Fronius TransSteel 2700c Operating Instructions Manual Download Page 3

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Contents

Safety rules

Explanation of safety notices

General

Proper use

Environmental conditions

Obligations of the operator

Obligations of personnel

Mains connection

Protecting yourself and others

Danger from toxic gases and vapours

Danger from flying sparks

Risks from mains current and welding current

Meandering welding currents

EMC Device Classifications

EMC measures

EMF measures

Specific hazards

Requirement for the shielding gas

Danger from shielding gas cylinders

Danger from escaping shielding gas

Safety measures in normal operation

Commissioning, maintenance and repair

General information

Warning notices on the device

VRD: safety principle

Control elements and connections

Synergic Central control panel

General

Safety

Synergic control panel

Service-Parameter

Keylock

Connections, switches and mechanical components

Front and rear sides, TSt 2700c

Front and rear sides, TSt 3500c

Side view

Installation and commissioning

Minimum equipment needed for welding task

General

MIG/MAG welding, gas-cooled

Summary of Contents for TransSteel 2700c

Page 1: ...free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TransSteel 2700c TransSteel 2700c MV TransSteel 3500c EN Operating instructions MIG MAG powe...

Page 2: ......

Page 3: ...operation 15 Commissioning maintenance and repair 15 Safety inspection 16 Disposal 16 Safety symbols 16 Data protection 16 Copyright 17 General information 19 General 21 Device concept 21 Functional p...

Page 4: ...ion 50 Welding time in single phase operation 50 Fitting connecting the system components 52 Information on system components 52 Mounting on the trolley 52 Connecting the gas cylinder 52 Connecting a...

Page 5: ...A welding in the Setup menu level 2 89 Measuring welding circuit resistance r 90 General 90 Measuring welding circuit resistance MIG MAG welding 90 Displaying welding circuit inductivity L 92 General...

Page 6: ...Quick reference 114 TSt 2700c welding program table 116 TSt 2700c USA welding program table 117 TransSteel 3500 Euro welding program tables 118 TransSteel 3500 US welding program tables 119 6...

Page 7: ...evice 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 instructi...

Page 8: ...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 alti...

Page 9: ...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 regulatio...

Page 10: ...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...

Page 11: ...ins supply with ground conductor and a connector system with ground conductor contact for proper operation Operation of the device on a mains supply without ground conductor and on a socket without gr...

Page 12: ...though a device complies with the standard limit values for emis sions it may affect the application area for which it was designed e g when there is sensitive equipment at the same location or if th...

Page 13: ...wire feed unit and wear suitable protective goggles Never touch the workpiece during or after welding risk of burns Slag can jump off cooling workpieces The specified protective equipment must theref...

Page 14: ...tent 25 mg m Use filters if necessary Danger from shielding gas cyl inders Shielding gas cylinders contain gas under pressure and can explode if damaged As the shielding gas cylinders are part of the...

Page 15: ...ing of safety devices Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane Only the manufacturer s original coolant is suitable for us...

Page 16: ...n can be obtained from your service centre They will provide you on request with any documents you may require Disposal Do not dispose of this device with normal domestic waste To comply with the Euro...

Page 17: ...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 purchaser If you have any sugg...

Page 18: ...18...

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

Page 20: ...20...

Page 21: ...Power 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 repr...

Page 22: ...40 0006 3035 inside Welding is dangerous The following basic requirements must be met welders must be sufficiently qualified suitable protective equipment must be used all persons not involved in the...

Page 23: ...t operation Possible serious injury and damage to property Do not use the functions described here until you have read and completely under stood these Operating Instructions Do not use the functions...

Page 24: ...1 2 3 4 5 6 TSt 3500c 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 24...

Page 25: ...s 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 for the currently selected welding p...

Page 26: ...VRD is active again The output voltage is limited to 35 V once more 26...

Page 27: ...Control elements and connections 27...

Page 28: ...28...

Page 29: ...available at all times All the parameters can be adjusted manually The Synergic control panel also allows paramet ers to be set manually NOTE Due to software updates you may find that your device has...

Page 30: ...length correction for correcting the arc length Welding voltage in V Before the start of welding the system automatically displays a standard value based on the programmed parameters During welding t...

Page 31: ...usting dial left for changing the sheet thickness welding current and wire feed speed para meters as well as changing parameters in the Setup menu 5 Save buttons Easy Job for saving up to 5 operating...

