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Fronius TRANS STEEL 3500 C0MPACT, Operating Instructions And Spare Parts List

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Contents

Safety rules ................................................................................................................................................

7

Explanation of safety symbols ..............................................................................................................

7

General .................................................................................................................................................

7

Intended purpose ..................................................................................................................................

8

Environmental conditions......................................................................................................................

8

Obligations of the operator....................................................................................................................

8

Obligations of personnel .......................................................................................................................

9

Mains connection ..................................................................................................................................

9

Protecting yourself and others ..............................................................................................................

9

Danger from toxic gases and vapours ..................................................................................................

10

Danger from flying sparks .....................................................................................................................

11

Risks from mains current and welding current......................................................................................

11

Meandering welding currents................................................................................................................

12

EMC device classifications ...................................................................................................................

13

EMC measures .....................................................................................................................................

13

EMF measures......................................................................................................................................

13

Specific danger points...........................................................................................................................

14

Danger from shielding gas cylinders.....................................................................................................

15

Safety measures at the installation location and during transport ........................................................

15

Safety measures in normal operation ...................................................................................................

16

Maintenance and repair ........................................................................................................................

17

Safety inspection...................................................................................................................................

18

Disposal ................................................................................................................................................

18

Safety symbols......................................................................................................................................

18

Data protection......................................................................................................................................

18

Copyright...............................................................................................................................................

19

General information

21

General ......................................................................................................................................................

23

Device concept .....................................................................................................................................

23

Functional principle ...............................................................................................................................

23

Application areas ..................................................................................................................................

23

Warning notices on the device..............................................................................................................

23

System components ..................................................................................................................................

25

General .................................................................................................................................................

25

Safety....................................................................................................................................................

25

Overview ...............................................................................................................................................

25

Control elements and connections

27

Description of the control panel .................................................................................................................

29

General .................................................................................................................................................

29

Safety....................................................................................................................................................

29

Synergic control panel ...............................................................................................................................

30

General .................................................................................................................................................

30

Synergic control panel ..........................................................................................................................

30

Service parameters...............................................................................................................................

32

Connections, switches and mechanical components ................................................................................

34

Front and rear .......................................................................................................................................

34

Page......................................................................................................................................................

35

Installation and commissioning

37

Minimum equipment needed for welding task............................................................................................

39

General .................................................................................................................................................

39

MIG/MAG welding, gas-cooled .............................................................................................................

39

MIG/MAG welding, water-cooled ..........................................................................................................

39

Manual metal arc welding .....................................................................................................................

39

Before installation and commissioning.......................................................................................................

40

Summary of Contents for TRANS STEEL 3500 C0MPACT

Page 1: ...T YDELLIST HITSAUSTA TRANS STEEL 3500 C0MPACT Operating Instructions Spare Parts List v 01 2012 ENG...

Page 2: ...0...

Page 3: ...h 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...

Page 4: ...2...

Page 5: ...normal operation 16 Maintenance and repair 17 Safety inspection 18 Disposal 18 Safety symbols 18 Data protection 18 Copyright 19 General information 21 General 23 Device concept 23 Functional principl...

Page 6: ...ed rollers 48 Inserting the wirespool inserting the basket type spool 49 Safety 49 Inserting the wirespool 49 Inserting the basket type spool 49 Feeding in the wire electrode 51 Feed in the wire elect...

Page 7: ...83 Restrictions 83 Setting the set up parameters 83 Welding parameters for MIG MAG welding in the Level 2 set up menu 84 Measuring welding circuit resistance r 86 General 86 Measuring welding circuit...

Page 8: ...6...

Page 9: ...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 involv...

Page 10: ...acturer likewise accepts no liability for unexpected or incorrect re sults Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose...

Page 11: ...quirement at the interface with the public mains network see Technical Data In this case the plant operator or the person using the device should check whether the device may be connected where approp...

Page 12: ...ble 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...

Page 13: ...e or outside the device During MIG MAG or TIG welding the welding wire the wirespool the drive rollers and all metal parts that are in contact with the welding wire are live Always set the wire feed u...

Page 14: ...that all components in the device are de energised If work on live parts cannot be avoided appoint a second person to switch off the main switch at the right moment If the following instructions are i...

Page 15: ...nal and international require ments Safety features power signal and data transfer lines IT and telecommunications devices measuring and calibrating devices Supporting measures for avoidance of EMC pr...

Page 16: ...pro tective equipment must therefore also be worn when reworking workpieces and steps must be taken to ensure that other people are also adequately pro tected Welding torches and other parts with a h...

Page 17: ...e according to instruc tions 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 cylinde...

