Fronius TransSteel 3000c Pulse Operating Instructions Manual Download Page 48

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Commissioning

Safety

WARNING!

An electric shock can be fatal.

If the power source is connected to the grid during installation, there is a danger of seri-
ous personal injury and property damage.

▶

Only carry out work on the device when the power source's power switch is in the -
O - position.

▶

Only carry out work on the device when the power source has been disconnected
from the grid.

WARNING!

Danger of electrical current due to electrically conductive dust in the device.

This can result in severe personal injury and damage to property.

▶

Only operate the device if an air filter is fitted. The air filter is a very important safety
device for achieving IP 23 protection.

General

Commissioning is described with reference to a manual, water-cooled MIG/MAG applica-
tion.

Information on
system compon-
ents

The steps and activities described below include references to various system compon-
ents, such as
-

Trolley

Upright bracket

Cooling units

Welding torches, etc.

For more detailed information about installing and connecting the system components,
please refer to the appropriate Operating Instructions for the system components.

Summary of Contents for TransSteel 3000c Pulse

Page 1: ...ntal chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TransSteel 3000c Pulse EN US Operating instructions MIG MAG power source 42 04...

Page 2: ......

Page 3: ...Safety Measures in Normal Operation 15 Maintenance and repair 16 Safety Inspection 16 Disposal 16 Safety Symbols 17 Data backup 17 Copyright 17 General information 19 General 21 Device concept 21 Oper...

Page 4: ...h connection 49 Inserting changing feed rollers 50 Inserting the wirespool 51 Installing the basket type spool 52 Feed in the wire electrode 53 Setting the contact pressure 55 Adjust the brake 56 Desi...

Page 5: ...ng data 95 New CSV file 96 PDF report Fronius signature 96 Activating deactivating Easy Documentation 97 Activating Easy Documentation 97 Set the date and time 97 Deactivating Easy Documentation 98 Se...

Page 6: ...23 Every 2 Months 123 Every 6 Months 124 Disposal 124 Appendix 125 Average consumption values during welding 127 Average wire electrode consumption during MIG MAG welding 127 Average shielding gas con...

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: ...C to 40 C 14 F to 104 F During transport and 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 Ambient air free of dust acids corrosive gases or substanc...

Page 9: ...y helmet Cuffless pants Protective clothing involves the following Protecting the face and eyes from UV radiation heat and flying sparks with a face guard featuring a regulation compliant filter Weari...

Page 10: ...o welding is taking place close the valve of the shielding gas cylinder or the main gas supply Danger from Fly ing Sparks Flying sparks can cause fires and explosions Never undertake welding near flam...

Page 11: ...m with ground conductor contact for proper operation Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national r...

Page 12: ...vice 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 the site where...

Page 13: ...body devices with wirefeeder and use suitable protective goggles Do not touch the workpiece during or after welding burning hazard Slag may fly off cooling workpieces Therefore also wear regulation c...

Page 14: ...condensation point 20 C Max oil content 25 mg m Use filters if necessary Danger from Shielding Gas Cylinders Shielding gas cylinders contain compressed gas and may explode if damaged Shielding gas cy...

Page 15: ...nce of 0 5 m 1 ft 7 69 in to allow cooling air to circulate unhindered Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when tr...

Page 16: ...e of them or that they satisfy safety requirements Use only original spare and wearing parts also applies to standard parts Do not carry out any modifications alterations etc to the device without the...

Page 17: ...3 EU The full text of the EU Declaration of Conformity is available on the follow ing website http www fronius com Devices marked with the CSA test mark satisfy the requirements of the relevant stand...

Page 18: ...18...

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

Page 20: ...20...

Page 21: ...cessor control the entire welding process During the welding process the actual data is measured continuously and the device responds immediately to any changes Control algorithms ensure that the desi...

Page 22: ...lding qualifications Appropriate protective equipment Exclusion of unauthorized persons Do not use the functions described here until you have fully read and understood the fol lowing documents These...

Page 23: ...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 24: ...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 25: ...arc A short circuit free transfer of material in the high power range Brief description of MIG MAG pulsed synergic welding MIG MAG pulsed synergic MIG MAG pulsed synergic welding is a pulsed arc proc...

Page 26: ...re personal injury and damage to property Do not use the functions described here until you have fully read and understood the Operating Instructions Do not use the functions described here until you...

Page 27: ...Operating controls and connections 27...

Page 28: ...28...

