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/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0086,EN 023-19042018
TransSteel 3500 Rob, TransSteel
5000 Rob
Operating Instructions
Spare parts list
MIG/MAG Power source
EN
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EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is required.
DANGER! Indicates immediate and real danger. If it is not avoided, death or serious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
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Contents
Safety rules ................................................................................................................................................ 9
General ................................................................................................................................................. 9
Proper use ............................................................................................................................................ 9
Environmental conditions...................................................................................................................... 10
Obligations of the operator.................................................................................................................... 10
Obligations of personnel ....................................................................................................................... 10
Mains connection.................................................................................................................................. 10
Protecting yourself and others .............................................................................................................. 11
Danger from toxic gases and vapours .................................................................................................. 11
Danger from flying sparks..................................................................................................................... 12
Risks from mains current and welding current...................................................................................... 12
Meandering welding currents................................................................................................................ 13
EMC Device Classifications.................................................................................................................. 14
EMC measures ..................................................................................................................................... 14
EMF measures...................................................................................................................................... 14
Specific hazards.................................................................................................................................... 15
Factors affecting welding results........................................................................................................... 16
Danger from shielding gas cylinders..................................................................................................... 16
Danger from escaping shielding gas..................................................................................................... 17
Safety measures at the installation location and during transport ........................................................ 17
Safety measures in normal operation ................................................................................................... 17
Commissioning, maintenance and repair.............................................................................................. 18
Safety inspection................................................................................................................................... 18
Disposal ................................................................................................................................................ 19
Safety symbols...................................................................................................................................... 19
Data protection...................................................................................................................................... 19
Copyright............................................................................................................................................... 19
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Requirements........................................................................................................................................ 23
Functional principle............................................................................................................................... 23
Application areas .................................................................................................................................. 23
Warning notices on the device.............................................................................................................. 24
Options....................................................................................................................................................... 25
General ................................................................................................................................................. 25
Machine interface.................................................................................................................................. 25
Gas test button...................................................................................................................................... 25
Gas preheater CO2 connection ............................................................................................................ 25
VRD: safety function ............................................................................................................................. 26
VRD: safety principle ............................................................................................................................ 26
Control elements and connections 27
Synergic control panel ............................................................................................................................... 29
General ................................................................................................................................................. 29
Safety.................................................................................................................................................... 29
Synergic control panel .......................................................................................................................... 29
Service parameters............................................................................................................................... 32
Keylock ................................................................................................................................................. 32
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
MIG/MAG welding, gas-cooled ............................................................................................................. 37
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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
Connecting the mains cable.................................................................................................................. 39
Fitting the Europe strain-relief device ................................................................................................... 40
Fitting the strain-relief device for Canada / US and TSt 5000 MV Europe............................................ 41
Generator-powered operation.................................................................................................................... 42
Generator-powered operation............................................................................................................... 42
Start-up ...................................................................................................................................................... 43
Information on system components...................................................................................................... 43
TSt 3500 Rob / 5000 Rob start-up ............................................................................................................. 44
Fitting the system components (overview)............................................................................................ 44
Strain relief device ................................................................................................................................ 44
Connecting the interconnecting hosepack............................................................................................ 44
Connecting the gas cylinder.................................................................................................................. 45
Creating a grounding (earthing) connection, connecting the welding torch.......................................... 45
Other activities ...................................................................................................................................... 45
Welding 47
Power limitation.......................................................................................................................................... 49
Safety function ...................................................................................................................................... 49
MIG/MAG modes ....................................................................................................................................... 50
General remarks ................................................................................................................................... 50
Symbols ................................................................................................................................................ 50
2-step mode.......................................................................................................................................... 50
4-step mode.......................................................................................................................................... 50
Special 4-step mode ............................................................................................................................. 51
MIG/MAG welding...................................................................................................................................... 52
Safety.................................................................................................................................................... 52
General tasks before MIG/MAG welding .............................................................................................. 52
Overview............................................................................................................................................... 52
MIG/MAG standard synergic welding ........................................................................................................ 53
General ................................................................................................................................................. 53
MIG/MAG standard synergic welding ................................................................................................... 53
Corrections during welding ................................................................................................................... 54
MIG/MAG standard manual welding .......................................................................................................... 55
General ................................................................................................................................................. 55
Available parameters ............................................................................................................................ 55
MIG/MAG standard manual welding..................................................................................................... 55
Corrections during welding ................................................................................................................... 56
MMA welding ............................................................................................................................................. 57
Safety.................................................................................................................................................... 57
Preparations.......................................................................................................................................... 57
MMA welding ........................................................................................................................................ 57
Corrections during welding ................................................................................................................... 58
HotStart function ................................................................................................................................... 58
Anti-stick function.................................................................................................................................. 58
Saving and retrieving operating points....................................................................................................... 60
General ................................................................................................................................................. 60
Saving operating points ........................................................................................................................ 60
Retrieving operating points ................................................................................................................... 60
Deleting operating points ...................................................................................................................... 60
Retrieving operating points on the Up/Down welding torch .................................................................. 60
Setup settings 63
Setup menu................................................................................................................................................ 65
General remarks ................................................................................................................................... 65
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Entering/exiting the Setup menu........................................................................................................... 65
Setup parameters for MIG/MAG standard manual welding .................................................................. 66
Setup parameters for MIG/MAG standard synergic welding................................................................. 68
Setup parameters for MMA welding...................................................................................................... 69
Welding parameters for "Special 4-step mode" in the Mode setup menu............................................. 70
Setup menu - Level 2................................................................................................................................. 71
Level 2 setup menu............................................................................................................................... 71
Welding parameters for MIG/MAG welding in the Setup menu level 2................................................. 72
Parameters for manual metal arc (MMA) welding in the Setup menu level 2....................................... 73
Measuring welding circuit resistance r ....................................................................................................... 74
General ................................................................................................................................................. 74
Measure the welding circuit resistance r............................................................................................... 74
Displaying welding circuit inductivity L ....................................................................................................... 75
General ................................................................................................................................................. 75
Displaying welding circuit inductivity L.................................................................................................. 75
Laying the hosepacks correctly............................................................................................................. 75
Troubleshooting and maintenance 77
Troubleshooting ......................................................................................................................................... 79
General ................................................................................................................................................. 79
Safety.................................................................................................................................................... 79
Power source - troubleshooting ............................................................................................................ 79
Displayed service codes ....................................................................................................................... 81
Care, maintenance and disposal ............................................................................................................... 87
General ................................................................................................................................................. 87
Safety.................................................................................................................................................... 87
At every start-up.................................................................................................................................... 87
Every 2 months..................................................................................................................................... 87
Every 6 months..................................................................................................................................... 87
Disposal ................................................................................................................................................ 87
Technical data............................................................................................................................................ 88
Special voltages.................................................................................................................................... 88
Explanation of the term "duty cycle" ..................................................................................................... 88
TSt 3500 Rob........................................................................................................................................ 88
TSt 5000 Rob........................................................................................................................................ 89
TSt 3500 MV Rob ................................................................................................................................. 90
TSt 5000 MV Rob ................................................................................................................................. 91
Welding program tables .............................................................................................................................
93
TransSteel 3500 Euro welding program tables .................................................................................... 93
TransSteel 5000 Euro welding program tables .................................................................................... 94
TransSteel 3500 US welding program tables ...................................................................................... 95
TransSteel 5000 US welding program tables ...................................................................................... 96
Quick reference.......................................................................................................................................... 97
Appendix 99
Spare parts list: TSt 3500 Rob, TSt 5000 Rob........................................................................................... 100
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Safety rules
General
Proper use
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must:
- be suitably qualified,
- have sufficient knowledge of welding and
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
- carefully reading and following all the instructions given in the operating
instructions
- studying and obeying all safety and danger notices carefully
- performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
- Thawing out pipes
- Charging batteries
- Starting engines
The device is designed for use in industry and the workshop. The manufacturer accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
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Environmental
conditions
Obligations of the
operator
Obligations of
personnel
Mains connection
Operation or storage of the device outside the stipulated area will be deemed
as not in accordance with the intended purpose. The manufacturer shall not
be held liable for any damage arising from such usage.
Ambient temperature range:
- during operation: -10 °C to + 40 °C (14 °F to 104 °F)
- during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F)
Relative humidity:
- up to 50% at 40 °C (104 °F)
- up to 90% at 20 °C (68 °F)
The surrounding air must be free from dust, acids, corrosive gases or substances, etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
The operator must only allow persons to work with the device who:
- are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
- have read and understood these operating instructions, especially the
section "safety rules", and have confirmed as much with their signatures
- are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Before using the device, all persons instructed to do so undertake:
- to observe the basic instructions regarding safety at work and accident
prevention
- to read these operating instructions, especially the "Safety rules" section
and sign to confirm that they have understood them and will follow them.
Before leaving the workplace, ensure that people or property cannot come to
any harm in your absence.
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number of types of device in terms of:
- connection restrictions
- criteria with regard to the maximum permissible mains impedance
*)
- criteria with regard to the minimum short-circuit power requirement
*)
*)
at the interface with the public grid
see Technical Data
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the
matter with the power supply company.
NOTE! Ensure that the mains connection is earthed properly
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Protecting yourself and others
Danger from toxic
gases and vapours
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
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 may, under certain circumstances,
cause birth defects or cancer.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
- must not be breathed in
- must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/
hour.
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Danger from flying sparks
Risks from mains
current and welding current
Otherwise, a protective mask with an air supply must be worn.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
ing place.
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.
Amongst others, the following components are responsible for the degree of
toxicity of welding fumes:
- Metals used for the workpiece
- Electrodes
- Coatings
- Cleaners, degreasers, etc.
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's
radiation area.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to
store gases, propellants, mineral oils or similar products. Residues pose an
explosive hazard.
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool,
the feed rollers and all pieces of metal that are in contact with the welding wire
are live.
Always set the 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
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
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Meandering welding currents
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 pre-load.
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.
The device must only be operated on a mains supply with a ground conductor
and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and in a socket
without a ground conductor contact will be deemed gross negligence. The
manufacturer shall not be held liable for any damage arising from such usage.
If necessary, provide an adequate earth connection for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on
again.
After opening the device:
- Discharge all live components
- Ensure that all components in the device are de-energised
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
If the following instructions are ignored, meandering welding currents can develop with the following consequences:
- Fire hazard
- Overheating of parts connected to the workpiece
- Irreparable damage to ground conductors
- Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be weld-
ed.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the follow-
ing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used
is kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wire-feed unit.
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EMC Device Classifications
EMC measures
EMF measures
Devices in emission class A:
- Are only designed for use in industrial settings
- Can cause line-bound and radiated interference in other areas
Devices in emission class B:
- Satisfy the emissions criteria for residential and industrial areas.
This is also true for residential areas in which the energy is supplied from the public low-voltage mains.
EMC device classification as per the rating plate or technical data.
In certain cases, even though a device complies with the standard limit values
for emissions, it may affect the application area for which it was designed (e.g.
when there is sensitive equipment at the same location, or if the site where the
device is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to rectify the situation.
