Fronius TransSteel 5000, TransSteel 3500 Operating Instructions/spare Parts List

42,0426,0076,EN 012009

TransSteel 3500 / 5000

Operating instructions
Spare parts list

MIG/MAG Power source

GB

ud_fr_st_et_00493 012004

Dear Reader

Thank you for choosing Fronius - and congratulations on your new, technically high­grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great features of your new Fronius product. This really is the best way to get the most
out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you
will help to ensure more safety at your product location. And of course, if you treat your
product carefully, this definitely helps to prolong its enduring quality and reliability - things
which are both essential prerequisites for getting outstanding results.

Introduction

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I

Safety rules

DANGER!

WARNING!

CAUTION!

“NOTE!” indicates a situation which implies a risk of impaired welding result

and damage to the equipment.

NOTE!

This equipment has been made in accordance with the state of the art and
all recognised safety rules. Nevertheless, incorrect operation or misuse may
still lead to danger for

- the life and well-being of the operator or of third parties,

- the equipment and other tangible assets belonging to the owner/operator,

- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing and
maintaining the equipment must

- be suitably qualified

- know about welding and

- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. In
addition to the instruction manual, copies of both the generally applicable
and the local accident prevention and environmental protection rules must be
kept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:

- must be kept in a legible condition

- must not be damaged, must not be removed

- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings are
located on the machine, please see the section of your machine’s instruction
manual headed “General remarks”.

General remarks

Important!

“DANGER!” indicates an imminently hazardous situation which, if not

avoided, will result in death or serious injury. This signal word is to be
limited to the most extreme situations. This signal word is not used for
property damage hazards unless personal injury risk appropriate to this
level is also involved.

“WARNING!” indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury. This signal word is not used
for property damage hazards unless personal injury risk appropriate to this
level is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avo­ided, may result in minor or moderate injury. It may also be used to alert
against unsafe practices that may cause property damage.

“Important!” indicates practical hints and other useful special-information. It
is no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay even
closer attention to the contents of the manual!

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II

Operation or storage of the power source outside the stipulated range is
deemed to be “not in accordance with the intended use”. The manufacturer
shall not be liable for any damage resulting herefrom.

Temperature range of ambient air:

- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)

- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric humidity:

- up to 50 % at 40 °C (104 °F)

- up to 90 % at 20 °C (68 °F)

Ambient air: Free of dust, acids, corrosive gases or substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Ambient
conditions

The machine may only be used for jobs as defined by the “Intended
purpose”.

The machine may ONLY be used for the welding processes stated on the
rating plate.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be "not in accordance with the intended purpose". The manufacturer shall not
be liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises

- complete reading and following of all the instructions given in this manual

- complete reading and following of all the safety instructions and danger
warnings

- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:

- Thawing pipes

- Charging batteries/accumulators

- Starting engines

The machine is designed to be used in industrial and workshop
environments. The manufacturer shall not be liable for any damage resulting
from use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty work
results.

Utilisation for
intended purpose
only

Any malfunctions which might impair machine safety must be eliminated
immediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

The owner/operator undertakes to ensure that the only persons allowed to
work with the machine are persons who

- are familiar with the basic regulations on workplace safety and accident
prevention and who have been instructed in how to operate the machine

- have read and understood the sections on “safety rules” and the “war­nings“ contained in this manual, and have confirmed as much with their
signatures

- be trained in such a way that meets with the requirements of the work
results

Regular checks must be performed to ensure that personnel are still working
in a safety-conscious manner.

Obligations of
owner/operator

General remarks

(continued)

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III

Before starting work, all persons to be entrusted with carrying out work with
(or on) the machine shall undertake

- to observe the basic regulations on workplace safety and accident
prevention

- to read the sections on “safety rules” and the “warnings” contained in this
manual, and to sign to confirm that they have understood these and will
comply with them.

Before leaving the workplace, personnel must ensure that there is no risk of
injury or damage being caused during their absence.

Obligations of
personnel

Protection for
yourself and
other persons

When welding, you are exposed to many different hazards such as:

- flying sparks and hot metal particles

- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace­maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

Mains connection High-performance devices can affect the quality of the mains power 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 or not the device is allowed to be connected, where appropriate
through discussion with the power supply company.

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable pro­tective clothing with the following characteristics:

- flame-retardant

- isolating and dry

- must cover whole body, be undamaged and in good condition

- protective helmet

- trousers with no turn-ups

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IV

The fumes given off during welding contain gases and vapors that are
harmful to health.

