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TRANS STEEL 3500 C0MPACT

Fronius TRANS STEEL 3500 C0MPACT Operating Instructions And Spare Parts List

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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
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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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Page 29
Control elements and connections
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Description of the 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 synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.
Safety
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
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Synergic control panel
General 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.
Synergic control panel
No. Function
(1) "Parameter selection" button (right)
a) for selecting the following welding parameters
Arc length correction
for correcting the arc length
Welding voltage *)
Welding voltage in V. Before the start of welding, the system automatically displays a standard val-
ue based on the programmed parameters. During welding, the actual value is
(11)
(12)
(4)
(7)
(10) (9) (8) (6)
(3)
(2)
(1)
(5)
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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
The relevant symbol lights up when a welding parameter is selected.
*) In the MIG/MAG standard synergic welding process, if one of these parameters is selected then the synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically.
b) for changing parameters in the set-up menu
(2) "Parameter selection" button (left)
a) for selecting the following welding parameters
Sheet thickness
Sheet thickness in mm or in. If the welding current to be selected is not known it is sufficient to enter the
sheet thickness. The required welding current and any other parameters marked with *) will then be adjusted automatically.
Welding current *) Welding current in A Before the start of welding, the system automatically displays a standard val-
ue based on the programmed parameters. During welding, the actual value is displayed.
Wire feed speed
*)
Wire feed speed (m/min or ipm).
The relevant symbol lights up when a welding parameter is selected.
*) In the MIG/MAG standard synergic welding process, if one of these parameters is selected then the synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically.
b) for changing parameters in the set-up menu
(3) Adjusting dial (right)
for changing the arc length correction, welding voltage and dynamic welding pa­rameters
for changing welding parameters in the set-up menu
(4) Adjusting dial (left)
for changing the sheet thickness, welding current and wire feed speed welding pa­rameters
for selecting welding parameters in the set-up menu
(5) "Save" buttons (Easy Job)
for saving up to 5 operating points
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(6) "Process" button
for selecting the welding process
MANUAL - MIG/MAG standard manual welding SYNERGIC - MIG/MAG standard synergic welding STICK - MMA welding
(7) "Mode" button
for selecting the mode
2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode
(8) "Protective gas shield" button
For selecting the shielding gas to be used. The SP parameter is intended for addi­tional shielding gases.
When a shielding gas is selected, the LED behind the relevant shielding gas lights up.
(9) "Wire diameter" button
For selecting the wire diameter to be used. The SP parameter is intended for addi­tional wire diameters.
When a wire diameter is selected, the LED behind the relevant wire diameter lights up.
(10) "Material" button
For selecting the filler metal to be used. The SP parameter is intended for addition­al filler metals.
When a material is selected, the LED behind the relevant filler metal lights up.
(11) Intermediate arc indicator
A spatter-prone intermediate arc forms between the short circuit arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area.
(12) HOLD indicator
Whenever welding stops, the actual values for welding current and welding voltage are stored, and the “Hold” indicator lights up.
Service parame­ters
Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.
Opening the display
The first "firmware version" parameter is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Press and hold the "Parameter selection" button (left)
Press the "Parameter Selection" button (right)
Release the "Parameter selection" buttons
1
2
3
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Available parameters
Select the required setup parameter using the "Mode" and "Proc­ess" buttons or the left adjusting dial
1
Explanation
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.
2nd 2nd menu level for service engineers
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Connections, switches and mechanical components
Front and rear
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 socket for remote control
(5) Mains switch
for switching the power source on and off
(6) Mains cable with strain relief device
(7) "Feeder inching"/"Gas test" button
Push button downwards 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 wire threading
(1) (9) (8)
(2) (3) (4) (5) (7)(6)
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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)
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Installation and commissioning
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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
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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.
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NOTE! Inadequately dimensioned electrical installations can cause serious dam­age. 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.
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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 PE conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase con­ductors.