Check and evaluate the immunity to interference of nearby devices according
to national and international regulations. Examples of equipment that may be
susceptible to interference from the device include:
- Safety devices
- Power, signal and data transfer lines
- IT and telecommunications devices
- Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1. Mains supply
- If electromagnetic interference arises despite correct mains connection, additional measures are necessary (e.g. use a suitable line filter).
2. Welding power leads
- must be kept as short as possible
- must run close together (to avoid EMF problems)
- must be kept well apart from other leads
3. Equipotential bonding
4. Earthing of the workpiece
- If necessary, establish an earth connection using suitable capacitors.
5. Shielding, if necessary
- Shield off other nearby devices
- Shield off entire welding installation
Electromagnetic fields may pose as yet unknown risks to health:
- effects on the health of others in the vicinity, e.g. wearers of pacemakers
and hearing aids
- wearers of pacemakers must seek advice from their doctor before approaching the device or any welding that is in progress
- for safety reasons, keep distances between the welding cables and the
welder's head/torso as large as possible
- do not carry welding cables and hosepacks over the shoulders or wind
them around any part of the body
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EN
Specific hazards
Keep hands, hair, clothing and tools away from moving parts. For example:
- Fans
- Cogs
- Rollers
- Shafts
- Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive components.
Covers and side panels may only be opened/removed while maintenance or
repair work is being carried out.
During operation
- Ensure that all covers are closed and all side panels are fitted properly.
- Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Therefore always keep the welding torch away from the body (devices with
wire-feed unit) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment
must therefore also be worn when reworking workpieces, and steps must be
taken to ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be allowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion - observe relevant
national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located
in such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre
or downloaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
- Hook chains and/or ropes onto all suspension points provided on the
load-carrying equipment.
- Chains and ropes must be at the smallest angle possible to the vertical.
- Remove gas cylinder and wire-feed unit (MIG/MAG and TIG devices).
If the wire-feed unit is attached to a crane holder during welding, always use
a suitable, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
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Factors affecting
welding results
Danger from
shielding gas cylinders
If the device has a carrying strap or handle, this is intended solely for carrying
by hand. The carrying strap is not to be used if transporting with a crane, counterbalanced lift truck or other mechanical hoist.
All lifting accessories (straps, handles, chains, etc.) used in connection with
the device or its components must be tested regularly (e.g. for mechanical
damage, corrosion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter
is used for the shielding gas connection. Prior to assembly, seal the deviceside thread of the adapter for the shielding gas connection using suitable Teflon tape.
The following requirements with regard to shielding gas quality must be met if
the welding system is to operate in a correct and safe manner:
- Size of solid matter particles < 40 μm
- Pressure dew point < -20 °C
- Max. oil content < 25 mg/m³
Filters must be used if necessary.
NOTE! There is an increased risk of soiling if ring mains are being
used
Shielding gas cylinders contain gas under pressure and can explode if damaged. As the shielding gas cylinders are part of the welding equipment, they
must be handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive
heat, mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only
use shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on
the cylinder.
The manufacturer's instructions must be observed as well as applicable na-
tional and international regulations for shielding gas cylinders and accessories.
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EN
Danger from escaping shielding
gas
Safety measures
at the installation
location and during transport
Safety measures
in normal operation
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can dis-
place 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.
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
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 func-
tioning of safety devices.
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Commissioning,
maintenance and
repair
Safety inspection
Always fasten the shielding gas cylinder securely and remove it beforehand if
the device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices
due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other
system components 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 certain conditions. Transport the coolant only in its original, sealed
containers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant national and international regulations. 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.
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.
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may
require.
Page 19
19
EN
Disposal
Safety symbols
Data protection
Copyright
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 either be returned to your
dealer or given to one of the approved collection and recycling facilities in your
area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic 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.
The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal
settings.
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
Page 20
20
Page 21
General information
Page 22
Page 23
23
EN
General
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
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.
Application areas The devices are used in workshops and industry for 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
Page 24
24
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.
Safety symbols on the rating plate
Welding is dangerous. The following
basic requirements must be met:
- Welders must be sufficiently qualified
- Suitable protective equipment
must be used
- All persons not involved in the
welding process must be kept at a
safe distance
Do not use the functions described here
until you have thoroughly read and understood the following documents:
- these operating instructions
- all the operating instructions for the
system components, especially
the safety rules
Page 25
25
EN
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
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.
The power of the gas preheaters must not exceed 150 W.
The gas preheater supply is protected against overloads and short-circuits.
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.
Technical data - start/end of welding signal input
U
maxAC
5 V
I
max
4 mA
Technical data - current flow signal output
U
max
24 V
I
max
20 mA
NOTE! Voltage is only supplied to gas preheaters during welding operations.
Technical data
U
A
36 V
AC
P
A, max
150 W
Page 26
26
VRD: safety function
A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. It
is recommended for environments in which the risk of an electric shock or electrical accident is increased considerably during arc welding:
- Due to a low human body resistance of the welder
- If the welder is exposed to a clear risk of touching the workpiece or other parts of the
welding circuit
A low human body resistance is possible when there is:
- water in the area
- humidity
- heat, particularly ambient temperatures in excess of 32°C (89.6°F)
In wet, damp or hot locations, humidity or sweat can significantly reduce the skin resistance
and the insulation resistance of protective equipment and clothing.
Such environments can include:
- Temporary dams for draining certain areas of a site during construction work (cofferdams)
- Trenches
- Mines
- Rain
- Areas partly submerged by water
- Spraywater areas
The VRD option reduces the voltage between the electrode and the workpiece. In safe
conditions, the indicator for the currently selected welding process is permanently lit. A
safe condition is defined as follows:
- The output voltage in an open circuit is limited to 35 V.
For as long as the welding operation is active (welding circuit resistance < 200 Ohm), the
indicator of the currently selected welding process flashes and the output voltage may exceed 35 V.
VRD: safety principle
The welding circuit resistance is greater
than the minimum human body resistance
(greater than or equal to 200 Ohm):
- VRD is active
- Open circuit voltage is limited to 35 V
- Unintentional contact with the output
voltage does not put the welder at risk
The welding circuit resistance is less than
the minimum human body resistance (less
than 200 Ohm):
- VRD is inactive
- Output voltage not restricted in order to
ensure sufficient welding power
- Example: Welding starts
In MMA welding mode:
Within 0.3 seconds of end of welding:
- VRD is active again
- The output voltage is limited to 35 V once more
Page 27
Control elements and connections
Page 28
Page 29
29
EN
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.
The power source uses the Synergic control panel and certain general items of data such
as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored knowledge is available at all times. All the parameters
can be adjusted manually. The Synergic control panel also allows parameters to be set
manually.
Safety
Synergic control
panel
NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
(11)
(12)
(4)
(7)
(10) (9) (8) (6)
(3)
(2)
(1)
(5)
Page 30
30
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
(2) "Parameter selection" button (left)
a) for selecting the following welding parameters
Sheet thickness
Sheet thickness in mm or in.
If the welding current to be selected is not known it is sufficient to enter the
sheet thickness. The required welding current and any other parameters
marked with *) will then be adjusted automatically.
Welding current *)
Welding current in A
Before the start of welding, the device automatically displays a standard value
based on the programmed parameters. During welding, the actual value is
displayed.
Wire feed speed
*)
Wire feed speed in m/min or ipm.
b) for changing parameters in the Setup menu
(3) Adjusting dial (right)
for changing the arc length correction, welding voltage and arc-force dynamic parameters
for changing welding parameters in the setup menu
(4) Adjusting dial (left)
for changing the sheet thickness, welding current and wire feed speed parameters
for selecting welding parameters in the Setup menu
(5) "Save" buttons (Easy Job)
for saving up to 5 operating points
Page 31
31
EN
(6) "Process" button
***)
for selecting the welding process
MANUAL - MIG/MAG standard manual welding
SYNERGIC - MIG/MAG standard synergic welding
STICK - Manual metal arc welding
(7) "Mode" button
for selecting the operating mode
2 T - 2-step mode
4 T - 4-step mode
S 4 T - Special 4-step mode
(8) "Shielding gas" button
for selecting the shielding gas to be used. Parameter SP is reserved for additional
shielding gases.
When a shielding gas is selected, the LED behind the relevant shielding gas lights
up.
(9) "Wire diameter" button
for selecting the wire diameter to be used. Parameter SP is reserved for additional
wire diameters.
When a wire diameter is selected, the LED behind the relevant wire diameter lights
up.
(10) "Material" button
for selecting the filler metal to be used. Parameter SP is reserved for additional filler
metals.
When a material is selected, the LED behind the relevant filler metal lights up.
(11) Intermediate arc indicator
A spatter-prone "intermediate arc" occurs between the dip transfer arc and the
spray arc. To alert you to this critical area - and help you avoid it - the intermediate
arc indicator lights up.
(12) HOLD indicator
At the end of each welding operation, the actual values for welding current and
welding voltage are stored, and the "HOLD" indicator lights up.
*) If one of these parameters is selected in the MIG/MAG standard synergic welding
process, then the synergic function ensures that all other parameters, including the
welding voltage parameter, are adjusted automatically.
**) The Real Energy Input display must be activated in level 2 of the Setup menu –
EnE parameter. The value continuously rises during welding in line with the permanently increasing energy yield. The final value at the end of welding remains stored
until welding starts again or the power source is switched back on - the "HOLD"
indicator lights up.
***) In conjunction with the VRD option, the currently selected welding process indica-
tor is simultaneously an additional indicator:
- The indicator is permanently lit: the Voltage Reduction Device (VRD) is active
and is limiting the output power to less than 35 V.
- The indicator starts to flash as soon as a welding action starts in which the output voltage can exceed 35 V.
Page 32
32
Service parameters
Various service parameters can be retrieved by pressing the "Parameter selection" buttons
at the same time.
Opening the display
The first parameter ("Firmware version") is displayed, e.g. "1.00 | 4.21"
Selecting parameters
Available parameters
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the
control panel. As long as the keylock is active
- no settings can be made on the control panel
- only parameter settings can be retrieved
- any assigned "Save" button can be retrieved provided that an assigned "Save" button
was selected when the keylock was enabled
Activate/deactivate the keylock as follows:
Press and hold the "Parameter selection" button (left)
Press the "Parameter selection" button (right)
Release the "Parameter selection" buttons
Select the required setup parameter using the "Mode" and "Process" buttons or the left-hand adjusting dial
1
2
3
1
Explanation
Example:
1.00 | 4.21
Firmware version
Example:
2 | 491
Welding program configuration
Example:
r 2 | 290
Number of the currently selected welding program
Example:
iFd | 0.0
Motor current for wire drive in A
The value changes as soon as the motor is running.
654 | 32.1
= 65,432.1 hours
= 65,432 hours 6 mins
Indicates the actual arc time since using for the first time
Note: The arc time indicator is not suitable as a basis for calculating hiring fees, warranty services, etc.