Welding fumes contain substances which may cause birth defects and
cancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.
Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with an
independent air supply.

If you are not sure whether your fume-extraction system is sufficiently power­ful, compare the measured pollutant emission values with the permitted
threshold limit values.

Hazards from
noxious gases
and vapours

Keep other people - especially children - well away from the equipment and
the welding operation while this is in progress. If there are still any other
persons nearby during welding, you must

- draw their attention to all the dangers (risk of being dazzled by the arc or
injured by flying sparks, harmful welding fumes, high noise immission
levels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or

- erect suitable protective partitions or curtains.

Protection for
yourself and
other persons

(continued)

“Protective clothing” also includes:

- protecting your eyes and face from UV rays, heat and flying sparks with
an appropriate safety shield containing appropriate regulation filter glass

- wearing a pair of appropriate regulation goggles (with sideguards) behind
the safety shield

- wearing stout footwear that will also insulate even in wet conditions

- protecting your hands by wearing appropriate gloves (electrically insula­ting, heat-proof)

- To lessen your exposure to noise and to protect your hearing against
injury, wear ear-protectors!

Information on
noise emission
values

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum
permissible operating point under maximum rated load conditions according to
EN 60974-1.

It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the
workpiece, the workplace environment, etc.

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V

Hazards from
mains and weld­ing current

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from the
arc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas through
small cracks and openings. Take suitable measures here to ensure that there
is no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion,
or in enclosed tanks, barrels or pipes, unless these latter have been
prepared for welding in accordance with the relevant national and
international standards.

Welding must NEVER be performed on containers that have had gases,
fuels, mineral oils etc. stored in them. Even small traces of these substances
left in the containers are a major explosion hazard.

Hazards from
flying sparks

An electric shock is potentially life-threatening, and can be fatal.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the drive
rollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or else
use a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of a
dry base or cover that provides adequate insulation against the ground/frame
potential. The base or cover must completely cover the entire area between
your body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properly
insulated and adequately dimensioned. Immediately replace any loose
connections, scorched, damaged or underdimensioned cables or other
leads.

The harmfulness of the welding fumes will depend on e.g. the following
components:

- the metals used in and for the workpiece

- the electrodes

- coatings

- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheets
and the information given by the manufacturer regarding the components
listed above.

Keep all flammable vapors (e.g. from solvents) well away from the arc
radiation.

Hazards from
noxious gases
and vapours

(continued)

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VI

If the following instructions are ignored, stray welding currents may occur.
These can cause:

- fires

- overheating of components that are connected to the workpiece

- destruction of PE conductors

- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a way
that it is sufficiently insulated from the floor.

Stray welding
currents

Hazards from
mains and weld­ing current

(continued)

Do not loop any cables or other leads around your body or any part of your
body.

Never immerse the welding electrode (rod electrode, tungsten electrode,
welding wire, ...) in liquid in order to cool it, and never touch it when the
power source is ON.

Twice the open-circuit voltage of one single welding machine may occur
between the welding electrodes of two welding machines. Touching the
potentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by a
qualified electrician to ensure that the PE (protective earth) conductor is
functioning correctly.

Only run the machine on a mains network with a PE conductor, and plugged
into a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor and
plugged into a power outlet socket without a protective-conductor contact,
this counts as gross negligence and the manufacturer shall not be liable for
any resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece is
sufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from the
mains.

Put up a clearly legible and easy-to-understand warning sign to stop anybody
inadvertently plugging the machine back into the mains and switching it back
on again.

After opening up the machine:

- discharge any components that may be storing an electrical charge

- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a second
person on hand to immediately switch off the machine at the main switch in
an emergency.

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VII

When using current supply distributors, twin head wire feeder fixtures etc.,
please note the following: The electrode on the unused welding torch/welding
tongs is also current carrying. Please ensure that there is sufficient insula­ting storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulated
filler wire is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.

Stray welding
currents

(continued)

EMC device
classifications

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 as per the rating plate or technical specifications

EMC measures 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.

Examine and evaluate any possible electromagnetic problems that may
occur on equipment in the vicinity, and the degree of immunity of this
equipment, in accordance with national and international regulations:

- safety features

- mains, signal and data-transmission leads

- IT and telecoms equipment

- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply

- If electromagnetic interference still occurs, despite the fact that the mains
connection is in accordance with the regulations, take additional
measures (e.g. use a suitable mains filter).

b) Welding cables

- Keep these as short as possible

- Arrange them so that they run close together (to prevent EMI problems
as well)

- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)

- where necessary, run the connection to ground (earth) via suitable
capacitors.

e) Shielding, where necessary

- Shield other equipment in the vicinity

- Shield the entire welding installation.

