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Inserting/chan-
ging feed rollers

CAUTION!

Danger due to feed roller holders shooting upwards.

Serious injuries may result.

▶

When unlocking the clamping lever, keep fingers away from the area to the left and
right of the clamping lever.

CAUTION!

Danger due to open feed rollers.

Serious injuries may result.

▶

After inserting/changing the feed rollers, always install the protective cover of the 4-
roller drive.

Содержание TransSteel 3000c Pulse

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 18: ...18...

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

Страница 20: ...20...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 27: ...Operating controls and connections 27...

Страница 28: ...28...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 39: ...Installation and Startup 39...

Страница 40: ...40...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 58: ...58...

Страница 59: ...MIG MAG welding 59...

Страница 60: ...60...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 79: ...TIG welding 79...

Страница 80: ...80...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 86: ...86...

Страница 87: ...Manual Metal Arc Welding 87...

Страница 88: ...88...

Страница 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...

Страница 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...

Страница 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...

Страница 92: ...92...

Страница 93: ...Easy Documentation 93...

Страница 94: ...94...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 99: ...Setup Settings 99...

Страница 100: ...100...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 115: ...Troubleshooting and Maintenance 115...

Страница 116: ...116...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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: ...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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 137: ...137 EN US...

Страница 138: ...138...

Страница 139: ...139 EN US...

Страница 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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