TÄYDELLISTÄ HITSAUSTA
TRANS STEEL 3500 C0MPACT
/ Operating Instructions
/ Spare Parts List
v.01/2012 ENG
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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.
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Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety symbols .............................................................................................................. 7
General ................................................................................................................................................. 7
Intended purpose .................................................................................................................................. 8
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 9
Mains connection .................................................................................................................................. 9
Protecting yourself and others .............................................................................................................. 9
Danger from toxic gases and vapours .................................................................................................. 10
Danger from flying sparks ..................................................................................................................... 11
Risks from mains current and welding current...................................................................................... 11
Meandering welding currents................................................................................................................ 12
EMC device classifications ................................................................................................................... 13
EMC measures ..................................................................................................................................... 13
EMF measures...................................................................................................................................... 13
Specific danger points........................................................................................................................... 14
Danger from shielding gas cylinders..................................................................................................... 15
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 16
Maintenance and repair ........................................................................................................................ 17
Safety inspection................................................................................................................................... 18
Disposal ................................................................................................................................................ 18
Safety symbols...................................................................................................................................... 18
Data protection...................................................................................................................................... 18
Copyright............................................................................................................................................... 19
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Functional principle ............................................................................................................................... 23
Application areas .................................................................................................................................. 23
Warning notices on the device.............................................................................................................. 23
System components .................................................................................................................................. 25
General ................................................................................................................................................. 25
Safety.................................................................................................................................................... 25
Overview ............................................................................................................................................... 25
Control elements and connections 27
Description of the control panel ................................................................................................................. 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Synergic control panel ............................................................................................................................... 30
General ................................................................................................................................................. 30
Synergic control panel .......................................................................................................................... 30
Service parameters............................................................................................................................... 32
Connections, switches and mechanical components ................................................................................ 34
Front and rear ....................................................................................................................................... 34
Page...........................................................................................................................
........................... 35
Inst
allation and commissioning 37
Minimum equipment needed for welding task............................................................................................ 39
General ................................................................................................................................................. 39
MIG/MAG welding, gas-cooled ............................................................................................................. 39
MIG/MAG welding, water-cooled .......................................................................................................... 39
Manual metal arc welding ..................................................................................................................... 39
Before installation and commissioning....................................................................................................... 40
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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
Fit the strain-relief device...................................................................................................................... 43
Fit the Canada/US strain-relief device .................................................................................................. 43
System components .................................................................................................................................. 45
Information on system components ...................................................................................................... 45
Fitting the system components (overview)............................................................................................ 45
Connect the gas cylinder ........................................................................................................................... 46
Connect the gas cylinder ...................................................................................................................... 46
Connecting the welding torch and establishing a ground (earth) connection ............................................ 47
Safety.................................................................................................................................................... 47
Connecting MIG/MAG manual welding torches .................................................................................... 47
Establishing a ground (earth) connection ............................................................................................ 47
Inserting/replacing feed rollers ................................................................................................................... 48
General ................................................................................................................................................. 48
Inserting/replacing feed rollers.............................................................................................................. 48
Inserting the wirespool, inserting the basket-type spool ............................................................................ 49
Safety.................................................................................................................................................... 49
Inserting the wirespool .......................................................................................................................... 49
Inserting the basket-type spool ............................................................................................................. 49
Feeding in the wire electrode ..................................................................................................................... 51
Feed in the wire electrode..................................................................................................................... 51
Set the contact pressure ....................................................................................................................... 52
Adjust the brake ......................................................................................................................................... 54
General ................................................................................................................................................. 54
Adjusting the brake ............................................................................................................................... 54
Design of the brake............................................................................................................................... 55
Start-up ...................................................................................................................................................... 56
General ................................................................................................................................................. 56
Prerequisites ......................................................................................................................................... 56
Starting up............................................................................................................................................. 56
Welding 57
Power limitation.......................................................................................................................................... 59
Safety function ...................................................................................................................................... 59
MIG/MAG modes ....................................................................................................................................... 60
General ................................................................................................................................................. 60
Symbols ................................................................................................................................................ 60
2-step mode .......................................................................................................................................... 60
4-step mode .......................................................................................................................................... 60
Special 2-step mode .............................................................................................................
