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TransSteel 3500 Rob, TransSteel
5000 Rob
Operating Instructions
EN
MIG/MAG Power source
[
42,0426,0086,EN 025-21102020
2
Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety notices ................................................................................................................ 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 7
Environmental conditions...................................................................................................................... 8
Obligations of the operator.................................................................................................................... 8
Obligations of personnel ....................................................................................................................... 8
Mains connection.................................................................................................................................. 8
Protecting yourself and others .............................................................................................................. 9
Danger from toxic gases and vapours .................................................................................................. 9
Danger from flying sparks..................................................................................................................... 10
Risks from mains current and welding current...................................................................................... 10
Meandering welding currents................................................................................................................ 11
EMC Device Classifications.................................................................................................................. 12
EMC measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 13
Specific hazards.................................................................................................................................... 13
Requirement for the shielding gas ........................................................................................................ 14
Danger from shielding gas cylinders..................................................................................................... 14
Danger from escaping shielding gas..................................................................................................... 14
Safety measures at the installation location and during transport ........................................................ 15
Safety measures in normal operation ................................................................................................... 15
Commissioning, maintenance and repair.............................................................................................. 16
Safety inspection................................................................................................................................... 16
Disposal ................................................................................................................................................ 16
Safety symbols...................................................................................................................................... 17
Data protection...................................................................................................................................... 17
Copyright............................................................................................................................................... 17
EN
General information 19
General ...................................................................................................................................................... 21
Device concept ..................................................................................................................................... 21
Requirements........................................................................................................................................ 21
Functional principle............................................................................................................................... 21
Application areas .................................................................................................................................. 21
Warning notices on the device.............................................................................................................. 22
Options....................................................................................................................................................... 23
General ................................................................................................................................................. 23
Machine interface.................................................................................................................................. 23
Gas test button...................................................................................................................................... 23
Gas preheater CO2 connection ............................................................................................................ 23
VRD: safety function ............................................................................................................................. 24
VRD: safety principle ............................................................................................................................ 24
Control elements and connections 27
Synergic control panel ............................................................................................................................... 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Synergic control panel .......................................................................................................................... 30
Service parameters............................................................................................................................... 32
Keylock ................................................................................................................................................. 33
Connections, switches and mechanical components ................................................................................ 34
TSt 3500 Rob / 5000 Rob power source............................................................................................... 34
Installation and commissioning 35
Minimum equipment needed for welding task............................................................................................ 37
General ................................................................................................................................................. 37
3
MIG/MAG welding, gas-cooled ............................................................................................................. 37
MIG/MAG welding, water-cooled .......................................................................................................... 37
Before installation and commissioning....................................................................................................... 38
Utilisation for intended purpose only..................................................................................................... 38
Setup regulations.................................................................................................................................. 38
Mains connection.................................................................................................................................. 38
Connecting the mains cable....................................................................................................................... 39
General ................................................................................................................................................. 39
Stipulated mains cables and strain relief devices ................................................................................. 39
Safety.................................................................................................................................................... 39
Connecting the mains cable.................................................................................................................. 40
Fitting the Europe strain-relief device ................................................................................................... 40
Fitting the strain-relief device for Canada / US and TSt 5000 MV Europe............................................ 41
Generator-powered operation.................................................................................................................... 43
Generator-powered operation............................................................................................................... 43
Start-up ...................................................................................................................................................... 44
Information on system components...................................................................................................... 44
TSt 3500 Rob / 5000 Rob start-up ............................................................................................................. 45
Fitting the system components (overview)............................................................................................ 45
Strain relief device ................................................................................................................................ 45
Connecting the interconnecting hosepack............................................................................................ 45
Connecting the gas cylinder.................................................................................................................. 46
Creating a grounding (earthing) connection, connecting the welding torch.......................................... 46
Other activities ...................................................................................................................................... 46
Welding 49
Power limitation.......................................................................................................................................... 51
Safety function ...................................................................................................................................... 51
MIG/MAG modes ....................................................................................................................................... 52
General remarks ................................................................................................................................... 52
Symbols ................................................................................................................................................ 52