Page 29: ...ware updates certain functions may be available for your device but not described in these Operating Instructions or vice versa In addition individual figures may also differ slightly from the operati...

Page 30: ...ion button right a for selecting the following parameters Arc length correction For correcting the arc length Welding voltage in V Before welding begins the device automatically displays a standard va...

Page 31: ...tion button left a for selecting the following parameters Sheet thickness Sheet thickness in mm or in If the welding current to be selected is not known it is sufficient to enter the sheet thickness T...

Page 32: ...e buttons For saving up to 5 operating points 6 Process button For selecting the welding process MIG MAG standard manual welding MIG MAG standard synergic welding MIG MAG pulsed synergic welding TIG w...

Page 33: ...the button once shielding gas flows out Tap the button again shielding gas flow stops If the Gas test button is not tapped again the shielding gas flow will stop after 30 s 13 SF spot stitch SynchroPu...

Page 34: ...ng process if one of these parameters is selected then the syner gic function ensures that all other parameters including the welding voltage para meter are adjusted automatically In conjunction with...

Page 35: ...ter Available parameters 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 654 32 1 65...

Page 36: ...ameter settings can be retrieved Any assigned Save button can be retrieved provided that an assigned Save but ton was selected when the keylock was enabled Activating deactivating the keylock 1 Keyloc...

Page 37: ...g the TIG welding torch 4 Current socket with bayonet latch Used for Connecting the polarity reverser or grounding cable for MIG MAG welding depending on the wire electrode used Connecting the electro...

Page 38: ...cket For the shielding gas supply for the current socket 5 Side view 2 1 No Function 1 Wirespool holder with brake For holding standard wirespools with a max diameter of 300 mm 11 81 in and a max weig...

Page 39: ...Installation and Startup 39...

Page 40: ...40...

Page 41: ...Gas cooled MIG MAG welding torch Gas connection shielding gas supply Wire electrode Water cooled MIG MAG welding Power source Cooling unit including coolant Grounding cable Water cooled MIG MAG weldin...

Page 42: ...to be not in accordance with the intended purpose The manufacturer shall not be liable for any damage resulting from such improper use Intended use also means Following all instructions in the Operat...

Page 43: ...s are designed for the grid voltage stated on the rating plate If the mains cable or mains plug has not been attached to your version of the appliance these must be installed according to national sta...

Page 44: ...circuits and damage to property may result Fit ferrules to all phase conductors and the ground conductor of the stripped mains cable Connecting the mains cable If no mains cable is connected a mains c...

Page 45: ...Fitting the strain relief device 1 2 1 2 Nm 3 4 IMPORTANT Tie the phase conductors near the block terminal using cable ties Fitting the strain relief device for Canada US 1 2 45 EN US...

Page 46: ...3 4 IMPORTANT Tie the phase conductors near the block terminal using cable ties 46...

Page 47: ...and U1 according to the device rating plate and technical data The generator apparent power SGEN needed is calculated using the following rule of thumb SGEN S1max x 1 35 A smaller generator can be us...

Page 48: ...evice This can result in severe personal injury and damage to property Only operate the device if an air filter is fitted The air filter is a very important safety device for achieving IP 23 protectio...

Page 49: ...ge The following activities must only be carried out by trained and qualified personnel Please note the information in the Safety instructions chapter The following diagram shows an overview of how th...

Page 50: ...clamping lever keep fingers away from the area to the left and right of the clamping lever 2 1 4 4 5 6 3 1 6 3 3 1 2 4 5 7 2 CAUTION Danger due to open feed rollers Serious injuries may result After...

Page 51: ...es caused by the wire electrode springing back CAUTION Risk of injury from falling wirespool Ensure that the wirespool is fitted securely to the wirespool holder CAUTION Danger of injury and property...

Page 52: ...itted securely to the wirespool holder NOTE When working with basket type spools only use the basket type spool adapter supplied with the device CAUTION Danger of injury and property damage if the bas...

Page 53: ...o the welding torch from sharp end of wire electrode Deburr the end of the wire electrode well before threading in 1 2 CAUTION Risk of injury from emerging wire electrode When pressing the Wire thread...

Page 54: ...lect 2 step mode 2 Set the Ito parameter to Off in the Setup menu CAUTION Danger of injury and damage from electric shock and from the wire electrode emerging from the torch When you press the torch t...

Page 55: ...result in severe damage to property and poor weld properties Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding 1 1 Contact pres...