Page 32: ...MIG MAG standard synergic weld ing process then the synergic function ensures that all other parameters includ ing the welding voltage parameter are adjusted automatically The Real Energy Input displa...

Page 33: ...lculating hiring fees for war ranty purposes etc 2nd 2nd menu level for service engineers Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the control pane...

Page 34: ...ting 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 b...

Page 35: ...r grounding 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...

Page 36: ...e 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 2700c only with the setup para...

Page 37: ...Installation and commissioning 37...

Page 38: ...38...

Page 39: ...lding 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 wat...

Page 40: ...other form of usage is deemed not in accordance with the intended purpose The manufacturer shall not be held liable for any damages arising from such usage Utilisation in accordance with the intended...

Page 41: ...vices are designed for the mains voltage specified on the rating plate If your ver sion of the appliance does not come with mains cables and plugs ready fitted these must be fitted in accordance with...

Page 42: ...A TSt 2700c 3 x 200 V AWG 12 4G2 5 TSt 2700c 3 x 230 240 V AWG 14 4G2 5 TSt 2700c 3 x 380 400 V AWG 14 4G2 5 3 x 460 V AWG 14 4G2 5 TSt 3500c 3 x 380 400 V AWG 12 4G2 5 3 x 460 V AWG 12 4G2 5 Canada...

Page 43: ...vice To connect the mains cable proceed as follows 1 Remove the side panel from the device 2 Push the mains cable in far enough to make it possible to connect the ground con ductor and the phase condu...

Page 44: ...5 IMPORTANT Tie the phase conductors near the strain relief device using cable ties Fitting the strain relief device TSt 2700c 1 1 2 Nm 2 3 4 44...

Page 45: ...5 IMPORTANT Tie the phase conductors near the strain relief device using cable ties Fitting the strain relief device TSt 2700c MV 1 3 5 Nm 2 3 4 45 EN...

Page 46: ...Tie the phase conductors near the strain relief device using cable ties Fitting the strain relief device TSt 3500c 1 2 1 2 Nm 3 4 IMPORTANT Tie the phase conductors near the luster terminal using cab...

Page 47: ...Fitting the Canada U S strain relief device TSt 3500c 1 2 3 4 IMPORTANT Tie the phase conductors near the luster terminal using cable ties 47 EN...

Page 48: ...mb SGEN S1max x 1 35 A smaller generator may be used when not welding at full power IMPORTANT The generator apparent power SGEN must always be higher than the max imum apparent power S1max of the powe...

Page 49: ...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 in si...

Page 50: ...operation For single phase operation duty cycle values are given in the chapter Technical data depending on the existing fuse value and the welding current The percentage rates of this duty cycle val...

Page 51: ...20 140 150 160 170 180 190 200 I2 A 1 2 3 4 5 6 7 8 9 10 11 1 Mains fuse protection 10 A 2 Mains fuse protection 13 A 3 Mains fuse protection 15 A 4 Mains fuse protection 16 A 5 Mains fuse protection...

Page 52: ...ut by trained and qualified personnel All instructions in the section headed Safety rules must be observed The following diagram shows an overview of how the individual system components are put toget...

Page 53: ...are supplied with an adapter for the gas hose Seal male thread spacers on the gas solenoid valve using suitable means before screwing on the adapter Test the adapter to ensure that it is gas tight Con...

Page 54: ...n unlocking the lever keep fingers away from the area to the left and right of the lever In order to achieve optimum wire electrode feed the feed rollers must be suitable for the diameter and alloy of...

Page 55: ...caused by the wire electrode springing back CAUTION Risk of injury from falling wirespool basket type spool Make sure that the wirespool or basket type spool with basket type spool adapter is fitted...

Page 56: ...g in the wire electrode CAUTION Risk of injury from springiness of spooled wire electrode When inserting the wire electrode into the 4 roller drive hold the end of the wire electrode firmly to avoid i...

Page 57: ...cond the wire feed speed increases over the next 1 5 seconds Hold the button for more than 2 5 seconds after 2 5 seconds the wire is fed at a constant rate equal to the wire feed speed set for the Fdi...

Page 58: ...e feeder creep speed depending on the welding pro gram for the first 3 seconds After these 3 seconds wirefeeding is briefly interrupted The welding system detects that the welding process should not s...

Page 59: ...Steel 4 5 CrNi 4 5 Tubular cored electrodes 2 3 Adjusting the brake NOTE After releasing the torch trigger the wirespool must stop unreeling If it continues unreeling readjust the brake 4 STOP 6 7 1...

