Fronius TransSteel 2200 Operating Instructions Manual Download

Page: 41 / 136

Before installation and initial opera-

tion

Summary of Contents for TransSteel 2200

Page 1: ...emental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TransSteel 2200 EN US Operating instructions MIG MAG power source 42 0426 0...

Page 2: ......

Page 3: ...14 Danger Posed by Shielding Gas Leak 15 Safety Measures at the Setup Location and During Transport 15 Safety Measures in Normal Operation 16 Maintenance and repair 16 Safety Inspection 17 Disposal 1...

Page 4: ...D100 wirespool holder 61 Description of MIG MAG Operating Modes 62 2 step mode 62 4 step mode 63 Special 4 step mode 64 Spot welding 65 2 step stitch welding 66 4 step stitch welding 67 MIG MAG Stand...

Page 5: ...ring the welding circuit resistance 107 General 107 Measuring the welding circuit resistance MIG MAG welding 107 Measuring the welding circuit resistance stick welding 108 Displaying the welding circu...

Page 6: ...Special voltage 128 Explanation of the Term Duty Cycle 128 TransSteel 2200 129 TransSteel 2200 MV 130 Welding program tables 133 TSt 2200 welding program table 133 6...

Page 7: ...e 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 weld...

Page 8: ...e energy quality of the grid due to their cur rent consumption This may affect a number of device types in terms of connection restrictions criteria regarding maximum permissible grid impedance criter...

Page 9: ...ting a device to the public grid The residual current circuit breaker recommended for the device by the manufacturer can be found in the technical data Personal Protec tion and Protec tion of Others Y...

Page 10: ...t 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 inte...

Page 11: ...temporary backing or cover must completely cover the entire area between the body and the ground potential All cables and leads must be secured undamaged insulated and adequately dimen sioned Replace...

Page 12: ...ents e g insulation against electrically conductive floors or electrically conductive mounts Observe the following when using electrical distributors double headed retainers etc Even the electrode of...

Page 13: ...e health of persons close by e g those with pacemakers and hearing aids Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the weldin...

Page 14: ...efeeder hoisting attachment MIG MAG and TIG devices If the device is equipped with a carrier belt or handle then this is used exclusively for transport by hand The carrier belt is not suitable for tra...

Page 15: ...e is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m per hour Please observe the safety and maintenance information for the shielding gas cylin der or the main gas suppl...

Page 16: ...Only use appropriate original coolant from the manufacturer Do not mix original coolant from the manufacturer with other coolants Only connect system components from the manufacturer to the cooling u...

Page 17: ...locate the approved collection and recycling facilities in your area Ignoring this European Directive may have potentially adverse affects on the environment and your health Safety Symbols Devices wi...

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Page 19: ...General information 19...

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Page 21: ...e that the desired target state is maintained Power limita tion function The power source has a Power limitation safety feature This function is only available for the MIG MAG standard synergic weldin...

Page 22: ...Application areas MIG MAG welding TIG welding Manual metal arc welding 22...

Page 23: ...k S ldkg sldgk sdlks ldfgk s dgl k Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk 5 6 3 1 4 1 3 2 3...

Page 24: ...nd tools away from moving parts such as Gears Feed rollers Wirespools and wire electrodes Do not reach into rotating gears of the wire drive or into rotating drive parts Covers and side panels must on...

Page 25: ...0160 Welding is dangerous To ensure that this device can be used correctly and safely the following basic requirements must be met Adequate welding qualifications Appropriate protective equipment Kee...

Page 26: ...from moving parts such as Gears Feed rollers Wirespools and wire electrodes Do not reach into rotating gears of the wire drive or into rotating drive parts Covers and side panels must only be opened...

Page 27: ...tric shock can be fatal 1 1 Wear dry insulating gloves Do not touch the wire electrode with bare hands Do not wear wet or damaged gloves 1 2 Use a base that is insulated from the floor and work area t...

Page 28: ...ot weld on drums or closed containers 4 Arc rays can burn the eyes and injure the skin 4 1 Wear headgear and protective goggles Use ear protection and wear a shirt col lar with button Use a welding he...

