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52

MIG/MAG welding

Safety

General tasks be-
fore MIG/MAG
welding

Only where cooling units and a water-cooled welding torch are used:

Connect the water hoses of the welding torch to the correct plug-type connectors on
the wire-feed unit
Plug in the mains plug
Move the mains switch to the "I" position:

-

all the indicators on the control panel light up briefly

-

where applicable, the cooling unit starts to run

IMPORTANT!

Follow the safety rules and note operating conditions in the cooling unit op-

erating instructions.

Overview

MIG/MAG welding is composed of the following sections:
-

MIG/MAG standard synergic welding

-

MIG/MAG standard manual welding

-

Special functions and options

WARNING!

Operating the equipment incorrectly can cause serious injury and

damage. Do not use the functions described until you have thoroughly read and
understood the following documents:
-

these operating instructions

-

all the operating instructions for the system components, especially the safe-
ty rules

WARNING!

An electric shock can be fatal. If the power source is connected to the

mains electricity supply during installation, there is a high risk of very serious in-
jury and damage. Before carrying out any work on the device make sure that:
-

the power source mains switch is in the "O" position

-

the power source is unplugged from the mains

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Содержание TransSteel 3500 Rob

Страница 1: ...Perfect Charging Perfect Welding Solar Energy 42 0426 0086 EN 023 19042018 TransSteel 3500 Rob TransSteel 5000 Rob Operating Instructions Spare parts list MIG MAG Power source EN...

Страница 2: ...2...

Страница 3: ...essential prerequisites for excellent results Explanation of safety symbols If you see any of the symbols depicted in the Safety rules chapter special care is re quired DANGER Indicates immediate and...

Страница 4: ...4...

Страница 5: ...17 Safety measures in normal operation 17 Commissioning maintenance and repair 18 Safety inspection 18 Disposal 19 Safety symbols 19 Data protection 19 Copyright 19 General information 21 General 23 D...

Страница 6: ...ion connecting the welding torch 45 Other activities 45 Welding 47 Power limitation 49 Safety function 49 MIG MAG modes 50 General remarks 50 Symbols 50 2 step mode 50 4 step mode 50 Special 4 step mo...

Страница 7: ...75 General 75 Displaying welding circuit inductivity L 75 Laying the hosepacks correctly 75 Troubleshooting and maintenance 77 Troubleshooting 79 General 79 Safety 79 Power source troubleshooting 79 D...

Страница 8: ...8...

Страница 9: ...t be covered pasted or painted over For the location of the safety and danger notices on the device refer to the section headed General in the operating instructions for the device Before switching on...

Страница 10: ...atures are trained to produce the required results Checks must be carried out at regular intervals to ensure that operators are working in a safety conscious manner Before using the device all persons...

Страница 11: ...on behind the protec tive visor Wear stout footwear that provides insulation even in wet conditions Protect the hands with suitable gloves electrically insulated and providing protection against heat...

Страница 12: ...t be available and ready for use Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings Take appropriate precautions to prevent any danger of in jury or fire We...

Страница 13: ...ssary provide an adequate earth connection for the workpiece Switch off unused devices Wear a safety harness if working at height Before working on the device switch it off and pull out the mains plug...

Страница 14: ...susceptible to interference from the device include Safety devices Power signal and data transfer lines IT and telecommunications devices Measuring and calibrating devices Supporting measures for avo...

Страница 15: ...d Welding torches and other parts with a high operating temperature must be al lowed to cool down before handling Special provisions apply in areas at risk of fire or explosion observe relevant nation...

Страница 16: ...ring mains are being used Shielding gas cylinders contain gas under pressure and can explode if dam aged As the shielding gas cylinders are part of the welding equipment they must be handled with the...

Страница 17: ...ng plate When setting up the device ensure there is an all round clearance of 0 5 m 1 ft 7 69 in to ensure that cooling air can flow in and out freely When transporting the device observe the relevant...

Страница 18: ...ool It is impossible to guarantee that bought in parts are designed and manufac tured to meet the demands made of them or that they satisfy safety require ments Use only original spare and wearing par...