2nd 2nd menu level for service engineers
Press and hold the "Mode" button
1
Page 33
33
EN
Keylock activated:
The message "CLO | SEd" appears on the displays.
Keylock deactivated:
The message "OP | En" appears on the displays.
Press the "Parameter selection" button (right)
Release the "Mode" and "Parameter Selection" buttons
2
3
Page 34
34
Connections, switches and mechanical components
TSt 3500 Rob /
5000 Rob power
source
No. Function
(1) (-) - Current socket with bayonet latch
used for
- connecting the grounding (earthing) cable during MIG/MAG welding
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(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 during MIG/MAG
welding
- connecting the electrode cable or grounding (earthing) cable during MMA welding
(depending on the type of electrode used)
(4) Gas preheater socket (option)
(5) Machine interface (option)
(6) Mains cable with strain relief device
(7) LocalNet connection
standardised connection socket for the wire-feed unit (interconnecting hosepack)
(8) Air filter
remove from the side for cleaning
(1)
(7)
(2)
(5)
(4)
(3)
(6)
(8)
Page 35
Installation and commissioning
Page 36
Page 37
37
EN
Minimum equipment needed for welding task
General Depending on which welding process you intend to use, a certain minimum equipment lev-
el will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for the welding task
are then described.
MIG/MAG welding, gas-cooled
- Power source
- Earth cable
- MIG/MAG robot welding torch, gas-cooled
- Gas connection (protective gas supply)
- Wire-feed unit (VR 5000rob)
- Interconnecting hosepack
- Wire electrode
MIG/MAG welding, water-cooled
- Power source
- Cooling unit
- Earth cable
- MIG/MAG robot welding torch, water-cooled
- Gas connection (protective gas supply)
- Wire-feed unit (VR 5000rob)
- Interconnecting hosepack, water-cooled
- Wire electrode
Page 38
38
Before installation and commissioning
Utilisation for intended purpose
only
The power source may only be used for MIG/MAG and MMA welding.
Any other form of usage is deemed "not in accordance with the intended purpose".
The manufacturer shall not be held liable for any damages arising from such usage.
Utilisation in accordance with the "intended purpose" also comprises
- following all the information in the operating instructions
- carrying out all the specified inspection and servicing work
Setup regulations The device is tested to IP 23, meaning:
- protection against penetration by solid foreign bodies with diameters > 12 mm (0.49
in.)
- protection against water sprayed directly at any angle up to 60° from the vertical
The device can be set up and operated outdoors in accordance with degree of protection
IP 23.
Avoid direct wetting (e.g. from rain).
The venting duct is a very important safety feature. When choosing the installation location,
ensure that the cooling air can enter and exit unhindered through the air ducts on the front
and back of the device. Electroconductive metallic dust (e.g. from grinding work) must not
be allowed to get sucked into the device.
Mains connection The devices are designed to run on the mains voltage shown on the respective rating
plates. If your version of the device does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. For details
of fuse protection of the mains lead, please see the Technical Data.
WARNING! If one of these machines topples over or falls it could cause serious
or even fatal injury. Place device on a solid, level surface in such a way that it remains stable.
CAUTION! Electroconductive metallic dust may damage the device. The air filter
is a very important safety feature for achieving IP 23. Always fit the air filter when
operating the device.
NOTE! Inadequately dimensioned electrical installations can cause serious damage. The incoming mains lead and its fuse must be dimensioned to suit the local
power supply. The technical data shown on the rating plate applies.
Page 39
39
EN
Connecting the mains cable
General If no mains cable is connected, a mains cable that is suitable for the connection voltage
must be fitted before commissioning.
A strain-relief device for the following cable cross-sections is fitted to the power source:
*) Canada / US cable type: Extra-hard usage
Strain-relief devices for other cable cross-sections must be designed accordingly.
Stipulated mains
cables and strain
relief devices
*) Canada/US cable type: Extra-hard usage
The item numbers of the different cables can be found in the spare parts list towards the
end of the document.
American wire gauge
Connecting the
mains cable
If no mains cable is connected, a mains cable that is suitable for the connection voltage
must be fitted before commissioning.
The PE conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.
An illustration of the mains cable connection can be found in the following sections: "Fitting
the strain-relief device" or "Fitting the strain-relief device for Canada / US". To connect the
mains cable, proceed as follows:
Power source Cable cross-section
fitted strain-relief device for
Canada / US Europe
TSt 3500 Rob AWG 12 *) 4G2.5
TSt 5000 Rob AWG 10 *) 4G4
TSt 3500 MV Rob AWG 10 *) 4G4
TSt 5000 MV Rob AWG 6 *) 4G10
Power source Mains voltage Cable cross-sec-
tion
Canada/US
Europe
TSt 3500 Rob 3 x 380 / 400 V AWG 12 *) 4G2.5
3 x 460 V AWG 12 *) 4G2.5
TSt 5000 Rob 3 x 380 / 400 V AWG 8 *) 4G4
3 x 460 V AWG 10 *) 4G4
TSt 3500 MV
Rob
3 x 208 / 230 / 400 /
460 V
AWG 10 *) 4G4
TSt 5000 MV
Rob
3 x 208 / 230 / 400 /
460 V
AWG 6 *) 4G10
CAUTION! If no ferrules are used, there is a risk of injury and damage from short
circuits between the phase conductors or between the phase conductors and the
PE conductor. Fit ferrules to all phase conductors and the PE conductor of the
stripped mains cable.
Page 40
40
Remove the side panel from the device
Push the mains cable in far enough to make it possible to connect the PE conductor
and the phase conductors to the block terminal properly.
Fit ferrules to the PE conductor and phase conductors
Connect the PE conductor and phase conductors to the block terminal
Use the strain-relief device to secure the mains cable
Fir the side panel of the device
Fitting the Europe
strain-relief device
1 2
3 4
5
IMPORTANT! Tie the phase conductors
near the block terminals using cable ties.
1
2
3
4
5
6
3
1
2
5
4
7
1
3
4
100mm
(4inch)
PE
2
2
3
1
3
3
3
3
3
4
4x
3
1,2 Nm
4
1
4
3
2
5
6
5
Page 41
41
EN
Fitting the strainrelief device for
Canada / US and
TSt 5000 MV Europe
1 2
3 4
5
3
1
2
5
4
7
1
2
3
1
3
3
3
3
3
4
4x
3
3,5 Nm
4
1
4
3
2
5
6
5
IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
Page 42
42
Generator-powered operation
Generator-powered operation
The power source is generator-compatible.
The maximum apparent power S
1max
of the power source must be known in order to select
the correct generator output.
The maximum apparent power S
1max
of the power source is calculated as follows:
The generator apparent power S
GEN
needed is calculated using the following rule of
thumb:
A smaller generator may be used when not welding at full power.
IMPORTANT! The generator apparent power S
GEN
must always be higher than the maxi-
mum apparent power S
1max
of the power source.
When using single-phase devices with a 3-phase generator, note that the specified generator apparent power is often only available as a whole across all three phases of the generator. If necessary, obtain further information on the single-phase power of the generator
from the generator manufacturer.
3-phase devices:
S
1max
= I
1max
x U1 x √3
Single-phase devices:
S
1max
= I
1max
x U
1
See device rating plate or technical data for I
1max
and U1 values
S
GEN
= S
1max
x 1.35
NOTE! The voltage delivered by the generator must never exceed the upper or
lower limits of the mains voltage tolerance range. Details of the mains voltage tolerance can be found in the "Technical data" section.
Page 43
43
EN
Start-up
Information on
system components
The steps and activities described below include references to various system components, including:
- trolley
- upright console
- cooling units
- wire-feed units
- interconnecting hosepacks
- welding torches, etc.
For more detailed information about installing and connecting the system components,
please refer to the appropriate operating instructions.
Page 44
44
TSt 3500 Rob / 5000 Rob start-up
Fitting the system
components
(overview)
For detailed information about the individual steps, please refer to the operating instructions for the system components.
Strain relief device
1
Connecting the
interconnecting
hosepack
1
WARNING! Work that is carried out incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel. All instructions in the section headed "Safety rules" must be observed.
1
2
3
4
1
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.
1
Page 45
45
EN
Connecting the
gas cylinder
1
- Briefly open the gas cylinder valve to
blow off any dust or dirt
- Check the seal on the pressure regulator
Creating a
grounding (earthing) connection,
connecting the
welding torch
1
Other activities Carry out the following steps in accordance with the wire-feed unit operating instructions:
Insert the feed rollers in the wire-feed unit
Feed in the wire electrode
Set the contact pressure
WARNING! If gas cylinders topple over, there is a risk of very serious injury and
damage. When using gas cylinders:
- Place them on a solid, level surface in such a way that they remain stable
- Secure the gas cylinders to prevent them from falling over
- Fit the VR holder option
Follow the gas cylinder manufacturer's safety rules.
1
NOTE! US devices are supplied with an adapter for the gas hose:
- Seal male thread spacers on the gas solenoid valve using suitable means before screwing on the adapter.
- Test the adapter to ensure that it is gas-tight.
2
1
3
1
1
2
3
Page 46
46
Page 47
Welding
Page 48
Page 49
49
EN
Power limitation
Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the power
source can be operated at the power limit whilst maintaining process safety.
Wire feed speed is a determining parameter for welding power. If it is too high, the arc gets
smaller and smaller and may be extinguished. In order to prevent this, the welding power
is lowered.
For the selected "MIG/MAG standard synergic welding" process, the symbol for the
"Wire feed speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.
If the "Wire feed speed" parameter is selected, the reduced value for wire feed
speed is displayed.
Page 50
50
MIG/MAG modes
General remarks
For details of the meaning, settings, setting range and units of the available parameters
(e.g. GPr), please refer to the section entitled "Setup parameters".
The illustrated welding torch symbols represent setting, maintaining and cancelling the robot signal for the start of welding.
Symbols
2-step mode "2-step mode" is suitable for
- Tacking work
- Short weld seams
4-step mode
"4-step mode" is suitable for longer weld
seams.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
press hold release
I
GPr
GPo
t
I
+
I
GPr
GPo
t
I
+
+
Page 51
51
EN
Special 4-step
mode
"Special 4-step mode" is ideal for welding in
higher power ranges. In special 4-step mode, the arc starts at a low power, which makes it easier to stabilise.
+ +
I
GPr
I-S I-E
SL SL
GPo
t
I
Page 52
52
MIG/MAG welding
Safety
General tasks before MIG/MAG
welding
Only where cooling units and a water-cooled welding torch are used:
Connect the water hoses of the welding torch to the correct plug-type connectors on
the wire-feed unit
Plug in the mains plug
Move the mains switch to the "I" position:
- all the indicators on the control panel light up briefly
- where applicable, the cooling unit starts to run
IMPORTANT! Follow the safety rules and note operating conditions in the cooling unit operating instructions.