Page 18: ...ines regarding the risks arising during transportation Before transporting the device allow coolant to drain completely and detach the following components Wire feed unit Wirespool Shielding gas cylin...

Page 19: ...In addition no warranty claims will be entertained The coolant can ignite under certain conditions Transport the coolant only in its original sealed containers and keep well away from any sourc es of...

Page 20: ...with normal domestic waste To comply with the European Directive 2002 96 EC on Waste Electrical and Electronic Equip ment and its implementation as national law electrical equipment that has reached t...

Page 21: ...t 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 pur chaser If you have a...

Page 22: ...20...

Page 23: ...General information...

Page 24: ......

Page 25: ...target state is maintained 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...

Page 26: ...protective equipment must be used Keep all persons not involved in the welding process at a safe dis tance Do not use the functions described here until you have thoroughly read and un derstood the f...

Page 27: ...ty Overview No Function 1 Welding torch 2 Stabilising the gas cylinder holder 3 Power source 4 Cooling unit 5 Trolley and gas cylinder holder 6 Grounding earthing cable and electrode cable WARNING Ope...

Page 28: ...26...

Page 29: ...Control elements and connections...

Page 30: ......

Page 31: ...anged Safety 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 Individ ual illustrations may also d...

Page 32: ...parameters can be adjusted manually The Synergic control panel also allows parameters to be set manually Synergic control panel No Function 1 Parameter selection button right a for selecting the foll...

Page 33: ...hen be adjusted automatically Welding current Welding current in A Before the start of welding the system automatically displays a standard val ue based on the programmed parameters During welding the...

Page 34: ...button For selecting the filler metal to be used The SP parameter is intended for addition al filler metals When a material is selected the LED behind the relevant filler metal lights up 11 Intermedia...

Page 35: ...justing dial 1 Explanation Example 1 00 4 21 Firmware version Example 2 491 Welding program configuration Example r 2 290 Number of the currently selected welding program Example iFd 0 0 Motor current...

Page 36: ...nt socket with bayonet latch used for connecting the electrode cable or grounding earthing cable during MMA welding depending on the type of electrode used 4 LocalNet connection Standardised connectio...

Page 37: ...n again shielding gas flow stops If the Gas test button is not tapped again the shielding gas flow will stop after 30 s 8 Air filter 9 Shielding gas connection Page No Function 1 Wirespool holder with...

Page 38: ...36...

Page 39: ...Installation and commissioning...

Page 40: ......

Page 41: ...the welding task are then described MIG MAG weld ing gas cooled Power source Grounding earthing cable MIG MAG welding torch gas cooled Gas connection shielding gas supply Wire electrode MIG MAG weld i...

Page 42: ...he device Mains connection The devices are designed to run on the mains voltage shown on the respective rating plates If your version of the device does not come with mains cables and plugs ready fit...

Page 43: ...dequately dimensioned electrical installations can cause serious dam age The incoming mains lead and its fuse must be dimensioned to suit the local power supply The technical data shown on the rating...

Page 44: ...ions Fitting the strain relief device or Fitting the strain relief device for Canada US To connect the mains cable proceed as follows Remove the side panel from the device Push the mains cable in far...

Page 45: ...43 g Fit the strain re lief device Fit the Canada US strain relief de vice 1 2 3 IMPORTANT Tie the phase conductors near the luster terminal using cable ties 1 2...

Page 46: ...44 3 IMPORTANT Tie the phase conductors near the luster terminal using cable ties...

Page 47: ...erating instructions Fitting the system components overview The diagram below provides an overview of how to fit the individual system compon ents For detailed information about the individu al steps...

Page 48: ...and damage When using gas cylinders Place them on a solid level surface in such a way that they remain stable Secure the gas cylinders to prevent them from falling over Fit the VR holder option Follow...

Page 49: ...th connection Safety Connecting MIG MAG manual welding torches Establishing a ground earth connection NOTE When connecting the welding torch check that all connections are connected properly all cable...

Page 50: ...ers that match the wire electrode An overview of the feed rollers available and their possible areas of use can be found in the spare parts lists Inserting replac ing feed rollers CAUTION Risk of inju...

Page 51: ...e electrode springing back CAUTION Risk of injury from falling wirespool basket type spool Make sure that the wirespool or basket type spool with adapter is fitted securely to the wire spool holder CA...

Page 52: ...ided in such a way that the bars on the spool are inside the adapter guideways CAUTION Risk of injury and impaired performance if the basket type spool top ples over because the locking ring has been...