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VIII

Power sources for use in spaces with increased electrical danger (e.g.
boilers) must be identified by the (for “safety”) mark.
However, the power source should not be in such rooms.

Allow welding torches - and other items of equipment that are used at high
operating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.

Risk of scalding from accidental discharge of hot coolant. Before unplugging
the connectors for coolant forward flow and return flow, switch off the cooling
unit.

When the welding wire emerges from the torch, there is a high risk of injury
(the wire may pierce the welder’s hand, injure his face and eyes ...). For this
reason, when feeder-inching etc., always hold the torch so that it is pointing
away from your body (machines with wirefeeder).

While the machine is in use:

- ensure that all the covers are closed and that all the sideguards are
properly mounted ...

- ... and that all covers and sideguards are kept closed.

Do not touch the workpiece during and after welding - risk of injury from
burning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,
continue to wear the regulation protective gear, and to ensure that other
persons are suitably protected, when doing post-weld finishing on
workpieces.

Electromagnetic fields may cause as yet unknown damage to health.

- Effects on the health of persons in the vicinity, e.g. users of heart pace­makers and hearing aids

- Users of heart pacemakers must take medical advice before going
anywhere near welding equipment or welding workplaces

- Keep as much space as possible between welding cables and head/body
of welder for safety reasons

- Do not carrywelding cables and hose pack over shoulder and do not loop
around body or or any part of body

EMI Precautions

Keep your hands, hair, clothing and tools well away from all moving parts,
e.g.:

- fans

- toothed wheels, rollers, shafts

- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of the
wirefeed drive.0

Covers and sideguards may only be opened or removed for as long as is
absolutely necessary to carry out maintenance and repair work.

Particular danger
spots

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IX

Shielding-gas cylinders contain pressurized gas and may explode if they are
damaged. As shielding-gas cylinders are an integral part of the overall
welding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such a
way that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,
from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gas
cylinder.

Use only shielding-gas cylinders that are suitable for the application in
question, together with matching, suitable accessories (pressure regulators,
hoses and fittings, ...). Only use shielding-gas cylinders and accessories that
are in good condition.

When opening the valve of a shielding-gas cylinder, always turn your face
away from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in place
on the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national and
international rules applying to shielding-gas cylinders and accessories.

Danger from
shielding-gas
cylinders

Particular danger
spots

(continued)

When hoisting the machines by crane, only use suitable manufacturer­supplied lifting devices.

- Attach the chains and/or ropes to all the hoisting points provided on the
suitable lifting device.

- The chains and/or ropes must be at an angle which is as close to the
vertical as possible.

- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG
units).

When hoisting the wirefeed unit by crane during welding, always use a
suitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember that
this strap is ONLY to be used for lifting and carrying the machine by hand.
The carrying strap is NOT suitable for transporting the machine by crane,
fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, when
using an adapter for the inert gas protection. Seal the adapter thread for the
inert gas connection using Teflon tape before assembly.

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X

Only operate the machine if all of its protective features are fully functional. If
any of the protective features are not fully functional, this endangers:

- the life and well-being of the operator or other persons

- the equipment and other tangible assets belonging to the owner/operator

- efficient working with the equipment.

Any safety features that are not fully functional must be put right before you
switch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered by
your doing so.

- At least once a week, check the machine for any damage that may be
visible from the outside, and check that the safety features all function
correctly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogether
before hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frost­proofing, materials-compatibility, combustibility etc.), only original coolant
of the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.

- Do not mix original coolant of the manufacturer with other coolants.

Safety precau­tions in normal
operation

Safety precauti­ons at the instal­lation site and
when being
transported

A machine that topples over can easily kill someone! For this reason, always
place the machine on an even, firm floor in such a way that it stands firmly.

- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observe
all relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace and
the area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with the
protection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m
(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national and
regional guidelines and accident protection regulations are followed. This
applies in particular to guidelines in respect of dangers during transportation
and carriage.

Before transportation, completely drain any coolant and dismantle the follo­wing components:

- Wire feed

- Wire wound coil

- Gas bottle

Before commissioning and after transportation, a visual check for damage
must be carried out. Any damage must be repaired by trained service per­sonnel before commissioning.

