The item numbers of the different cables can be found in the spare parts list towards the end of the document.
American Wire Gauge
Connecting the mains cable
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 for fit­ting the strain-relief device. 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
Power source Cable cross-section
Canada / US Europe
TSt 2500c AWG 14 to AWG 6 *) 4G2.5
TSt 3500c AWG 12 *) 4G2.5
Power source Mains voltage Cable cross-sec-
tion
Canada / US
Europe
TSt 2500c 1 x 230 / 240 V AWG 14 (15 A) *) 3G2.5 (16 A)
TSt 2500c 1 x 240 V AWG 12 (20 A) *) -
TSt 2500c 3 x 200 V AWG 12 4G2.5
TSt 2500c 3 x 230 / 240 V AWG 14 4G2.5
TSt 2500c 3 x 380 / 400 V AWG 14 *) 4G2.5
3 x 460 V AWG 14 *) 4G2.5
TSt 3500c 3 x 380 / 400 V AWG 12 *) 4G2.5
3 x 460 V AWG 12 *) 4G2.5
CAUTION! If no ferrules are used, there is a risk of injury and damage from short circuits between the phase conductors or between the phase conductors and the PE conductor. Fit ferrules to all phase conductors and the PE conductor of the stripped mains cable.
1
2
3
Page 45
43
EN
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
Fitting the strain­relief device, TSt 2500c MV, single­phase operation
1 2
3 4
5
4
5
6
1
3,5 Nm
2
3
2
NL2
L1
4
5
IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.
Page 46
44
Fitting the strain­relief device, TSt 2500c
1 2
3 4
5
1
1,2 Nm
2
3 4
5
IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.
Page 47
45
EN
Fitting the strain­relief device, TSt 2500c MV
1 2
3 4
5
1
3,5 Nm
2
3 4
5
IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.
Page 48
46
Fitting the strain­relief device, TSt 3500c
1 2
3 4
Fitting the Cana­da / U S strain-re­lief device, TSt 3500c
1 2
1
2
1,2 Nm
3 4
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
1
2
Page 49
47
EN
3 4
3 4
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
Page 50
48
Generator-powered operation
Generator-pow­ered operation
The power source is generator-compatible.
The maximum apparent power S
1max
of the power source must be known in order to select the correct generator output. The maximum apparent power S
1max
of the power source is calculated as follows:
The generator apparent power S
GEN
needed is calculated using the following rule of thumb:
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power S
GEN
must always be higher than the maxi-
mum apparent power S
1max
of the power source.
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 single-phase power of the generator from the generator manufacturer.
3-phase devices:
S
1max
= I
1max
x U1 x √3
Single-phase devices:
S
1max
= I
1max
x U
1
See device rating plate or technical data for I
1max
and U1 values
S
GEN
= S
1max
x 1.35
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.
Page 51
49
EN
Single-phase operation
Single-phase op­eration
As an alternative to three-phase operation, the multivoltage variant (MV) of the TSt 2500c power source enables a welding operation with limited power or duration from just a single­phase supply. The maximum possible welding power is limited due to the dimensioning of the mains fuse protection, upon which the safety cut-out of the power source is dependant.
If the mains cable has a 20 A fuse, the FUS parameter may be changed to 20 A. Welding with a higher maximum power or for longer periods is therefore possible. The FUS param­eter is in the level 2 Setup menu and can be set for a single-phase supply as well as to a US setting (SEt parameter to US).
In order to use the TSt 2500c MV power source in single-phase operation, the following prerequisites must be fulfilled:
- Correct single-phase power source supply in accordance with the chapter "Installation
and commissioning," section "Connecting the mains cable" - "Fitting the strain-relief device, TSt 2500c MV, single-phase operation."
The following table shows which mains voltages and fuse values limit the welding current in single-phase operation:
The welding current data applies at an ambient temperature of 40°C (104°F).
Mains voltage Fuse value Welding current limitation
230 V 16 A MIG/MAG welding:
max. 180 A; 130 A at 100%* MMA welding: max. 150 A; 120 A at 100%*
240 V 15 A MIG/MAG welding:
max. 180 A; 130 A at 100%* MMA welding: max. 150 A; 120 A at 100%*
240 V 20 A MIG/MAG welding:
max. 210 A; 150 A at 100%* MMA welding: max. 180 A; 130 A at 100%*
* The 100% values relate to welding with no time limits and without cooling breaks
Page 52
50
Fitting/connecting the system components
Information on system compo­nents
The steps and activities described below include references to various system compo­nents, such as
- Trolley
- Cooling units (TSt 3500c only)
- Welding torches, etc.