Page 60: ...ult in severe personal injury and damage to property Do not dismantle the brake Maintenance and servicing of brakes is to be carried out by trained quali fied personnel only The brake is only availabl...

Page 61: ...quisites The following conditions must be satisfied before the device is started Welding torch connected Feed rollers inserted Wirespool or basket type spool with adapter inserted Wire electrode fed i...

Page 62: ...62...

Page 63: ...Welding 63...

Page 64: ...64...

Page 65: ...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 the Wi...

Page 66: ...ribed here until you have fully read and understood all of the Operating Instructions for the system components in particular the safety rules For details of the meaning settings setting range and uni...

Page 67: ...p mode I I S I E GPr SL SL GPo Special 4 step mode allows the starting and final current to be configured in addition to the advantages of 4 step mode Spot welding I I GPr GPo SPt t The Spot welding m...

Page 68: ...short weld seams on thin sheets to prevent the weld seams from dropping through the base material 4 step stitch welding I I GPr SPt SPt SPb GPo 4 step stitch welding The 4 step stitch welding mode is...

Page 69: ...s in particular the safety rules WARNING An electric shock can be fatal If the power source is connected to the mains electricity supply during installation there is a high risk of very serious injury...

Page 70: ...ystem component TR 2000 or TR 3000 remote control on the control panel of the power source 6 Use the Parameter selection buttons to select the welding parameters to be used to specify the welding powe...

Page 71: ...ch any conductive or earthed parts e g housing 10 Press the torch trigger and start welding Corrections dur ing welding To obtain the best possible welding results the arc length correction and dynami...

Page 72: ...ue MIG MAG stand ard manual weld ing 1 Press the Process button to select the desired welding process MIG MAG standard manual welding 2 Press the Mode button to select the desired MIG MAG mode 2 step...

Page 73: ...ows the required gas flow rate Tap the Gas test button again CAUTION Risk of injury and damage from electric shock and from the wire electrode emer ging from the torch When pressing the torch trigger...

Page 74: ...mine whether the rod elec trodes are for or welding 3 Plug the grounding earthing cable into the or current socket depending upon which type of electrode is to be used and latch it by turning it clock...

Page 75: ...e welding parameter value is shown in the digital display located above it HotStart function To obtain optimum welding results it will sometimes be necessary to adjust the HotStart function Advantages...

Page 76: ...urn out is prevented by activating the anti stick function If the rod electrode begins to stick the power source immediately switches the welding current off After the rod electrode has been detached...

Page 77: ...d settings Deleting EasyJob operating points 1 Press 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...

Page 78: ...Number 2 Number 3 Number 4 Number 5 78...

Page 79: ...Setup settings 79...

Page 80: ...80...

Page 81: ...s button to select the MIG MAG standard syn ergic welding process 2 Press and hold the Mode button 3 Press the Process button 4 Release the Mode and Process buttons The control panel is now in the Set...

Page 82: ...t s Setting range AUt 0 0 3 Factory setting AUt IGC Ignition current Unit A Setting range 100 650 Factory setting 500 Ito Length of wire that is fed before the safety cut out trips Unit mm in Setting...

Page 83: ...Setup parameters for MIG MAG standard syner gic welding Min and max are used for setting ranges that differ according to power source weld ing program etc GPr Gas pre flow time Unit s Setting range 0...

Page 84: ...pause time Unit s Setting range OFF 0 1 10 in 0 1 s increments Factory setting OFF FAC Factory reset power source to factory settings Press and hold down one of the Parameter selection buttons for 2...

Page 85: ...tory settings when PrG appears on the digital display the power source has been reset IMPORTANT When the power source is reset all personal settings are lost When the power source is reset operating p...

Page 86: ...g 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 1 Press and hold the...

Page 87: ...the Setup menu level 2 C C Cooling unit Control only with connected cooling unit Unit Setting range Aut On OFF Factory setting Aut Aut The cooling unit cuts out after a 2 minute welding off time IMPO...

Page 88: ...e the full range of values 1 kJ 99999 kJ cannot be displayed on the three digit display the following display format has been selected Value in kJ indicator on display 1 to 999 1 to 999 1000 to 9999 1...

Page 89: ...e Setup menu level 2 r r resistance welding circuit resistance in mOhm See Measuring welding circuit resistance r from page 90 L L inductivity welding circuit inductivity in microhenry see Displaying...

