Fronius TransSteel 3500 Operating Instructions Manual Download Page 1

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42,0426,0076,EN 035-15052020

TransSteel 3500, TransSteel 5000

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Operating Instructions

MIG/MAG Power source

Summary of Contents for TransSteel 3500

Page 1: ...al chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0076 EN 035 15052020 TransSteel 3500 TransSteel 5000 Operating Instructions MIG MAG Power source EN ...

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Page 3: ...s to ensure greater safety when using the product Careful handling of the product will repay you with years of safe and reliable operation These are essential prerequisites for excellent results Explanation of safety notices DANGER Indicates immediate danger If not avoided death or serious injury will result WARNING Indicates a potentially hazardous situation If not avoided death or serious injury...

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Page 5: ... during transport 14 Safety measures in normal operation 15 Commissioning maintenance and repair 15 Safety inspection 16 Disposal 16 Safety symbols 16 Data protection 16 Copyright 16 General information 17 General 19 Device concept 19 Requirements 19 Functional principle 19 Application areas 19 Warning notices on the device 20 System components 22 General 22 Safety 22 Overview 22 Options 23 Genera...

Page 6: ...n 42 Generator powered operation 42 Start up 43 General 43 Information on system components 43 Fitting the system components overview 43 Strain relief device 44 Connecting the interconnecting hosepack 45 Connecting the gas cylinder 45 Creating a grounding earthing connection connecting the welding torch 46 Laying the hosepacks correctly 46 Other activities 46 Troubleshooting and maintenance 47 Tro...

Page 7: ...d General in the operating instructions for the device Before switching on the device rectify any faults that could compromise safety This is for your personal safety Proper use The device is to be used exclusively for its intended purpose The device is intended solely for the welding processes specified on the rating plate Any use above and beyond this purpose is deemed improper The manufacturer ...

Page 8: ...ting instructions especially the Safety rules section and sign to confirm that they have understood them and will follow them Before leaving the workplace ensure that people or property cannot come to any harm in your absence Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current consumption This may affect a number device types in terms of Co...

Page 9: ...Danger from toxic gases and va pours The fumes produced during welding contain harmful gases and vapours Welding fumes contain substances that cause cancer as stated in Monograph 118 of the International Agency for Research on Cancer Use at source extraction and a room extraction system If necessary use a welding torch with an integrated extraction device Keep your face away from welding fumes and...

Page 10: ...that are in contact with the welding wire are live Always set the wirefeeder up on a sufficiently insulated surface or use a suitable insulated wirefeeder holder Make sure that you and others are protected with an adequately insulated dry base or cov er for the earth or ground potential This base or cover must extend over the entire area between the body and the earth or ground potential All cable...

Page 11: ...curely by the workpiece clamp Attach the workpiece clamp as close as possible to the area that is to be welded Position the device with sufficient insulation against electrically conductive environments e g Insulation against conductive floor or insulation to conductive racks If distribution boards twin head mounts etc are being used note the following The elec trode of the welding torch electrode...

Page 12: ...ation EMF measures Electromagnetic fields may pose as yet unknown risks to health effects on the health of others in the vicinity e g wearers of pacemakers and hearing aids wearers of pacemakers must seek advice from their doctor before approaching the de vice or any welding that is in progress for safety reasons keep distances between the welding cables and the welder s head torso as large as pos...

Page 13: ...G MAG and TIG devices If the wire feed unit is attached to a crane holder during welding always use a suitable insulated wirefeeder hoisting attachment MIG MAG and TIG devices If the device has a carrying strap or handle this is intended solely for carrying by hand The carrying strap is not to be used if transporting with a crane counterbalanced lift truck or other mechanical hoist All lifting acc...

Page 14: ...ourless and odourless and in the event of a leak can displace the ox ygen in the ambient air Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m hour Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply Close the shielding gas cylinder valve or main gas supply if no welding is taking place Check the shielding gas cylinder or m...

Page 15: ...mability etc Only use suitable original coolant from the manufacturer Do not mix the manufacturer s original coolant with other coolants Only connect the manufacturer s system components to the cooling circuit The manufacturer accepts no liability for damage resulting from use of other system com ponents or a different coolant In addition all warranty claims will be forfeited Cooling Liquid FCL 10...

Page 16: ...ty Any device that you no longer require must either be returned to your dealer or given to one of the approved collection and recycling facilities in your area Ignoring this European Directive may have potentially adverse af fects on the environment and your health Safety symbols Devices with the CE mark satisfy the essential requirements of the low voltage and elec tromagnetic compatibility dire...

Page 17: ...General information ...