For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.
Mounting on the trolley
The following diagram shows an overview of how the individual system components are put together. For detailed information about the individual steps, please refer to the corresponding op­erating instructions for the system components.
TSt 2500c TSt 3500c
Connecting the gas cylinder
WARNING! Work that is carried out incorrectly can cause serious injury and dam-
age. The following activities must only be carried out by trained and qualified per­sonnel. All instructions in the section headed "Safety rules" must be observed.
WARNING! If gas cylinders topple over, there is a risk of very serious injury and damage. When using gas cylinders
- place them on a solid, level surface in such a way that they remain stable
- secure the gas cylinders to prevent them from falling over
- fit the optional wirefeeder holder
Follow the gas cylinder manufacturer's safety rules.
Page 53
51
EN
TSt 2500c TSt 3500c
Secure the gas cylinder with a belt
Briefly open the gas cylinder valve to remove any dust or dirt
Check the seal on the pressure regulator
Connecting a MIG/MAG welding torch
1
NOTE! US devices (TSt 3500c only) are supplied with an adapter for the gas hose:
- Seal male thread spacers on the gas solenoid valve using suitable means be­fore screwing on the adapter.
- Test the adapter to ensure that it is gas-tight.
1
2
3
NOTE! When connecting the welding torch, check that
- all connections are connected properly
- all cables, leads and hosepacks are undamaged and correctly insulated.
1
Page 54
52
Establishing a ground (earth) connection
1
Inserting/replac­ing feed rollers
In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.
An overview of the available feed rollers can be found in the spare parts lists.
1 2
3 4
1
CAUTION! Risk of injury if the feed roller holders fly upwards. When unlocking the lever, keep fingers away from the area to the left and right of the lever.
2
1
4
4
5
6
3
1
6
3
31 2
4 5
7
2
3
8
6
7
9
3
1
2
2
5
4
4
3
4
5
5
6
1
2
3
4
Page 55
53
EN
Inserting the wire­spool/basket-type spool
1
CAUTION! Risk of injury from springiness of spooled wire electrode. When insert­ing the wirespool / basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back.
CAUTION! Risk of injury from falling wirespool/basket-type spool. Make sure that the wirespool or basket-type spool with basket-type spool adapter is fitted secure­ly to the wirespool holder.
CAUTION! Risk of injury and material damage if the wirespool/basket-type spool topples over because the locking ring has been placed the wrong way round. Al­ways place the locking ring as shown in the diagram on the left.
1
NOTE! When working with basket-type spools, only use the basket-type spool adapter included in the scope of supply.
Page 56
54
1 2
Feeding in the wire electrode
1 2
IMPORTANT! To facilitate wire threading, the following sequences are possible when the "Wire threading" button is pressed and held down.
1
2
CAUTION! Risk of injury from 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 feeding in.
2
1
4
3
1
4
1
2
3
2
CAUTION! Risk of injury from wire electrode emerging at speed. When pressing the "Wire threading" button or the torch trigger, keep the welding torch away from your face and body, and wear suitable protective goggles.
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EN
- Hold the button for up to one second ... the wire feed speed stays at 1 m/min or 39.37 ipm for the first second.
- Hold the button for up to 2.5 seconds ... after one second, the wire feed speed increases over the next 1.5 se­conds.
- Hold the button for more than 2.5 se- conds ... after 2.5 seconds, the wire is fed at a constant rate equal to the wire feed speed set for the Fdi welding pa­rameter.
If you release the "Wire threading" button and press it again before one second has elapsed, the sequence starts again from the beginning. This makes it possible to continu­ously position the wire at a low wire feed speed of 1 m/min or 39.37 ipm where necessary.
If there is no "Wire threading" / "Gas-test" button, the torch trigger can be used in the usu­al 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
IMPORTANT! If the torch trigger is pressed instead of the "Wire threading"/"Gas-test" button, the welding wire runs at the feeder creep speed (depending on the welding pro­gram) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.
The welding system detects that the welding process should not start, but that the wire is to be 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 kept pressed, wire feeding restarts immediately without shielding gas and welding voltage, and the process continues as described above.
1 2
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
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 etc.)
1
2
2
4
5
3
1
3
1
1
2
3
4
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56
Setting the con­tact pressure
Adjusting the brake
1 2
3
NOTE! Set the contact pressure in such a way that the wire electrode is not de­formed but nevertheless ensures proper wirefeed.