Overview MIG/MAG welding is composed of the following sections:
- MIG/MAG standard synergic welding
- MIG/MAG standard manual welding
- Special functions and options
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
WARNING! An electric shock can be fatal. If the power source is connected to the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Before carrying out any work on the device make sure that:
- the power source mains switch is in the "O" position
- the power source is unplugged from the mains
1
2
3
Page 53
53
EN
MIG/MAG standard synergic welding
General The MIG/MAG standard synergic welding process is only available in combination with the
Synergic control panel.
MIG/MAG standard synergic
welding
On the Synergic control panel:
Press the "Material" button to select the filler metal used.
Assignment of the SP position depends on the welding database used for the power
source.
Press the "Wire diameter" button to select the diameter of the wire electrode used.
Assignment of the SP position depends on the welding database used for the power
source.
Press the "Shielding gas" button to select the shielding gas used.
Assignment of the SP position depends on the welding database used for the power
source.
Press the "Process" button to select the desired welding process:
MIG/MAG standard synergic welding
Press the "Mode" button to select the desired MIG/MAG mode:
2-step mode
4-step mode
Special 4-step mode
If they were not set via a robot interface, press the "Parameter selection" buttons to
select the desired welding parameters to be used to specify the welding power:
Sheet thickness
Welding current
Wire feed speed
Welding voltage
Use the appropriate adjusting dial to set the relevant welding parameters.
The welding parameter values are shown in the digital display located above them.
All welding parameter set values remain stored until the next time they are changed. This
applies even if the power source is switched off and on again in the meantime.
IMPORTANT! Under certain circumstances, welding parameters that have been set
on a control panel of a system component (TR 2000 and TR 3000 remote controls or
robot interface) may not be changed on the control panel of the power source.
1
2
3
4
5
6
7
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To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
Open the gas cylinder valve
Set the shielding gas flow rate:
If there is a "Gas test" button:
- Press and release the "Gas test" button
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Press and release the "Gas test" button again
If there is no "Gas test" button:
- Press the "Mode" button to select 2-step mode
- Set the "Ito" parameter to "Off" in the Setup menu
- Disengage the feed rollers
- use the robot to set the welding start-up or gas test signal
- turn the adjusting screw on the underside of the gas pressure regulator until the
pressure gauge shows the required shielding gas flow rate
- cancel the welding start-up or gas test signal
- engage the feed rollers
use the robot to set the welding start-up signal and initiate welding
Corrections during welding
To obtain the best possible welding results, the arc length correction and arc-force dynamic
welding parameters will sometimes need to be corrected.
If not already set via the robot interface (or not one of the signals provided by the robot
interface), use the "Parameter selection" buttons to select the parameters you wish to
correct.
Use the adjusting dials to set the selected welding parameters to the required values.
Welding parameter values are shown in the indicators located above them.
CAUTION! Risk of injury and damage from electric shock and from the wire
electrode emerging from the torch. If the welding start-up signal is set:
- keep the welding torch away from your face and body
- do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or
earthed parts, such as the housing, etc.
CAUTION! Risk of injury and damage from electric shock and from the wire
electrode emerging from the torch. If the welding start-up signal is set:
- keep the welding torch away from your face and body
- do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or
earthed parts, such as the housing, etc.
8
9
10
1
2
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EN
MIG/MAG standard manual welding
General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no
synergic function.
Changing one parameter does not result in any automatic adjustments to the other parameters. All of the variable parameters must therefore be adjusted individually, as dictated by
the welding process in question.
Available parameters
The following parameters are available in MIG/MAG manual welding:
Wire feed speed
1 m/min (39.37 ipm) - maximum wire feed speed, e.g. 25 m/min (984.25 ipm)
Welding voltage
TSt 3500: 15.5 - 31.5 V
TSt 5000: 14.5 - 39 V
Dynamic
... for influencing the short-circuiting dynamic at the moment of particle transfer
Welding current
Only for displaying the actual value
MIG/MAG standard manual welding
Press the "Process" button to select the desired welding process:
MIG/MAG standard manual welding
Press the "Mode" button to select the desired MIG/MAG mode:
2-step mode
4-step mode
In MIG/MAG standard manual welding, special 4-step mode corresponds to conventional
4-step mode.
Press the "Parameter selection" button to select the wire feed speed parameter
Use the adjusting dial to set the desired value for the wire feed speed
Press the "Parameter selection" button to select the welding voltage parameter
Use the adjusting dial to set the desired value for the welding voltage
The welding parameter values are shown in the digital display located above them.
All welding parameter set values that have been set using the adjusting dial remain stored
until the next time they are changed. This applies even if the power source is switched off
and on again in the meantime.
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown on the digital display during welding.
IMPORTANT! Under certain circumstances, welding parameters that have been set on a
control panel of a system component (TR 2000 and TR 3000 remote controls or robot interface) may not be changed on the control panel of the power source.
1
2
3
4
5
6
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Open the gas cylinder valve
Set the shielding gas flow rate:
If there is a "Gas test" button:
- Press and release the "Gas test" button
- Turn the adjusting screw on the underside of the pressure regulator until the pres-
sure gauge shows the required gas flow rate
- Press and release the "Gas test" button again
If there is no "Gas test" button:
- Press the "Mode" button to select 4-step mode
- Set the "Ito" parameter to "Off" in the Setup menu
- Disengage the feed rollers
- use the robot to set the welding start-up or gas test signal
- turn the adjusting screw on the underside of the gas pressure regulator until the
pressure gauge shows the required shielding gas flow rate
- cancel the welding start-up or gas test signal
- engage the feed rollers
use the robot to set the welding start-up signal and initiate welding
Corrections during welding
To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.
Press the "Parameter selection" button to select the arc-force dynamic parameter
Use the adjusting dial to set the desired arc-force dynamic value
The welding parameter value is shown in the digital display located above it.
CAUTION! Risk of injury and damage from electric shock and from the wire
electrode emerging from the torch. If the welding start-up signal is set:
- keep the welding torch away from your face and body
- do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or
earthed parts, such as the housing, etc.
CAUTION! Risk of injury and damage from electric shock and from the wire
electrode emerging from the torch. If the welding start-up signal is set:
- keep the welding torch away from your face and body
- do not point the welding torch at people
- make sure that the wire electrode does not touch any conductive or
earthed parts, such as the housing, etc.
7
8
9
1
2
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EN
MMA welding
Safety
Preparations Move the mains switch to the - O - position
Unplug the device from the mains
Detach all cables to the wire-feed unit at the power source
Plug the grounding (earthing) cable into either the (-) or the (+) current socket, depending on the type of electrode, and latch it in firmly
With the other end of the earthing (grounding) cable, establish a connection to the
workpiece
Plug the bayonet current plug of the electrode holder cable into the free current socket
with the opposite polarity, according to the type of electrode, and twist it clockwise to
latch it in place
Plug in the mains plug
MMA welding
Move the mains switch to the "I" position: all the indicators on the control panel light
up briefly
Press the "Process" button to select the MMA welding process:
The welding voltage is connected to the welding socket with a 3-second time lag.
If the MMA welding process is selected, any cooling unit present is automatically de-
activated. It is not possible to switch it on.
Press the "Parameter selection" button to select the amperage parameter.
Use the adjusting dial to set the desired amperage.
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safety rules
WARNING! An electric shock can be fatal. If the machine is plugged into the
mains electricity supply during installation, there is a high risk of very serious injury and damage. Do not carry out any work on the device unless
- the mains switch is in the "O" position,
- the device is unplugged from the mains.
IMPORTANT! Check the rod electrode packaging to determine whether the rod electrodes are for (+) or (-) welding.
1
2
3
4
5
6
7
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the rod electrode in the electrode holder is LIVE. Make
sure that the rod electrode does not touch any persons or electrically conducting
or earthed parts (e.g. the housing etc.)
IMPORTANT! Under certain circumstances, welding parameters that have been set
on a control panel of a system component (TR 2000 and TR 3000) may not be
changed on the control panel of the power source.
1
2
3
4
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The amperage value is shown in the left-hand digital display.
All welding parameter set values that have been set using the adjusting dial remain
stored until the next time they are changed. This applies even if the power source is
switched on and off again in the meantime.
Start welding
To display the actual welding current during welding:
- Press the "Parameter selection" button to select the welding current parameter
- The actual welding current is shown in the digital display during welding.
Corrections during welding
To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.
Press the "Parameter selection" button to select the arc-force dynamic parameter
Use the adjusting dial to set the desired arc-force dynamic value
The welding parameter value is shown in the digital display located above it.
HotStart function To obtain optimum welding results, it will sometimes be necessary to adjust the HotStart
function.
Advantages
- Improved ignition, even when using electrodes with poor ignition properties
- Better fusion of the base material during the start-up phase, meaning fewer cold-shut
defects
- Largely prevents slag inclusions
For details on setting the available welding parameters, please refer to "Setup parameters", "Setup menu - level 2".
Legend
Hti: Hot-current time,
0 - 2 s, factory setting: 0.5 s
HCU: HotStart-current,
100 - 200 %, factory setting 150 %
I
H
: Main current = set welding current
Function
During the specified hot-current time (Hti),
the welding current is increased to a certain
value. This value (HCU) is higher than the
selected welding current (IH).
Anti-stick function
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will
tend to "stick". This may also cause "burn-out" of the rod electrode.
5
1
2
200
300
I (A)
Hti
HCU > I
H
t (s)
I
H
HCU
0,5 1 1,5
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EN
Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. After the rod
electrode has been detached from the workpiece, the welding operation can be continued
without difficulty.
The anti-stick (Ast) function can be activated and deactivated in the Setup parameters in
"Setup menu: level 2".
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Saving and retrieving operating points
General The "Save" buttons allow up to 5 operating points to be saved. Every operating point
matches the settings on the control panel.
IMPORTANT! Setup parameters are not saved at this time.
Saving operating
points
Press and hold one of the "Save" buttons to save the current settings on the control
panel, e.g.:
- The left indicator displays "Pro"
- After a short time, the left indicator switches to the original value
Release the "Save" button
Retrieving operating points
To retrieve saved settings, press the corresponding "Save" button briefly, e.g.:
- The control panel will show the saved settings
Deleting operating points
Press and hold the relevant "Save" button to delete the memory content of that "Save"
button, e.g.:
- The left indicator displays "Pro"
- After a short time, the left indicator switches to the original value
Keep the "Save" button held down
- The left display shows "CLr".
- After a while, both displays show "---"
Release the "Save" button
Retrieving operating points on the
Up/Down welding
torch
One of the "Save" buttons on the control panel must be pressed to retrieve the saved settings using the Up/Down welding torch.
Press one of the "Save" buttons on the control panel, e.g.:
- The control panel will show the saved settings
The "Save" buttons can now be selected using the buttons on the Up/Down welding torch.
Vacant "Save" buttons are skipped.