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XI

With parts sourced from other suppliers, there is no certainty that these parts
will have been designed and manufactured to cope with the stressing and
safety requirements that will be made of them. Use only original spares and
wearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machine
without getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your machine.

Preventive and
corrective main­tenance

- If any damage occurs in cases where other coolants have been used, the
manufacturer shall not be liable for any such damage, and all warranty
claims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport the
coolant in closed original containers, and keep it away from sources of
ignition.

- Used coolant must be disposed of properly in accordance with the
relevant national and international regulations. A safety data sheet is
available from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check the
coolant level.

Safety precauti­ons in normal
operation

(continued)

The owner/operator is obliged to have a safety inspection performed on the
machine at least once every 12 months.

The manufacturer also recommend the same (12-month) interval for regular
calibration of power sources.

A safety inspection, by a trained and certified electrician, is prescribed:

- after any alterations

- after any modifications or installations of additional components

- following repairs, care and maintenance

- at least every twelve months.

Observe the relevant national and international standards and directives in
connection with the safety inspection.

More detailed information on safety inspections and calibration is available
from your regional or national service centre, who will be pleased to provide
you with copies of the necessary documents upon request.

Safety inspection

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 be returned to our agent, or find out about the approved collec­tion and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!

Disposal

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XII

Copyright to this instruction manual remains the property of the
manufacturer.

The text and illustrations are all technically correct at the time of going to
print. The right to effect modifications is reserved. The contents of the in­struction manual shall not provide the basis for any claims whatever on the
part of the purchaser. If you have any suggestions for improvement, or can
point out to us any mistakes which you may have found in the manual, we
should be most grateful for your comments.

Copyright

Equipment with CE-markings fulfils the basic requirements of the Low­Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product
standards according to EN 60 974). .

Safety markings

Equipment marked with the CSA-Test Mark fulfils the requirements made in
the relevant standards for Canada and the USA.

The user is responsible for the data security of changes made to factory
settings. The manufacturer is not liable, if personal settings are deleted.

Data security

1

Table of contents

General information 3

General .......................................................................................................................................................... 5

Device concept .......................................................................................................................................... 5

Functional principle .................................................................................................................................... 5

Application areas ....................................................................................................................................... 5

System components ....................................................................................................................................... 6

General ..................................................................................................................................................... 6

Overview ................................................................................................................................................... 6

Control elements and connections 7

Descriptions of the control panels ................................................................................................................... 9

General ..................................................................................................................................................... 9

Safety ........................................................................................................................................................ 9

Overview ................................................................................................................................................... 9

“Remote” control panel ................................................................................................................................. 10

General ................................................................................................................................................... 10

“Remote” control panel ............................................................................................................................ 10

Connections, switches and mechanical components..................................................................................... 11

TSt 3500/5000 power source....................................................................................................................11

Installation 13

Minimum equipment needed for welding task............................................................................................... 15

General ................................................................................................................................................... 15

MIG/MAG welding, gas-cooled ................................................................................................................ 15

MIG/MAG welding, water-cooled ............................................................................................................. 15

MMA welding ........................................................................................................................................... 15

Before installation and commissioning.......................................................................................................... 16

Safety ...................................................................................................................................................... 16

Utilisation for intended purpose only ........................................................................................................ 16

Mains connection .................................................................................................................................... 16

Setup regulations .................................................................................................................................... 16

Connecting up the mains cable on MV power sources ................................................................................. 17

General ................................................................................................................................................... 17

Stipulated mains cables and strain-relief devices .................................................................................... 17

Safety ...................................................................................................................................................... 17

Connecting the mains cable .................................................................................................................... 17

Commissioning ............................................................................................................................................. 19

Safety ...................................................................................................................................................... 19

Information on system components ......................................................................................................... 19

Overview ................................................................................................................................................. 19

Commissioning a TSt 3500/5000 power source ........................................................................................... 20

General ................................................................................................................................................... 20

Fitting the system components (overview) ............................................................................................... 20

Fixing the strain-relief device in place ...................................................................................................... 21

Connecting the interconnecting hosepack ............................................................................................... 21

Connecting up the gas cylinder ............................................................................................................... 22

Creating a ground earth connection, connecting the welding torch .......................................................... 22

Other activities ......................................................................................................................................... 22

2

Troubleshooting and maintenance 23

Troubleshooting ............................................................................................................................................ 25

General ................................................................................................................................................... 25

Safety ...................................................................................................................................................... 25

Power source - troubleshooting ............................................................................................................... 25

Care, maintenance and disposal .................................................................................................................. 27

General ................................................................................................................................................... 27

Safety ...................................................................................................................................................... 27

At every start-up ...................................................................................................................................... 27

Every 2 months ....................................................................................................................................... 27

Every 6 months ....................................................................................................................................... 27

Disposal .................................................................................................................................................. 27

Annex 29

Technical data .............................................................................................................................................. 31

Special voltages....................................................................................................................................... 31

TSt 3500 .................................................................................................................................................. 31

TSt 5000 .................................................................................................................................................. 31

3

General information

4

5

The TransSteel (TSt) 3500 and TSt 5000
power sources are completely digitised,
microprocessor-controlled inverter power
sources.