Page 29: ...Operating controls and connections 29...

Page 30: ...30...

Page 31: ...ally the safety rules Control panel 4 5 3 2 1 1 Spot welding indicator The spot welding indicator lights up if Spot welding stitch welding mode is selected The SPt parameter spot welding time stitch w...

Page 32: ...or welding current and welding voltage are stored the HOLD indicator lights up 5 Intermediate arc indicator A spatter prone intermediate arc occurs between the dip transfer arc and the spray arc The i...

Page 33: ...ergic parameter means that all other synergic parameters are set automatically Welding current in amperes synergic parameter 1 Before welding begins the device automatically displays a standard value...

Page 34: ...fer Harder and more stable arc 0 Neutral arc Soft and low spatter arc Real Energy Input2 For displaying the energy applied during the welding operation 1 If one of these parameters is selected in the...

Page 35: ...ion dial left For changing the sheet thickness welding current and wire speed parameters and for changing parameters in the Setup menu 10 Wire threading button For threading the wire into the torch ho...

Page 36: ...4 T Special 4 step mode Spot welding stitch welding 15 Wire diameter button For selecting the wire diameter to be used 16 Save button 2 For saving an EasyJob 17 Process button For selecting the weldi...

Page 37: ...gs cannot be adjusted on the control panel Parameter settings can be displayed It is possible to switch between EasyJobs if an EasyJob was selected before the keylock was activated Activating deactiva...

Page 38: ...bayonet latch Used for Connecting the grounding cable or polarity reverser for MIG MAG welding depending on the wire electrode used Connecting the electrode cable or grounding cable for manual metal...

Page 39: ...ehind these vents 10 Mains cable with strain relief Not prefitted on all models 11 TIG shielding gas connection socket For the shielding gas supply for the current socket 2 Side view 2 1 3 1 D100 wire...

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Page 41: ...Before installation and initial opera tion 41...

Page 42: ...42...

Page 43: ...ree of protection IP 23 This means Protection against penetration by solid foreign bodies with diameters 12 mm 0 49 in Protection against spraywater at any angle up to 60 from the vertical The device...

Page 44: ...liance these must be installed according to national standards Fuse protection for the grid lead can be found in the technical data CAUTION An inadequately dimensioned electrical installation can lead...

Page 45: ...ller generator may be used when not welding at full power NOTE The generator apparent power SGEN must not be less than the maximum apparent power S1max of the power source When single phase devices ar...

Page 46: ...c setting Power source fuse rating Welding current limitation 230 V Std 10 A MIG MAG welding max 145 A 110 A at 100 SMAW max 125 A 90 A at 100 TIG welding max 180 A 135 A at 100 230 V Std 13 A MIG MAG...

Page 47: ...at 100 SMAW max 150 A 120 A at 100 TIG welding max 200 A 160 A at 100 230 V Std 16 A MIG MAG welding max 210 A 150 A at 100 SMAW max 180 A 130 A at 100 TIG welding max 230 A 170 A at 100 240 V US 15 A...

Page 48: ...mains fuse protection selected on the power source limits the power drawn in from the grid and in turn the possible welding current This prevents the automatic circuit breaker e g in the fuse box from...

Page 49: ...g duration without the automatic circuit breaker tripping If the precalculated weld time is exceeded thus causing the welding current to switch off the service code toF is displayed A countdown immedi...

Page 50: ...Fitting the Carrying Strap Fitting the carry ing strap to the power source 1 2 3 4 5 6 50...

Page 51: ...MIG MAG 51...

Page 52: ...52...

Page 53: ...ing Instructions Fit wearing parts to the torch body fit the inner liner 2 3 Unscrew the knurled screw 1 slightly so that the welding torch can be easily pushed into the welding torch connection 1 4 5...

Page 54: ...device may be damaged Always tighten the welding torch to the specified tightening torque Inserting the feed rollers In order to achieve optimum wire electrode feed the feed rollers must be suitable...

Page 55: ...Inserting the D100 wirespool 1 2 Inserting the D200 wirespool 1 2 3 55 EN US...