In addition to the "Save" button number lighting up, a number is displayed directly on the
Up/Down welding torch:
1
2
1
1
2
3
Number 1
Number 2
1
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EN
Number 3
Number 4
Number 5
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Page 63
Setup settings
Page 64
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EN
Setup menu
General remarks The Setup menu provides simple access to expert knowledge in the power source and to
additional functions. The Setup menu can be used to make simple adjustments of the parameters to suit the various job settings.
Entering/exiting
the Setup menu
Setting the setup parameters is described here with reference to the "MIG/MAG standard
synergic welding" process. The procedure for changing other setup parameters is identical.
Accessing the Setup menu
The control panel is now in the Setup menu for the "MIG/MAG standard synergic welding"
process - the last setup parameter that was selected is displayed.
Changing welding parameters
Exiting the Setup menu
Use the "Process" button to select the "MIG/MAG standard synergic welding" process
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Use the "Mode" and "Process" buttons or the left-hand adjusting
dial to select the required setup parameter
1
2
3
4
5
Use the "Parameter selection" buttons or the right-hand adjusting
dial to change the value of the setup parameter
6
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
7
8
9
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Setup parameters
for MIG/MAG
standard manual
welding
"Min." and "max." are used for setting ranges that differ according to power source, wirefeed unit, welding program, etc.
GPr Gas pre-flow time
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.5
GPo Gas post-flow time
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.5
Fdi Feeder inching (speed)
Unit: m/min (ipm.)
Setting range: 1 - max. (39.37 - max.)
Factory setting: 10 (393.7)
SL Slope (special 4-step mode only)
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.1
I-S I (current) - Starting - Starting current (special 4-step mode only)
Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 100
I-E I (current) - End: Final current (special 4-step mode only)
Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 50
t-S t (time) - Starting - Starting current duration (special 4-step mode only)
Unit: s
Setting range: OFF, 0.1 - 9.9
Factory setting: OFF
t-S t (time) - End: Final current duration (special 4-step mode only)
Unit: s
Setting range: OFF, 0.1 - 9.9
Factory setting: OFF
bbc burn-back time correction
Unit: ms
Setting range: 0 - 20
Factory setting: 0
IGC Ignition current
Unit: A
Setting range: 100 - 650
Factory setting: 500
Ito Ignition time-out function - Length of wire that is fed before the safety cut-out
is triggered
Unit: mm (in.)
Setting range: Off, 5 - 100 (Off, 0.2 - 3.94)
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EN
Factory setting: Off
SPt Spot time - spot / stitch welding time
Unit: s
Setting range: OFF, 0.1 - 5
Factory setting: OFF
SPb Spot break - stitch pause time
Unit: s
Setting range: OFF, 0.1 - 10 (in 0.1 s increments)
Factory setting: OFF
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selection" (Synergic A control panel) button for 2 seconds to restore the factory settings.
When "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all the personal settings in the Setup menu are lost. Operating points that were saved using the "Save" buttons are
retained when the power source is reset. The functions in the second level of the
Setup menu (2nd) are also not deleted. Exception: Ignition time-out function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
NOTE! The "Ignition time-out" function (ito) is a safety function. The length of
wire that is fed before the safety cut-out trips may differ from the preset wire
length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and
options" section.
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Setup parameters
for MIG/MAG
standard synergic welding
"Min." and "max." are used for setting ranges that differ according to power source, wirefeed unit, welding program, etc.
GPr Gas pre-flow time
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.1
GPo Gas post-flow time
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.1
SL Slope
Unit: s
Setting range: 0 - 9.9
Factory setting: 0.1
I-S I (current) - Starting current
Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 100
I-E I (current) - End: Final current
Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 50
Fdi Feeder inching (speed)
Unit: m/min (ipm.)
Setting range: 1 - max. (39.37 - max.)
Factory setting: 10 (393.7)
bbc burn back time correction -
Burn back effect due to wire withdrawal at the end of welding
Unit: s
Setting range: Aut, 0 - 0.3
Factory setting: Aut
Ito Ignition time-out function - Length of wire that is fed before the safety cut-out
is triggered
Unit: mm (in.)
Setting range: Off, 5 - 100 (Off, 0.2 - 3.94)
Factory setting: Off
SPt Spot time - spot / stitch welding time
Unit: s
Setting range: OFF, 0.1 - 5
Factory setting: OFF
NOTE! The "Ignition time-out" function (ito) is a safety function. The length of
wire that is fed before the safety cut-out trips may differ from the preset wire
length, particularly when the wire is being fed at fast wire feed speeds.
The "Ignition time-out" function (ito) is explained in the "Special functions and
options" section.
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EN
SPb Spot break - stitch pause time
Unit: s
Setting range: OFF, 0.1 - 10 (in 0.1 s increments)
Factory setting: OFF
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selection" (Synergic A control panel) button for 2 seconds to restore the factory settings.
When "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all the personal settings in the Setup menu are lost. When the power source is reset, operating points that were
saved using the "Save" buttons are not deleted, but are retained in the memory.
The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ignition time-out function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
Setup parameters
for MMA welding
IMPORTANT! If you reset the power source using the FAC factory setup parameter, the
hot-current time (Hti) and HotStart current (HCU) setup parameters are also reset.
HCU HotStart current
Unit: %
Setting range: 100 - 200
Factory setting: 150
Hti Hot-current time
Unit: s
Setting range: 0 - 2.0
Factory setting: 0.5
Ast Anti-Stick
Unit: Setting range: On, Off
Factory setting: Off
FAC Factory - Reset power source to factory setting
Press and hold down the "Dynamic" (manual control panel) or "Parameter selection" (Synergic A control panel) button for 2 seconds to restore the factory settings.
When "PrG" is shown on the digital display, the power source has been reset.
IMPORTANT! When the power source is reset, all personal settings are lost.
When the power source is reset, operating points that were saved using the "Save"
buttons are not deleted, but are retained in the memory. The functions in the second level of the Setup menu (2nd) are also not deleted. Exception: Ignition timeout function parameter (ito).
2nd Second level of the Setup menu (see "Setup menu - level 2")
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Welding parameters for "Special
4-step mode" in
the Mode setup
menu
I-S I (current) - Starting: Starting current
Unit: % (of welding current)
Setting range: 0 - 200
Factory setting: 100
SL Slope: 0 - 9.9 s
Unit: s
Setting range: 0 - 9.9
Factory setting: 0
I-E I (current) - End: Final current
Unit: % of welding current
Setting range: 0 - 200
Factory setting: 50
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EN
Setup menu - Level 2
Level 2 setup
menu
Accessing the setup menu
The control panel is now in the setup menu - the last setup parameter that was selected is
displayed.
Selecting the "2nd" parameter
Accessing the Level 2 setup menu
Changing parameters
Exiting the Level 2 setup menu
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Use the "Mode" and "Process" buttons or the left-hand adjusting
dial to select the "2nd" setup parameter
1
2
3
4
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
Use the "Mode" and "Process" buttons or the left-hand adjusting
dial to select the required setup parameter
5
6
7
8
Change the value of the setup parameter using the "Parameter
selection" buttons or the right-hand adjusting dial
9
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
10
11
12
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Exiting the setup menu
Welding parameters for MIG/MAG
welding in the
Setup menu level
2
Press and hold the "Mode" button
Press the "Process" button
Release the "Mode" and "Process" buttons
13
14
15
C-C Cooling unit control
Unit: Setting range: Aut, On, Off
Factory setting: Aut
Aut: The cooling unit cuts out after a 2-minute welding off-time.
IMPORTANT! If the coolant temperature and flow monitoring options have been
installed in the cooling unit, the cooling unit cuts out as soon as the return-flow
temperature drops below 50°C, but at the earliest after a 2-minute welding offtime.
On: The cooling unit is permanently ON
Off: The cooling unit is permanently OFF
IMPORTANT! If the FAC welding parameter is used, the C-C parameter is not
restored to the factory setting. If the MMA welding process is selected, the cooling unit is always switched off, even if the switch is in the "On" position.
C-t Cooling time - time from when flow monitoring is triggered until the "no | H2O"
service code is output. For example, if there are air bubbles in the cooling system, the cooling unit will not cut out until the end of this pre-set time.
Unit: s
Setting range: 5 - 25
Factory setting: 10
IMPORTANT! Every time the power source is switched on, the cooling unit carries out a test run for 180 seconds.
SEt Setting - country-specific setting (Standard/USA) ... Std / US
Unit: Setting range: Std, US (Standard/USA)
Factory setting:
Standard version: Std (measurements: cm/mm)
USA version: US (measurements: inches)
r r (resistance) - welding circuit resistance (in mOhm)
see "Measuring welding circuit resistance r"
L L (inductivity) - welding circuit inductivity (in microhenry)
see "Displaying welding circuit inductivity L"
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EN
Parameters for
manual metal arc
(MMA) welding in
the Setup menu
level 2
EnE Real Energy Input – electrical energy of the arc relative to the welding speed
Unit: kJ
Setting range: ON / OFF
Factory setting: OFF
Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the threedigit display, the following display format has been selected:
Value in kJ / indication on display:
1 to 999 / 1 to 999
1000 to 9999 / 1.00 to 9.99 (without "ones" digit, e.g. 5270 kJ -> 5.27)
10000 to 99999 / 10.0 to 99.9
(without "ones" and "tens" digits, e.g. 23580 kJ -> 23.6)
PFS Permanent Feeder Speed - wire feed speed is permanently displayed
Unit: mm (in.)
Setting range: ON / OFF
Factory setting: OFF
If the setting is "ON", the wire feed speed (m/min) is permanently displayed on
the manual control panel instead of the welding current (A). In this case the hold
value for the welding current (A) is deactivated.
ALC Arc Length Correction - correction of the arc length via the welding voltage
Setting range: ON / OFF
Factory setting: OFF
The arc length depends on the welding voltage. The welding voltage can be adjusted to suit individual needs in Synergic operation.
If the ALC parameter is set to "OFF", the welding voltage cannot be adjusted.
The welding voltage is automatically determined by the selected welding current
or wire speed. If the arc length correction is adjusted, the voltage changes, but
the welding current and wire speed remain the same. When setting the arc length
correction using the adjusting dial, the left display is used for the correction value
of the arc length. The welding voltage value on the right display changes simultaneously. Afterwards the left display shows the original value, e.g. welding current.
r r (resistance) - welding circuit resistance (in mOhm)
see "Measuring welding circuit resistance r"
L L (inductivity) - welding circuit inductivity (in microhenry)
see "Displaying welding circuit inductivity L"
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Measuring welding circuit resistance r
General Measuring the welding circuit resistance r makes it possible to have a constant welding re-
sult at all times, even with hosepacks of different lengths. The welding voltage at the arc is
then always precisely regulated, regardless of the length and cross-sectional area of the
hosepack. The use of arc length correction is no longer required.
The calculated welding circuit resistance is shown on the display.
r = welding circuit resistance in milliohm (mOhm)
If the welding circuit resistance r has been measured correctly, the set welding voltage will
correspond exactly to the welding voltage at the arc. If you manually measure the voltage
on the output jacks of the power source, this voltage will be higher than the welding voltage
at the arc - that is, higher by the same amount as the voltage drop of the hosepack.