An illustration of the mains cable connection can be found in the following sections: "Fitting the strain-relief device" or "Fitting the strain-relief device for Canada / US". To connect the mains cable, proceed as follows:
Remove the side panel from the device
Push the mains cable in far enough to make it possible to connect the PE conductor and the phase conductors to the block terminal properly.
Fit ferrules to the PE conductor and phase conductors
Connect the PE conductor and phase conductors to the block terminal
Use the strain-relief device to secure the mains cable
Fir the side panel of the device
Power source Cable cross-section
Canada/US Europe
TSt 3500c AWG 12 *) 4G2.5
Power source Mains voltage Cable cross-sec-
tion
Canada/US
Europe
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
4
5
6
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Fit the strain-re­lief device
Fit the Canada/US strain-relief de­vice
1
2
3
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
1
2
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44
3
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
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System components
Information on system compo­nents
The steps and activities described below include references to various system compo­nents, including:
- Trolleys
- Cooling units
- Welding torches, etc.
For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.
Fitting the system components (overview)
The diagram below provides an overview of how to fit the individual system compon­ents. For detailed information about the individu­al steps, please refer to the relevant opera­ting instructions for the system components.
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.
1
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46
Connect the gas cylinder
Connect the gas cylinder
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
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 VR holder option
Follow the gas cylinder manufacturer's safety rules.
1
2
3
NOTE! US devices are supplied with an adapter for the gas hose:
- Seal male thread spacers on the gas solenoid valve using suitable equip­ment before screwing on the adapter.
- Test the adapter to ensure that it is gas-tight.
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Connecting the welding torch and establishing a ground (earth) connection
Safety
Connecting MIG/ MAG manual welding torches
Establishing a ground (earth) connection
NOTE! When connecting the welding torch, check that
- all connections are connected properly
- all cables, leads and hosepacks are undamaged and correctly insulated.
1
1
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Inserting/replacing feed rollers
General In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the
diameter and alloy of the wire being welded.
IMPORTANT! Only use feed rollers that match the wire electrode.
An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists.
Inserting/replac­ing feed rollers
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
7
5
6
8
3
1
2
2
4
3
4
5
5
6
1
2
3
4
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Inserting the wirespool, inserting the basket-type spool
Safety
Inserting the wire­spool
Inserting the bas­ket-type spool
CAUTION! Risk of injury from springiness of spooled wire electrode. When insert-
ing 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 adapter is fitted securely to the wire­spool holder.
CAUTION! Risk of injury and impaired performance if the wirespool 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.
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CAUTION! Risk of injury from falling basket-type spool. Place the basket-type spool on the adapter provided in such a way that the bars on the spool are inside the adapter guideways.
CAUTION! Risk of injury and impaired performance if the 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
1
2
2
1
2
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Feeding in the wire electrode
Feed in the wire electrode
IMPORTANT To facilitate the exact positioning of the wire electrode, the following se-
quences are possible when the "Feeder inching" button is pressed and held down.
- 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 has elapsed, the wire feed speed increases at a uniform rate over the next 1.5 seconds.
- Hold the button for longer than 2.5 se- conds ... After a total of 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 "Feeder inching" 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 "Feeder inching"/"Gas test" button, the torch trigger can be used in the same way. Before using the torch trigger for wire threading, proceed as follows:
Press the "Mode" button to select 2-step mode
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
2
1
1
4
1
2
3
2
CAUTION! Risk of injury from wire electrode emerging at speed. Keep the weld­ing torch away from your face and body when pressing the "Feeder inching" but­ton or torch trigger.
Fdi
1
234
5
2,51
t (s)
(m/min, ipm)
1
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52
Set the "Ito" parameter to "Off" in the set-up menu
IMPORTANT If the torch trigger is pressed instead of the "Feeder inching"/"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 shielding 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.
Set the contact pressure
CAUTION! Risk of injury and damage from electric shock and from the wire elec-
trode emerging from the torch. When pressing the torch trigger:
- keep the welding torch away from your face and body
- do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or earthed (grounded) parts, such as the housing, etc.