1
Standard values U-grooved rollers
Steel 4 - 5
CrNi 4 - 5
Tubular cored elec­trodes
2 -3
NOTE! After releasing the torch trigger the wirespool must stop unreeling. If it continues unreeling, readjust the brake.
4
STOP
6
7
1
2
3
5
3
5
1
2
1
2
2
4
STOP
OK
1
3
3
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57
EN
Design of the brake
WARNING! Fitting the equipment
incorrectly can cause serious inju­ry and damage.
- Do not dismantle the brake.
- Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only.
The brake is only available as a complete unit. This illustration is for information purposes only.
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Start-up
General
The device is started up by pressing the torch trigger (for manual applications).
Prerequisites The following conditions must be satisfied before the device is started:
- Welding torch connected
- Feed rollers inserted
- Wirespool or basket-type spool with adapter inserted
- Wire electrode fed in
- Brake adjusted
- Feed roller contact pressure set
- All covers closed, all side panels in place, all protection devices intact and in their proper place
- Where applicable, water connections connected
Commissioning Before proceeding further as described in the "Welding mode" section, the following activ-
ities are required for the "MIG/MAG standard synergic welding" and "MIG/MAG standard manual welding" processes:
Plug in the mains plug
Turn the mains switch to position "I"
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
1
2
Page 61
Welding
Page 62
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61
EN
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 feed 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 feed speed" parameter flashes as soon as the safety function trips. The flash­ing continues until the next welding start-up, or until the next parameter change.
If the "Wire feed speed" parameter is selected, the reduced value for wire feed speed is displayed.
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MIG/MAG modes
General
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 "Set-up parameters" section.
Symbols
2-step mode "2-step mode" is suitable for
- Tacking work
- Short weld seams
4-step mode
"4-step mode" is suitable for longer weld seams.
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
press hold release
I
GPr
GPo
t
I
+
I
GPr
GPo
t
I
+
+
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EN
Special 2-step mode
"Special 2-step mode" is ideal for welding in the higher power range. In special 2-step mode, the arc starts at a low power, which makes it easier to stabilise.
Special 4-step mode
"Special 4-step mode" is ideal for welding in higher power ranges. In special 4-step mo­de, the arc starts at a low power, which ma­kes it easier to stabilise.
+
I
GPr t-S
I-S I-E
t-ESL SL
GPo
t
I
+ +
I
GPr
I-S I-E
SL SL
GPo
t
I
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64
MIG/MAG welding
Safety
Overview MIG/MAG welding is composed of the following sections:
- MIG/MAG standard synergic welding
- MIG/MAG standard manual welding
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! An electric shock can be fatal. If the power source is connected to the mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
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EN
MIG/MAG standard synergic 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 electrode used.
Press the "Shielding gas" button to select the shielding gas to be used. The assignment of the SP position depends on 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
Press the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power:
Sheet thickness
Welding current
Wire feed 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 in the meantime. To display the actual welding current during welding, select the welding current parameter.
Open the gas cylinder valve
Set the shielding gas flow rate:
- Tap the "Gas-test" button
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Tap the "Gas-test" button again
Press the torch trigger and start welding
Corrections dur­ing welding
To obtain the best possible welding results, the arc length correction and dynamic welding parameters will sometimes need to be corrected.
Press the "Parameter selection" buttons to select the parameters you wish to correct.
Use the adjusting dials to set the selected welding parameters to the required values.
Welding parameter values are shown in the indicators located above them.
IMPORTANT! Under certain circumstances, welding parameters that have been set on a system component control panel (TR 2000 and TR 3000 remote controls or robot interface) may not be changed on the control panel of the power source.
1
2
3
4
5
6
7
8
9
10
1
2
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66
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
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 2500c: 15.5 - 31.5 V TSt 3500c: 15.5 - 31.5 V
Dynamic
... for influencing the short-circuiting dynamic at the moment of droplet transfer
Welding current
only for displaying the actual value
MIG/MAG stand­ard manual weld­ing
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 corresponds to conventional 4-step mode.
IMPORTANT! under certain circumstances, welding parameters that have been set on a system component control panel (TR 2000 and TR 3000 remote control or robot interface) may not be changed on the control panel of the wire-feed unit.
Press the "Parameter selection" button to select the wire feed speed parameter
Use the adjusting dial to set the desired value for the wire feed speed
Press the "Parameter selection" button to select the welding voltage parameter
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 in the meantime. To display the actual welding current during welding, select the welding current parameter.