Страница 19: ...dards of the EN 60 974 series Fronius International GmbH hereby declares that the device is compliant with Directive 2014 53 EU The full text on the EU Declaration of Conformity can be found at the fo...

Страница 20: ...20...

Страница 21: ...General information...

Страница 22: ......

Страница 23: ...Functional princi ple The central control and regulation unit of the power source is coupled with a digital signal processor The central control and regulation unit and signal processor control the en...

Страница 24: ...symbols on the rating plate Welding is dangerous The following basic requirements must be met Welders must be sufficiently quali fied Suitable protective equipment must be used All persons not involv...

Страница 25: ...tive 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 remains inactive Gas pre...

Страница 26: ...ater 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 c...

Страница 27: ...Control elements and connections...

Страница 28: ......

Страница 29: ...esult stored knowledge is available at all times All the parameters can be adjusted manually The Synergic control panel also allows parameters to be set manually Safety Synergic control panel NOTE Due...

Страница 30: ...kness Sheet thickness in mm or in If the welding current to be selected is not known it is sufficient to enter the sheet thickness The required welding current and any other parameters marked with wil...

Страница 31: ...he spray arc To alert you to this critical area and help you avoid it the intermediate arc indicator lights up 12 HOLD indicator At the end of each welding operation the actual values for welding curr...

Страница 32: ...activate the keylock as follows Press and hold the Parameter selection button left Press the Parameter selection button right Release the Parameter selection buttons Select the required setup paramete...

Страница 33: ...activated The message CLO SEd appears on the displays Keylock deactivated The message OP En appears on the displays Press the Parameter selection button right Release the Mode and Parameter Selection...

Страница 34: ...tching the power source on and off 3 Current socket with bayonet latch used for connecting the current cable from the interconnecting hosepack during MIG MAG welding connecting the electrode cable or...

Страница 35: ...Installation and commissioning...

Страница 36: ......

Страница 37: ...for the welding task are then described MIG MAG weld ing gas cooled Power source Earth cable MIG MAG robot welding torch gas cooled Gas connection protective gas supply Wire feed unit VR 5000rob Inte...

Страница 38: ...at the cooling air can enter and exit unhindered through the air ducts on the front and back of the device Electroconductive metallic dust e g from grinding work must not be allowed to get sucked into...

Страница 39: ...mm 0 4 0 6 in longer than the phase con ductors An illustration of the mains cable connection can be found in the following sections Fitting the strain relief device or Fitting the strain relief devic...

Страница 40: ...ductor 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 Euro...

Страница 41: ...g the strain relief device for Canada US and TSt 5000 MV Eu rope 1 2 3 4 5 3 1 2 5 4 7 1 2 3 1 3 3 3 3 3 4 4x 3 3 5 Nm 4 1 4 3 2 5 6 5 IMPORTANT Tie the phase conductors near the luster terminal using...

Страница 42: ...he 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 acros...

Страница 43: ...ude references to various system compo nents including trolley upright console cooling units wire feed units interconnecting hosepacks welding torches etc For more detailed information about installin...

Страница 44: ...nterconnecting hosepack 1 WARNING Work that is carried out incorrectly can cause serious injury and dam age The following activities must only be carried out by trained and qualified per sonnel All in...

Страница 45: ...electrode Set the contact pressure WARNING If gas cylinders topple over there is a risk of very serious injury and damage When using gas cylinders Place them on a solid level surface in such a way tha...

Страница 46: ...46...

Страница 47: ...Welding...

Страница 48: ......

Страница 49: ...it is too high the arc gets smaller and smaller and may be extinguished In order to prevent this the welding power is lowered For the selected MIG MAG standard synergic welding process the symbol for...

Страница 50: ...t of welding Symbols 2 step mode 2 step mode is suitable for Tacking work Short weld seams 4 step mode 4 step mode is suitable for longer weld seams WARNING Operating the equipment incorrectly can cau...

Страница 51: ...N Special 4 step mode Special 4 step mode is ideal for welding in higher power ranges In special 4 step mo de the arc starts at a low power which ma kes it easier to stabilise I GPr I S I E SL SL GPo...