Measure the
welding circuit resistance r
Establish a grounding (earthing) connection to the workpiece
Accessing the Level 2 (2nd) Setup menu
Select parameter "r"
Remove the gas nozzle from the welding torch
Screw on the contact tip
Place the contact tip flush against the workpiece surface
Press the torch trigger briefly
- The welding circuit resistance is calculated. "run" is shown on the display during
the measurement.
The measurement is finished when the welding circuit resistance is shown on the display
in mOhm (e.g. 11.4).
Fit the gas nozzle back onto the welding torch
NOTE! The welding circuit resistance r depends on the hosepack used:
- If the length or cross-sectional area of the hosepack has changed, measure
the welding circuit resistance r again
- Measure the welding circuit resistance for every welding process separately
with the appropriate welding power-leads
NOTE! In order to obtain good welding results, it is essential to measure the welding circuit resistance correctly. Make sure that the contact between the earthing
clamp and the workpiece is on a cleaned workpiece surface.
NOTE! Make sure that the contact between the contact tip and the workpiece is
on a cleaned workpiece surface.
1
2
3
4
5
6
7
8
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EN
Displaying welding circuit inductivity L
General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore
affects the welding process. It is important to lay the hosepacks correctly in order to obtain
the best possible welding result.
Displaying welding circuit inductivity L
The setup parameter "L" is used to display the most recently calculated welding circuit inductivity. The welding circuit inductivity is calibrated at the same time as the welding circuit
resistance r is calculated. Detailed information can be found in the "Measuring welding circuit resistance r" section.
Access the setup menu level 2 (2nd)
Select parameter “L”
The most recently calculated welding circuit inductivity L is shown on the right-hand digital
display.
L ... Welding circuit inductivity (in microhenry)
Laying the hosepacks correctly
1
2
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Page 77
Troubleshooting and maintenance
Page 78
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EN
Troubleshooting
General The power sources are equipped with an intelligent safety system. This means that it has
been possible to dispense with melting-type fuses entirely. Melting-type fuses therefore no
longer need to be replaced. After a possible malfunction has been remedied, the power
source is ready for use again.
Safety
Power source troubleshooting
Make a note of the serial number and configuration of the device and contact our AfterSales Service team with a detailed description of the error, if
- errors occur that are not listed below
- the troubleshooting measures listed are unsuccessful
Over-temperature LED lights up
Cause: Over-temperature in control circuit
Remedy: Leave power source to cool
Power source has no function
Mains switch is on, but indicators are not lit up
Cause: There is a break in the mains lead; the mains plug is not plugged in
Remedy: Check the mains lead, ensure that the mains plug is plugged in
Cause: Mains socket or mains plug faulty
Remedy: Replace faulty parts
Cause: Mains fuse protection
Remedy: Change the mains fuse protection
WARNING! Work that is carried out incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel. Observe the safety rules in the power source operating instructions.
Page 80
80
No welding current
Mains switch is on, one of the overtemperature service codes "to" is displayed. Detailed
information on the service codes "to0" to "to6" can be found in the section "Displayed service codes".
Cause: Overload
Remedy: Take the duty cycle into account
Cause: Thermostatic safety cut-out has tripped
Remedy: Wait until the power source automatically comes back on after the end of the
cooling phase
Cause: Limited supply of cooling air
Remedy: Remove air filter on the rear of the housing from the side and clean. Ensure
that the cooling air ducts are accessible.
Cause: The fan in the power source is faulty
Remedy: Contact After-Sales Service
No welding current
Mains switch is ON and indicators are lit up
Cause: Grounding (earthing) connection is incorrect
Remedy: Check the grounding (earthing) connection for correct polarity
Cause: There is a break in the power cable in the welding torch
Remedy: Replace the welding torch
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 protective gas shield
All other functions are OK
Cause: Gas cylinder is empty
Remedy: Change the gas cylinder
Cause: The gas pressure regulator is faulty
Remedy: Replace the gas pressure regulator
Cause: Gas hose is not fitted or is damaged
Remedy: Fit or change the gas hose
Cause: Welding torch is faulty
Remedy: Change the welding torch
Cause: Gas solenoid valve is faulty
Remedy: Contact After-Sales Service
Page 81
81
EN
Poor weld properties
Cause: Incorrect welding parameters
Remedy: Check the settings
Cause: Poor ground earth connection
Remedy: Ensure good contact to workpiece
Cause: Inadequate or no protective gas shield
Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con-
nection, etc.
Cause: Welding torch is leaking
Remedy: Change the welding torch
Cause: Wrong contact tip, or contact tip is worn out
Remedy: Replace the contact tip
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check the wire electrode that has been inserted
Cause: Wrong wire alloy or wrong wire diameter
Remedy: Check weldability of the base material
Cause: The shielding gas is not suitable for this wire alloy
Remedy: Use the correct shielding gas
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: Inadequate coolant flow
Remedy: Check coolant level, flow rate, contamination, etc., Coolant pump blocked:
Tighten the coolant pump shaft
Displayed service
codes
If an error message that is not described here appears on the displays, proceed as follows
to resolve the problem:
Turn the power source mains switch to the "O" position
Wait 10 seconds
Move the mains switch to the I position
If the error occurs again despite several attempts to eliminate it, or if the troubleshooting
measures listed here are unsuccessful.
Make a note of the error message displayed
Note down the configuration of the power source
Contact our After-Sales Service team with a detailed description of the error
1
2
3
1
2
3
Page 82
82
ESr | 20
Cause: The selected cooling unit is not compatible with the power source
Remedy: Connect compatible cooling unit
-----
Cause: An invalid welding process was called up on the robot interface (no. 37) or an
empty flag was selected (no. 32)
Remedy: Call up a valid welding process or select assigned "Save" button
ELn | 8
Cause: The connected wire-feed unit is not supported
Remedy: Connect supported wire-feed unit
ELn | 12
Cause: Different control panels for selecting materials are in the system
Remedy: Connect similar control panels to select materials
ELn | 13
Cause: Invalid change of welding process during welding
Remedy: During welding do not carry out any illegal change of the welding process, re-
set error message by pressing any button
ELn | 14
Cause: More than only one robot interface is connected
Remedy: Only one robot interface may be connected, check the system configuration
ELn | 15
Cause: More than only one remote control unit is connected
Remedy: Only one remote control unit may be connected, check the system configura-
tion
Err | IP
Cause: The control unit of the power source has detected a primary overvoltage
Remedy: Check mains voltage, if the service code still remains, switch off the power
source, wait for 10 seconds and then switch the power source on again, if the
error keeps recurring, contact After-Sales Service
Err | PE
Cause: The earth current watchdog has triggered the safety cut-out of the power
source.
Remedy: Switch off the power source
Place the power source on an insulating surface
Connect the grounding (earthing) cable to a section of the workpiece that is
closer to the arc
Wait for 10 seconds and then switch the power source on again
If you have tried this several times and the error keeps recurring, contact After-Sales Service
Err | Ur
Cause: If the VRD option is available, the open circuit voltage limit of 35 V has been
exceeded.
Remedy: Switch off power source
Wait for 10 seconds and then switch the power source on again
Page 83
83
EN
no | UrL
Cause: The VRD option has tripped too early.
Remedy: Check whether all welding power-leads and control lines are connected.
Switch off the power source
Wait 10 seconds and switch the power source back on again
If the error occurs again - contact After Sales Service.
E-Stop
Cause: "External stop" has tripped
Remedy: Remedy the event that triggered the external stop
-St | oP-
Cause: At the robot interface the flag was not deleted by the robot
Remedy: Delete the signal robot ready at the robot interface
PHA | SE
Cause: Phase failure
Remedy: Check the mains fuse, the mains lead and the mains plug
PHA | SE1
Cause: The power source is operated in single-phase mode.
Remedy: -
PHA | SE3
Cause: The power source is operated in 3-phase mode
Remedy: -
Err | 51
Cause: Mains undervoltage: The mains voltage has fallen below the tolerance range
Remedy: Check the mains voltage, if the error keeps recurring, contact the After-Sales
Service
Err | 52
Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check the mains voltage, if the error keeps recurring, contact the After-Sales
Service
EFd 5
Cause: Incorrect wire-feed unit connected
Remedy: Connect correct wire-feed unit
EFd 8
Cause: Overtemperature on the wire-feed unit
Remedy: Allow wire-feed unit to cool down
EFd | 81, EFd | 83
Cause: Fault in the wire feed system (overcurrent in wire-feed unit drive)
Remedy: Arrange the hosepack in as straight a line as possible; check that there are
no kinks or dirt in the inner liner; check the contact pressure on the 4 roller
drive
Cause: Wire-feed unit motor is sticking or defective
Remedy: Check the wire-feed unit motor or contact After-Sales Service
Page 84
84
to0 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the primary circuit of the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to1 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature on the booster located in the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to2 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the secondary circuit of the power source
Remedy: Allow power source to cool down, check that fan is on
to3 | xxx
Remark: xxx stands for a temperature value
Cause: Overtemperature in the wire-feed unit motor
Remedy: Allow wire-feed unit to cool down
to4 | xxx
Remark: xxx stands for a temperature value
Cause: Overtemperature in welding torch
Remedy: Allow welding torch to cool down
to5 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in cooling unit
Remedy: Allow cooling unit to cool down, check that fan is on
to6 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature at the transformer of the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
to7 | xxx
Note: xxx stands for a temperature value
Cause: Overtemperature in the power source
Remedy: Allow power source to cool down, check air filter and clean if necessary,
check that fan is on
Page 85
85
EN
tu0 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the power source primary circuit
Remedy: Place power source in a heated room and allow to warm up
tu1 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature on the booster located in the power source
Remedy: Place power source in a heated room and allow it to warm up
tu2 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the power source secondary circuit
Remedy: Place power source in a heated room and allow to warm up
tu3 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the wire-feed unit motor
Remedy: Place wire-feed unit in a heated room and allow to warm up
tu4 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the welding torch
Remedy: Place welding torch in a heated room and allow to warm up
tu5 | xxx
Remark: xxx stands for a temperature value
Cause: Undertemperature in the cooling unit
Remedy: Place cooling unit in a heated room and allow to warm up
tu6 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature on the transformer of the power source
Remedy: Place power source in a heated room and allow it to warm up
tu7 | xxx
Note: xxx stands for a temperature value
Cause: Undertemperature in the power source
Remedy: Place power source in a heated room and allow it to warm up
no | H2O
Cause: Coolant flow rate too low
Remedy: Check coolant flow rate and cooling unit, including cooling circuit (for mini-
mum coolant flow, see "Technical Data" section in the device operating instructions)
Page 86
86
hot | H2O
Cause: The coolant temperature is too high
Remedy: Allow cooling unit and cooling circuit to cool down, until "hot | H2O" is no
longer displayed. Open the cooling unit and clean the cooler, check fan is
working properly. Robot interface or field bus coupler: before resuming welding, set the "Source error reset" signal.
no | Prg
Cause: No preconfigured program has been selected
Remedy: Select a configured program
no | IGn
Cause: "Ignition time out" function is active; no current started flowing before the
length of wire specified in the set-up menu had been fed. The power source
safety cut-out has tripped.
