/ 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).
16
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.
17
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.
18
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.
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.
20
General information
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
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
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
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
Control elements and connections
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)
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
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