Страница 52: ...following sections MIG MAG standard synergic welding MIG MAG standard manual welding Special functions and options WARNING Operating the equipment incorrectly can cause serious injury and damage Do no...

Страница 53: ...ding process MIG MAG standard synergic welding Press the Mode button to select the desired MIG MAG mode 2 step mode 4 step mode Special 4 step mode If they were not set via a robot interface press the...

Страница 54: ...tions dur ing welding To obtain the best possible welding results the arc length correction and arc force dynamic welding parameters will sometimes need to be corrected If not already set via the robo...

Страница 55: ...n MIG MAG standard manual welding special 4 step mode corresponds to conventional 4 step mode Press the Parameter selection button to select the wire feed speed parameter Use the adjusting dial to set...

Страница 56: ...obtain the best possible welding results the arc force dynamic parameter will some times need to be adjusted Press the Parameter selection button to select the arc force dynamic parameter Use the adju...

Страница 57: ...ter Use the adjusting dial to set the desired amperage WARNING Operating the equipment incorrectly can cause serious injury and damage Do not use the functions described until you have thoroughly read...

Страница 58: ...own in the digital display located above it HotStart function To obtain optimum welding results it will sometimes be necessary to adjust the HotStart function Advantages Improved ignition even when us...

Страница 59: ...ins to stick the power source immediately switches the welding current off After the rod electrode has been detached from the workpiece the welding operation can be continued without difficulty The an...

Страница 60: ...ess and hold the relevant Save button to delete the memory content of that Save button e g The left indicator displays Pro After a short time the left indicator switches to the original value Keep the...

Страница 61: ...61 EN Number 3 Number 4 Number 5...

Страница 62: ...62...

Страница 63: ...Setup settings...

Страница 64: ......

Страница 65: ...panel is now in the Setup menu for the MIG MAG standard synergic welding process the last setup parameter that was selected is displayed Changing welding parameters Exiting the Setup menu Use the Pro...

Страница 66: ...4 step mode only Unit of welding current Setting range 0 200 Factory setting 100 I E I current End Final current special 4 step mode only Unit of welding current Setting range 0 200 Factory setting 5...

Страница 67: ...PORTANT When the power source is reset all the personal settings in the Set up menu are lost Operating points that were saved using the Save buttons are retained when the power source is reset The fun...

Страница 68: ...t m min ipm Setting range 1 max 39 37 max Factory setting 10 393 7 bbc burn back time correction Burn back effect due to wire withdrawal at the end of welding Unit s Setting range Aut 0 0 3 Factory se...

Страница 69: ...ding IMPORTANT If you reset the power source using the FAC factory setup parameter the hot current time Hti and HotStart current HCU setup parameters are also reset HCU HotStart current Unit Setting r...

Страница 70: ...menu I S I current Starting Starting current Unit of welding current Setting range 0 200 Factory setting 100 SL Slope 0 9 9 s Unit s Setting range 0 9 9 Factory setting 0 I E I current End Final curre...

Страница 71: ...de and Process buttons Use the Mode and Process buttons or the left hand adjusting dial to select the 2nd setup parameter 1 2 3 4 Press and hold the Mode button Press the Process button Release the Mo...

Страница 72: ...t restored to the factory setting If the MMA welding process is selected the cool ing unit is always switched off even if the switch is in the On position C t Cooling time time from when flow monitori...

Страница 73: ...current A is deactivated ALC Arc Length Correction correction of the arc length via the welding voltage Setting range ON OFF Factory setting OFF The arc length depends on the welding voltage The weldi...

Страница 74: ...nnection to the workpiece Accessing the Level 2 2nd Setup menu Select parameter r Remove the gas nozzle from the welding torch Screw on the contact tip Place the contact tip flush against the workpiec...

Страница 75: ...p parameter L is used to display the most recently calculated welding circuit in ductivity The welding circuit inductivity is calibrated at the same time as the welding circuit resistance r is calcula...

Страница 76: ...76...