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Page 19: ...er sources can be used in conjunction with the VR 5000 wire feed unit Functional princi ple The central control and regulation unit of the power sources is coupled with a digital signal processor The central control and regulation unit and signal processor control the entire welding process During the welding process the actual data is measured continuously and the device re sponds immediately to ...

Page 20: ... offshore industry Metal and gantry construction Rolling stock construction Warning notices on the device Warning notices and safety symbols are affixed to the power source These warning notic es and safety symbols must not be removed or painted over They warn against operating the device incorrectly as this may result in serious injury and damage ...

Page 21: ... Suitable protective equipment must be used All persons not involved in the welding process must be kept at a safe distance Do not use the functions described here until you have thoroughly read and un derstood the following documents these operating instructions all the operating instructions for the system components especially the safety rules ...

Page 22: ...eration 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 described here until you have fully read and understood all of the Operating Instructions for the system components in particular the safety rules Overview Welding torch Grounding earthing cable and elect...

Page 23: ...ates the welding circuit up to a maximum of 500 V DC To ensure reliable isolation from the welding circuit use a relay with an insulation voltage greater than 1500 V DC Gas test button The gas test button sets the protective gas flow The protective gas flow is activated when the gas test button is pressed and is deactivated after 30 seconds or if the button is pressed again The wire feed unit rema...

Page 24: ...enches 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 for the currently selected welding process is permanently lit A safe condition is defined as follows The output voltage in an open circuit is limited to 35 V For as long as the welding operation is active welding circuit resi...

Page 25: ...25 EN 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 ...

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

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Page 29: ...isplayed on the digital display during welding The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed NOTE Due to software updates you may find that your device has certain functions that are not described in these operating instructions or vice versa Individual illustrations may also differ slightly from the actual controls on your...

Page 30: ...l panel Remote control panel No Function 1 Overtemperature indicator Lights up if the power source overheats e g because the duty cycle has been ex ceeded For more information on this see the Troubleshooting section 2 Error indicator Lights up if an error occurs The corresponding service code is displayed on all de vices connected to the LocalNet that have a digital display 3 Power source ON indic...

Page 31: ... switch for switching the power source on and off 3 Current socket with bayonet latch used to connect the current cable from the interconnecting hosepack when MIG MAG welding to connect the electrode cable or grounding earthing cable when MMA welding depending on the type of electrode used 4 Gas preheater option 5 Machine interface option 6 Mains cable with strain relief device 7 LocalNet connecti...

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Page 33: ...Installation and commissioning ...

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Page 35: ...els required for the welding task are then described MIG MAG weld ing gas cooled Power source Earth cable MIG MAG welding torch gas cooled Gas connection protective gas supply Wire feed unit Interconnecting hosepack Wire electrode MIG MAG weld ing water cooled Power source Cooling unit Earth cable MIG MAG welding torch water cooled Gas connection protective gas supply Wire feed unit water cooled I...

Page 36: ...for MIG MAG and MMA welding Any 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 purpose also comprises following all the information in the operating instructions carrying out all the specified inspection and servicing work Setup regulations The de...

Page 37: ... The devices are designed for the mains voltage specified on the rating plate If your version of the appliance does not come with mains cables and plugs ready fitted these must be fitted in accordance with national regulations and standards For details of fuse protection of the mains lead please see the technical data CAUTION An inadequately dimensioned electrical installation can cause serious da...

Page 38: ...nnected a mains cable that is suitable for the connection voltage must be fitted before commissioning CAUTION If no ferrules are used there is a risk of injury and damage from short circuits be tween the phase conductors or between the phase conductors and the PE conduc tor Fit ferrules to all phase conductors and the PE conductor of the stripped mains cable The PE conductor should be approx 10 15...

Page 39: ...mains cable in far enough to make it possible to connect the PE conductor and the phase conductors to the block terminal properly Fit ferrules to the PE conductor and phase conductors Connect the PE conductor and phase conductors to the block terminal Use the strain relief device to secure the mains cable Fir the side panel of the device Fitting the Europe strain relief de vice 1 2 3 4 1 2 3 4 5 6...

Page 40: ...RTANT Tie the phase conductors near the block terminals using cable ties Fitting the strain relief device for Canada US and TSt 5000 MV Eu rope 1 2 3 4 1 4 3 2 5 6 5 3 1 2 5 4 7 1 2 3 1 3 3 3 3 3 4 4x 3 3 5 Nm 4 ...

Page 41: ...41 EN 5 IMPORTANT Tie the phase conductors near the luster terminal using cable ties 1 4 3 2 5 6 5 ...

Page 42: ... thumb 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 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 across all three phases of the gen erator If ...