2
2
4
5
3
1
3
1
1
2
3
4
NOTE! Set the contact pressure in such a way that the wire electrode is not de­formed but nevertheless ensures proper wirefeed.
1
1
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Contact pressure standard values U-grooved rollers
Steel 4 - 5
CrNi 4 - 5
Tubular cored electrodes 2 - 3
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Adjust the brake
General
Adjusting the brake
NOTE! After releasing the torch trigger the wirespool must stop unreeling. If it
continues unreeling, readjust the brake.
1
4
STOP
6
7
1
2
3
5
1
2
1
2
2
4
STOP
OK
1
3
3
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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
Starting up Before proceeding further as described in the "Welding mode" section, the following activ-
ities are required for "MIG/MAG standard synergic welding" and "MIG/MAG standard man­ual welding":
Plug in the mains plug
Turn the mains switch to the "I" position
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 59
Welding
Page 60
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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 "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 the torch trigger Hold the torch trigger Release the torch trigger
I
GPr GPo
t
I
+
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Special 2-step mode
"Special 2-step mode" is ideal for welding in the upper 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 particularly suitable 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 GPo
t
I
+
+
GPr
GPo
I
I-S
SLt-S t-ESL
I-E
+
t
I
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62
GPr
GPo
I
I-S
SL SL
I-E
+
t
I
+
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MIG/MAG welding
Safety
Overview MIG/MAG welding is composed of the following sections:
- MIG/MAG standard synergic welding
- Special functions and options
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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MIG/MAG standard Synergic welding
MIG/MAG stand­ard synergic welding
Press the "Material" button to select the filler metal to be used.
Assignment of the SP position depends on the welding database used for the power source.
Press the "Wire diameter" button to select the diameter of the wire electrode to be used.
Assignment of the SP position depends on the welding database used for the power source.
Press the "Protective gas shield" button to select the shielding gas to be used.
Assignment of the SP position depends on the welding database used for the power source.
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:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown in the digital display during welding.
Open the gas cylinder valve
Set the shielding gas flow rate:
IMPORTANT! Under certain circumstances, welding parameters that have been set on a system component control panel (TR 2000 and TR 3000 remote control units or robot interface) may not be changed on the control panel of the power source.
1
2
3
4
5
6
7
8
9
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If there is a "Feeder inching"/"Gas test" button:
- Press the "Feeder inching" / "Gas test" button upwards and release
- Turn the adjusting screw on the underside of the pressure regulator until the pres­sure gauge shows the required gas flow rate
- Press the "Feeder inching" / "Gas test" button upwards again and release
If there is no "Feeder inching"/"Gas test" button:
- Press the "Mode" button to select 2-step mode
- Set the "Ito" parameter to "Off" in the set-up menu
- Disengage the feed rollers
- press and hold the torch trigger
- turn the adjusting screw on the underside of the pressure regulator until the pres­sure gauge shows the required shielding gas flow rate
- release the torch trigger
- engage the feed rollers
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.
Arc length correction
for correcting the arc length
- shorter arc length 0 neutral arc length + longer arc length
Dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer
- harder, more stable arc 0 neutral arc + soft, low-spatter arc
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
- do not point the welding torch at people
- make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.
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
- do not point the welding torch at people
- make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.
10
11
1
2
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MIG/MAG standard manual welding
General remarks 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 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 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 units 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:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown in the digital display during welding.
Open the gas cylinder valve
1
2
3
4
5
6
7
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Set the shielding gas flow rate:
If there is a "Feeder inching"/"Gas test" button:
- Press the "Feeder inching" / "Gas test" button upwards and release
- Turn the adjusting screw on the underside of the pressure regulator until the pres­sure gauge shows the required gas flow rate
- Press the "Feeder inching" / "Gas test" button upwards again and release
If there is no "Feeder inching"/"Gas test" button:
- Press the "Mode" button to select 4-step mode
- Set the "Ito" parameter to "Off" in the set-up menu
- Disengage the feed rollers
- press the torch trigger briefly
- turn the adjusting screw on the underside of the pressure regulator until the pres­sure gauge shows the required shielding gas flow rate
- press the torch trigger again briefly
- engage the feed rollers
Press the torch trigger and start welding
Corrections dur­ing welding
To obtain the best possible welding results, the dynamic welding parameter will sometimes need to be adjusted.
