Fronius TransSteel 2500c Operating Instructions Manual Download Page 41

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Minimum equipment needed for welding task

General

Depending on which welding process you intend to use, a certain minimum equipment lev-
el will be needed in order to work with the power source.
The welding processes and the minimum equipment levels required for 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-
ing, water-cooled

Power source

Cooling unit including coolant

Grounding (earthing) cable

MIG/MAG welding torch, water-cooled

Gas connection (shielding gas supply)

Wire electrode

Manual metal arc
welding

Power source

Grounding (earthing) cable

Electrode holder

Rod electrode

Summary of Contents for TransSteel 2500c

Page 1: ...t Charging Perfect Welding Solar Energy 42 0426 0107 EN 034 09012018 TransSteel 2500c TransSteel 2500c MV TransSteel 2700c TransSteel 2700c MV TransSteel 3500c Operating Instructions MIG MAG Power sou...

Page 2: ...2...

Page 3: ...essential prerequisites for excellent results Explanation of safety symbols If you see any of the symbols depicted in the Safety rules chapter special care is re quired DANGER Indicates immediate and...

Page 4: ...4...

Page 5: ...Commissioning maintenance and repair 18 Safety inspection 18 Disposal 18 Safety symbols 19 Data protection 19 Copyright 19 General information 21 General 23 Device concept 23 Functional principle 23 A...

Page 6: ...ingle phase operation 52 Fitting connecting the system components 54 Information on system components 54 Mounting on the trolley 54 Connecting the gas cylinder 54 Connecting a MIG MAG welding torch 55...

Page 7: ...MMA welding in the Setup menu level 2 90 Measuring welding circuit resistance r 91 General 91 Measure the welding circuit resistance r 91 Displaying welding circuit inductivity L 92 General 92 Displa...

Page 8: ...8...

Page 9: ...t 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...

Page 10: ...atures 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 Before using the device all persons...

Page 11: ...tection behind the protec tive visor wear stout footwear that provides insulation even in wet conditions protect the hands with suitable gloves electrically insulated and providing protection against...

Page 12: ...t 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 in jury or fire We...

Page 13: ...ssary provide an adequate earth connection for the workpiece Switch off unused devices Wear a safety harness if working at height Before working on the device switch it off and pull out the mains plug...

Page 14: ...susceptible to interference from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avo...

Page 15: ...d Welding torches and other parts with a high operating temperature must be al lowed to cool down before handling Special provisions apply in areas at risk of fire or explosion observe relevant nation...

Page 16: ...ring mains are being used Shielding gas cylinders contain gas under pressure and can explode if dam aged As the shielding gas cylinders are part of the welding equipment they must be handled with the...

Page 17: ...device ensure that no one is likely to be endangered Check the device at least once a week for obvious damage and proper func tioning of safety devices Always fasten the shielding gas cylinder secure...

Page 18: ...power source be calibrated during the same 12 month period A safety inspection should be carried out by a qualified electrician after any changes are made after any additional parts are installed or a...

Page 19: ...ements of the rele vant standards for Canada and the USA The user is responsible for the safekeeping of any changes made to the fac tory settings The manufacturer accepts no liability for any deleted...

Page 20: ...20...

Page 21: ...General information...

Page 22: ......

Page 23: ...ower limitation safety feature This means that the power source can be operated at the power limit without compromising process safety This results in a precise welding process a high degree of reprod...

Page 24: ...on the rating plate Welding is dangerous The following basic requirements must be met welders must be sufficiently quali fied suitable protective equipment must be used all persons not involved in the...

Page 25: ...ety Overview TSt 2500c TSt 2700c No Function 1 Welding torch 2 Gas cylinder holder stabiliser 3 Power source 4 Trolley and gas cylinder holder 5 Grounding earthing cable and electrode cable WARNING Op...

Page 26: ...3500c No Function 1 Welding torch 2 Gas cylinder holder stabiliser 3 Power source 4 Cooling unit TSt 3500c only 5 Trolley and gas cylinder holder 6 Grounding earthing cable and electrode cable 1 2 3...

Page 27: ...ion work coffer dams Trenches Mines Rain Areas partly submerged by water Spraywater areas The VRD option reduces the voltage between the electrode and the workpiece In safe conditions the indicator fo...

Page 28: ...28 In MMA welding mode Within 0 3 seconds of end of welding VRD is active again The output voltage is limited to 35 V once more...

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

Page 30: ......

Page 31: ...rs can be adjusted manually The Synergic control panel also allows parameters to be set manually Safety Synergic control panel NOTE Due to software updates you may find that your device has certain fu...