2-step mode.......................................................................................................................................... 52
4-step mode.......................................................................................................................................... 52
Special 4-step mode ............................................................................................................................. 53
MIG/MAG welding...................................................................................................................................... 54
Safety.................................................................................................................................................... 54
General tasks before MIG/MAG welding .............................................................................................. 54
Overview............................................................................................................................................... 54
MIG/MAG standard synergic welding ........................................................................................................ 55
General ................................................................................................................................................. 55
MIG/MAG standard synergic welding ................................................................................................... 55
Corrections during welding ................................................................................................................... 56
MIG/MAG standard manual welding .......................................................................................................... 57
General ................................................................................................................................................. 57
Available parameters ............................................................................................................................ 57
MIG/MAG standard manual welding..................................................................................................... 57
Corrections during welding ................................................................................................................... 58
MMA welding ............................................................................................................................................. 59
Safety.................................................................................................................................................... 59
Preparation ........................................................................................................................................... 59
MMA welding ........................................................................................................................................ 59
Corrections during welding ................................................................................................................... 60
HotStart function ................................................................................................................................... 60
Anti-stick function.................................................................................................................................. 61
Saving and retrieving operating points....................................................................................................... 62
General ................................................................................................................................................. 62
Storing EasyJob operating points ......................................................................................................... 62
Retrieving EasyJob operating points .................................................................................................... 62
Deleting EasyJob operating points ....................................................................................................... 62
Retrieving operating points on the Up/Down welding torch .................................................................. 62
Setup settings 65
4
Setup menu................................................................................................................................................ 67
General remarks ................................................................................................................................... 67
Entering/exiting the Setup menu........................................................................................................... 67
Setup parameters for MIG/MAG standard manual welding .................................................................. 68
Setup parameters for MIG/MAG standard synergic welding................................................................. 70
Setup parameters for MMA welding...................................................................................................... 71
Welding parameters for "Special 4-step mode" in the Mode setup menu............................................. 72
Setup menu - Level 2................................................................................................................................. 73
Level 2 setup menu............................................................................................................................... 73
Welding parameters for MIG/MAG welding in the Setup menu level 2................................................. 74
Parameters for manual metal arc (MMA) welding in the Setup menu level 2....................................... 75
Measuring welding circuit resistance r ....................................................................................................... 76
General ................................................................................................................................................. 76
Measuring welding circuit resistance (MIG/MAG welding).................................................................... 76
Displaying welding circuit inductivity L ....................................................................................................... 78
General ................................................................................................................................................. 78
Displaying welding circuit inductivity..................................................................................................... 78
Laying the hosepacks correctly............................................................................................................. 78
Troubleshooting and maintenance 79
Troubleshooting ......................................................................................................................................... 81
General ................................................................................................................................................. 81
Safety.................................................................................................................................................... 81
Power source - troubleshooting ............................................................................................................ 81
Displayed service codes ....................................................................................................................... 83
Care, maintenance and disposal ............................................................................................................... 89
General ................................................................................................................................................. 89
Safety.................................................................................................................................................... 89
At every start-up.................................................................................................................................... 89
Every 2 months..................................................................................................................................... 89
Every 6 months..................................................................................................................................... 89
Disposal ................................................................................................................................................ 90
Technical data............................................................................................................................................ 91
Special voltages.................................................................................................................................... 91
Explanation of the term "duty cycle" ..................................................................................................... 91
TSt 3500 Rob........................................................................................................................................ 91
TSt 5000 Rob........................................................................................................................................ 92
TSt 3500 MV Rob ................................................................................................................................. 93
TSt 5000 MV Rob ................................................................................................................................. 94
Welding program tables ............................................................................................................................. 96
TransSteel 3500 Euro welding program tables .................................................................................... 96
TransSteel 5000 Euro welding program tables .................................................................................... 97
TransSteel 3500 US welding program tables ...................................................................................... 98
TransSteel 5000 US welding program tables ...................................................................................... 99
Quick reference.......................................................................................................................................... 100
EN
5
6
Safety rules
EN
Explanation of
safety notices
DANGER!
Indicates immediate danger.
► If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
► If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
► If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to recognised
safety standards. If used incorrectly or misused, however, it can cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the device
must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In
addition to the operating instructions, attention must also be paid to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the section headed
"General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Proper use The device is to be used exclusively for its intended purpose.
