FRO­NIUS TransSteel 3500 Syn User manual

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42,0426,0258,EN 004-03042017
TransSteel 3500 Syn
TransSteel 5000 Syn
VR 5000 Remote
Operating Instructions
MIG/MAG Power source
EN

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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
Explanation of
safety symbols
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
DANGER! Indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! Indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! Indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.

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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
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 ................................................................................................................................................ 18
Safety symbols...................................................................................................................................... 19
Data protection...................................................................................................................................... 19
Copyright............................................................................................................................................... 19
General information 21
General ...................................................................................................................................................... 23
Device concept ..................................................................................................................................... 23
Functional principle ............................................................................................................................... 23
Application areas .................................................................................................................................. 23
Warning notices on the device.............................................................................................................. 24
Welding processes, processes and welding characteristics ...................................................................... 26
General ................................................................................................................................................. 26
Welding characteristics ......................................................................................................................... 26
Summary of MIG/MAG standard synergic welding ............................................................................... 26
System components .................................................................................................................................. 27
General ................................................................................................................................................. 27
Safety.................................................................................................................................................... 27
Overview ............................................................................................................................................... 27
Options....................................................................................................................................................... 28
General ................................................................................................................................................. 28
Machine interface.................................................................................................................................. 28
Gas preheater CO2 connection ............................................................................................................ 28
Keylock switch ...................................................................................................................................... 28
VRD: safety function ............................................................................................................................. 29
VRD: safety principle ............................................................................................................................ 29
Wirefeeder options................................................................................................................................ 30
Control elements and connections 31
Synergic control panel ............................................................................................................................... 33
General ................................................................................................................................................. 33
Safety.................................................................................................................................................... 33
Synergic control panel .......................................................................................................................... 34
Service parameters............................................................................................................................... 36
Keylock ................................................................................................................................................. 37
Connections, switches and mechanical components ................................................................................ 39

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TSt 3500/5000 Syn power source......................................................................................................... 39
VR 5000 Remote - front of wirefeeder .................................................................................................. 40
Rear of wirefeeder ................................................................................................................................ 40
Side of wirefeeder ................................................................................................................................. 41
Wire-feed unit underside....................................................................................................................... 42
Installation and commissioning 43
Minimum equipment needed for welding task............................................................................................ 45
General ................................................................................................................................................. 45
Gas-cooled MIG/MAG welding ............................................................................................................. 45
MIG/MAG welding, water-cooled .......................................................................................................... 45
MMA welding ........................................................................................................................................ 45
Before installation and commissioning....................................................................................................... 46
Safety.................................................................................................................................................... 46
Utilisation for intended purpose only..................................................................................................... 46
Setup regulations .................................................................................................................................. 46
Mains connection .................................................................................................................................. 46
Connecting the mains cable....................................................................................................................... 48
General ................................................................................................................................................. 48
Stipulated mains cables and strain-relief devices ................................................................................. 48
Connecting the mains cable.................................................................................................................. 48
Fitting the Europe strain-relief device ................................................................................................... 49
Fitting the Canada/US strain-relief device ............................................................................................ 50
Generator-powered operation.................................................................................................................... 51
Generator-powered operation............................................................................................................... 51
Start-up ...................................................................................................................................................... 52
General ................................................................................................................................................. 52
Information on system components ...................................................................................................... 52
Assembling the system components (overview)................................................................................... 52
Placing wire-feed unit on power source ................................................................................................ 53
Fitting the interconnecting hosepack strain-relief device ...................................................................... 54
Connecting the interconnecting hosepack ............................................................................................ 54
Connecting the gas cylinder.................................................................................................................. 55
Establishing a ground earth connection................................................................................................ 56
Connecting a MIG/MAG welding torch.................................................................................................. 56
Inserting/replacing feed rollers.............................................................................................................. 56
Inserting the wirespool .......................................................................................................................... 57
Inserting the basket-type spool ............................................................................................................. 58
Feed in the wire electrode..................................................................................................................... 59
Setting the contact pressure ................................................................................................................. 61
Adjusting the brake ............................................................................................................................... 61
Design of the brake............................................................................................................................... 62
Welding 63
Power limitation.......................................................................................................................................... 65
Safety function ...................................................................................................................................... 65
MIG/MAG modes ....................................................................................................................................... 66
General ................................................................................................................................................. 66
Symbols and their explanations ............................................................................................................ 66
2-step mode .......................................................................................................................................... 67
4-step mode .......................................................................................................................................... 67
Special 4-step mode ............................................................................................................................. 67
Spot welding ......................................................................................................................................... 67
2-step stitch welding ............................................................................................................................. 68
4-step stitch welding ............................................................................................................................. 68
MIG/MAG welding...................................................................................................................................... 69
Safety.................................................................................................................................................... 69
Preparatory work................................................................................................................................... 69
Overview ............................................................................................................................................... 69
MIG/MAG standard synergic welding ........................................................................................................ 70
MIG/MAG standard synergic welding ................................................................................................... 70
Corrections during welding ................................................................................................................... 70