Remedy: Shorten the wire end; press the torch trigger again; clean the surface of the
workpiece; if necessary, increase the wire length until the safety cut-out trips
in "Set-up menu: Level 2".
EPG | 17
Cause: The welding program selected is invalid
Remedy: Select valid welding program
EPG | 29
Cause: The required wire-feed unit is not available for the selected characteristic
Remedy: Connect correct wire-feed unit, check plug connections for the hosepack
EPG | 35
Cause: Measurement of the welding circuit resistance "r" failed
Remedy: Check grounding cable, current cable or hosepack and replace if necessary,
recalculate welding circuit resistance "r"
no | GAS
Cause: The Gas watchdog option has detected that there is no gas pressure
Remedy: Connect a new gas cylinder or open the gas cylinder valve/pressure regulator,
restart "Gas watchdog" option, reset "no | GAS" error message by pressing
any button.
Page 87
87
EN
Care, maintenance and disposal
General Under normal operating conditions, the welding system requires only a minimum of care
and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years.
Safety
At every start-up - Check mains plug, mains cable, welding torch, interconnecting hosepack and ground-
ing (earthing) connection for damage
- Check that there is a gap of 0.5 m (1 ft. 8 in.) all around the device to ensure that cooling air can flow and escape unhindered
Every 2 months
- If required, clean air filter using dry compressed air or by washing it.
Every 6 months - Dismantle device side panels and clean inside of device with dry reduced compressed
air
- If a lot of dust has accumulated, clean the cooling air ducts.
Disposal 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 machine from the mains
- Prevent it from being switched on again
- Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have discharged
WARNING! Work that is carried out incorrectly can cause serious injury and damage. The following activities must only be carried out by trained and qualified personnel. All instructions in the section headed "Safety rules" must be observed.
NOTE! Air inlets and outlets must never be covered, not even partially.
CAUTION! Risk of damage. The air filter must only be fitted when dry.
NOTE! Risk of damage to electronic components. Do not bring air nozzle too
close to electronic components.
Page 88
88
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.
Explanation of
the term "duty cycle"
Duty cycle (D.C.) is the proportion of time in a 10-minute cycle at which the device may be
operated at its rated output without overheating.
Example: Welding at 150 A at 60% D.C.
- Welding phase = 60% of 10 minutes = 6 minutes
- Cooling phase = remaining time = 4 minutes
- After the cooling phase, the cycle begins anew.
If the device is to be continuously operated without stopping:
look in the technical data for a D.C. value of 100% for the reigning ambient temperature.
Reduce the output or amperage in line with this value so that the device can remain in
use without observing a cooling phase.
TSt 3500 Rob
NOTE! The D.C. values specified on the rating plate are based on an ambient
temperature of 40°C. If the ambient temperature is higher, either the D.C. or output must be reduced accordingly.
10 Min.6 Min.
150 A
0 Min.
0 A
4 Min.6 Min.
60 %
1
2
Mains voltage (U1) 3 x 380 V 400 V 460 V
Max. effective primary current (I
1eff
) 15.0 A 14.4 A 12.6 A
Max. primary current (I
1max
) 23.6 A 22.7 A 19.8 A
Mains fuse 35 A slow-blow
Mains voltage tolerance -10 / +15 %
Grid frequency 50/60 Hz
Page 89
89
EN
1) Interface to a 230/400 V, 50 Hz public grid
2) ED = duty cycle
TSt 5000 Rob
Cos phi (1) 0.99
Max. permitted mains impedance Z
max
at PCC
1)
77 mOhm
Recommended earth-leakage circuit breaker Type B
Welding current range (I2)
MIG/MAG 10 - 350 A
Rod electrode 10 - 350 A
Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 %
350 A 300 A 250 A
Output voltage range according to standard characteristic
(U2)
MIG/MAG 14.5 - 31.5 V
Rod electrode 20.4 - 35.0 V
Open circuit voltage (U0 peak / U0 r.m.s) 60 V
Apparent power at 400 V AC / 350 A / 40 % ED
2)
15,673 kVA
Degree of protection IP 23
Type of cooling AF
Insulation class B
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE, CSA
Dimensions l x w x h 747 x 300 x 497 mm
29.4 x 11.8 x 19.6 in.
Weight 29 kg
63.5 lb.
Efficiency at 250 A and 26.5 V 89 %
Max. noise emission (LWA) 72 dB (A)
Mains voltage (U1) 3 x 380 V 400 V 460 V
Max. effective primary current (I
1eff
) 27 A 25.9 A 23.2 A
Max. primary current (I
1max
) 42.7 A 41.0 A 36.7 A
Mains fuse 35 A slow-blow
Mains voltage tolerance -10 / +15 %
Grid frequency 50/60 Hz
Cos phi (1) 0.99
Max. permitted mains impedance Z
max
at PCC
1)
11 mOhm
Recommended earth-leakage circuit breaker Type B
Welding current range (I2)
Page 90
90
1) Interface to a 230/400 V, 50 Hz public grid
2) ED = duty cycle
TSt 3500 MV Rob
MIG/MAG 10 - 500 A
Rod electrode 10 - 500 A
Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 %
500 A 420 A 360 A
Output voltage range according to standard characteristic (U2)
MIG/MAG 14.3 - 39 V
Rod electrode 20.2 - 40 V
Open circuit voltage (U0 peak / U0 r.m.s) 65 V
Apparent power at 400 V AC / 500 A / 40 % ED
2)
28,361 kVA
Degree of protection IP 23
Type of cooling AF
Insulation class B
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE, CSA
Dimensions l x w x h 747 x 300 x 497 mm
29.4 x 11.8 x 19.6 in.
Weight 32.3 kg
71.2 lb.
Efficiency at 360 A and 32 V 91 %
Max. noise emission (LWA) 74 dB (A)
Mains voltage (U1) 3 x 200 V 230 V
Max. effective primary current (I
1eff
) 24.1 A 20.8 A
Max. primary current (I
1max
) 38.1 A 32.9 A
Mains fuse 35 A slow-blow
Mains voltage (U1) 3 x 400 V 460 V
Max. effective primary current (I
1eff
) 11.9 A 10.6 A
Max. primary current (I
1max
) 18.7 A 16.7 A
Mains fuse 35 A slow-blow
Mains voltage tolerance -10 / +15 %
Grid frequency 50/60 Hz
Cos phi (1) 0.99
Max. permitted mains impedance Z
max
at PCC
1)
122 mOhm
Recommended earth-leakage circuit breaker Type B
Welding current range (I2)
MIG/MAG 10 - 350 A
Page 91
91
EN
1) Interface to a 230/400 V, 50 Hz public grid
2) ED = duty cycle
TSt 5000 MV Rob
Rod electrode 10 - 350 A
Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 %
U
1
: 200 - 460 V 350 A 300 A 250 A
Output voltage range according to standard characteristic (U
2
)
MIG/MAG 14.5 - 31.5 V
Rod electrode 20.4 - 35 V
Open circuit voltage (U0 peak / U0 r.m.s) 50 V
Apparent power at 200 V AC / 350 A / 40 % ED
2)
13,189 kVA
at 400 V AC / 350 A / 40 % ED
2)
12,965 kVA
Degree of protection IP 23
Type of cooling AF
Insulation class B
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE, CSA
Dimensions l x w x h 747 x 300 x 497 mm
29.4 x 11.8 x 19.6 in.
Weight 37.3 kg
82 lb.
Efficiency at 250 A and 26.5 V 87 %
Max. noise emission (LWA) 74 dB (A)
Mains voltage (U1) 3 x 200 V 230 V
Max. effective primary current (I
1eff
) 39.5 A 36.3 A
Max. primary current (I
1max
) 66.7 A 57.4 A
Mains fuse 63 A slow-blow
Mains voltage (U1) 3 x 400 V 460 V
Max. effective primary current (I
1eff
) 20.6 A 18.1 A
Max. primary current (I
1max
) 32.5 A 28.6 A
Mains fuse 35 A slow-blow
Mains voltage tolerance -10 / +15 %
Mains frequency 50/60 Hz
Cos phi (1) 0.99
Max. permitted mains impedance Z
max
on PCC
1)
63 mOhm
Recommended earth-leakage circuit breaker Type B
Welding current range (I2)
MIG/MAG 10 - 500 A
Page 92
92
1) Interface to a 230/400 V, 50 Hz public grid
2) ED = duty cycle
Rod electrode 10 - 500 A
Welding current at 10 min / 40 °C (104 °F) 35% 60% 100%
U
1
: 200 V 500 A 420 A 360 A
Welding current at 10 min / 40 °C (104 °F) 40% 60% 100%
U
1
: 208 - 460 V 500 A 420 A 360 A
Output voltage range according to standard characteristic (U
2
)
MIG/MAG 14.3 - 39 V
Rod electrode 20.2 - 40 V
Open circuit voltage (U
0
peak / U0 r.m.s) 57 V
Apparent power at 200 V AC / 500 A / 40 % ED
2)
23,089 kVA
at 400 V AC / 500 A / 40 % ED
2)
22,492 kVA
Degree of protection IP 23
Type of cooling AF
Insulation class B
Overvoltage category III
Pollution level according to IEC60664 3
Safety symbols S, CE, CSA
Dimensions l x w x h 747 x 300 x 497 mm
29.4 x 11.8 x 19.6 in.
Weight 43.6 kg
96.1 lb.
Efficiency at 250 A and 26.5 V 88%
Max. noise emission (LWA) 75 dB (A)
Page 93
93
EN
Welding program tables
TransSteel 3500
Euro welding program tables
Welding program database:
TransSteel 3500 Euro
VAT ID 3431
* Diameter = 1,2 mm (0.45 in.)
A
B
C
D
E
F
1
Pos.
Pos.
2
3
4
5
6
7
8
Standard Programs
Material
A
Pos.
2290 2300 2310 2322 2334
2288 2298 2308 2324 2332
2485 2486 2487 2488 2489
2285 2297 2307 2323 2331
2292 2302 2312 2326 2336
2293 2303 2313 2327 2337
2291 2301 2311 2325 2335
2502 2501 2499 2500
2295 2305 2315 2329 2339
2296 2306 2316
2314
2330 2340
2294 2304 2328 2338
2410 2321
2411 2320
2391 2345
2317
2390 2344
2318
2433 2342
2420 2385
2432 2341
2421 2536
2387 2415
2350 2349
2388 2343
2348
Gas Diameter
B
C
D
B
C
D
A
B
C
D
A
C
A
C
B
C
1
Pos.