7
The device is intended solely for the welding processes specified on the rating plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts
no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Obligations of the
operator
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and accident
prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the 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.
Obligations of
personnel
Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current
8
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident prevention
- to read these operating instructions, especially the "Safety rules" section and sign to
confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to any harm in
your absence.
consumption.
This may affect a number device types in terms of:
- Connection restrictions
- Criteria with regard to the maximum permissible mains impedance
- Criteria with regard to the minimum short-circuit power requirement
*)
at the interface with the public grid
*)
*)
see "Technical data"
In this case, the plant operator or the person using the device should check whether the
device may be connected, where appropriate by discussing the matter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
EN
Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
- flying sparks and hot pieces of metal
- Arc radiation, which can damage eyes and skin
- Hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers
- Risk of electrocution from mains current and welding current
- Greater noise pollution
- Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The protective
clothing must have the following properties:
- Flame-resistant
- Insulating and dry
- Covers the whole body, is undamaged and in good condition
- Safety helmet
- Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
- Protect eyes and face from UV rays, heat and sparks using a protective visor and regulation filter
- Wear regulation protective goggles with side protection behind the protective visor
- Wear stout footwear that provides insulation even in wet conditions
- Protect the hands with suitable gloves (electrically insulated and providing protection
against heat)
- Wear ear protection to reduce the harmful effects of noise and to prevent injury
Danger from toxic
gases and vapours
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vicinity:
- Make them aware of all the dangers (risk of dazzling by the arc, injury from flying
sparks, harmful welding fumes, noise, possible risks from mains current and welding
current, etc.)
- Provide suitable protective equipment
- Alternatively, erect suitable safety screens/curtains.
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph 118 of the
International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
9
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least
20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the measured toxic
emission values should be compared with the permissible limit values.
The following components are responsible, amongst other things, for the degree of toxicity
of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
- Welding process used
The relevant material safety data sheets and manufacturer's specifications for the listed
components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Danger from flying sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the arc, or al-
ternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or
openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or near sealed
tanks, vessels or pipes unless these have been prepared in accordance with the relevant
national and international standards.
Do not carry out welding on containers that are being or have been used to store gases,
propellants, mineral oils or similar products. Residues pose an explosive hazard.
Risks from mains
current and welding current
10
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers
and all pieces of metal that are in contact with the welding wire are live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable, insulated
wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry base or cover for the earth or ground potential. This base or cover must extend over the entire area
between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable around the
longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
- never be immersed in liquid for cooling
- Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both electrodes at the same time
may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the
ground conductor is functioning properly.
Protection class I devices require a mains supply with ground conductor and a connector
system with ground conductor contact for proper operation.
EN
Meandering welding currents
Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be held liable
for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to prevent any-
one from plugging the mains plug back in and switching it on again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main switch at
the right moment.
If the following instructions are ignored, meandering welding currents can develop with the
following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
11
Position the device with sufficient insulation against electrically conductive environments,
e.g. Insulation against conductive floor or insulation to conductive racks.
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 wirefeeder.
EMC Device Classifications
EMC measures In certain cases, even though a device complies with the standard limit values for emis-
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas. This is also true for
residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
sions, it may affect the application area for which it was designed (e.g. when there is sensitive equipment at the same location, or if the site where the device is installed is close to
either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to national
and international regulations. Examples of equipment that may be susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, addition-
al measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
12
EMF measures 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
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or repair work is
being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
EN
The welding wire emerging from the welding torch poses a high risk of injury (piercing of
the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with wire-feed unit)
and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must therefore
also be worn when reworking workpieces, and steps must be taken to ensure that other
people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool
down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry
the "Safety" sign. However, the power source must not be located in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the
manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when transporting
devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the load-carrying
equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
13
If the wire-feed unit is attached to a crane holder during welding, always use a suitable,
insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The
carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or
other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with the device or
its components must be tested regularly (e.g. for mechanical damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national standards
and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the
shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for
the shielding gas connection using suitable Teflon tape.
Requirement for
the shielding gas
Danger from
shielding gas cylinders
Especially with ring lines, contaminated shielding gas can cause damage to equipment and
reduce welding quality.
