Castolin Eutectic totalarc2 3000, Operating Manual, Page: 30 / 161

30
Dear Castolin Customer
This brochure is intended to familiarise you with how to
operate and maintain your TotalArc² 3000 / 4000 / 5000. You
will find it well worthwhile to read through the manual carefully
and to follow all the instructions it contains. This will help you
to avoid operating errors - and the resultant malfunctions. Your
machine will repay you by giving you constant operational
readiness for many years to come.
Contents
Dear Castolin Customer .................................................... 30
Safety rules .......................................................................... 31
General remarks ............................................................. 31
Utilisation for intended purpose only .............................. 31
Obligations of owner/operator ........................................ 31
Obligations of personnel ................................................. 31
Personal protective equipment ....................................... 31
Hazards from noxious gases and vapours .................... 31
Hazards from flying sparks ............................................. 31
Hazards from mains and welding current ...................... 31
Particular danger spots ................................................... 31
Informal safety precautions ............................................. 31
Safety precautions at the installation location ................ 32
Vagrant welding currents ................................................. 32
Safety precautions in normal operation ......................... 32
Safety inspection ............................................................. 32
Alterations to the welding machine ................................ 32
Spares and wearing parts ............................................... 32
Calibration of welding machines .................................... 32
CE-marking ...................................................................... 32
Copyright .......................................................................... 32
General remarks ................................................................. 33
Principle of the digital family of machines ...................... 33
Machine concept .............................................................. 33
Areas of use ..................................................................... 33
Description of control panel ............................................... 34
Controls and connections .................................................. 36
Power source TotalArc² 3000 .......................................... 36
Power source TotalArc² 4000 / 5000 ............................... 37
DS III wire feeder ............................................................. 38
RC 2 remote-control unit ................................................. 39
RC 4 remote-control unit ................................................. 39
Torch operating modes ...................................................... 40
4-step mode .................................................................... 40
2-step mode .................................................................... 40
4-step mode (aluminium) ............................................... 40
Spot welding .................................................................... 41
Starting to use the welding machine .................................. 42
Utilisation for intended purpose only .............................. 42
Machine set-up regulations ............................................ 42
Mains connection ............................................................. 42
Mounting the optional wirefeeder fixture ......................... 42
Fixing the interconnecting cable
to the power source ......................................................... 42
Connecting the interconnecting cable
to the wirefeeder .............................................................. 43
Mounting / connecting the gas cylinder .......................... 43
Installing the welding torch ............................................. 43
Starting up the cooling unit .............................................. 43
Setting the shielding-gas rate ........................................ 44
Mounting the wire spool .................................................. 44
Feeding in the wire electrode ......................................... 44
Changing the feed rollers ............................................... 44
MIG/MAG welding ................................................................ 45
Manual .............................................................................. 46
Ignition time-out function ................................................. 46
Special 2-step mode for automatic interface ................. 46
Manual electrode welding .................................................. 47
TIG Welding ......................................................................... 47
Job mode ............................................................................ 48
Creating a Job ................................................................. 48
Copy / overwrite Job ........................................................ 48
Deleting a Job .................................................................. 49
Retrieving a Job ............................................................... 49
The set-up menu ................................................................. 50
Accessing the setup-menu ............................................. 50
Changing the parameter ................................................. 50
Exit the set-up menu ....................................................... 50
Parameters for "MIG/MAG standard /
pulsed-arc welding" process .......................................... 50
Parameters for "TIG welding" ......................................... 50
Parameters for "Manual electrode welding" process .... 50
Special 2-step mode for robot interface ......................... 51
Parameters for "Aluminium 4-step" mode ..................... 51
Parameters for "Spot welding" mode ............................. 51
2nd - Second level of Set-up Menu ................................. 51
PushPull Unit ...................................................................... 52
Error codes on the display .............................................. 52
Troubleshooting .................................................................. 53
Error messages on the displays .................................... 53
TotalArc² 3000 / 4000 / 5000 power source ................... 54
Care and maintenance ....................................................... 55
Technical Data .................................................................... 56
Total Arc² 3000 / 4000 / 5000 power source ................... 56
Cooling unit (built in power source) ............................... 56
DS III wire feeder ............................................................. 56
Circuit Diagram
Spare parts list
Warning! The machine may only be put into service by
trained personnel, and only in accordance with the
technical directions. Before you start using the machine,
you
must read the section headed "Safety rules".