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
1
2
3
4
5
6
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EN
Open the gas cylinder valve
Set the shielding gas flow rate:
- Tap the "Gas-test" button
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Tap the "Gas-test" button again
Press the torch trigger and start welding
Corrections 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 parameter
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.
7
8
9
1
2
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68
MMA welding
Safety
Preparation Move the mains switch to the "O" position
Disconnect the mains plug
Plug the grounding (earthing) cable into the (-) or (+) current socket (depending upon which type of electrode is to be used) and latch it by turning it clockwise
Use the other end of the grounding (earthing) cable to establish a connection to the workpiece
Plug the electrode holder cable bayonet plug into the free current socket with the op­posite polarity, according to the type of electrode, and turn it clockwise to latch it in place
Plug in the mains plug
MMA welding
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 connected to the welding socket with a 3-second time lag.
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.
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 in the meantime.
WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe­ty rules
WARNING! An electric shock can be fatal. If the machine is plugged into the mains electricity supply during installation, there is a high risk of very serious in­jury and damage. Do not carry out any work on the device unless
- the mains switch is in the "O" position,
- the device is unplugged from the mains.
IMPORTANT! Check the rod electrode packaging to determine whether the rod electrodes are for (+) or (-) welding.
1
2
3
4
5
6
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 conducting or earthed parts (e.g. the housing, etc.).
IMPORTANT! Under certain circumstances, welding parameters that have been set on a system component control panel (TR 2000 and TR 3000) may not be changed on the control panel of the power source.
1
2
3
4
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EN
Start welding
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
Corrections 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 parameter
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.
HotStart function To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart
function.
Advantages
- Improved ignition, 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 % I
H
: Main current = set welding current
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).
Anti-stick func­tion
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to "stick". This may also cause "burn-out" of the rod electrode.
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 operation can be continued without difficulty.
The anti-stick (Ast) function can be activated and deactivated in the Setup parameters in "Setup menu: level 2".
5
1
2
200
300
I (A)
Hti
HCU > I
H
t (s)
I
H
HCU
0,5 1 1,5
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70
Saving and retrieving operating points
General The "Save" buttons allow up to 5 operating points to be saved. Every operating point
matches the settings on the control panel.
IMPORTANT! Setup parameters are not saved at this time.
Saving operating points
Press and hold one of the "Save" buttons to save the current settings 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
Retrieving operat­ing points
To retrieve saved settings, press the corresponding "Save" button briefly, e.g.:
- The control panel will show the saved settings
Deleting operat­ing points
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 "---"
Release the "Save" button
Retrieving operat­ing points on the Up/Down welding torch
One of the "Save" buttons on the control panel must be pressed 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:
1
2
1
1
2
3
Number 1
Number 2
1
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EN
Number 3
Number 4
Number 5
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72
Page 75
Setup settings
Page 76
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75
EN
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.
Configuring the setup parameters
Configuring the setup parameters is described here with reference to the "MIG/MAG stand­ard synergic welding" process. The procedure for changing other setup parameters is iden­tical.
Accessing the Setup menu
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.
Changing welding parameters
Exiting the Setup menu
Use the "Process" button to select the "MIG/MAG standard syn­ergic welding" process
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Select the required setup parameter using the "Mode" and "Pro­cess" buttons or the left-hand adjusting dial
1
2
3
4
5
Change the value of the setup parameter using the "Parameter selection" buttons or the right-hand adjusting dial
6
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
7
8
9
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76
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: 0.1
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
Unit: ms Setting range: 0 - 20 Factory setting: 0
IGC Ignition current
Unit: A Setting range: 100 - 650 Factory setting: 500
Ito Ignition time-out function - Length of wire that is fed before the safety cut-out
is triggered
Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94) Factory setting: OFF
FAC Factory - 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
IMPORTANT! When the power source is reset, all the 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")
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 preset wire length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and options" section.
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EN
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: 0.1
SL Slope
Unit: s Setting range: 0 - 9.9 Factory setting: 0.1
I-S I (current) - Starting current
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 100
I-E I (current) - End: Final current
Unit: % (of welding current) Setting range: 0 - 200 Factory setting: 50
t-S t (time) - Starting - Starting current duration
Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF
t-E t (time) - End: Final current time
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 due to wire withdrawal at end of welding 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
is triggered
Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94) Factory setting: OFF
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FAC Factory - Reset power source to factory setting
Press and hold down one of the "Dynamic" (manual control panel) or "Parameter Selection" (Synergic A control panel) buttons for 2 s to restore the factory settings.