Page 32: ...g parameters and for changing parameters in the Setup menu The relevant symbol lights up when a welding parameter is selected Sheet thickness in mm or in If the welding current to be selected is not k...

Page 33: ...s test button to set the required gas flow rate at the pressure regulator Tap button once shielding gas flows out Tap button again shielding gas flow stops If the Gas test button is not tapped again t...

Page 34: ...lected welding process indica tor is simultaneously an additional indicator The indicator is permanently lit The Voltage Reduction Device VRD is active and is limiting the output voltage to less than...

Page 35: ...retrieved any assigned Save button can be retrieved provided that an assigned Save button was selected when the keylock was enabled Activate deactivate the keylock as follows Keylock activated The mes...

Page 36: ...ecting the electrode cable or grounding earthing cable during MMA welding depending on the type of electrode used 3 LocalNet connection Standardised connection for remote control 4 Current socket with...

Page 37: ...ounding earthing cable during MMA welding depending on the type of electrode used 3 Current socket with bayonet latch used for connecting the electrode cable or grounding earthing cable during MMA wel...

Page 38: ...for holding standard wirespools with a max diameter of 300 mm 11 81 in and a max weight of up to 19 kg 41 89 lbs 2 4 roller drive 3 LED wirespool interior lighting TSt 2500c TSt 2700c only with the se...

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...

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: ...s Remove the side panel from the device Push the mains cable in far enough to make it possible to connect the ground conduc tor and the phase conductors to the block terminal properly Fit ferrules to...

Page 45: ...strain relief device to secure the mains cable Fit the side panel of the device Fitting the strain relief device TSt 2500c MV TSt 2700c single phase operation 1 2 3 4 5 4 5 6 1 3 5 Nm 2 3 2 N L2 L1 4...

Page 46: ...46 Fitting the strain relief device TSt 2500c TSt 2700c 1 2 3 4 5 1 1 2 Nm 2 3 4 5 IMPORTANT Tie the phase conductors near the strain relief device using cable ties...

Page 47: ...47 EN Fitting the strain relief device TSt 2500c MV TSt 2700c MV 1 2 3 4 5 1 3 5 Nm 2 3 4 5 IMPORTANT Tie the phase conductors near the strain relief device using cable ties...

Page 48: ...tting the strain relief device TSt 3500c 1 2 3 4 Fitting the Cana da U S strain re lief device TSt 3500c 1 2 1 2 1 2 Nm 3 4 IMPORTANT Tie the phase conductors near the luster terminal using cable ties...

Page 49: ...49 EN 3 4 3 4 IMPORTANT Tie the phase conductors near the luster terminal using cable ties...

Page 50: ...he maxi mum apparent power S1max of the power source When using single phase devices with a 3 phase generator note that the specified gener ator apparent power is often only available as a whole acros...

Page 51: ...n and commissioning section Connecting the mains cable Fitting the strain relief device single phase operation The following table shows which mains voltages and fuse values limit the welding current...

Page 52: ...hase operation For single phase operation duty cycle values are given in the chapter Technical data de pending on the existing fuse value and the welding current The percentage rates of this duty cycl...

Page 53: ...end Mains fuse protection 10 A Mains fuse protection 13 A Mains fuse protection 15 A Mains fuse protection 16 A Mains fuse protection 20 A t min 130 120 140 150 160 170 180 190 200 I2 A 1 2 3 4 5 6 7...

Page 54: ...individual steps please refer to the corresponding op erating instructions for the system components TSt 2500c TSt 2700c TSt 3500c Connecting the gas cylinder WARNING Work that is carried out incorrec...

Page 55: ...torch 1 NOTE US devices TSt 3500c only are supplied with an adapter for the gas hose Seal male thread spacers on the gas solenoid valve using suitable means be fore screwing on the adapter Test the a...

Page 56: ...e diameter and alloy of the wire being welded An overview of the available feed rollers can be found in the spare parts lists 1 2 3 4 1 CAUTION Risk of injury if the feed roller holders fly upwards Wh...

Page 57: ...falling wirespool basket type spool Make sure that the wirespool or basket type spool with basket type spool adapter is fitted secure ly to the wirespool holder CAUTION Risk of injury and material da...

Page 58: ...ode into the 4 roller drive hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back CAUTION Risk of damage to the welding torch from sharp end of wire electrode D...

Page 59: ...to be fed in At the same time the gas solenoid valve closes and the welding voltage on the wire electrode is switched off If the torch trigger is kept pressed wire feeding restarts immediately withou...

Page 60: ...y that the wire electrode is not de formed but nevertheless ensures proper wirefeed 1 Standard values U grooved rollers Steel 4 5 CrNi 4 5 Tubular cored elec trodes 2 3 NOTE After releasing the torch...