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MIG/MAG standard manual welding .......................................................................................................... 72
General ................................................................................................................................................. 72
Available parameters ............................................................................................................................ 72
MIG/MAG standard manual welding ..................................................................................................... 72
Corrections during welding ................................................................................................................... 73
Spot and stitch welding .............................................................................................................................. 74
General ................................................................................................................................................. 74
Spot welding ......................................................................................................................................... 74
Stitch welding........................................................................................................................................ 75
Saving and retrieving operating points....................................................................................................... 76
General ................................................................................................................................................. 76
Saving operating points ........................................................................................................................ 76
Retrieving operating points ................................................................................................................... 76
Deleting operating points ...................................................................................................................... 76
Retrieving operating points on the Up/Down welding torch .................................................................. 76
MMA welding ............................................................................................................................................. 78
Safety.................................................................................................................................................... 78
Preparations.......................................................................................................................................... 78
MMA welding ........................................................................................................................................ 78
Corrections during welding ................................................................................................................... 79
HotStart function ................................................................................................................................... 79
Anti-stick function.................................................................................................................................. 79
Setup settings 81
Setup menu................................................................................................................................................ 83
General remarks ................................................................................................................................... 83
Entering/exiting the Setup menu........................................................................................................... 83
Setup parameters for MIG/MAG standard manual welding .................................................................. 84
Setup parameters for MIG/MAG standard synergic welding................................................................. 86
Setup parameters for MMA welding...................................................................................................... 88
Setup menu - Level 2................................................................................................................................. 89
Level 2 setup menu............................................................................................................................... 89
Parameters for MIG/MAG welding in the Setup menu level 2 .............................................................. 90
Parameters for manual metal arc (MMA) welding in the Setup menu level 2 ....................................... 91
Measuring welding circuit resistance r ....................................................................................................... 92
General ................................................................................................................................................. 92
Measure the welding circuit resistance r............................................................................................... 92
Retrieving the welding circuit inductivity L ................................................................................................. 93
General ................................................................................................................................................. 93
Displaying welding circuit inductivity L .................................................................................................. 93
Laying the hosepacks correctly............................................................................................................. 93
Troubleshooting and maintenance 95
Troubleshooting ......................................................................................................................................... 97
General ................................................................................................................................................. 97
Safety.................................................................................................................................................... 97
Fault diagnosis...................................................................................................................................... 97
Displayed service codes ....................................................................................................................... 100
Care, maintenance and disposal ............................................................................................................... 106
General ................................................................................................................................................. 106
Safety.................................................................................................................................................... 106
At every start-up.................................................................................................................................... 106
Every 2 months ..................................................................................................................................... 106
Every 6 months ..................................................................................................................................... 106
Disposal ................................................................................................................................................ 106
Appendix 107
Technical data............................................................................................................................................ 109
Special voltages.................................................................................................................................... 109
Explanation of the term "duty cycle" ..................................................................................................... 109
TSt 3500 Syn ........................................................................................................................................ 110

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TSt 3500 MV Syn.................................................................................................................................. 111
TSt 5000 Syn ........................................................................................................................................ 112
TSt 5000 MV Syn.................................................................................................................................. 113
VR 5000 Remote .................................................................................................................................. 114
Welding program tables ............................................................................................................................. 115
TransSteel 3500 Syn - Euro welding program tables .......................................................................... 115
TransSteel 5000 Syn - Euro welding program tables .......................................................................... 117
TransSteel 3500 Syn - US welding program tables ............................................................................. 119
TransSteel 5000 Syn - US welding program tables .............................................................................. 121
TransSteel 3500 Yard welding program tables .................................................................................... 123
TransSteel 5000 Yard welding program tables .................................................................................... 124
Standard value tables for MIG/MAG standard manual welding ................................................................. 125
Settings tables ...................................................................................................................................... 125

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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 operat-
ing 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 be-
ing used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident preven-
tion 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 safe-
ty.
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 manufac-
turer 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 manufactur-
er accepts no responsibility for any damage caused through use in a domestic
setting.
The manufacturer likewise accepts no liability for inadequate or incorrect re-
sults.

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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 sub-
stances, 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