Meet the following requirements regarding shielding gas quality:
- Solid particle size < 40 µm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the
shielding gas cylinders are part of the welding equipment, they must be handled with the
greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent
them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Danger from escaping shielding
gas
14
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 inter-
national regulations for shielding gas cylinders and accessories.
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace the oxygen in the ambient air.
- Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour.
- Observe safety and maintenance instructions on the shielding gas cylinder or the main
gas supply.
- Close the shielding gas cylinder valve or main gas supply if no welding is taking place.
- Check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before every start-up.
EN
Safety measures
at the installation
location and during transport
A device toppling over could easily kill someone. Place the device on a solid, level surface
such that it remains stable
- The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
- Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is always
clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection shown on
the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft. 7.69 in.)
to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport or lifting.
Before transporting the device, allow coolant to drain completely and detach the following
components:
- Wirefeeder
- Wirespool
- Shielding gas cylinder
Safety measures
in normal operation
After transporting the device, the device must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a risk of
- injury or death to the operator or a third party
- damage to the device and other material assets belonging to the operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety
devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device
is to be transported by crane.
15
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other system com-
ponents or a different coolant. In addition, all warranty claims will be forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite under cer-
tain conditions. Transport the coolant only in its original, sealed containers and keep well
away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and
international regulations. The coolant safety data sheet may be obtained from your service
centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
Safety inspection The manufacturer recommends that a safety inspection of the device is performed at least
It is impossible to guarantee that bought-in parts are designed and manufactured to meet
the demands made of them, or that they satisfy safety requirements.
- Use only original spare and wearing parts (also applies to standard parts).
- Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
- Components that are not in perfect condition must be replaced immediately.
- When ordering, please give the exact designation and part number as shown in the
spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the housing
parts.
Only use original housing screws in the correct number and tightened to the specified
torque.
once every 12 months.
The manufacturer recommends that the power source be calibrated during the same 12month 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.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive 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
16
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!
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directives (e.g. relevant product standards of the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with Directive
2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following
address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Data protection The user is responsible for the safekeeping of any changes made to the factory settings.
The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
EN
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.
17
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General information
General
EN
Device concept
The TransSteel (TSt) 3500 Rob and TSt
5000 Rob power sources are fully-digitised,
microprocessor-controlled inverter power
sources.
The modular design and potential for system add-ons ensure a high degree of flexibility. The devices are designed for the
welding of steel.
All devices are suitable for:
- MAG welding
- Manual metal arc welding
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.
Requirements The TSt 3500 Rob and TSt 5000 Rob power sources can be used in conjunction with the
VR 5000rob wire-feed unit.
Functional principle
Application areas The devices are used in workshops and industry for manual and automated applications
The central control and regulation unit of the power source is coupled with a digital signal
processor. The central control and regulation unit and signal processor control the entire
welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired command
values are kept.
This results in:
- a precise welding process,
- a high degree of reproducibility of all results,
- excellent weld properties.
with classical steel and galvanised sheets.
The TSt 3500/5000 power sources are designed for:
- Machine and equipment construction
- Steelwork
- Plant and container construction
- Shipyards and the offshore industry
- Metal and gantry construction
- Rolling stock construction
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Warning notices
on the device
Warning notices and safety symbols are affixed to the power source. These warning notices and safety symbols must not be removed or painted over. They warn against operating
the device incorrectly, as this may result in serious injury and damage.
22
Safety symbols on the rating plate
Welding is dangerous. The following
basic requirements must be met:
- Welders must be sufficiently qual-
ified
- Suitable protective equipment
must be used
- All persons not involved in the
welding process must be kept at
a safe distance
Do not use the functions described
here until you have thoroughly read
and understood the following documents:
- these operating instructions
- all the operating instructions for
the system components, especially the safety rules
Options
General The options listed below are available with all power source variants.
Machine interface The machine interface connects the power source to the machine control. The following
signals can be transmitted across the machine interface:
Signal input: Start of welding / end of welding
- Signal input for a floating contact (sensor, relay, etc.) between pin X1:1 and pin X1:2
- The machine control signal input is processed by the power source in the same way
as a welding torch signal input. Ensure that the correct mode is set (2-step or 4-step)
- Use gold-plated contacts for optimum signal transmission
Signal output: Current flow signal
- Floating contact between pin X1:3 and pin X1:4
NOTE!