Page 56: ...of the wire elec trode firmly 1 2 3 4 Adjust the contact pressure as shown below Doing so will prevent deformation of the wire electrode and ensure that the wire is transported properly Standard valu...

Page 57: ...ectrode emerging unexpectedly as it is being threaded It can cause injuries Wear suitable protective goggles Keep the tip of the welding torch away from your face and body Do not point the tip of the...

Page 58: ...er Selecting the desired country specific setting The country specific setting of the power source defines the unit cm mm or inch in which the set welding parameters are displayed The country specific...

Page 59: ...rrectly connected polar ity reverser This can result in poor quality weld proper ties Connect the polarity reverser accord ing to the wire electrode being used Check the wire electrode packaging to de...

Page 60: ...ction Adjusting the brake of the D200 wirespool holder D100 wirespool holder Adjust the brake when using the wirespool holder for the first time and after changing the wirespool To do so proceed as de...

Page 61: ...right increase braking force Turn the brake to the left decrease braking force Adjusting the brake of the D100 wirespool holder CAUTION Danger from emerging wire electrode and moving parts Personal i...

Page 62: ...p mode is suitable for Tacking work Short weld seams GPr I GPo 2 step mode Explanation of symbols Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations used GPr Gas pr...

Page 63: ...e is suitable for longer weld seams GPr GPo I 4 step mode Explanation of symbols Press the torch trigger Release the torch trigger Abbreviations used GPr Gas pre flow time I Welding current GPo Gas po...

Page 64: ...kes it easier to stabilize I I S I E GPr SL SL GPo Special 4 step mode Explanation of symbols Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations used GPr Gas pre fl...

Page 65: ...oints on overlapped sheets GPr GPo SPt I Spot welding Explanation of symbols Press the torch trigger Release the torch trigger Abbreviations used GPr Gas pre flow time I Welding current SPt Spot weldi...

Page 66: ...from dropping through the parent material GPr SPt SPt SPb GPo I I 2 step stitch welding Explanation of symbols Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations u...

Page 67: ...eld seams from dropping through the parent material I I GPr SPt SPt SPb GPo 4 step stitch welding Explanation of symbols Press the torch trigger Release the torch trigger Abbreviations used GPr Gas pr...

Page 68: ...MANUAL 2 Press the Mode button to select the desired MIG MAG mode 2 step mode 4 step mode Spot welding stitch welding 3 Select and set the wire speed parameter 4 Select and set the welding voltage par...

Page 69: ...being used 4 Press the Wire diameter button to select the diameter of the wire electrode being used 5 Press the Shielding gas button to select the shielding gas being used 6 Press the Parameter select...

Page 70: ...sed to optimize the welding result Arc length correction shorter arc reduced welding voltage 0 neutral arc longer arc increased welding voltage Arc force dynamic For influencing the short circuiting d...

Page 71: ...the Setup menu spot welding time stitch welding time to the desired value 4 Set the desired parameters depending on the process MANUAL or SYNERGIC 5 Ensure that the ground earth connection has been e...

Page 72: ...7 Ensure that the ground earth connection has been established 8 Ensure that the shielding gas supply has been established Power source is ready for welding 72...

Page 73: ...TIG 73...

Page 74: ...74...

Page 75: ...Commissioning Start Up 1 2 3 4 5 75 EN US...

Page 76: ...Press the Process button to select TIG 2 Set the desired welding current When using a welding torch with a torch trigger and TIG Multi Connector plug with 2 step mode factory setting 3 Position the g...

Page 77: ...m or inch in which the set welding parameters are displayed The country specific setting can be changed in the Setup menu 2nd level Para meter SEt A description of the SEt parameter and how to adjust...

Page 78: ...s 2 Raise the tungsten electrode arc ignites 3 Release torch trigger end of welding Explanation of symbols Pull back the torch trigger and hold it in this position Release the torch trigger forwards A...

Page 79: ...torch trigger activation of intermediate lowering with reduced current I 2 5 Release torch trigger welding with main current I 1 6 Pull back and hold the torch trigger lowering to final current I E 7...