Press the "Parameter selection" button to select the dynamic welding parameter
Use the adjusting dial to set the desired dynamic value
The welding parameter value is shown in the digital display located above it.
Dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer 0 harder, more stable arc 10 soft, low-spatter arc
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
- do not point the welding torch at people
- make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.
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
- do not point the welding torch at people
- make sure that the wire electrode does not touch any electrically conducting or earthed (grounded) parts, such as the housing, etc.
8
9
1
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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
Manual metal arc 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.
If the MMA welding process is selected, any cooling unit present is automatically de­activated. It is not possible to switch it on.
Press the "Parameter selection" button to select the amperage parameter.
Use the adjusting dial to set the desired amperage.
The amperage value is shown in the left-hand digital display.
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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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.
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 in the digital display during welding.
Corrections dur­ing welding
To obtain the best possible welding results, the dynamic welding parameter will sometimes need to be adjusted.
Press the "Parameter selection" button to select the dynamic welding parameter
Use the adjusting dial to set the desired dynamic value
The welding parameter value is shown in the digital display located above it.
Dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer 0 harder, more stable arc 100 soft, low-spatter arc
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 metal in 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
How it works
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 (I
H
).
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.
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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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".
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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, e.g.:
Release the "Save" button
Retrieving operat­ing points
To retrieve saved settings, press the corresponding "Save" button briefly, e.g.:
The control panel will display the saved settings, e.g.:
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".
1
2
1
1
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After a short time, the left indicator switches to the original value, e.g.:
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 display the saved settings, e.g.:
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:
2
3
4
Number 1
Number 2
Number 3
1
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Number 4
Number 5
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Setup settings
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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.
Setting the set-up parameters
Setting the set-up parameters is described here with reference to the "MIG/MAG standard synergic welding" process. The procedure for changing other set-up parameters is identi­cal.
Opening the set-up menu
The control panel is now in the set-up menu for the "MIG/MAG standard synergic welding" process - the last set-up parameter that was selected is displayed.
Changing welding parameters
Exiting the set-up 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 set-up parameter using the "Mode" and "Proc­ess" buttons or the left-hand adjusting dial
1
2
3
4
5
change the value of the set-up parameter using the "Parameter selection" button 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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Set-up 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
Wire threading 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 - length of wire that is fed before the safety cut-out trips Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94) Factory setting: Off
FAC
Reset power source to factory setting Press and hold down one of the "Parameter selection" buttons for 2 s to restore the
factory settings
NOTE! The "Ignition time-out" function (ito) is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the pre-set wire length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and options" section.
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- 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 set-up menu (2nd) are also not deleted. Exception: Ignition time-out (ito) parameter.
2nd
second level of the set-up menu (see "Set-up menu - Level 2")
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Set-up 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 - 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 duration Unit: s Setting range: OFF, 0.1 - 9.9 Factory setting: OFF
Fdi
Wire threading 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 the end of welding
Unit: s Setting range: Aut, 0 - 0.3
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Factory setting: Aut
Ito
Ignition time-out - length of wire that is fed before the safety cut-out trips Unit: mm (in.) Setting range: Off, 5 - 100 (Off, 0.2 - 3.94) Factory setting: Off
FAC
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 set-up menu (2nd) are also not deleted. Exception: Ignition time­out (ito) parameter.
2nd
second level of the set-up menu (see "Set-up 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 pre-set 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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Set-up parame­ters for MMA welding
IMPORTANT! If you reset the power source using the FAC factory set-up parameter, the
hot-current time (Hti) and HotStart current (HCU) set-up 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
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 set-up menu (2nd) are also not deleted. Exception: Ignition time­out (ito) parameter.