- when "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all the 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 time­out function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
Setup parameters for MMA welding
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
FAC Factory - 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.
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 time­out function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
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 preset wire length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and options" section.
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EN
Setup menu - Level 2
Restrictions In conjunction with the level 2 of the Setup menu, the following restrictions occur:
Level 2 of the Setup menu cannot be selected:
- during welding
- if the "Gas test" function is active
- if the "Wire threading" function is active
- if the "Wire withdrawal" function is active
- if the "Blow through" function is active
If level 2 of the Setup menu is selected, the following functions are not available, even in robot mode:
- Welding start-up - the "Power source ready" signal will not be emitted
- Gas testing
- Threading the wire
- Wire withdrawal
- Blow-through
Configuring the setup parameters
Accessing the Setup menu
The control panel is now in the Setup menu - the last setup parameter that was selected is displayed.
Selecting the "2nd" parameter
Accessing the Level 2 Setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the "2nd" setup parameter
1
2
3
4
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
5
6
7
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Changing welding parameters
Exiting the Level 2 Setup menu
Exiting the Setup menu
Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the required setup parameter
8
Change the value of the setup parameter using the "Parameter selection" buttons or the right-hand adjusting dial
9
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
10
11
12
13
14
15
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EN
Welding parame­ters for MIG/MAG welding in the Level 2 setup menu
C-C Cooling unit Control
(TSt 3500c with connected cooling unit only)
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 off­time.
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 restored 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
(TSt 3500c with connected cooling unit only) 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 pre-set 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) ... Std / US
Unit: ­Setting range: Std, US (Standard / USA) Factory setting: Standard version: Std (measurements: cm / mm) USA version: US (measurements: inches)
FUS Fuse - mains fuse protection in single-phase operation
(TSt 2500c MV with SEt parameter set to US only) The FUS parameter can only be set when the power source is operating on a sin­gle-phase supply. In single-phase operation the maximum possible welding pow­er is limited by the degree of mains fuse protection. This also determines the safety cut-out of the power source.
If the mains cable has a 20 A fuse, the FUS parameter may be changed from 15 A to 20 A. Welding with a higher maximum power or for longer periods is there­fore possible.
Unit: A Setting range: 15 / 20 Factory setting: 15
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"
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Parameters for manual metal arc (MMA) welding in the Setup menu level 2
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 three­digit display, the following display format has been selected:
Value in kJ / indication 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)
PFS Permanent Feeder Speed - wire feed speed is permanently displayed
Unit: mm (in.) Setting range: ON / OFF Factory setting: OFF
If the setting is "ON", the wire feed speed (m/min) is permanently displayed on the manual control panel instead of the welding current (A). In this case the hold value for the welding current (A) is deactivated.
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"
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EN
Measuring welding circuit resistance r
General Measuring the welding circuit resistance "r" makes it possible to have a constant welding
result at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. Adjustment using the arc length correction parameter is no longer necessary.
The calculated welding circuit resistance is shown on the display.
r ... welding circuit resistance in mOhm
If the welding circuit resistance r has been measured correctly, the welding voltage will cor­respond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.
Measure the welding circuit re­sistance r
Make a ground earth connection to the workpiece
Open the Setup menu level 2 (2nd)
Select parameter "r"
Remove the gas nozzle from the welding torch
Screw on the contact tip
Place the contact tip down firmly on the surface of the workpiece
Briefly press the torch trigger or the "Wire threading" button
The welding circuit resistance is calculated. "run" is shown on the display during the measurement.
The measurement is finished when the welding circuit resistance is shown on the display in mOhm (e.g. 11.4).
Fit the gas nozzle back onto the welding torch
NOTE! The welding circuit resistance r depends on the hosepack used:
- if the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance r again
- measure the welding circuit resistance for every welding process separately with the appropriate welding leads
NOTE! In order to obtain good welding results, it is essential to measure the weld­ing circuit resistance correctly. Make sure that the contact between the earthing clamp and the workpiece is on a cleaned workpiece surface.
NOTE! Make sure that the contact between the contact tip and the workpiece is on a cleaned workpiece surface.
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Displaying welding circuit inductivity L
General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore
affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result.
Displaying weld­ing circuit induc­tivity L
The setup parameter "L" is used to display the most recently calculated welding circuit in­ductivity. The welding circuit inductivity is calibrated at the same time as the welding circuit resistance r is calculated. Detailed information can be found in the "Measuring welding cir­cuit resistance r" section.