The modular design and potential for
system add-ons ensure a high degree of
flexibility. The devices are designed for the
welding of steel.

All devices are suitable for:

- MIG/MAG welding

- MMA welding

TSt 3500/5000 power source

The devices are used in workshops and industry: manual and automated applications
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

General

Functional prin­ciple

Device concept

Application areas

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 specified
target status is maintained.

This results in:

- a precise welding process,

- high reproducibility of all results

- excellent weld properties.

6

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.

Overview

Wire-feed unit

Interconnecting

hosepacks

Trolleys and gas-cylinder holders

Wire-feed unit

holder

Overview of system components

Welding torch

Power sources

Cooling unit

Grounding (earthing) cable and electrode cable

7

Control elements and connections

8

9

Descriptions of the control panels

General The functions on the control panels are all arranged in a very logical way. The various

parameters needed for welding are easy to select, by pressing the appropriate button,
and can easily be

- altered with buttons (“Standard”) or the adjusting dial (“Comfort”), and

- displayed during welding on the digital display

Thanks to the synergic function, whenever you alter any one parameter, appropriate
changes will automatically be made to all the other parameters.

NOTE! Owing to software updates, you may find that your device has certain
functions that are not described in these operating instructions, or vice versa.
Certain illustrations may also differ slightly from the actual control elements on
your device. However, these control elements 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

Safety

Overview „Description of the control panels“ is composed of the following sections:

- “Remote” control panel

10

REMOTE

(3)

(2)

(1)

“Remote” control panel

The “Remote” control panel is fitted as standard as part of the power source. The power
source is operated from the control panel on the wire-feed unit.

The remote power source can be operated via the following system add-ons:

- remote control units

No. Function

(1) Overtemperature indication

lights up if the power source overheats (e.g. because the duty cycle has been
exceeded). For more information, refer to the „Troubleshooting“ section.

(2) Error indication

lights up if an error has occurred. All the units which are connected to the LocalNet,
and which have a digital display, support the display of the relevant error message.

(3) Power source ON indication

lights up when the mains cable is plugged into the mains and the mains switch is in
the - I - position

“Remote” control panel

General

“Remote” control
panel

11

Connections, switches and mechanical components

TSt 3500/5000
power source

TSt 3500/5000 power source

No. Function

(1) (-) - current socket with bayonet latch

used

- for connecting the grounding (earthing) cable in MIG/MAG welding

- for connecting the electrode (or grounding/earthing) cable in MMA welding,
depending on the type of electrode being used

(2) Mains switch

for switching the power source on and off.

(3) (+) - Current socket with bayonet latch

used

- for connecting the current cable from the interconnecting hosepack in MIG/
MAG welding

- for connecting the electrode (or grounding/earthing) cable in MMA welding,
depending on the type of electrode being used

(4) Gas preheater (option)

(5) Blanking cover

(6) Gas test button (option)

(7) Mains cable with strain relief

(8) LocalNet connection

Standardised connection socket for the wire-feed unit (intermediary hosepack)

Rear viewFront view

(1)

(2)

(3)

(4)

(5)

(6)

(7)

(8)

12

13

Installation

14

15

Minimum equipment needed for welding task

Depending on which welding process you intend to use, a certain minimum equipment
level 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.

General

- Power source

- Grounding (earthing) cable

- MIG/MAG welding torch, gas-cooled

- Gas connection (shielding gas supply)

- Wire-feed unit

- Interconnecting hosepack

- Wire electrode

MIG/MAG wel­ding, gas-cooled

- Power source

- Cooling unit

- Grounding (earthing) cable

- MIG/MAG welding torch, water-cooled

- Gas connection (shielding gas supply)

- Wire-feed unit

- Interconnecting hosepack

- Wire electrode

MIG/MAG wel­ding, water­cooled

- Power source

- Grounding (earthing) cable

- Electrode holder

- Rod electrodes

MMA welding

16

Before installation and commissioning

Safety

The power source may only be used for MIG/MAG and MMA welding.
Utilisation for any other purpose, or in any other manner, shall be deemed to be „not in
accordance with the intended purpose“. The manufacturer shall not be liable for any
damage resulting from such improper use.