Page 90: ...sistance for every welding process separately with the appropriate welding power leads Measuring weld ing circuit resist ance MIG MAG welding NOTE Risk of incorrect measurement of the welding circuit...

Page 91: ...10 Fit the gas nozzle back onto the welding torch 91 EN...

Page 92: ...parameter L is used to display the most recently calculated welding circuit inductivity The welding circuit inductivity is calibrated at the same time as the welding circuit resistance is measured Det...

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

Page 94: ...94...

Page 95: ...mains switch to the O position Unplug the device from the mains Put up an easy to understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring device ch...

Page 96: ...ing torch Cause Remedy Cause Remedy Nothing happens when the torch trigger is pressed Power source mains switch is on power source ON indication is lit up on the power source indications on wire feed...

Page 97: ...t After Sales Service Cause Remedy Cause Remedy Cause Remedy Cause Remedy Cause Remedy Irregular wire feed speed Braking force has been set too high Loosen the brake Hole in the contact tip is too nar...

Page 98: ...ode that has been inserted Wrong wire alloy or wrong wire diameter Check weldability of the base material The shielding gas is not suitable for this wire alloy Use the correct shielding gas Cause Reme...

Page 99: ...connected Only one remote control unit may be connected check the system configur ation Cause Remedy Err IP The power source control has detected a primary overvoltage Check the mains voltage If the...

Page 100: ...n effect If a change in supply from three phase to single phase occurs during weld ing display PHA SE1 or from single phase to three phase display PH ASE 3 the welding operation stops Check the mains...

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

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

Page 103: ...ion is active current did not start flowing before the length of wire specified in the set up menu had been fed The power source safety cut out has tripped Shorten the free wire end press the torch tr...

Page 104: ...The following activities must only be carried out by trained and qualified personnel All instructions in the section headed Safety rules must be observed At every start up Check mains plug mains cable...

Page 105: ...with dry reduced com pressed air 2 If a lot of dust has accumulated clean the cooling air ducts WARNING An electric shock can be fatal Risk of electric shock from improperly connected ground cables a...

Page 106: ...umption 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 Aluminium wire elect...

Page 107: ...es specified on the rating plate are based on an ambient temperature of 40 C If the ambient temperature is higher either the D C or output must be reduced accord ingly Example Welding at 150 A at 60 D...

Page 108: ...A Welding current at 10 min 40 C 104 F 30 270 A 60 210 A 100 170 A Output voltage range according to standard character istic U2 MIG MAG 14 5 34 9 V Output voltage range according to standard charact...

Page 109: ...rrent I1max 22 1 A Mains fuse protection 25 A slow blow Mains voltage U1 3 x 380 V Max effective primary current I1eff 7 A Max primary current I1max 13 1 A Mains fuse protection 15 A slow blow Apparen...

Page 110: ...protection 30 A slow blow Apparent power 6 74 kVA Mains voltage tolerance 10 15 Mains frequency 50 60 Hz Max permitted mains impedance Zmax on PCC1 142 mOhm Welding current range I2 MIG MAG Rod elect...

Page 111: ...x h 687 x 276 x 445 mm 27 1 x 10 9 x 17 5 in Weight 30 kg 66 1 lb Max shielding gas pressure 7 bar 101 49 psi Wire feed speed 1 25 m min 40 980 ipm Wire drive 4 roller drive Wire diameter 0 8 1 6 mm 0...

Page 112: ...Rod electrode 10 350 A 10 350 A Welding current at 10 min 40 C 104 F 40 350 A 60 300 A 100 250 A Output voltage range according to standard character istic U2 MIG MAG Rod electrode 14 5 38 5 V 20 4 3...

Page 113: ...An overview of which critical raw materials are contained in this device can be found at the following Internet address www fronius com en about fronius sustainability To calculate the year of produc...

Page 114: ...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 para...

Page 115: ...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 setup 2n...

Page 116: ...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 052 1 6 mm 1 16 SP Ar 8 12 CO2 Ar 15 25 C...

Page 117: ...etal 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 Ar 3 6 O2 Ar 8 12 CO2 100 CO2 Ar 8 12 CO2 Ar 15 25...

Page 118: ...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 FCW Metal cored Metal cored Se...

Page 119: ...teel 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 052 1 6 mm 1 16 SP Ar 10 CO2 Ar...

Page 120: ...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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