Access the setup menu level 2 (2nd)
Select parameter “L”
The most recently calculated welding circuit inductivity L is shown on the right-hand digital display.
L ... Welding circuit inductivity (in microhenry)
Laying the hose­packs correctly
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2
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Troubleshooting and maintenance
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EN
Troubleshooting
General The devices are equipped with an intelligent safety system. This means that to a large ex-
tent it has been possible to dispense with melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again.
Safety
Fault diagnosis Make a note of the serial number and configuration of the device and contact our After-
Sales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
Power source has no function
Mains switch is on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty
Remedy: Replace faulty parts
Cause: Mains fuse protection
Remedy: Change the mains fuse protection
Nothing happens when the torch trigger is pressed
Power source mains switch is ON and indicators are lit up
Cause: Only for welding torches with an external control plug: The control plug is not
plugged in
Remedy: Plug in the control plug
Cause: Welding torch or welding torch control line is faulty
Remedy: Replace welding torch
WARNING! Work that is carried out incorrectly can cause serious injury or dam­age. The following activities must only be carried out by trained and qualified per­sonnel. Observe the safety rules in the power source operating instructions.
WARNING! An electric shock can be fatal. Before opening the unit
- Turn the mains switch to the "O" position
- Unplug the device from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again
- Using a suitable measuring device, check to make sure that electrically charged components (e.g. capacitors) have discharged
CAUTION! Inadequate PE conductor connections can cause serious injury and damage. The housing screws provide a suitable PE conductor connection for earthing (grounding) the housing and must NOT be replaced by any other screws which do not provide a reliable PE conductor connection.
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Nothing happens when the torch trigger is pressed
Power source mains switch is on, power source ON indication is lit up on the power source, indications on wire-feed unit are not lit up
Cause: The interconnecting hosepack is faulty or not connected properly
Remedy: Check interconnecting hosepack
No welding current
Mains switch is on, one of the overtemperature service codes "to" is displayed. Detailed information on the service codes "to0" to "to6" can be found in the section "Displayed ser­vice codes".
Cause: Overload
Remedy: Take the duty cycle into account
Cause: Thermostatic safety cut-out has tripped
Remedy: Wait until the power source automatically comes back on after the end of the
cooling phase
Cause: Limited supply of cooling air
Remedy: Remove air filter on the rear of the housing from the side and clean. Ensure
that the cooling air ducts are accessible.
Cause: The fan in the power source is faulty
Remedy: Contact After-Sales Service
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is incorrect
Remedy: Check the grounding (earthing) connection for correct polarity
Cause: There is a break in the power cable in the welding torch
Remedy: Replace the welding torch
No protective gas shield
All other functions are OK
Cause: Gas cylinder is empty
Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty
Remedy: Replace the gas pressure regulator
Cause: Gas hose is not fitted or is damaged
Remedy: Fit or change the gas hose
Cause: Welding torch is faulty
Remedy: Change the welding torch
Cause: Gas solenoid valve is faulty
Remedy: Contact After-Sales Service
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Irregular wire feed speed
Cause: Braking force has been set too high
Remedy: Loosen the brake
Cause: Hole in the contact tip is too narrow
Remedy: Use a suitable contact tip
Cause: Faulty inner liner in welding torch
Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary
Cause: The feed rollers are not suitable for the wire electrode being used
Remedy: Use suitable feed rollers
Cause: Feed rollers have the wrong contact pressure
Remedy: Optimise the contact pressure
Wirefeed problems
when using applications with long welding torch hosepacks
Cause: Incorrect arrangement of welding torch hosepack
Remedy: Arrange the welding torch hosepack in as straight a line as possible, avoiding
bends
Welding torch becomes very hot
Cause: The specification of the welding torch is inadequate
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled systems: Inadequate coolant flow
Remedy: Check coolant level, coolant flow, for coolant contamination, etc. For further
information refer to the cooling unit operating instructions.
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Poor weld properties
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor ground earth connection
Remedy: Ensure good contact to workpiece
Cause: Inadequate or no protective gas shield
Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.
Cause: Welding torch is leaking
Remedy: Change the welding torch
Cause: Wrong contact tip, or contact tip is worn out
Remedy: Replace the contact tip
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the wire electrode that has been inserted
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check weldability of the base material
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
Displayed service codes
If an error message that is not described here appears on the displays, proceed as follows to resolve the problem:
Turn the power source mains switch to the "O" position
Wait 10 seconds
Move the mains switch to the I position
If the error occurs again despite several attempts to eliminate it, or if the troubleshooting measures listed here are unsuccessful.