Utilisation in accordance with the „intended purpose“ also includes

- following all the instructions in this manual

- carrying out all the specified inspection and servicing work

Utilisation for
intended purpose
only

Setup regulations

Mains connection

The device is tested to “Degree of protection IP23”, meaning:

- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49
in.)

- Protection against direct sprays of water up to 60° from the vertical

The device can be set up and operated outdoors in accordance with IP23. Direct wetting
(e.g. from rain) should be avoided.

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 ready­fitted, 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.

NOTE! An inadequately dimensioned electrical installation 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.

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

The venting duct is a very important safety feature. When choosing the location for the
device, ensure that the cooling air can enter and exit unhindered through the air ducts on
the front and back of the device. Any electroconductive metallic dust from e.g. grinding
work must not be allowed to get sucked into the device.

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.

17

Connecting up the mains cable on MV power sources

Safety

Important! The PE conductor (green, or green with yellow stripes) should be approx. 10

- 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

NOTE! If wire end ferrules are not used, there is a risk of short circuits between
the phase conductors or between phase conductors and the PE conductor. Fit
wire-end ferrules to all phase conductors and the PE conductor of the stripped
mains cable.

Connecting the
mains cable

Stipulated mains
cables and
strain-relief
devices

Power source Mains voltage Cable cross-section

US Europe

TSt 3500 MV 3 x 460 V AWG 10 4G4

3 x 230 V AWG 8

TSt 5,000 MV 3 x 460 V AWG 10 4G10

3 x 230 V AWG 6

3 x 400 V - 4G2,5

AWG ... American wire gauge

General If there is no mains cable attached to the power source, a mains cable appropriate for

the connection voltage must be fitted prior to putting the unit into service.

A strain-relief device for a cable cross-section AWG 10 is installed on the power source.
Strain-relief devices for other cable cross-sections must be designed accordingly.

WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and
qualified personnel. Pay particular attention to the „Safety rules“ section.

1

3

1

2

5

4

7

2

2

3

4

100mm

(4inch)

PE

1

18

Connecting the
mains cable

(continued)

Important! 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.

3

1

2

3

4x

4

1

4

3

2

5

6

19

WARNING! An electric shock can be fatal. If the device is plugged into the
mains electricity supply during installation, there is a high risk of very serious
injury and damage. Only carry out work on the device when

- the mains switch is in the „O“ position,

- the device is unplugged from the mains.

„Commissioning“ comprises the following sections:

- Commissioning a TSt 3500/5000 power source

The steps and activities described below include references to various system compon­ents, including

- Trolleys

- Cooling units

- Wire-feed unit holders

- Wire-feed units

- Interconnecting hosepacks

- Welding torch

- etc.

For more detailed information about installing and connecting the system components,
please refer to the appropriate operating instructions.

Commissioning

Safety

Information on
system compon­ents

Overview

20

The diagram below is intended to show you how to fit the individual system components.
For detailed information about the individual steps, please refer to the operating instruc­tions for the system components.

Fitting the sys­tem components
(overview)

Commissioning a TSt 3500/5000 power source

General Commissioning a TSt 3500/5000 power source is described by reference to a manual

water-cooled MIG/MAG application.

Fitting the system components

WARNING! Operating the equipment incorrectly can cause serious injury and
damage. The following activities must only be carried out by trained and
qualified personnel. Pay particular attention to the „Safety rules“ section.

21

1

2

3

4

1

1

Fixing the strain­relief device in
place

Connecting the
interconnecting
hosepack

Important! There is no cooling unit present in the case of gas-cooled systems. There is

no need to attach the water connections in the case of gas-cooled systems.

red

black

2

1

2

3

4

1

2

2

3

6

7

4

5

22

Creating a
ground earth
connection,
connecting the
welding torch

Other activities Carry out the following steps in accordance with the wire-feed unit operating instructions:

1. Insert the feed rollers in the wire-feed unit

2. Insert the wirespool or basket-type spool and basket spool adapter in the wire-feed
unit

3. Feeding in the wire electrode

4. Setting the contact pressure

Connecting up
the gas cylinder

WARNING! There is a high risk of very serious injury and damage from

toppling gas cylinders. Place gas cylinders on a solid, level surface in such a
way that they remain stable. Secure gas cylinders to prevent them from
toppling over.
Follow the gas cylinder manufacturer’s safety instructions.

