FRO­NIUS TransSteel 3000c Pulse User manual

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TransSteel 3000c Pulse
EN-US
Operating instructions
MIG/MAG power source
42,0426,0354,EA 003-15122020

Table of contents
Safety Instructions 7
Explanation of Safety Instructions 7
General 7
Intended Use 7
Environmental Conditions 8
Obligations of the Operating Company 8
Obligations of Personnel 8
Grid Connection 8
Personal Protection and Protection of Others 9
Danger from toxic gases and vapors 9
Danger from Flying Sparks 10
Risks from grid current and welding current 10
Stray welding currents 11
EMC Device Classifications 12
EMC Measures 12
EMF measures 13
Particular Hazard Areas 13
Requirement for the shielding gas 14
Danger from Shielding Gas Cylinders 14
Danger Posed by Shielding Gas Leak 15
Safety Measures at the Setup Location and During Transport 15
Safety Measures in Normal Operation 15
Maintenance and repair 16
Safety Inspection 16
Disposal 16
Safety Symbols 17
Data backup 17
Copyright 17
General information 19
General 21
Device concept 21
Operating principle 21
Application areas 21
Warning notices on the device 21
Description of the warnings on the device 23
Welding processes, procedures, and welding characteristics for MIG/MAG welding 25
General 25
Brief description of MIG/MAG standard synergic welding 25
Brief description of MIG/MAG pulsed synergic welding 25
Brief description of SynchroPulse welding 25
System components 26
General 26
Safety 26
Overview 26
Operating controls and connections 27
Control Panel 29
General 29
Safety 29
Control panel 30
Service parameters 35
Keylock 36
Connections, Switches, and Mechanical Components 37
Front and back 37
Side view 38
Installation and Startup 39
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Minimum equipment for welding operations 41
General 41
Gas-cooled MIG/MAG welding 41
Water-cooled MIG/MAG welding 41
Manual metal arc welding 41
TIG DC Welding 41
Before installation and initial operation 42
Safety 42
Intended Use 42
Setup regulations 42
Grid Connection 43
Connecting the Mains Cable 44
Stipulated mains cables and strain-relief devices 44
Safety 44
Connecting the mains cable 44
Fitting the strain-relief device 45
Fitting the strain-relief device for Canada / US 45
Generator-Powered Operation 47
Generator-powered operation 47
Commissioning 48
Safety 48
General 48
Information on system components 48
Assembling system components 49
Establishing a ground earth connection 49
Inserting/changing feed rollers 50
Inserting the wirespool 51
Installing the basket-type spool 52
Feed in the wire electrode 53
Setting the contact pressure 55
Adjust the brake 56
Design of the Brake 56
Setting the date and time when starting for the first time 57
MIG/MAG welding 59
Power Limitation 61
Safety function 61
MIG/MAG Operating Modes 62
General 62
Symbols and explanations 62
2-step mode 63
4-step mode 63
Special 2-step mode 64
Special 4-step mode 64
Spot welding 65
2-step stitch welding 65
4-step stitch welding 66
MIG/MAG welding 67
Safety 67
Preparation 67
Overview 67
MIG/MAG synergic welding 68
MIG/MAG synergic welding 68
Corrections during welding 70
SynchroPulse welding 70
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
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General 74
Spot welding 74
Stitch welding 75
EasyJob mode 77
General 77
Saving EasyJob operating points 77
Retrieving EasyJob operating points 77
Deleting EasyJob operating points 77
Retrieving EasyJob operating points on the Up/Down welding torch 78
TIG welding 79
TIG welding 81
Safety 81
Preparation 81
TIG welding 82
Igniting the arc 83
Ending the welding process 83
Pulse welding 84
Applications 84
Operating principle 84
Activating pulse welding 85
Manual Metal Arc Welding 87
Manual Metal Arc Welding 89
Safety 89
Preparation 89
Manual metal arc welding 90
Corrections during welding 90
HotStart function 91
Anti-Stick function 91
Easy Documentation 93
General 95
General 95
Documented welding data 95
New CSV file 96
PDF report / Fronius signature 96
Activating / deactivating Easy Documentation 97
Activating Easy Documentation 97
Set the date and time 97
Deactivating Easy Documentation 98
Setup Settings 99
Setup Menu 101
General 101
Operation 101
Setup parameters for MIG/MAG synergic welding 102
Setup parameters for MIG/MAG standard manual welding 104
Setup parameters for MMA welding 105
Parameters for TIG welding 105
Setup Menu 2nd Level 107
Limitations 107
Operation (Setup Menu 2nd Level) 107
Parameters for MIG/MAG synergic welding in Setup menu 2nd level 108
Parameters for MIG/MAG standard manual welding in Setup menu 2nd level 109
Parameters for manual metal arc welding in Setup menu 2nd level 111
Parameters for TIG welding (Setup menu 2nd level) 111
Measuring the Welding Circuit Resistance r 112
General 112
Measuring the welding circuit resistance (MIG/MAG welding) 112
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Measuring the welding circuit resistance (MMA welding) 113
Displaying the welding circuit Inductivity L 114
General 114
Displaying the welding circuit inductivity 114
Laying the hosepacks correctly 114
Troubleshooting and Maintenance 115
Troubleshooting 117
General 117
Safety 117
Displayed Service Codes 117
Displayed service codes in connection with OPT Easy Documentation 122
Service, maintenance and disposal 123
General 123
Safety 123
At every start-up 123
Whenever required 123
Every 2 Months 123
Every 6 Months 124
Disposal 124
Appendix 125
Average consumption values during welding 127
Average wire electrode consumption during MIG/MAG welding 127
Average shielding gas consumption during MIG/MAG welding 127
Average shielding gas consumption during TIG welding 127
Technical data 128
Overview with critical raw materials, year of production of the device 128
Special Voltage 128
Explanation of the Term Duty Cycle 128
TransSteel 3000c Pulse TransSteel 3000c Pulse nc 130
Welding program tables 132
Welding program label on the device 132
Welding program tables for TransSteel 3000c Pulse 133
Welding program tables for TransSteel 3000c Pulse - US 135
6