Make a note of the error message displayed
Note down the configuration of the power source
Contact our After-Sales Service team with a detailed description of the error
ESr | 20
Cause: The selected cooling unit is not compatible with the power source
Remedy: Connect compatible cooling unit
-----
Cause: An invalid welding process was called up on the robot interface (no. 37) or an
empty flag was selected (no. 32)
Remedy: Call up a valid welding process or select assigned "Save" button
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2
3
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EN
ELn | 12
Cause: Different control panels for selecting materials are in the system
Remedy: Connect similar control panels to select materials
ELn | 13
Cause: Illegal change of welding process during welding
Remedy: During welding do not carry out any illegal change of the welding process, re-
set error message by pressing any button
Err | PE
Cause: The earth current watchdog has triggered the safety cut-out of the power
source.
Remedy: Switch off the power source
Place the power source on an insulating surface Connect the grounding (earthing) cable to a section of the workpiece that is closer to the arc Wait for 10 seconds and then switch the power source on again
If you have tried this several times and the error keeps recurring, contact Af­ter-Sales Service
Err | Ur
Cause: If the VRD option is available, the open circuit voltage limit of 35 V has been
exceeded.
Remedy: Switch off power source
Wait for 10 seconds and then switch the power source on again
no | UrL
Cause: The VRD option has tripped too early.
Remedy: Check whether all welding power-leads and control lines are connected.
Switch off the power source Wait 10 seconds and switch the power source back on again
If the error occurs again - contact After Sales Service.
E-Stop
Cause: "External stop" has tripped
Remedy: Remedy the event that triggered the external stop
PHA | SE
Cause: Phase failure
with TransSteel 2500 Standard in particular:
If the failure occurs during welding, the welding operation stops.
with TransSteel 2500 Multivoltage in particular:
A single-phase operation with limited power is possible: When switching on the power source, "PHA | SE1" is displayed in order to show that a power reduction will be in effect. If a change in supply from three-phase to single-phase occurs during welding (display: "PHA | SE1") or from single-phase to three-phase (display: "PH | ASE 3"), the welding operation stops.
Remedy: Check the mains fuse, mains cable and mains plug.
Switch off the power source, wait 10 seconds and switch the power source back on again.
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Err | 51
Cause: Mains undervoltage: The mains voltage has fallen below the tolerance range
Remedy: Check the mains voltage
Err | 52
Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check the mains voltage
EFd 5
Cause: Incorrect wire-feed unit connected
Remedy: Connect correct wire-feed unit
EFd | 81, EFd | 83
Cause: Fault in the wire feed system (overcurrent in wire-feed unit drive)
Remedy: Arrange the hosepack in as straight a line as possible; check that there are
no kinks or dirt in the inner liner; check the contact pressure on the 4 roller drive
Cause: Wire-feed unit motor is sticking or defective
Remedy: Check the wire-feed unit motor or contact After-Sales Service
to0 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the primary circuit of the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to1 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature on the booster located in the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to2 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the secondary circuit of the power source
Remedy: Allow power source to cool down, check that fan is on
to5 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in cooling unit
Remedy: Allow cooling unit to cool down, check that fan is on
to3 | xxx
Remark: xxx stands for a temperature value
Cause: Overtemperature in the wire-feed unit motor
Remedy: Allow wire-feed unit to cool down
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to4 | xxx
Remark: xxx stands for a temperature value
Cause: Overtemperature in welding torch
Remedy: Allow welding torch to cool down
to6 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature at the output choke of the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to7 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the power source
Remedy: Allow power source to cool down, check that fan is on
toF | xxx
Cause: With the TSt 2500 MV power source operating in single-phase mode, the
power source safety cut-out has tripped in order to prevent the mains fuse from tripping.