Page 56: ...1 2 2 4 STOP OK 1 3 3 Design of the Brake WARNING Danger from incorrect installation Serious personal injury and damage to property may result Do not dismantle the brake Maintenance and servicing of...

Page 57: ...time After switching on the power source for the first time the date and time must be set For this purpose the power source changes to the second level of the service menu the yEA parameter is selecte...

Page 58: ...58...

Page 59: ...MIG MAG welding 59...

Page 60: ...60...

Page 61: ...s smaller and smaller and may be extinguished In order to prevent this the welding power is lowered If the MIG MAG standard synergic welding or MIG MAG pulsed synergic welding pro cess is selected the...

Page 62: ...le welding parameters e g gas pre flow time please refer to the Setup parameters chapter Symbols and explanations Press the torch trigger Hold the torch trigger Release the torch trigger GPr Gas pre f...

Page 63: ...2 step mode t I I GPr GPo 2 step mode is suitable for Tacking work Short weld seams Automatic and robot operation 4 step mode t I I GPr GPo 4 step mode is suitable for longer weld seams 63 EN US...

Page 64: ...ep mode 1 Select 2 step mode 2 In the Setup menu set the t S starting current duration and t E final current dura tion parameters to a value 0 Special 2 step mode is activated 3 In the Setup menu set...

Page 65: ...the SPt spot welding time duration GPo gas post flow time If the torch trigger is pressed again before the end of the spot welding time SPt the process is canceled immediately 2 step stitch welding GP...

Page 66: ...welding I I GPr SPt SPt SPb GPo 4 step stitch welding The 4 step stitch welding mode is suitable for welding longer weld seams on thin sheets to prevent the weld seams from dropping through the paren...

Page 67: ...out work on the device when the power source s power switch is in the O position Only carry out work on the device when the power source has been disconnected from the grid Preparation 1 Connect the...

Page 68: ...desired welding process MIG MAG standard synergic welding MIG MAG pulsed synergic welding 5 Press the Mode button to select the desired MIG MAG mode 2 step mode 4 step mode Special 4 step mode IMPORTA...

Page 69: ...ld ing current during welding select the welding current parameter 8 Open the gas cylinder valve 9 Adjust quantity of shielding gas Tap the Gas test button Turn the adjusting screw on the bottom of th...

Page 70: ...ith aluminum alloys whose weld seams should have a rippled appearance This effect is achieved using a welding power that changes between two operating points The two operating points result from a pos...

Page 71: ...SynchroPulse works when used in Special 4 step mode I S starting current phase SL Slope I E crater fill phase v wire speed I vD Al 2 L S L S dFd 1 F v I S dFd t I E SynchroPulse mode of operation 71 E...

Page 72: ...ual welding Wire speed 1 m min 39 37 ipm maximum wire speed e g 25 m min 984 25 ipm Welding voltageTransSteel 4000 Pulse 15 5 31 5 V TransSteel 5000 Pulse 14 5 39 V Arc force dynamic For influencing t...

Page 73: ...e welding current parameter The actual welding current is shown on the digital display during welding 7 Open the gas cylinder valve 8 Adjust quantity of shielding gas Tap the Gas test button Turn the...

Page 74: ...p menu set the spot welding time stitch welding time SPt IMPORTANT Stitch pause time SPb OFF must be set for spot welding 2 Only for synergic welding Use the corresponding buttons to select the filler...

Page 75: ...st flow time 5 Raise the welding torch Stitch welding 1 In the Setup menu set the stitch pause time SPb Stitch welding is enabled The Int Interval parameter is displayed in the Setup menu 2 In the Set...

Page 76: ...that the wire electrode does not touch any conductive or grounded parts e g housing etc 10 Stitch welding Procedure for stitch welding 1 Keep the welding torch vertical 2 Depending on the stitch mode...

Page 77: ...reads Pro After a short time the left display switches to the original value 2 Release the Save button Retrieving Easy Job operating points 1 To retrieve saved settings press the corresponding Save bu...

Page 78: ...e Save buttons on the control panel e g The control panel will show the saved settings The Save buttons can now be selected using the buttons on the Up Down welding torch Vacant Save buttons are skipp...

Page 79: ...TIG welding 79...

Page 80: ...80...

Page 81: ...Only carry out work on the device when the power source s power switch is in the O position Only carry out work on the device when the power source has been disconnected from the grid Preparation 1 Se...

Page 82: ...cond time lag IMPORTANT Under certain circumstances it may not be possible to change welding parameters that have been set on the control panel of a system component such as wirefeeder or remote contr...