Safety Instructions
Explanation of
Safety Instruc-
tions
DANGER!
Indicates an immediate danger.
▶Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
▶Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
▶Minor injury or damage to property may result if appropriate precautions are not
taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
General The device has been manufactured using state-of-the-art technology and according to
recognized 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 equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- 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, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
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EN-US

The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in
accordance with the intended purpose." The manufacturer is not responsible for any
damage resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
The manufacture shall also not be liable for faulty or incorrect work results.
Environmental
Conditions
Operation or storage of the device outside the stipulated area will be deemed as not in
accordance with the intended purpose. The manufacturer accepts no liability for any
damage resulting from improper use.
Temperature range of the ambient air:
- 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)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
Obligations of the
Operating Com-
pany
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section
"Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
Obligations of
Personnel
All persons who are assigned to work with the device must do the following before begin-
ning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and con-
firm that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can
occur in one's absence.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-
rent consumption.
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This may affect a number of device types in terms of:
- connection restrictions
-criteria regarding maximum permissible grid impedance *)
-criteria regarding the minimum required short-circuit power *)
*) both at the interface with the public grid
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
IMPORTANT! Ensure secure grounding of the grid connection!
Personal Protec-
tion and Protec-
tion of Others
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pace-
makers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during
the welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
Danger from
toxic gases and
vapors
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that cause cancer, as stated in monograph 118 from
the International Agency for Research on Cancer.
Use at-source extraction source and a room extraction system.
If possible, use a welding torch with an integrated extraction device.
Keep your head out of the welding fumes and gases.
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Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in.
- Extract them from the work area using appropriate equipment.
Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow
rate of at least 20 m³ per hour.
Use a welding helmet with air supply if there is insufficient ventilation.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the
measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
- The welding process used
Consult the corresponding material safety data sheets and manufacturer's instructions
for the components listed above.
Recommendations for exposure scenarios, risk management measures and identifying
working conditions can be found on the European Welding Association website under
Health & Safety (https://european-welding.org).
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
Danger from Fly-
ing Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro-
tected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks,
drums, or pipes if these have not been prepared in accordance with corresponding
national and international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like
are/were stored. Residues pose a risk of explosion.
Risks from grid
current and weld-
ing current
An electric shock can be fatal.
Do not touch voltage-carrying parts inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed
rollers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
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