Remedy: After a pause in welding of around 60 s, the message disappears and the
power source is operational again.
tu1 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature on the booster located in the power source
Remedy: Place power source in a heated room and allow it to warm up
tu0 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the power source primary circuit
Remedy: Place power source in a heated room and allow to warm up
tu6 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature on the output choke of the power source
Remedy: Place power source in a heated room and allow it to warm up
tu2 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the power source secondary circuit
Remedy: Place power source in a heated room and allow to warm up
tu3 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the wire-feed unit motor
Remedy: Place wire-feed unit in a heated room and allow to warm up
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tu4 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the welding torch
Remedy: Place welding torch in a heated room and allow to warm up
tu5 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the cooling unit
Remedy: Place cooling unit in a heated room and allow to warm up
tu7 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature in the power source
Remedy: Place power source in a heated room and allow it to warm up
no | H2O
Cause: Coolant flow rate too low
Remedy: Check coolant flow rate and cooling unit, including cooling circuit (for mini-
mum coolant flow, see "Technical Data" section in the device operating in­structions)
hot | H2O
Cause: The coolant temperature is too high
Remedy: Allow cooling unit and cooling circuit to cool down, until "hot | H2O" is no
longer displayed. Open the cooling unit and clean the cooler, check fan is working properly. Robot interface or field bus coupler: before resuming weld­ing, set the "Source error reset" signal.
no | Prg
Cause: No preconfigured program has been selected
Remedy: Select a configured program
no | IGn
Cause: "Ignition time out" function is active; no current started flowing before the
length of wire specified in the set-up menu had been fed. The power source safety cut-out has tripped.
Remedy: Shorten the wire end; press the torch trigger again; clean the surface of the
workpiece; if necessary, increase the wire length until the safety cut-out trips in "Set-up menu: Level 2".
EPG | 29
Cause: The required wire-feed unit is not available for the selected characteristic
Remedy: Check plug connections for the hosepack
EPG | 35
Cause: RL calibration failed.
Remedy: Check grounding (earthing) cable, current cable or hosepack and replace if
necessary, restart RL calibration
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no | GAS
Cause: The Gas watchdog option has detected that there is no gas pressure
Remedy: Connect a new gas cylinder or open the gas cylinder valve/pressure regulator,
restart "Gas watchdog" option, reset "no | GAS" error message by pressing any button.
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Care, maintenance and disposal
General Under normal operating conditions, the welding system requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the weld­ing system remains in a usable condition for many years.
Safety
At every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and ground-
ing (earthing) connection for damage
- Check that there is a gap of 0.5 m (1 ft. 8 in.) all around the device to ensure that cool­ing air can flow and escape unhindered
If necessary If a lot of dust has accumulated:
TSt 2500c
- Remove the fin element on the rear of the housing (possible without tools)
- Detach the air filter located behind and clean
TSt 3500c
- Remove the air filter on the rear of the housing from the side and clean
Every 2 months
- If required, clean air filter using dry compressed air or by washing it.
Every 6 months - Dismantle device side panels and clean inside of device with dry reduced compressed
air
- If a lot of dust has accumulated, clean the cooling air ducts.
WARNING! An electric shock can be fatal. Before opening the device
- Turn the mains switch to the "O" position
- Unplug the machine from the mains
- Prevent it from being switched on again
- Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have discharged
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 per­sonnel. All instructions in the section headed "Safety rules" must be observed.
NOTE! Air inlets and outlets must never be covered, not even partially.
CAUTION! Risk of damage. The air filter must only be fitted when dry.
NOTE! Risk of damage to electronic components. Do not bring air nozzle too
close to electronic components.
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EN
Disposal Dispose of in accordance with the applicable national and local regulations.
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Technical data
Special voltages For devices designed for special voltages, the technical data on the rating plate applies.
For all machines with a permitted mains voltage of up to 460 V: The standard mains plug allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly.
TSt 2500c
Mains voltage (U1) 3 x 380 V 400 V 460 V
Max. effective primary current (I
1eff
) 7 A 6.7 A 5.6 A
Max. primary current (I
1max
) 11.8 A 11.2 A 9.7 A
Mains fuse 16 A slow-blow
Mains voltage tolerance -15 / +15%
Mains frequency 50 / 60 Hz
Welding current range (I2)
MIG / MAG 10 - 250 A
Rod electrode 10 - 250 A
Welding current at 10 min / 40°C (104°F) 35% 60% 100%
250 A 210 A 170 A
Output voltage range according to standard characteristic (U2)
MIG / MAG 14.5 - 26.5 V
Rod electrode 20.4 - 30.0 V
Open circuit voltage (U0 peak / U0 r.m.s) 41 V
Protection class IP 23
Insulation class B
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE
Efficiency at 170 A and 22.5 V 88%
Dimensions l x w x h 687 x 276 x 445 mm
27.1 x 10.9 x 17.5 in.
Weight 30 kg
66.1 lb.
Max. shielding gas pressure 7 bar
101.49 psi
Gear ratio 16: 1
Wire drive 4-roller drive
Wire diameter 0.8 - 1.6 mm
0.03 - 0.06 in.
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