Page 53: ...e starts again from the beginning This makes it possible to continu ously position the wire at a low wire feed speed of 1 m min or 39 37 ipm where necessary If there is no Feeder inching Gas test butt...

Page 54: ...rode is switched off If the torch trigger is kept pressed wire feeding restarts immediately without shielding gas and welding voltage and the process continues as described above Set the contact press...

Page 55: ...53 g Contact pressure standard values U grooved rollers Steel 4 5 CrNi 4 5 Tubular cored electrodes 2 3...

Page 56: ...ust the brake General Adjusting the brake NOTE After releasing the torch trigger the wirespool must stop unreeling If it continues unreeling readjust the brake 1 4 STOP 6 7 1 2 3 5 1 2 1 2 2 4 STOP OK...

Page 57: ...ectly can cause serious inju ry and damage Do not dismantle the brake Maintenance and servicing of brakes is to be carried out by trained qualified personnel only The brake is only available as a comp...

Page 58: ...d in their proper place Where applicable water connections connected Starting up Before proceeding further as described in the Welding mode section the following activ ities are required for MIG MAG s...

Page 59: ...Welding...

Page 60: ......

Page 61: ...r If it is too high the arc gets smaller and smaller and may be extinguished In order to prevent this the welding power is lowered For the MIG MAG standard synergic welding process the symbol for the...

Page 62: ...weld seams 4 step mode 4 step mode is suitable for longer weld seams WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described until you have...

Page 63: ...mode the arc starts at a low power which makes it easier to stabilise Special 4 step mode Special 4 step mode is particularly suitable for welding in higher power ranges In special 4 step mode the ar...

Page 64: ...62 GPr GPo I I S SL SL I E t I...

Page 65: ...y read and understood the following documents these operating instructions all the operating instructions for the system components especially the safe ty rules WARNING An electric shock can be fatal...

Page 66: ...ction buttons to select the welding parameters to be used to specify the welding power Sheet thickness Welding current Wire feed speed Welding voltage Use the appropriate adjusting dial to set the rel...

Page 67: ...you wish to correct Use the adjusting dials to set the selected welding parameters to the required values Welding parameter values are shown in the indicators located above them Arc length correction...

Page 68: ...MAG standard manual welding special 4 step mode corresponds to conventional 4 step mode IMPORTANT Under certain circumstances welding parameters that have been set on a system component control panel...

Page 69: ...need to be adjusted Press the Parameter selection button to select the dynamic welding parameter Use the adjusting dial to set the desired dynamic value The welding parameter value is shown in the di...

Page 70: ...erage The amperage value is shown in the left hand digital display WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described until you have tho...

Page 71: ...sfer 0 harder more stable arc 100 soft low spatter arc HotStart function To obtain optimum welding results it will sometimes be necessary to adjust the HotStart function Advantages Improved ignition e...

Page 72: ...ns to stick the power source immediately switches the welding current off After the rod electrode has been detached from the workpiece the welding operation can be continued without difficulty The ant...

Page 73: ...ave the current settings on the control panel e g The left indicator displays Pro After a short time the left indicator switches to the original value e g Release the Save button Retrieving operat ing...

Page 74: ...on the control panel must be pressed to retrieve the saved set tings using the up down welding torch Press one of the Save buttons on the control panel e g The control panel will display the saved se...

Page 75: ...73 g Number 4 Number 5...

Page 76: ...74...

Page 77: ...Setup settings...

Page 78: ......

Page 79: ...nel is now in the set up menu for the MIG MAG standard synergic welding process the last set up parameter that was selected is displayed Changing welding parameters Exiting the set up menu use the Pro...

Page 80: ...tion current Unit A Setting range 100 650 Factory setting 500 Ito Ignition time out length of wire that is fed before the safety cut out trips Unit mm in Setting range Off 5 100 Off 0 2 3 94 Factory s...

Page 81: ...personal settings in the set up menu are lost Operating points that were saved using the Save buttons are retained when the power source is reset The functions in the second level of the set up menu 2...

Page 82: ...rting current Unit of welding current Setting range 0 200 Factory setting 100 I E I current End final current Unit of welding current Setting range 0 200 Factory setting 50 t S t time Starting Startin...

Page 83: ...l the personal settings in the set up menu are lost When the power source is reset operating points that were saved using the Save buttons are not deleted but are retained in the memory The functions...

Page 84: ...AC Reset power source to factory setting Press and hold down one of the Parameter selection buttons for 2 s to restore the factory settings when PrG appears on the digital display the power source has...

Page 85: ...as testing Wire threading Wire withdrawal Blow through Setting the set up parameters Opening the set up menu The control panel is now in the set up menu the last set up parameter that was selected is...