Page 83: ...torch up until the tungsten electrode touches the workpiece 3 Pull back the torch trigger and hold it in this position Shielding gas flows 4 Raise the welding torch and tilt it into the normal positio...

Page 84: ...lse 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...

Page 85: ...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 105 85 EN US...

Page 86: ...86...

Page 87: ...Manual Metal Arc Welding 87...

Page 88: ...88...

Page 89: ...property Only carry out work on the device if the power switch is in the O position Only carry out work on the device when it has been disconnected from the grid Preparation 1 Set the power switch to...

Page 90: ...3 Press the Parameter selection button to select the amperage parameter 4 Use the selection dial to set the desired amperage The amperage value is displayed on the left hand digital display All parame...

Page 91: ...rrent set welding current Function During the specified hot current time Hti the welding current is increased to a cer tain value This value HCU is higher than the selected welding current IH Anti Sti...

Page 92: ...92...

Page 93: ...Easy Documentation 93...

Page 94: ...94...

Page 95: ...n of power source Firmware of PC board DOCMAG Easy Documentation Document version https www easydocu weldcube com A PFDF report of selected welding data can be created under this link Nr Meter Start b...

Page 96: ...ched The welding data are documented as average values in the main process phase and for each welding operation New CSV file A new CSV file is generated When the USB thumb drive is disconnected and re...

Page 97: ...d Easy Documentation remains activated 2 Acknowledge the display by pressing the arrow key 3 Set the date and time Set the date and time Setting the date and time is carried out in the 2nd level of th...

Page 98: ...rameter FAC the date and time remain stored Deactivating Easy Documenta tion CAUTION Risk of data loss or data damage due to premature disconnection of the USB thumb drive Do not disconnect the USB th...

Page 99: ...Setup Settings 99...

Page 100: ...100...

Page 101: ...sses Accessing the Setup menu MANUAL STD SYNERGIC PULSE SYNERGIC 1 Press the Process button to select the MIG MAG standard synergic welding process MANUAL STD SYNERGIC PULSE SYNERGIC 2T 4T 2 The contr...

Page 102: ...e and special 4 step mode Unit of welding current Setting range 0 200 Factory setting 50 t S Starting current duration only for special 2 step mode Unit s Setting range 0 0 9 9 Factory setting 0 0 t E...

Page 103: ...F dFd Delta wire feed Offset welding power for SynchroPulse option Unit m min ipm Setting range 0 3 0 118 1 Factory setting 2 78 7 AL2 Arc length correction for upper SynchroPulse operating point Unit...

Page 104: ...ectrode Unit 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...

Page 105: ...are also reset HCU HotStart current Unit Setting range 100 200 Factory setting 150 Hti Hot current time Unit s Setting range 0 2 0 Factory setting 0 5 ASt Anti stick Unit Setting range On OFF Factory...

Page 106: ...flow time Unit seconds Setting range 0 9 9 Factory setting 9 9 tAC Tacking Unit seconds Setting range OFF 0 1 9 9 Factory setting OFF FAC Reset power source to factory settings Press and hold one of...

Page 107: ...RGIC 1 Press the Process button to select the MIG MAG standard synergic welding process MANUAL STD SYNERGIC PULSE SYNERGIC 2T 4T 2 The control panel is now located in the Setup menu of the MIG MAG sta...

Page 108: ...he coolant temperature and flow monitoring options have been installed in the cooling unit the cooling unit cuts out as soon as the return flow temperature drops below 50 C but at the earliest after a...

Page 109: ...ergic welding Setting range On OFF Factory setting OFF The arc length depends on the welding voltage The welding voltage can be indi vidually adjusted in synergic operation If the ALC parameter is set...

Page 110: ...service code is output For example if there are air bubbles in the cooling system the cooling unit will not cut out until the end of this preset time Unit s Setting range 5 25 Factory setting 10 IMPO...

Page 111: ...cooling unit cuts out after a 2 minute welding off time IMPORTANT If the coolant temperature and flow monitoring options have been installed in the cooling unit the cooling unit cuts out as soon as th...

Page 112: ...resistance for every welding process separately with the appropriate welding power leads Measuring the welding circuit resistance MIG MAG weld ing NOTE Incorrect measurement of the welding circuit re...

Page 113: ...d earth connection to the workpiece 3 Access the Setup menu 2nd level 2nd 4 Select parameter r NOTE Incorrect measurement of the welding circuit resistance can have a negative effect on the welding re...