1
1
1
2
2
2
3
3
3
3
4
4
5
5
6
6
7
Steel
Steel
Steel
Steel
Steel dynamic
Steel dynamic
Steel dynamic
Steel root
Steel root
Steel root
Steel root
Rutil FCW
Rutil FCW
Basic FCW
Basic FCW
Metal cored
Metal cored
Self-shielded
100 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
100 % CO2
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
100 % CO2
Ar + 18 % CO2
100 % CO2
Ar + 18 % CO2
Ar + 8 % CO2
Ar + 18 % CO2
Self-shielded
Special assignment
Material
F
Pos.
2427 2402 2426 2405
2440 2441 2442
2496 2495 2493
2443
2423 2424 2425
2444
Gas Diameter
F
C
E
1
Pos.
3
8
8
Stainless Steel
Stainless Steel root
FCW Stainless Steel
AlMg 5
Ar + 2,5 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 2,5 % CO2
Ar + 18 % CO2
100 % Ar
2497F8 CuSi 3 SP
3092E8
AlSi 100 % Ar
*
Page 94
94
TransSteel 5000
Euro welding program tables
Welding program database:
TransSteel 5000 Euro
VAT ID 2546
* Diameter = 1,2 mm (0.45 in.)
A
B
C
D
E
F
1
Pos.
Pos.
2
3
4
5
6
7
8
Standard Programs
Material
A
Pos.
2290 2300 2310 2322 2334
2288 2298 2308 2324 2332
2485 2486 2487 2488 2489
2285 2297 2307 2323 2331
2347
2394
2490
2395
2292 2302 2312 2326 2336
2293 2303 2313 2327 2337
2291 2301 2311 2325 2335
2502 2501 2499 2500 2529
2295 2305 2315 2329 2339
2296 2306 2316
2314
2330 2340
2294 2304 2328 2338
2410 2321
2411 2320
2391 2345
2317
2390 2344
2318
2433 2342
2420 2385
2432 2341
2421 2536
2387 2415
2350 2349
2388 2343
2348
Gas Diameter
B
C
D
B
C
D
A
B
C
D
A
C
A
C
B
C
1
Pos.
1
1
1
2
2
2
3
3
3
3
4
4
5
5
6
6
7
Steel
Steel
Steel
Steel
Steel dynamic
Steel dynamic
Steel dynamic
Steel root
Steel root
Steel root
Steel root
Rutil FCW
Rutil FCW
Basic FCW
Basic FCW
Metal cored
Metal cored
Self-shielded
100 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
100 % CO2
Ar + 8 % CO2
Ar + 18 % CO2
Ar + 4 % O2
100 % CO2
Ar + 18 % CO2
100 % CO2
Ar + 18 % CO2
Ar + 8 % CO2
Ar + 18 % CO2
Self-shielded
Special assignment
Material
F
Pos.
2427 2402 2426 2405 2428
2440 2441 2442 2443
2423 2424 2425
2444
Gas Diameter
F
C
E
1
Pos.
3
8
8
Stainless Steel
Stainless Steel root
FCW Stainless Steel
AlMg 5
Ar + 2,5 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 2,5 % CO2
Ar + 18 % CO2
100 % Ar
2496 2495 2493
2497 2498F8 CuSi 3 SP
3092E8
AlSi 100 % Ar
*
Page 95
95
EN
TransSteel 3500
US welding program tables
Welding program database:
TransSteel 3500 US
VAT ID 3431
* Diameter = 1,2 mm (0.45 in.)
A
B
C
D
E
F
1
2
3
4
5
6
7
8
Pos.
Pos.
Standard Programs
Material
A
Pos.
2290 2300 2310 2322 2334
2418 2370 2308 2377 2409
2419 2369 2309 2376 2333
2372 2371 2307 2378 2408
2374 2367 2312 2380 2336
2375 2366 2313 2379 2337
2373 2368 2311 2381 2335
2462
2502 2501 2499 2500
2295 2364 2315
2316
2314
2383 2339
2296
2294
2363 2382 2340
2365 2384
2471 2472
2338
2469
2456 24682470
2474
2467
2476
2473
2466
2475
2420 2385
2433
2415
2421 2386
2432
2387
2388 2416
2348
Gas Diameter
B
C
D
B
C
D
B
A
B
C
D
A
C
A
C
B
1
Pos.
1
1
1
2
2
2
2
3
3
3
3
4
4
5
5
6
6
Steel
Steel
Steel
Steel
Steel dynamic
Steel dynamic
Steel dynamic
Steel dynamic
Steel root
Steel root
Steel root
Steel root
Rutil FCW
Rutil FCW
Basic FCW
Basic FCW
Metal cored
100 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
Ar + 10 % CO2
100 % CO2
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
100 % CO2
Ar + 25 % CO2
100 % CO2
Ar + 25 % CO2
Ar + 10 % CO2
CMetal cored
Ar + 25 % CO2
2350 2349
7 Self-shielded
Self-shielded
Special assignment
Material
F
Pos.
2440 2441 2442 2443
2423 2424 2425
2404 2407
2403 2406
Gas Diameter
F
A
B
3
Pos.
6
8
8
Stainless Steel root
FCW Stainless Steel
Stainless Steel
Stainless Steel
Ar + 2,5 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 18 % CO2
Ar + 90 % He + 2,5 % CO2
Ar + 33 % He + 1 % CO2
2427 2402 2426 2405
2464 2465
2444
C
D
E
8
8
8
Stainless Steel
FCW MAP409Ti
AlMg 5
Ar + 2,5 % CO2
Ar + 2 % O2
100 % Ar
2496 2495 2493
2497F8 CuSi 3 SP
3092E8
AlSi 100 % Ar
*
Page 96
96
TransSteel 5000
US welding program tables
Welding program database:
TransSteel 5000 US
VAT ID 2539
* Diameter = 1,2 mm (0.45 in.)
A
B
C
D
E
F
1
2
3
4
5
6
7
8
Pos.
Pos.
Standard Programs
Material
A
Pos.
2290 2300 2310 2322 2334 2347
2418 2370 2308 2377 2409
2419 2369 2309 2376 2333
2372 2371 2307 2378 2408
2394
2346
2395
2374 2367 2312 2380 2336
2375 2366 2313 2379 2337
2373 2368 2311 2381 2335
2462
2502 2501 2499 2500 2529
2295 2364 2315
2316
2314
2383 2339
2296
2294
2363 2382 2340
2365 2384
2471 2472
2338
2469
2456 24682470
2474
2467
2476
2473
2466
2475
2420 2385
2433
2415
2421 2386
2432
2387
2388 2416
2348
Gas Diameter
B
C
D
B
C
D
B
A
B
C
D
A
C
A
C
B
1
Pos.
1
1
1
2
2
2
2
3
3
3
3
4
4
5
5
6
6
Steel
Steel
Steel
Steel
Steel dynamic
Steel dynamic
Steel dynamic
Steel dynamic
Steel root
Steel root
Steel root
Steel root
Rutil FCW
Rutil FCW
Basic FCW
Basic FCW
Metal cored
100 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
Ar + 10 % CO2
100 % CO2
Ar + 10 % CO2
Ar + 25 % CO2
Ar + 5 % O2
100 % CO2
Ar + 25 % CO2
100 % CO2
Ar + 25 % CO2
Ar + 10 % CO2
CMetal cored
Ar + 25 % CO2
2350 2349
7 Self-shielded
Self-shielded
Special assignment
Material
F
Pos.
2440 2441 2442 2443
2423 2424 2425
2404 2407
2403 2406
Gas Diameter
F
A
B
3
Pos.
6
8
8
Stainless Steel root
FCW Stainless Steel
Stainless Steel
Stainless Steel
Ar + 2,5 % CO2
0,8 mm
.030‘‘
0,9 mm
.035‘‘
1,0 mm
.040‘‘
1,2 mm
.045‘‘
1,4 mm
.052‘‘
1,6 mm
1/16‘‘
SP
Ar + 18 % CO2
Ar + 90 % He + 2,5 % CO2
Ar + 33 % He + 1 % CO2
2427 2402 2426 2405 2428
2464 2465
2444
C
D
E
8
8
8
Stainless Steel
FCW MAP409Ti
AlMg 5
Ar + 2,5 % CO2
Ar + 2 % O2
100 % Ar
2496 2495 2493
2497 2498F8 CuSi 3 SP
3092E8
AlSi 100 % Ar
*
Page 97
97
EN
Quick reference
4
1
3
2
5
Fronius International GmbH, www.fronius.com
Keylock
Important! If the keylock is activated, only the
parameter settings can be retrieved, as well
as any assigned “Save“ button provided that
an assigned “Save“ button was selected when
the keylock was enabled.
- press and hold
- press
- release
activate / deactivate:
activated: „CLO | SEd“ display
deactivated: „OP | En“ display
Quick Reference: English
Setting the welding power
Selecting the fi ller metal and
shielding gas
2 T 2-step mode
4 T 4-step mode
S 4 T Special 4-step mode
Selecting the process
Setting the mode
MANUAL MIG/MAG standard manual
SYNERGIC Standard synergic
STICK Manual metal arc welding
Correcting parameters
Important If external system components
are connected, some parameters can be
modifi ed on those components. The power
source control panel is only for display
purposes.
01/2013
Start-up sequence
Follow operating instructions
-
1 5
TransSteel Synergic
SP ... Special Program
- select desired parameter
- set desired parameter
Sheet thickness
Welding current
Wire feed speed
Arc length
correction
Welding voltage
Dynamic
- select desired parameter
- set desired parameter
Real Energy Input
Page 98
98
Gas pre-fl ow time
Gas post-fl ow time
Threading speed
Burn-back effect
Ignition current
Length of wire before the safety cut-out trips
Restoring factory setup
2nd menu level
Cooling unit control
Cooling unit watchdog
Country setting
Welding circuit resistance
Welding circuit inductivity
Real Energy Input
MIG/MAG - setup
Manual
Display service parameters
Operating points
briefl y press
retrieve:
press and hold down for several seconds release
delete:
save:
Welding circuit resistance
Welding circuit inductivity
Gas pre-fl ow time
Gas post-fl ow time
Slope (2-step, special 4-step)
Starting current (2-step, special 4-step)
Final current (2-step, special 4-step)
Starting current duration (2-step)
Final current duration (2-step)
Threading speed
Burn-back effect
Length of wire before the safety cut-out trips
Restoring factory setup
2nd menu level
Cooling unit control
Cooling unit watchdog
Country setting
Welding circuit resistance
Welding circuit inductivity
Real Energy Input
MIG/MAG - setup
Synergic
Hot-start current
Hot-current time
Anti-stick
Restoring factory setup
2nd menu level
Rod electrode - setup
Quick Reference: English
TransSteel Synergic
press and hold
release
5 „Save“ buttons
Setup
2. Menu level for service engineers
e.g.:
e.g.:
e.g.:
e.g.:
e.g.:
fi rmware version
welding program confi guration
number of the currently selected welding
program
motor current for wire drive in A
The value changes as soon as the motor
is running.
Arc burning time
Page 99
Appendix
Page 100
100
Spare parts list: TSt 3500 Rob, TSt 5000 Rob
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