Page 61: ...ment incorrectly 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 availabl...

Page 62: ...their proper place Where applicable water connections connected Commissioning Before proceeding further as described in the Welding mode section the following activ ities are required for the MIG MAG...

Page 63: ...Welding...

Page 64: ......

Page 65: ...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 selected MIG MAG standard synergic welding process the symbol for...

Page 66: ...e operating instructions for the system components especially the safe ty rules Press the torch trigger Hold the torch trigger Release the torch trigger GPr Gas pre flow time I S Starting current can...

Page 67: ...onger weld seams Special 4 step mode Special 4 step mode allows the starting and final current to be configured in addition to the advantages of 4 step mode Spot welding The Spot welding mode is suita...

Page 68: ...n sheets to prevent the weld seams from dropping through the base material 4 step stitch welding The 4 step stitch welding mode is suitable for welding longer weld seams on thin sheets to prevent the...

Page 69: ...ly 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 70: ...the power source is switched off and on again To display the actual welding current during welding select the welding current parameter Open the gas cylinder valve Setting the shielding gas flow rate...

Page 71: ...selection buttons to select the parameters 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 indicato...

Page 72: ...standard manual welding Press the Mode button to select the desired MIG MAG mode 2 step mode 4 step mode In MIG MAG standard manual welding special 4 step mode corresponds to conventional 4 step mode...

Page 73: ...ing welding To obtain the best possible welding results the arc force dynamic parameter will some times need to be adjusted Press the Parameter selection button to select the arc force dynamic paramet...

Page 74: ...is applies even if the power source is switched off and on again in the meantime WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described unti...

Page 75: ...ects Largely prevents slag inclusions For details on setting the available welding parameters please refer to Setup parame ters Setup menu level 2 Legend Hti Hot current time 0 2 s factory setting 0 5...

Page 76: ...ess and hold the relevant Save button to delete the memory content of that Save button e g The left indicator displays Pro After a short time the left indicator switches to the original value Keep the...

Page 77: ...77 EN Number 3 Number 4 Number 5...

Page 78: ...78...

Page 79: ...Setup settings...

Page 80: ......

Page 81: ...rol panel is now in the Setup menu for the MIG MAG standard synergic welding process the last setup parameter that was selected is displayed Changing welding parameters Exiting the Setup menu Use the...

Page 82: ...ly Unit of welding current Setting range 0 200 Factory setting 100 I E I current End Final current special 4 step mode only Unit of welding current Setting range 0 200 Factory setting 50 t S t time St...

Page 83: ...al display the power source has been reset IMPORTANT When the power source is reset all personal settings in the Setup menu are lost Operating points that were saved using the Save buttons are retaine...

Page 84: ...current Unit of welding current Setting range 0 200 Factory setting 50 t S t time Starting Starting current duration Unit s Setting range OFF 0 1 9 9 Factory setting OFF t E t time End Final current t...

Page 85: ...settings in the Setup 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 in the sec ond l...

Page 86: ...y 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 87: ...lding start up the Power source ready signal will not be emitted Gas testing Threading the wire Wire withdrawal Blow through Configuring the setup parameters Accessing the Setup menu The control panel...

Page 88: ...elect the required setup parameter 8 Change the value of the setup parameter using the Parameter selection buttons or the right hand adjusting dial 9 Press and hold the Mode button Press the Process b...

Page 89: ...d the cooling unit is always switched off even if the switch is in the On position C t Cooling Time only with connected cooling unit Time from when flow monitoring is triggered until the no H2O servic...

Page 90: ...ends on the welding voltage The welding voltage can be ad justed to suit individual needs in Synergic operation If the ALC parameter is set to OFF the welding voltage cannot be adjusted The welding vo...

Page 91: ...onnection to the workpiece Accessing the Level 2 2nd Setup menu Select parameter r Remove the gas nozzle from the welding torch Screw on the contact tip Place the contact tip flush against the workpie...

Page 92: ...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 calculate...

Page 93: ...Troubleshooting and maintenance...

Page 94: ......

Page 95: ...torch trigger is pressed Power source mains switch is ON and indicators are lit up Cause Only for welding torches with an external control plug The control plug is not plugged in Remedy Plug in the co...

Page 96: ...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 97: ...e wrong contact pressure Remedy Optimise the contact pressure Wirefeed problems when using applications with long welding torch hosepacks Cause Incorrect arrangement of welding torch hosepack Remedy A...

Page 98: ...emedy Use the correct shielding gas 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 power source mains...

