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Connections, Switches, and Mechanical Compon-

ents

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

Serious personal injury and damage to property may result.

▶

Read and understand this document.

▶

Read and understand all the Operating Instructions for the system components,
especially the safety rules.

Front and rear of
the power source

CO² 100%

Ar+ 15-20% CO²

Ar + 2.5%CO²

Steel

CuSi

CrNi

Self-shielded

Metal cored

Rutil FCW

0,6

.023
.030

0,8

.035

0,9

.040

1,0

.045

1,2

2T
4T

S4T

MANUAL
SYNERGIC

STICK

TIG

Ar 100%

(2)

(3)

(1)

(4)

(5)

(6)

(1)

Welding torch connection

For connecting the welding torch

(2)

(-) Current socket with 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 arc welding
(depending on the type of
electrode used)

Connecting the TIG welding
torch

(3)

TMC connection (TIG Multi Connector)

For connecting 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 electrode cable or grounding cable for manual metal arc
welding (depending on the type of electrode used)

Connecting the grounding cable for TIG welding

(5)

Ventilation openings (air outlet vents)

For device cooling

(6)

Polarity reverser

For selecting the welding potential on the MIG/MAG welding torch

Содержание TransSteel 2200

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...18...

Страница 19: ...General information 19...

Страница 20: ...20...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 29: ...Operating controls and connections 29...

Страница 30: ...30...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 40: ...40...

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

Страница 42: ...42...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 51: ...MIG MAG 51...

Страница 52: ...52...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 73: ...TIG 73...

Страница 74: ...74...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 83: ...Rod Electrode 83...

Страница 84: ...84...

Страница 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...

Страница 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...

Страница 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...

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

Страница 89: ...EasyJobs 89...

Страница 90: ...90...

Страница 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...

Страница 92: ...92...

Страница 93: ...Setup Menu 93...

Страница 94: ...94...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 104: ...104...

Страница 105: ...Optimizing Weld Quality 105...

Страница 106: ...106...

Страница 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...

Страница 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...

Страница 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...

Страница 110: ...110...

Страница 111: ...Troubleshooting and Maintenance 111...

Страница 112: ...112...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 124: ...124...

Страница 125: ...Appendix 125...

Страница 126: ...126...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 134: ...134...

Страница 135: ...135 EN US...

Страница 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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