................ 61
Special 4-step mode ............................................................................................................................. 61
MIG/MAG welding...................................................................................................................................... 63
Safety.................................................................................................................................................... 63
Overview ............................................................................................................................................... 63
MIG/MAG standard Synergic welding ........................................................................................................ 64
MIG/MAG standard synergic welding ................................................................................................... 64
Corrections during welding ................................................................................................................... 65
MIG/MAG standard manual welding .......................................................................................................... 66
General remarks ................................................................................................................................... 66
Available parameters ............................................................................................................................ 66
MIG/MAG standard manual welding ..................................................................................................... 66
Corrections during welding ................................................................................................................... 67
MMA welding ............................................................................................................................................. 68
Safety.................................................................................................................................................... 68
Preparation ........................................................................................................................................... 68
Manual metal arc welding ..................................................................................................................... 68
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Corrections during welding ................................................................................................................... 69
HotStart function ................................................................................................................................... 69
Anti-stick function.................................................................................................................................. 69
Saving and retrieving operating points....................................................................................................... 71
General ................................................................................................................................................. 71
Saving operating points ........................................................................................................................ 71
Retrieving operating points ................................................................................................................... 71
Deleting operating points ...................................................................................................................... 71
Retrieving operating points on the up/down welding torch ................................................................... 72
Setup settings 75
Setup menu................................................................................................................................................ 77
General remarks ................................................................................................................................... 77
Setting the set-up parameters............................................................................................................... 77
Set-up parameters for MIG/MAG standard manual welding ................................................................. 78
Set-up parameters for MIG/MAG standard synergic welding ............................................................... 80
Set-up parameters for MMA welding .................................................................................................... 82
Setup menu - Level 2................................................................................................................................. 83
Restrictions ........................................................................................................................................... 83
Setting the set-up parameters............................................................................................................... 83
Welding parameters for MIG/MAG welding in the Level 2 set-up menu ............................................... 84
Measuring welding circuit resistance r ....................................................................................................... 86
General ................................................................................................................................................. 86
Measuring welding circuit resistance r .................................................................................................. 86
Displaying welding circuit inductivity L ....................................................................................................... 87
General ................................................................................................................................................. 87
Displaying welding circuit inductivity L .................................................................................................. 87
Laying the hosepacks correctly............................................................................................................. 87
Troubleshooting and maintenance 89
Troubleshooting ......................................................................................................................................... 91
General ................................................................................................................................................. 91
Safety.................................................................................................................................................... 91
Fault diagnosis...................................................................................................................................... 91
Displayed service codes ....................................................................................................................... 94
Care, maintenance and disposal ............................................................................................................... 99
General ................................................................................................................................................. 99
Safety.................................................................................................................................................... 99
At every start-up.................................................................................................................................... 99
If necessary........................................................................................................................................... 99
Every 2 months ..................................................................................................................................... 99
Every 6 months ..................................................................................................................................... 99
Disposal ................................................................................................................................................ 99
Technical data............................................................................................................................................ 100
Special voltages.................................................................................................................................... 100
TSt 3500c.............................................................................................................................................. 100
Quick reference.......................................................................................................................................... 102
.............................................................................................................................................................. 102
Annex 105
Spare parts list: TransSteel 3500c ............................................................................................................. 106
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Safety rules
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules", special care is required.
General
DANGER! indicates immediate and real danger. If it is not avoided, death or se-
rious 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.
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
- 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 kept in a legible state
- must not be damaged/marked
- 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 remarks" in the operating instructions for the device.
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!
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Intended purpose
Environmental
conditions
Obligations of the
operator
The device is to be used exclusively for its intended purpose.
The device is intended for the welding process described on the rating plate
only.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be liable for any damage resulting from such improper use.
Utilisation in accordance with the "intended purpose" also comprises
- reading carefully and following all operating instructions to the letter
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and servicing work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries/accumulators
- 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 unexpected or incorrect results.
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 liable for any damage resulting from such improper use.
Ambient temperature:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -25 °C to +55 °C (-13 °F to 131 °F)
Relative humidity:
- up to 50 % at 40 °C (104 °F)
- up to 90 % at 20 °C (68 °F)
Ambient air: free from dust, acids, corrosive gases and substances, etc.
For use at altitudes above sea level: up to 2000 m (6500 ft)
The operator undertakes only to allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety and accident prevention, and have been instructed 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.
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Obligations of
personnel
Mains connection
Protecting yourself and others
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 work area, 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 types of device in terms of:
- connection restrictions
- criteria with regard to maximum permissible mains impedance
*)
- criteria with regard to minimum short-circuit power requirement
*)
*)
at the interface with the public mains network
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.
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:
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Danger from toxic
gases and vapours
- 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 safety
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 danger from
mains or 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.
If this cannot be provided, a protective mask with an air supply must be worn.
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.
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Danger from flying sparks
Risks from mains
current and welding current
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (35 ft) 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 life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG or TIG welding, the welding wire, the wirespool, the drive
rollers and all metal parts 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 wire-feed unit mount.