- Briefly open the gas cylinder valve to
blow off any dust or dirt

- Inspect the seal on the pressure
regulator

NOTE! US machines are supplied with an adapter for the gas hose:

- Glue in or seal the adapter

- Test the adapter to ensure that it is gas-tight.

3

1

2

3

4

5

5

1

2

1

3

1

23

Troubleshooting and maintenance

24

25

The power sources are equipped with an intelligent safety system. This means that apart
from the fuse for the coolant-pump, it has been possible to dispense with fuses entirely.
After a possible malfunction or error has been remedied, the power source can be put
back into normal operation again without any fuses having to be replaced.

Troubleshooting

General

WARNING! An electric shock can be fatal. Before opening the device

- 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 instrument, 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.

Safety

Power source ­troubleshooting

tSt | xxx

Remark: xxx stands for a temperature value

Cause: Overtemperature in the control circuit
Remedy: Allow the power source to cool down

Power source inoperative

Mains switch is on, power source ON indication not lit up

Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains supply lead, make sure that the mains plug is

plugged in

Cause Mains outlet socket or plug is faulty
Remedy: Replace faulty components

Power source inoperative

Mains switch is on, power source ON indication not lit up

Cause: Mains fuse is faulty
Remedy: Change the mains fuse

No welding current

Mains switch is ON, overtemperature indication is lit up

Cause: Overload; the duty cycle has been exceeded
Remedy: Do not exceed the duty cycle

Cause: Thermostatic cut-out system has been tripped
Remedy: Wait until the power source automatically comes back on after the

end of the cooling phase

Cause: The fan in the power source is defective
Remedy: Change the fan

26

No welding current

Mains switch is ON and indicators are lit up

Cause: Grounding (earthing) connection is wrong
Remedy: Check the earth (ground) connection and clamp for correct polarity

Cause: There is a break in the current cable in the welding torch
Remedy: Replace the torch

Nothing happens when the torch trigger is pressed

Mains switch is on, power source ON indication is lit up, indications on wire-feed unit not
lit up

Cause: The interconnecting hosepack is faulty or not connected properly
Remedy: Check interconnecting hosepack

No shielding gas

All other functions are OK

Cause: The gas cylinder is empty
Remedy: Change the gas cylinder

Cause: Gas pressure regulator is faulty
Remedy: Change the gas pressure regulator

Cause: The gas hose is not connected, or is damaged
Remedy: Mount/change the gas hose

Cause: The welding torch is defective
Remedy: Change the welding torch

Cause: Gas solenoid valve is defective
Remedy: Replace gas solenoid valve

Poor weld properties

Cause: Incorrect welding parameters
Remedy: Check the settings

Cause: Poor ground earth connection
Remedy: Ensure good contact to workpiece

Cause: Not enough protective gas shield, or none at all
Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch

gas connection, etc.

Cause: Welding torch is leaking
Remedy: Change the welding torch

Cause: Wrong contact tube, or contact tube is worn out
Remedy: Change the 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

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: Coolant flow is insufficient
Remedy: Check the water level, water flowrate, its cleanliness, etc.

Power source ­troubleshooting

(continued)

27

Care, maintenance and disposal

Under normal operating conditions the power source requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the
welding system remains in a usable condition for many years.

- Check mains plug, mains cable, welding torch, interconnecting hosepack and
grounding (earthing) connection for damage

- Check whether the all-round clearance of 0.5 m (1 ft 8 in.) is kept to ensure that the
cooling air can easily flow and escape.

NOTE! Air inlets and outlets must never be covered, not even partially.

- Clean air filter

- Dismantle device side panels and clean inside of device with dry reduced com­pressed air

NOTE! Risk of damage to electronic components. Do not bring air nozzle too
close to electronic components.

- If a lot of dust has accumulated, clean the cooling air ducts.

Dispose of in accordance with the applicable national and local regulations.

WARNING! An electric shock can be fatal. Before opening the device

- 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 instrument, check to make sure that electri­cally charged components (e.g. capacitors) have discharged

General

Safety

At every start-up

Every 2 months

Every 6 months

Disposal

WARNING! Operating the equipment incorrectly can cause serious injury and

damage. The following activities must only be carried out by trained and
qualified personnel. Pay particular attention to the „Safety rules“ section.