Страница 77: ...Troubleshooting and maintenance...

Страница 78: ......

Страница 79: ...e troubleshooting measures listed are unsuccessful Over temperature LED lights up Cause Over temperature in control circuit Remedy Leave power source to cool Power source has no function Mains switch...

Страница 80: ...ators are lit up Cause Grounding earthing connection is incorrect Remedy Check the grounding earthing connection for correct polarity Cause There is a break in the power cable in the welding torch Rem...

Страница 81: ...emedy Use the correct shielding gas The welding torch becomes very hot Cause The design dimensions of the welding torch are not sufficient for this task Remedy Observe the duty cycle and loading limit...

Страница 82: ...n ELn 15 Cause More than only one remote control unit is connected Remedy Only one remote control unit may be connected check the system configura tion Err IP Cause The control unit of the power sourc...

Страница 83: ...ode Remedy Err 51 Cause Mains undervoltage The mains voltage has fallen below the tolerance range Remedy Check the mains voltage if the error keeps recurring contact the After Sales Service Err 52 Cau...

Страница 84: ...xx Remark xxx stands for a temperature value Cause Overtemperature in the wire feed unit motor Remedy Allow wire feed unit to cool down to4 xxx Remark xxx stands for a temperature value Cause Overtemp...

Страница 85: ...om and allow to warm up tu4 xxx Remark xxx stands for a temperature value Cause Undertemperature in the welding torch Remedy Place welding torch in a heated room and allow to warm up tu5 xxx Remark xx...

Страница 86: ...torch trigger again clean the surface of the workpiece if necessary increase the wire length until the safety cut out trips in Set up menu Level 2 EPG 17 Cause The welding program selected is invalid...

Страница 87: ...If a lot of dust has accumulated clean the cooling air ducts Disposal Dispose of in accordance with the applicable national and local regulations WARNING An electric shock can be fatal Before opening...

Страница 88: ...s 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 value of 100 f...

Страница 89: ...00 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...

Страница 90: ...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...

Страница 91: ...ion 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...

Страница 92: ...teristic 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 protec...

Страница 93: ...C D A B C D A C A C B C 1 Pos 1 1 1 2 2 2 3 3 3 3 4 4 5 5 6 6 7 Steel Steel Steel Steel Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic...

Страница 94: ...B C D A C A C B C 1 Pos 1 1 1 2 2 2 3 3 3 3 4 4 5 5 6 6 7 Steel Steel Steel Steel Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic FCW B...

Страница 95: ...c Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic FCW Basic FCW Metal cored 100 CO2 0 8 mm 030 0 9 mm 035 1 0 mm 040 1 2 mm 045 1 4 mm 0...

Страница 96: ...dynamic Steel dynamic Steel dynamic Steel dynamic Steel root Steel root Steel root Steel root Rutil FCW Rutil FCW Basic FCW Basic FCW Metal cored 100 CO2 0 8 mm 030 0 9 mm 035 1 0 mm 040 1 2 mm 045 1...

Страница 97: ...2 T 2 step mode 4 T 4 step mode S 4 T Special 4 step mode Selecting the process Setting the mode MANUAL MIG MAG standard manual SYNERGIC Standard synergic STICK Manual metal arc welding Correcting par...

Страница 98: ...Final current 2 step special 4 step Starting current duration 2 step Final current duration 2 step Threading speed Burn back effect Length of wire before the safety cut out trips Restoring factory set...

Страница 99: ...Appendix...

Страница 100: ...100 Spare parts list TSt 3500 Rob TSt 5000 Rob...

Страница 101: ...P PP P PP P PP P PP P PP 3 576 0 17 17 1 0 76W 09 76W 76W 09 76W 09 76W 76W 76W 09 76W 09 3 35 0 76W 76W 76W 09 76W 09 76W 09 0 2267 67 0 67 0 1 0 09 76W 76W 09 76W 76W 09 76W 09 76W 09 76W 76W 76W 67...

Страница 102: ...102...

Страница 103: ...103...

Страница 104: ...1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all addresses of...

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