Page 86: ...tched on Off The cooling unit is permanently switched off IMPORTANT If the FAC welding parameter is used the C C parameter is not re stored to the factory setting If the MMA welding process is selecte...

Page 87: ...est run for 180 seconds SEt Setting country specific setting standard USA Std US Unit Setting range Std US standard USA Factory setting Standard version Std measurements cm mm USA version US measureme...

Page 88: ...rkpiece Access the setup menu level 2 2nd Select parameter r Remove the gas nozzle from the welding torch Screw on the contact tube Place the contact tube down firmly on the surface of the workpiece B...

Page 89: ...parameter L is used to display the most recently calculated welding circuit in ductivity The welding circuit inductivity is calibrated at the same time as the welding circuit resistance r is calculat...

Page 90: ...88...

Page 91: ...Troubleshooting and maintenance...

Page 92: ......

Page 93: ...rch trigger is pressed Power source mains switch is ON and indicators are lit up Cause Control plug not connected in the case of a welding torch with an external con trol plug Remedy Plug in the contr...

Page 94: ...supply of cooling air Remedy Remove air filter on the rear of the housing from the side and clean Ensure that the cooling air ducts are accessible Cause The fan in the power source is faulty Remedy C...

Page 95: ...Feed rollers have the wrong contact pressure Remedy Optimise the contact pressure Wirefeed problems when using applications with long welding torch hosepacks Cause Incorrect arrangement of welding tor...

Page 96: ...alloy Remedy Use the correct protective gas shield Displayed service codes If an error message that is not described here appears on the displays proceed as follows to resolve the problem Turn the pow...

Page 97: ...triggered the external stop PHA SE Cause Phase failure Remedy Check the mains fuse the mains lead and the mains plug Err 51 Cause Mains undervoltage The mains voltage has fallen below the tolerance r...

Page 98: ...to5 xxx Note xxx stands for a temperature value Cause Overtemperature in cooling unit Remedy Allow cooling unit to cool down check that fan is on to6 xxx Note xxx stands for a temperature value Cause...

Page 99: ...value Cause Undertemperature on the output choke of the power source Remedy Place power source in a heated room and allow it to warm up tu7 xxx Note xxx stands for a temperature value Cause Undertemp...

Page 100: ...ps in Set up menu Level 2 EPG 29 Cause The required wire feed unit is not available for the selected characteristic Remedy Check plug connections for the hosepack EPG 35 Cause RL calibration failed Re...

Page 101: ...and clean inside of device with dry reduced compressed air If a lot of dust has accumulated clean the cooling air ducts Disposal Dispose of in accordance with the applicable national and local regulat...

Page 102: ...ry continuous current 100 d c 3 16 13 A Primary continuous power 10 3 kVA Cos phi 0 99 Efficiency at 250 A 90 Welding current range 10 350 A Welding current at 10 min 40 C 104 F 40 d c 3 350 A 60 d c...

Page 103: ...101 g 1 connected to public grids with 230 400 V and 50 Hz 2 PCC interface to public grid 3 d c duty cycle Wirespool diameter max 300 mm max 11 81 in Wirespool weight max 19 kg max 41 89 in...

Page 104: ...parameters Important If external system components are connected some parameters can be modifi ed on those components The power source control panel is only for display purposes 01 2011 Text and illus...

Page 105: ...al 4 step Final current 2 step special 4 step Starting current duration 2 step Final current duration 2 step Threading speed Burn back effect Length of wire before the safety cut out trips Restoring f...

Page 106: ...104...

Page 107: ...Annex...

Page 108: ...106 Spare parts list TransSteel 3500c...

Page 109: ...07 178 936 A Asl gkds l gk s l df gk s dgl k Asldhf s gkds l gk s l df gk s dgl k Asl gkds l gk s l df gk s dgl k S l dkgsl dgksdl ks l df gk s dgl k 5 6 3 1 4 1 3 2 3 3 2 1 2 2 2 3 1 1 1 2 1 3 1 2 3...

Page 110: ...108...

Page 111: ...405 U 0 8 44 0001 1406 U 0 9 1 0 44 0001 1407 U 1 2 44 0001 1408 U 1 4 1 6 44 0001 1431 R 1 2 44 0001 1432 R 1 4 44 0001 1433 R 1 6 Motorplatte Alu 4R s 42 0405 1094 Z 42 0001 3751 44 0001 1399 42 040...

Page 112: ...Maahantuonti ja myynti Pronius Oy Keisarinviitta 20 B 33960 Pirkkala 358 0 44 200 9060 info pronius fi www pronius fi...

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