FRO­NIUS TransSteel 3500 Syn User manual

Operating
instructions
TransSteel 3500 Syn
TransSteel 5000 Syn
42,0426,0258,EN 017-02052022
EN Operating instructions

Contents
Safety rules 7
Explanation of safety notices 7
General 7
Proper use 8
Environmental conditions 8
Obligations of the operator 8
Obligations of personnel 8
Mains connection 9
Protecting yourself and others 9
Danger from toxic gases and vapours 10
Danger from flying sparks 10
Risks from mains current and welding current 11
Meandering welding currents 12
EMC Device Classifications 12
EMC measures 12
EMF measures 13
Specific hazards 13
Requirement for the shielding gas 14
Danger from shielding gas cylinders 14
Danger from escaping shielding gas 15
Safety measures at the installation location and during transport 15
Safety measures in normal operation 16
Commissioning, maintenance and repair 16
Safety inspection 17
Disposal 17
Safety symbols 17
Data protection 17
Copyright 17
General information 19
General 21
Device concept 21
Functional principle 21
Application areas 21
Warning notices on the device 21
Welding processes, procedures and welding characteristics for MIG/MAG welding 23
General 23
Welding characteristics 23
Summary of MIG/MAG standard synergic welding 23
Short description of arc air gouging 23
System components 24
General 24
Safety 24
Overview 24
Options 26
General 26
Machine interface 26
Gas preheater CO2 connection 26
Keylock switch 27
VRD: safety function 27
VRD: safety principle 28
Control elements and connections 29
Synergic control panel 31
General 31
Safety 31
Synergic control panel 32
Service parameters 35
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Keylock 36
Connections, switches and mechanical components 37
TSt 3500/5000 Syn power source 37
Installation and commissioning 39
Minimum equipment needed for welding task 41
General 41
Gas-cooled MIG/MAG welding 41
MIG/MAG welding, water-cooled 41
MMA welding 41
Before installation and commissioning 42
Safety 42
Utilisation for intended purpose only 42
Setup regulations 42
Mains connection 43
Connecting the mains cable 44
Safety 44
General 44
Stipulated mains cables and strain-relief devices 44
Connecting the mains cable 45
Fitting the Europe strain-relief device 45
Fitting the Canada/US strain-relief device 46
Generator-powered operation 48
Generator-powered operation 48
Start-up 49
General 49
Information on system components 49
Assembling the system components (overview) 49
Placing the wirefeeder on the power source 50
Fitting the interconnecting hosepack strain-relief device 51
Connecting the interconnecting hosepack 51
Connecting the gas cylinder 52
Establishing a ground earth connection 53
Connecting MIG/MAG welding torches 54
Inserting/replacing feed rollers 54
Inserting the wirespool 55
Inserting the basket-type spool 56
Feeding in the wire electrode 57
Setting the contact pressure 59
Adjusting the brake 59
Design of the brake 60
Welding 61
Power limitation 63
Safety function 63
MIG/MAG modes 64
General 64
Symbols and their explanations 64
2-step mode 65
4-step mode 65
Special 4-step mode 66
Spot welding 66
2-step stitch welding 67
4-step stitch welding 67
MIG/MAG welding 68
Safety 68
Preparatory work 68
Overview 68
MIG/MAG standard synergic welding 69
MIG/MAG standard synergic welding 69
Corrections during welding 70
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MIG/MAG standard manual welding 71
General 71
Available parameters 71
MIG/MAG standard manual welding 71
Corrections during welding 72
Spot and stitch welding 73
General 73
Spot welding 73
Stitch welding 74
EasyJob mode 76
General 76
Storing EasyJob operating points 76
Retrieving EasyJob operating points 76
Deleting EasyJob operating points 76
Retrieving EasyJob operating points on the Up/Down welding torch 76
MMA welding 78
Safety 78
Preparation 78
MMA welding 78
Corrections during welding 79
HotStart function 80
Anti-stick function 80
Arc Air Gauging (TSt 5000 Syn) 81
Safety 81
Preparation 81
Arc air gouging 82
Easy Documentation 85
General 87
General 87
Documented welding data 87
New CSV file 88
PDF report / Fronius signature 88
Activating / deactivating Easy Documentation 89
Setting the date and time 89
Deactivating Easy Documentation 89
Setup settings 91
Setup menu 93
General remarks 93
Operation 93
Setup parameters for MIG/MAG standard manual welding 93
Setup parameters for MIG/MAG standard synergic welding 95
Setup parameters for MMA welding 96
Setup menu - Level 2 98
Operation (level 2 Setup menu) 98
Parameters for MIG/MAG welding in the Setup menu level 2 99
Parameters for manual metal arc (MMA) welding in the Setup menu level 2 101
Measuring welding circuit resistance r 102
General 102
Measuring welding circuit resistance (MIG/MAG welding) 102
Retrieving the welding circuit inductivity L 104
General 104
Displaying welding circuit inductivity 104
Laying the hosepacks correctly 104
Troubleshooting and maintenance 105
Troubleshooting 107
General 107
Safety 107
Fault diagnosis 107
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Displayed service codes 110
Displayed service codes in connection with OPT Easy Documentation 115
Care, maintenance and disposal 117
General 117
Safety 117
At every start-up 117
Every 2 months 117
Every 6 months 118
Disposal 118
Appendix 119
Average consumption values during welding 121
Average wire electrode consumption during MIG/MAG welding 121
Average shielding gas consumption during MIG/MAG welding 121
Average shielding gas consumption during TIG welding 121
Technical data 122
Special voltages 122
Explanation of the term "duty cycle" 122
TSt 3500 Syn 123
TSt 3500 MV Syn 124
TSt 5000 Syn 125
TSt 5000 MV Syn 126
Overview with critical raw materials, year of production of the device 127
Welding program tables 128
TransSteel 3500 Syn - Euro welding program tables 128
TransSteel 5000 Syn - Euro welding program tables 130
TransSteel 3500 Syn - US welding program tables 132
TransSteel 5000 Syn - US welding program tables 134
TransSteel 3500 Yard welding program tables 136
TransSteel 5000 Yard welding program tables 137
Standard value tables for MIG/MAG standard manual welding 138
Settings tables 138
6

Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General 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 en-
vironmental 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 sec-
tion 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!
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Proper use 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 in-
structions
-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 set-
ting.
The manufacturer likewise accepts no liability for inadequate or incorrect 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 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.)
Obligations of
the operator
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 sec-
tion "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.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
-to observe the basic instructions regarding safety at work and accident pre-
vention
-to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
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Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Mains connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number device types 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 mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Protecting your-
self and others
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 us-
ing 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 protect-
ive 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 in-
jury
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 vi-
cinity:
-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 cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
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Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
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. Ensure that there is a ventilation rate of
at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
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.
The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:
-Metals used for the workpiece
-Electrodes
-Coatings
-Cleaners, degreasers, etc.
-Welding process used
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
Danger from fly-
ing sparks
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 accord-
ance with the relevant national and international standards.
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