Page 99: ...e still remains switch off the power source wait for 10 seconds and then switch the power source on again if the error keeps recurring contact After Sales Service Err PE Cause The earth current watchd...

Page 100: ...ingle phase to three phase display PH ASE 3 the welding operation stops Remedy Check the mains fuse mains cable and mains plug Switch off the power source wait 10 seconds and switch the power source b...

Page 101: ...rce Remedy Allow power source to cool down check air filter and clean if necessary check that fan is on to2 xxx Note xxx stands for a temperature value Cause Overtemperature in the secondary circuit o...

Page 102: ...he booster located in the power source Remedy Place power source in a heated room and allow it to warm up tu2 xxx Remark xxx stands for a temperature value Cause Undertemperature in the power source s...

Page 103: ...active no current started flowing before the length of wire specified in the set up menu had been fed The power source safety cut out has tripped Remedy Shorten the wire end press the torch trigger ag...

Page 104: ...ed clean air filter using dry compressed air or by washing it Every 6 months Dismantle device side panels and clean inside of device with dry reduced compressed air If a lot of dust has accumulated cl...

Page 105: ...105 EN Disposal Dispose of in accordance with the applicable national and local regulations...

Page 106: ...ted at its rated output without overheating Example Welding at 150 A at 60 D C Welding phase 60 of 10 minutes 6 minutes Cooling phase remaining time 4 minutes After the cooling phase the cycle begins...

Page 107: ...utput voltage range according to standard characteristic U2 MIG MAG 14 5 34 5 V Rod electrode 20 4 30 0 V Open circuit voltage U0 peak U0 r m s 41 V Apparent power at 400 V AC 7 76 kVA Protection clas...

Page 108: ...ance Zmax on PCC1 142 mOhm Welding current range I2 MIG MAG 10 250 A Rod electrode 10 250 A Welding current range I2 in single phase operation MIG MAG 10 220 A Rod electrode 10 180 A Welding current a...

Page 109: ...power at 400 V AC 7 76 kVA Protection class IP 23 Insulation class B Overvoltage category III Pollution level according to IEC60664 3 Safety symbols S CE CSA Efficiency at 220 A and 25 0 V 87 Dimensi...

Page 110: ...Output voltage range according to standard characteristic U2 MIG MAG 14 5 34 9 V Rod electrode 20 4 34 9 V Open circuit voltage U0 peak U0 r m s 41 V Apparent power at 400 V AC 8 66 kVA Protection cla...

Page 111: ...rance 10 15 Mains frequency 50 60 Hz Max permitted mains impedance Zmax on PCC1 142 mOhm Welding current range I2 MIG MAG 10 270 A Rod electrode 10 270 A Welding current range I2 in single phase opera...

Page 112: ...4 27 2 V Open circuit voltage U0 peak U0 r m s 42 V Protection class IP 23 Insulation class B Overvoltage category III Pollution level according to IEC60664 3 Safety symbols S CE CSA Efficiency at 220...

Page 113: ...voltage range according to standard characteristic U2 MIG MAG 14 5 38 5 V Rod electrode 20 4 35 0 V Open circuit voltage U0 peak U0 r m s 60 V Apparent power at 400 V AC 15 87 kVA Degree of protectio...

Page 114: ...as 2 T 2 step mode 4 T 4 step mode S 4 T Special 4 step mode Selecting the process Setting the mode MANUAL MIG MAG standard manual SYNERGIC Standard synergic STICK Manual metal arc welding Correcting...

Page 115: ...p 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 factory s...

Page 116: ...el dynamic Steel dynamic Steel root Steel root Steel root Steel root Stainless Steel root Rutil FCW Rutil FCW Basic FCW Basic FCW Metal cored 100 CO2 0 8 mm 030 0 9 mm 035 1 0 mm 040 1 2 mm 045 1 4 mm...

Page 117: ...eel root Rutil FCW Rutil FCW Basic FCW Basic FCW Metal cored 100 CO2 0 8 mm 030 0 9 mm 035 1 0 mm 040 1 2 mm 045 1 4 mm 052 1 6 mm 1 16 SP Ar 8 12 CO2 Ar 15 25 CO2 Ar 3 6 O2 Ar 8 12 CO2 Ar 15 25 CO2 A...

Page 118: ...A C A C B C 1 Pos 1 1 1 2 2 2 3 3 3 3 4 4 5 5 6 6 7 Steel Steel Steel Steel Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic FCW Basic FC...

Page 119: ...c Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic FCW Basic FCW Metal cored 100 CO2 0 8 mm 030 0 9 mm 035 1 0 mm 040 1 2 mm 045 1 4 mm 0...

Page 120: ...1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of...

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