2nd
second level of the set-up menu (see "Set-up menu - Level 2")
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Setup menu - Level 2
Restrictions In conjunction with the Level 2 set-up menu, the following restrictions occur:
The Level 2 set-up 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 the Level 2 set-up 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
- Wire threading
- Wire withdrawal
- Blow-through
Setting the set-up parameters
Opening the set-up menu
The control panel is now in the set-up menu - the last set-up parameter that was selected is displayed.
Select "2nd" welding parameter
Accessing the Level 2 set-up menu
Changing welding parameters
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 adjustment dial to select the set-up parameter "2nd"
1
2
3
4
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
select the required set-up parameter using the "Mode" and "Proc­ess" buttons or the left adjusting dial
5
6
7
8
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Exiting the Level 2 set-up menu
Exiting the set-up menu
Welding parame­ters for MIG/MAG welding in the Level 2 set-up menu
C-C
Cooling unit control
Unit: ­Setting range: Aut, On, Off Factory setting: Aut
Aut: The cooling unit cuts out after a 2-minute welding off-time.
IMPORTANT! If the coolant temperature and flow monitoring options have been installed in the cooling unit, the cooling unit cuts out as soon as the return-flow tem­perature drops below 50°C, but at the earliest after a 2-minute welding off-time.
On: The cooling unit is permanently switched on Off: The cooling unit is permanently switched 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 - time from when the rate-of-flow watchdog trips until output of the "no | H2O" service code. For example, if there are air bubbles in the cooling system,
change the value of the set-up parameter using the "Dynamic" button or the right 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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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! Each 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: in.)
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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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.
Measuring weld­ing circuit resist­ance r
Make a ground earth connection to the workpiece
Access the setup menu level 2 (2nd)
Select parameter “r”
Remove the gas nozzle from the welding torch
Screw on the contact tube
Place the contact tube 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 tube and the workpiece is on a cleaned workpiece surface.
1
2
3
4
5
6
7
8
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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
1
2
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Troubleshooting and maintenance
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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: Control plug not connected in the case of a welding torch with an external con-
trol plug
Remedy: Plug in the control plug
Cause: Welding torch or welding torch control line is faulty
Remedy: Change the 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 and terminal for correct polarity
Cause: There is a break in the current cable in the welding torch
Remedy: Change the welding torch
No shielding gas
All other functions are OK
Cause: Gas cylinder is empty
Remedy: Change the gas cylinder
Cause: Gas pressure regulator is faulty
Remedy: Change 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 tube is too narrow
Remedy: Use a suitable contact tube
Cause: Wire feed liner in the welding torch is faulty
Remedy: Check the wire feed liner for kinks, dirt, etc.
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
The welding torch becomes very hot
Cause: The design dimensions of the welding torch are not sufficient for this task
Remedy: Observe the duty cycle and loading limits
Cause: Only on water-cooled machines: water flow is insufficient
Remedy: Check the water level, water flowrate, its cleanliness, etc.
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Poor weld properties
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor grounding (earthing) connection
Remedy: Ensure good contact to workpiece
Cause: Inadequate protective gas shield, or none at all
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 tube, or contact tube is worn out
Remedy: Replace contact tube
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the wire spool that has been inserted
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the weldability of the base material
Cause: The protective gas shield is not suitable for this wire alloy
Remedy: Use the correct protective gas shield
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
1
2
3
1
2
3
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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
E-Stop
Cause: "External stop" has tripped
Remedy: Remedy the event that triggered the external stop
PHA | SE
Cause: Phase failure
Remedy: Check the mains fuse, the mains lead and the mains plug
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
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96
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
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
to4 | xxx
Remark: xxx stands for a temperature value
Cause: Overtemperature in welding torch
Remedy: Allow welding torch to cool down
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
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
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
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
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97
g
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
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
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
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 long-
er 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
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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
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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