The machine interface isolates the welding circuit up to a maximum of 500 V DC.
To ensure reliable isolation from the welding circuit, use a relay with an insulation voltage
greater than 1500 V DC.
EN
Technical data - start/end of welding signal input
U
maxAC
I
max
Technical data - current flow signal output
U
max
I
max
Gas test button The gas test button sets the protective gas flow. The protective gas flow is activated when
the gas test button is pressed and is deactivated after 30 seconds or if the button is pressed
again. The wire-feed unit remains inactive.
Gas preheater
CO2 connection
External gas preheaters for gas pressure regulators can be connected to the gas preheater
CO2 connection. Gas preheaters have a 36 V supply.
NOTE!
Voltage is only supplied to gas preheaters during welding operations.
5 V
4 mA
24 V
20 mA
The power of the gas preheaters must not exceed 150 W.
The gas preheater supply is protected against overloads and short-circuits.
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Technical data
U
A
P
150 W
A, max
36 V
AC
VRD: safety function
A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. It
is recommended for environments in which the risk of an electric shock or electrical accident is increased considerably during arc welding:
- Due to a low human body resistance of the welder
- If the welder is exposed to a clear risk of touching the workpiece or other parts of the
welding circuit
A low human body resistance is possible when there is:
- water in the area
- humidity
- heat, particularly ambient temperatures in excess of 32°C (89.6°F)
In wet, damp or hot locations, humidity or sweat can significantly reduce the skin resistance
and the insulation resistance of protective equipment and clothing.
Such environments can include:
- Temporary dams for draining certain areas of a site during construction work (cofferdams)
- Trenches
- Mines
- Rain
- Areas partly submerged by water
- Spraywater areas
The VRD option reduces the voltage between the electrode and the workpiece. In safe
conditions, the indicator for the currently selected welding process is permanently lit. A
safe condition is defined as follows:
- The output voltage in an open circuit is limited to 35 V.
VRD: safety principle
For as long as the welding operation is active (welding circuit resistance < 200 Ohm), the
indicator of the currently selected welding process flashes and the output voltage may exceed 35 V.
The welding circuit resistance is greater
than the minimum human body resistance
(greater than or equal to 200 Ohm):
- VRD is active
- Open circuit voltage is limited to 35 V
- Unintentional contact with the output
voltage does not put the welder at risk
The welding circuit resistance is less than
the minimum human body resistance (less
than 200 Ohm):
- VRD is inactive
- Output voltage not restricted in order to
ensure sufficient welding power
- Example: Welding starts
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In MMA welding mode:
Within 0.3 seconds of end of welding:
- VRD is active again
- The output voltage is limited to 35 V once more
EN
25
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Control elements and connections
Synergic control panel
General The functions on the control panel are all arranged in a logical way. The various welding
parameters can easily be selected using buttons and can just as easily be
- altered using buttons or the adjusting dial
- displayed on the digital display during welding
The synergic function ensures that all other welding parameters are adjusted whenever an
individual parameter is changed.
NOTE!
Due to software updates, you may find that your device has certain functions that
are not described in these operating instructions or vice versa.
Individual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
The power source uses the Synergic control panel and certain general items of data such
as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters
can be adjusted manually. The Synergic control panel also allows parameters to be set
manually.
EN
Safety
WARNING!
Danger due to incorrect operation and incorrectly performed work.
This can result in serious injury and damage to property.
► Read and understand this document.
► Read and understand all the Operating Instructions for the system components, espe-
cially the safety rules.
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Synergic control
(11)
(12)
(4)
(7)
(10) (9) (8) (6)
(3)
(2)
(1)
(5)
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 in V *)
Before the start of welding, the system automatically displays a standard value based on the programmed parameters. During welding, the actual value is
displayed.
Dynamic
for influencing the short-circuiting dynamic at the moment of droplet transfer
- ... harder, more stable arc
0 ... neutral arc
+ ... soft, low-spatter arc
Real Energy Input
for displaying the energy applied during the welding operation. **)
b) for changing parameters in the Setup menu
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