Page 43: ...on about installing and connecting the system components please refer to the appropriate operating instructions Fitting the system components overview WARNING Work that is carried out incorrectly can cause serious injury and damage The following activities must only be carried out by trained and qualified personnel All in structions in the section headed Safety rules must be observed The diagram b...

Page 44: ...44 Strain relief de vice 1 2 1 2 3 4 1 2 1 3 4 2 ...

Page 45: ... them on a solid level surface in such a way that they remain stable Secure the gas cylinders to prevent them from falling over Fit the VR holder option Follow the gas cylinder manufacturer s safety rules 1 Briefly open the gas cylinder valve to blow off any dust or dirt Check the seal on the pressure regula tor NOTE US devices are supplied with an adapter for the gas hose Seal male thread spacers...

Page 46: ...ther activities Carry out the following steps in accordance with the wire feed unit operating instructions Insert the feed rollers in the wire feed unit Place the wirespool or basket type spool and basket spool adapter in the wire feed unit Feed in the wire electrode Set the contact pressure 2 1 3 1 1 2 3 4 ...

Page 47: ...Troubleshooting and maintenance ...

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Page 49: ...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 check to make sure that electrically charged com ponents e g capacitors have discharged WARNING An inadequate ground conductor connection can cause serious injury or damage The housing screws provide a suitable ground conductor connection for earthing ...

Page 50: ...edy Wait until the power source automatically comes back on after the end of the cooling phase Cause Limited 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 Contact After Sales Service No welding current Mains switch is ON and indicators are lit up C...

Page 51: ... Check the pressure regulator gas hose gas solenoid valve torch gas con nection etc Cause Welding torch is leaking Remedy Change the welding torch Cause Wrong contact tip or contact tip is worn out Remedy Replace the contact tip Cause Wrong wire alloy or wrong wire diameter Remedy Check the wire electrode that has been inserted Cause Wrong wire alloy or wrong wire diameter Remedy Check weldability...

Page 52: ...y and damage 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 welding torch interconnecting hosepack and ground earth connection for damage Check that the device has an all round clearance of 0 5 m 1 ft 8 in around the device to ensure that cooling...

Page 53: ...53 EN If a lot of dust has accumulated clean the cooling air ducts Disposal Dispose of in accordance with the applicable national and local regulations ...

Page 54: ...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 accordingly 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 anew If the device is to be continuously operated without stopping look in the technical data for a D C ...

Page 55: ...peak U0 r m s 60 V Apparent power at 400 V AC 350 A 40 ED2 15 673 kVA Degree of protection IP 23 Type of cooling AF Insulation class B Overvoltage category III Pollution level according to IEC60664 3 Safety symbols S CE CSA Dimensions l x w x h 747 x 300 x 497 mm 29 4 x 11 8 x 19 6 in Weight 29 kg 63 5 lb Efficiency at 250 A and 26 5 V 89 Max noise emission LWA 72 dB A Mains voltage U1 3 x 380 V 4...

Page 56: ...tion level according to IEC60664 3 Safety symbols S CE CSA Dimensions l x w x h 747 x 300 x 497 mm 29 4 x 11 8 x 19 6 in Weight 32 3 kg 71 2 lb Efficiency at 360 A and 32 V 91 Max noise emission LWA 74 dB A Mains voltage U1 3 x 200 V 230 V Max effective primary current I1eff 24 1 A 20 8 A Max primary current I1max 38 1 A 32 9 A Mains fuse 35 A slow blow Mains voltage U1 3 x 400 V 460 V Max effecti...

Page 57: ...egory III Pollution level according to IEC60664 3 Safety symbols S CE CSA Dimensions l x w x h 747 x 300 x 497 mm 29 4 x 11 8 x 19 6 in Weight 37 3 kg 82 lb Efficiency at 250 A and 26 5 V 87 Max noise emission LWA 74 dB A Mains voltage U1 3 x 200 V 230 V Max effective primary current I1eff 39 5 A 36 3 A Max primary current I1max 66 7 A 57 4 A Mains fuse 63 A slow blow Mains voltage U1 3 x 400 V 46...

Page 58: ...ard characteristic U2 MIG MAG 14 3 39 V Rod electrode 20 2 40 V Open circuit voltage U0 peak U0 r m s 57 V Apparent power at 200 V AC 500 A 40 ED2 23 089 kVA at 400 V AC 500 A 40 ED2 22 492 kVA Degree of protection IP 23 Type of cooling AF Insulation class B Overvoltage category III Pollution level according to IEC60664 3 Safety symbols S CE CSA Dimensions l x w x h 747 x 300 x 497 mm 29 4 x 11 8 ...

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Page 60: ...S INTERNATIONAL GMBH Froniusstraße 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 locations ...

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