Page 80: ...the welding current in order to prevent any local overheating of the parent material tS Starting current duration tup UpSlope phase the welding current is continually increased Duration 0 5 seconds t...

Page 81: ...current I P and drops back to the base current I G after the Duty cycle dcY time This results in an average current that is lower than the set pulse current I P During pulse welding small sections of...

Page 82: ...Activating pulse welding 1 Set a value for the F P setup parameter pulse frequency Setting range 1 990 Hz For a parameter description see section Parameters for TIG welding from page 98 82...

Page 83: ...Rod Electrode 83...

Page 84: ...84...

Page 85: ...eparation 1 Check the rod electrode packaging to determine whether the rod electrode is for or welding 2 3 4 It is only necessary to connect the mains cable to the power source for multivoltage power...

Page 86: ...ting The country specific setting of the power source defines the unit cm mm or inch in which the set welding parameters are displayed The country specific setting can be changed in the Setup menu 2nd...

Page 87: ...U parameters can be set in the Setup menu For a parameter descrip tion see section Parameters for MMA Welding from page 99 Function During the specified hot current time Hti the welding current is inc...

Page 88: ...For a parameter description see section Parameters for MMA Welding from page 99 88...

Page 89: ...EasyJobs 89...

Page 90: ...90...

Page 91: ...r switches to the original value 2 Release the Save button Retrieving an EasyJob 1 To retrieve saved settings press the corresponding Save button briefly e g Num ber 1 The control panel will show the...

Page 92: ...92...

Page 93: ...Setup Menu 93...

Page 94: ...94...

Page 95: ...rocess the last selec ted setup parameter is displayed To change a parameter 1 Select the desired setup parameter using the left hand selection dial Change the setup parameter value using the right ha...

Page 96: ...set power source to factory settings Press and hold one of the Parameter selection buttons for two seconds to restore the factory settings when PrG appears on the digital display the power source has...

Page 97: ...3 94 Factory setting OFF The Ignition time out function Ito is a safety function If the power source determines that no ignition has occurred after the preset wire length has been fed wirefeeding is s...

Page 98: ...9 Factory setting 0 5 tdo DownSlope Unit seconds Setting range 0 01 9 9 Factory setting 1 I S Starting current Unit of main current Setting range 1 200 Factory setting 35 I 2 Lowering current Unit of...

Page 99: ...ting range 0 2 0 Factory setting 0 5 Ast Anti stick function Unit Setting range On OFF Factory setting On FAC Reset power source to factory settings Press and hold one of the Parameter selection butto...

Page 100: ...s now located in the 2nd level of the Setup menu of the MIG MAG standard synergic welding process the last selected setup para meter is displayed To change a parameter 1 Select the desired setup param...

Page 101: ...ay 1 to 999 Value in kJ 1000 to 9999 indicator on display 1 00 to 9 99 without unit digit e g 5270 kJ 5 27 Value in kJ 10 000 to 99 999 indicator on display 10 0 to 99 9 without unit digit or tens dig...

Page 102: ...he right hand display shows the value for the welding voltage at the same time Parameters for TIG welding SEt Country specific setting Standard USA Std US Unit Setting range Std US Standard USA Factor...

Page 103: ...fuse protection The maximum possible welding power is limited by the rating of the mains fuse protection used Unit A The available mains fuse ratings are determined by the SEt parameter setting SEt pa...

Page 104: ...104...

Page 105: ...Optimizing Weld Quality 105...

Page 106: ...106...

Page 107: ...ance for every welding process separately with the appropriate welding power leads Measuring the welding circuit resistance MIG MAG weld ing NOTE Risk of incorrect measurement of the welding circuit r...

Page 108: ...ection to the workpiece 3 Access the Setup menu 2nd level 2nd 4 Select parameter r NOTE Risk of incorrect measurement of the welding circuit resistance This can have a negative effect on the welding r...

Page 109: ...ircuit inductivity The setup parameter L is used to display the most recently calculated welding circuit inductivity The welding circuit inductivity is adjusted when the welding circuit resistance is...

Page 110: ...110...

Page 111: ...Troubleshooting and Maintenance 111...