Page 114: ...tivity 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 measured Det...

Page 115: ...Troubleshooting and Maintenance 115...

Page 116: ...116...

Page 117: ...that electrically charged components e g capacitors are discharged WARNING Danger due to insufficient ground conductor connection This can result in severe personal injury and damage to property The...

Page 118: ...urce control has detected a primary overvoltage Check the grid voltage If the service code persists switch off the power source wait for 10 seconds and then switch the power source on again If the err...

Page 119: ...medy Cause Remedy to0 xxx Note xxx stands for a temperature value Overtemperature in the primary circuit of the power source Allow power source to cool down check air filter and clean if necessary che...

Page 120: ...oom and allow it to warm up Cause Remedy tu1 xxx Note xxx stands for a temperature value Undertemperature on the booster located in the power source Place power source in a heated room and allow it to...

Page 121: ...working properly Cause Remedy no Prg No preconfigured program has been selected Select a configured program Cause Remedy no IGn Ignition time out function is active current did not start flowing befo...

Page 122: ...he OPT Easy Documentation is empty To reset the service code press the arrow key the display shows no dAt Contact service to change the battery After changing the battery the date and time in the are...

Page 123: ...d incorrectly can cause serious injury and damage The following activities must only be carried out by trained and qualified personnel Please note the information in the Safety instructions chapter At...

Page 124: ...ed compressed air 2 Also clean the cooling air ducts if there is a large accumulation of dust WARNING An electric shock can be fatal Danger of electric shock due to grounding cable and device groundin...

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: ...oltage For devices designed for special voltages the technical data on the rating plate applies The following applies for all devices with a permitted grid voltage of up to 460 V The standard mains pl...

Page 129: ...ptions 1 Search for a 100 D C value in the technical data which corresponds to the exist ing ambient temperature 2 Reduce the power or amperage value correspondingly so that the device can oper ate wi...

Page 130: ...B Welding current range I2 MIG MAG 10 300 A TIG 10 300 A MMA 10 300 A Welding current at 10 min 40 C 104 F 40 300 A 60 280 A 100 240 A Output voltage range according to stand ard characteristic U2 MI...

Page 131: ...6 mm 0 03 0 06 in Wirespool diameter max 300 mm max 11 81 in Wirespool weight max 19 0 kg max 41 9 lb Max noise emission LWA 72 dB A Idle state power consumption at 400 V 36 5 W Power source efficien...

Page 132: ...nch Tst 3000 Pulse KL DB 3992 Standard welding characteristics SP Configuration CrNi Stainless FCW Basic FCW E70T FCW Ar 15 25 CO2 Ar 2 5 CO2 Ar 15 25 CO2 A B C D F F F F F F F 1 2 3 4 5 CrNi Stainles...

Page 133: ...08 P3977 S2324 P3979 1 Steel ER70 120 Ar 2 12 CO C S2485 P4006 S2486 P3990 S2487 P3958 S2488 P3987 1 Steel ER70 120 Ar 13 25 CO D S2285 S2297 S2307 S2323 1 Steel ER70 120 Ar 2 8 O B S2427 P3969 S2402...

Page 134: ...25 CO SP F S2292 S2302 S2312 S2326 1 Steel dyn ER70 120 Ar 8 CO SP F S2293 S2303 S2313 S2327 2 Steel dyn ER70 120 Ar 18 CO SP F S2291 S2301 S2311 S2325 3 Steel dyn ER70 120 Ar 4 CO SP F S2502 S2501 S2...

Page 135: ...1 S2308 P3977 S2377 P3979 1 Steel ER70 120 Ar 2 12 CO C S2419 P4006 S2369 P3990 S2309 P3958 S2376 P3987 1 Steel ER70 120 Ar 13 25 CO D S2285 S2297 S2307 1 Steel ER70 120 Ar 2 8 O B S2427 P3969 S2402 P...

Page 136: ...5 25 CO SP F S2374 S2367 S2312 S2380 1 Steel dyn ER70 120 Ar 8 10 CO SP F S2375 S2366 S2313 S2379 2 Steel dyn ER70 120 Ar 15 25 CO SP F S2291 S2301 S2311 S2325 3 Steel dyn ER70 120 Ar 4 O SP F S2502 S...

Page 137: ...137 EN US...

Page 138: ...138...

Page 139: ...139 EN US...

Page 140: ...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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