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 complete, 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 either the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc) must
- never be immersed in liquid for cooling
- never be touched when current is flowing.
Double the open circuit voltage of a welding machine can occur between the
welding electrodes of two welding machines. Touching the potentials of both
electrodes at the same time may under certain circumstances be fatal.
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Meandering welding currents
Arrange for the mains and device supply to be checked regularly by a qualified
electrician to ensure the PE conductor is functioning properly.
The device must only be operated on a mains supply with a PE conductor and
a socket with an earth contact.
If the device is operated on a mains without a PE conductor and in a socket
without an earth contact, this will be deemed gross negligence. The manufacturer shall not be liable for any damage resulting from such improper use.
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 reconnecting it to the mains and switching it on again.
After opening the device:
- discharge all components holding an electric charge
- ensure that all components in the device are de-energised.
If work on live parts cannot be avoided, 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 PE 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 with emission class A:
- are only designed for use in an industrial setting
- can cause conducted and emitted interference in other areas.
Devices with emission class B:
- satisfy the emissions criteria for residential and industrial areas.
This also applies to residential areas in which power is supplied
from the public low-voltage grid.
EMC device classification according to the rating plate or the 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 for possible problems, and check and evaluate neighbouring devices'
resistance to interference according to national and international requirements:
- Safety features
- power, signal and data transfer lines
- IT and telecommunications devices
- measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
a) Mains supply
- if electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g. use a suitable line filter).
b) Welding leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
c) Equipotential bonding
d) Earthing the workpiece
- if necessary, establish an earth connection using suitable capacitors.
e) 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 danger
points
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.
When in use:
- ensure that all covers are closed and all side panels are fitted properly.
- keep all covers and side panels closed.
A high risk of injury exists when the welding wire emerges from the welding
torch (piercing of the hand, injuries to the face and eyes, etc.). Always keep
the torch well away from the body (devices with a wire-feed unit).
Never touch the workpiece during or after welding - risk of burns.
Slag can sometimes fly off workpieces as they cool down. 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 that are to be used in rooms/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.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains and/or ropes onto the suspension points provided on the
load-carrying equipment.
- Chains/ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
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Danger from
shielding gas cylinders
Safety measures
at the installation
location and during transport
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wire-feed unit holder (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, forklift or other mechanical hoist.
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 shielding gas connection using suitable Teflon tape.
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.
A device that topples over can easily kill someone. Place the device on a solid,
level surface in such a way that it remains stable
- The maximum permissible slope is 10°.
Special regulations apply in rooms at risk of fire or explosion
- observe relevant national and international requirements.
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Safety measures
in normal operation
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 a gap of 0.5 m (1 ft. 7.69 in.) all
round so that cooling air can enter and exit 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 transportation.
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, and before commissioning, you MUST carry out
a visual inspection to check whether it has been damaged in any way. Any
damage must be repaired by trained service technicians before commissioning takes place.
Only operate the device when all protection devices are fully functional. If the
protection 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.
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Maintenance and
repair
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable protection 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 conductivity, frost protection, material
compatibility, flammability, etc.)
- Only use suitable original coolant from the manufacturer.
- Do not mix the manufacturer's original coolant with other coolants.
- If damage results from using a different coolant, the manufacturer accepts
no liability. In addition, no warranty claims will be entertained.
- 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
- Used coolant must be disposed of properly in accordance with the relevant national and international regulations. A safety data sheet may be
obtained from your service centre or downloaded from the manufacturer's
website.
- Check the coolant level before you start to weld while the system is still
cool.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made on them, or that they satisfy safety requirements. Use only original replacement and wearing parts (also applies to
standard parts).
Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
Components that are not in perfect condition must be changed immediately.
When ordering, please give the exact designation and part number as shown
in the spare parts list, as well as the serial number of your device.
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Safety inspection
Disposal
Safety symbols
Data protection
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!
Devices with the CE marking 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.
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Copyright
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.
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General information
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General
Device concept
The TransSteel (TSt) 3500c power sources
are completely digitised, microprocessorcontrolled 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
- Manual metal arc 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. For more information,
see the "Welding mode" section.
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 3500c power sources are designed for:
- Machine and equipment construction
- Steelwork
- Plant and container construction
- Metal and gantry construction
- Rail vehicle construction
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 equipment incorrectly, as this may result in serious injury and damage.
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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
- Keep all persons not involved in
the welding process 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
25
g
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
No. Function
(1) Welding torch
(2) Stabilising the gas cylinder holder
(3) Power source
(4) Cooling unit
(5) Trolley and gas cylinder holder
(6) 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)
(6)
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Control elements and connections
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