Page 112: ...112...

Page 113: ...elect the required setup parameter Available parameters Example 1 00 4 21 Firmware version Example 2 491 Welding program configuration Example r 2 290 Number of the currently selected welding program...

Page 114: ...discharged WARNING Electrical current hazard caused by an inadequate ground conductor connection Serious personal injury and damage to property may result Always use the original housing screws in the...

Page 115: ...e Remedy Cause Remedy Cause Remedy Cause Remedy No welding current Power source switched on displays illuminate Incorrect ground connection Check ground connection for polarity Power cable in welding...

Page 116: ...ding torch gets very hot Welding torch is inadequately sized Observe duty cycle and load limits Cause Remedy Poor quality weld properties Incorrect welding parameters Check settings Poor ground earth...

Page 117: ...d then switch the power source on again If the error still persists contact the After Sales Service team Cause Remedy Err 51 Mains undervoltage Mains voltage has fallen below the tolerance range Check...

Page 118: ...ion Maintenance as required at least every two months on page 122 check whether the fan is running Cause Remedy to7 xxx Note xxx stands for a temperature value Overtemperature in the power source Allo...

Page 119: ...MAG20 voltage doubler Place power source in a heated room and allow it to warm up Cause Remedy tu7 xxx Note xxx stands for a temperature value Undertemperature in power source Place power source in a...

Page 120: ...ece if necessary set the Ito parameter in the Setup menu Cause Remedy no ARC Arc break during TIG welding Press the torch trigger repeatedly clean the surface of the workpiece Cause Remedy EPG 17 The...

Page 121: ...devices and components involved so they cannot be switched back on After opening the device use a suitable measuring instrument to check that electric ally charged components such as capacitors have b...

Page 122: ...ffect of compressed air This can result in damage to property Do not bring the air nozzle too close to electronic parts 1 Remove the right hand device side panel as viewed from the front and blow the...

Page 123: ...Removing Stiff Drive Rollers Removing a stiff drive roller If a drive roller is difficult to remove by hand the knurled screw on the D100 brake can be used to remove it 1 2 3 4 123 EN US...

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Page 125: ...Appendix 125...

Page 126: ...126...

Page 127: ...tion at a wire speed of 10 m min 1 0 mm wire electrode dia meter 1 2 mm wire electrode dia meter 1 6 mm wire electrode dia meter Steel wire electrode 3 7 kg h 5 3 kg h 9 5 kg h Aluminum wire electrode...

Page 128: ...the year of production 28 11 17 year of production 2017 Special voltage For devices designed for special voltages the technical data on the rating plate applies Explanation of the Term Duty Cycle The...

Page 129: ...current range I2 MIG MAG 10 210 A MMA 10 180 A TIG 10 230 A Welding current at 10 min 40 C 104 F 30 60 100 MIG MAG U1 230 V 210 A 170 A 150 A Welding current at 10 min 40 C 104 F 35 60 100 MMA U1 230...

Page 130: ...ded for use in residential areas in which the electrical power is supplied via a public low voltage grid The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies...

Page 131: ...210 A MMA 10 180 A TIG 10 230 A Welding current at 10 min 40 C 104 F 30 60 100 MIG MAG U1 120 V 15 A 105 A 95 A 80 A U1 120 V 20 A 135 A 120 A 105 A U1 230 V 210 A 170 A 150 A Welding current at 10 m...

Page 132: ...efficiency at 210 A 24 5 V 89 1 Interface to a 230 V 50 Hz public grid 2 Only applies to USA If an automatic circuit breaker is used instead of a fuse the current time charac teristic of the automati...

Page 133: ...0 9 mm 035 1 0 mm 040 1 2 mm 045 Steel Ar 15 20 CO CrNi Stainless Ar 2 5 CO CuSi Ar 100 AlMg Ar 100 AlSi Ar 100 Rutil E71T Ar 15 20 CO Rutil E71T CO 100 Metall Cored Ar 15 20 CO Self shielded no Gas 3...

Page 134: ...134...

Page 135: ...135 EN US...

Page 136: ...INTERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and lo...

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