28

29

Annex

30

31

Technical data

Special voltages For devices designed for special voltages, the technical data on the rating plate applies.

For all machines with a permitted mains voltage of up to 460 V: The standard mains plug
allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to
460 V fit a mains plug permitted for such use or install the mains supply directly.

TSt 3500

Mains voltage +- 10% 380 V / 400 V / 460 V

Welding current range 10 – 350 A

Welding current at 10 min / 40°C (104°F) 40 % d.c.* 350 A

100 % d.c.* 250 A

Open circuit voltage 60 V

Working voltage 15.5 – 31.5 V

Maximum impedance value on the PCC 22.5 mOhm

Degree of protection IP 23

Dimensions l x w x h 747 x 300 x 497 mm

Weight 26.5 kg

* d.c. = duty cycle

TSt 5000

Mains voltage +- 10% 380 V / 400 V / 460 V

Welding current range 10 – 500 A

Welding current at 10 min / 40°C (104°F) 40 % d.c.* 500 A

100 % d.c.* 360 A

Open circuit voltage 65 V

Working voltage 14.5 – 39 V

Maximum impedance value on the PCC 29.6 mOhm

Degree of protection IP 23

Dimensions l x w x h 747 x 300 x 497 mm

Weight 30.15 kg

* d.c. = duty cycle

32

ud_fr_st_tb_00150 012008

Liste de pièces de rechange

ErsatzteillisteD

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

GB

F

I

E

P

NL

N

CZ

RUS

Spare Parts List

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílů

Список запасных частей

SK Zoznam náhradných dielov

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TransSteel 3500/5000

1/2

el_fr_st_mi_01585 012009

43,0006,0204 TSt 3500

42,0405,0689

42,0405,0690

42,0405,0691

45,0200,1320

45,0200,1319

BU2,0201,3002

42,0201,2991

42,0405,0692

42,0405,0692

42,0201,2966

33,0010,0383

43,0001,1333

42,0401,1118 (6x)

42,0401,1118 (4x)

42,0400,0132 TSt 5000

41,0005,0288 TSt 5000

42,0401,1116 (4x)

40,0006,3002 (TSt 5000)

43,0006,0242 TSt 5000

TransSteel 3500 43,0001,1368
TransSteel 5000 43,0001,1369

40,0006,3001 (TSt 3500)

42,0405,0754

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi

TransSteel 3500/5000

2/2

el_fr_st_mi_01585 012009

43,0002,0405

41,0009,0255

42,0406,0294

41,0002,0060

42,0407,0440

41,0003,0320

33,0005,4148 (TSt 3500)
33,0005,4149 (TSt 5000)

32,0405,0229

45,0200,1321

42,0300,1511 -PVC PG16 SW
42,0407,0532 -M25AWG12
42,0407,0534 -M25AWG10
42,0407,0437 -M32
42,0407,0533 -M40

4,100,611

42,0409,3272 -PG16
42,0409,5112 -M25
42,0409,5113 -M32
42,0409,5114 -M40

42,0200,9158

44,0450,1214

43,0004,0507 -4G2,5mm² 5m
43,0004,0881 -4G2,5mm² 5m E5 32A
43,0004,4044 -4G2,5mm² 5m E4 32A
43,0004,0586 -4G4mm² 5m
43,0004,0987 -4G4mm² 5m E5 32A
43,0004,4045 -4G4mm² 5m E4 32A
43,0004,2323 -AWG 12
43,0004,2955 -AWG 10
43,0004,0664 -4G10mm²
43,0004,2324 - AWG6

43,0001,1187

43,0001,1186

4,0401,1120 (2x)

42,0401,1120 (3x)

42,0401,1115 (2x)

4,070,989

33,0024,0046

40,0009,0043

40,0009,0043

4,071,144,Z (LST MAG 35/50)
4,071,134,Z (LST MAG 50,Z)

4,071,067,Z (NT2500)

43,0003,0031

43,0004,4035

43,0003,1072

43,0003,0031

42,0407,0481

43,0001,1084

4,070,955 (GPR MAG50)

43,0010,0350

4,100,608 (BRTSFMAG 50)

4,070,991 (NF MAG50)

4,070,627,Z

42,0400,0105

43,0003,1071

ud_fr_st_so_00082 012008

FRONIUS INTERNATIONAL GMBH

Buxbaumstraße 2, A-4600 Wels, Austria

Tel: [phone], Fax: [phone]

E-Mail: [e-mail]

www.fronius.com

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of our Sales & service partners and Locations.