TransSteel 3500 / 5000 Spare parts list MIG/MAG … · TransSteel 3500 / 5000 Operating...

42,0426,0076,EN 012009

TransSteel 3500 / 5000 Operating instructionsSpare parts list

MIG/MAG Power source

GB

ud_fr_st_et_00493 012004

Dear Reader

Thank you for choosing Fronius - and congratulations on your new, technically high-

grade Fronius product! This instruction manual will help you get to know your new

machine. Read the manual carefully and you will soon be familiar with all the many

great features of your new Fronius product. This really is the best way to get the most

out of all the advantages that your machine has to offer.

Please also take special note of the safety rules - and observe them! In this way, you

will help to ensure more safety at your product location. And of course, if you treat your

product carefully, this definitely helps to prolong its enduring quality and reliability - things

which are both essential prerequisites for getting outstanding results.

Introduction

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Safety rules

DANGER!

WARNING!

CAUTION!

“NOTE!” indicates a situation which implies a risk of impaired welding resultand damage to the equipment.

NOTE!

This equipment has been made in accordance with the state of the art andall recognised safety rules. Nevertheless, incorrect operation or misuse maystill lead to danger for- the life and well-being of the operator or of third parties,- the equipment and other tangible assets belonging to the owner/operator,- efficient working with the equipment.

All persons involved in any way with starting up, operating, servicing andmaintaining the equipment must- be suitably qualified- know about welding and- read and follow exactly the instructions given in this manual.

The instruction manual must be kept at the machine location at all times. Inaddition to the instruction manual, copies of both the generally applicableand the local accident prevention and environmental protection rules must bekept on hand, and of course observed in practice.

All the safety instructions and danger warnings on the machine itself:- must be kept in a legible condition- must not be damaged, must not be removed- must not be covered, pasted or painted over

For information about where the safety instructions and danger warnings arelocated on the machine, please see the section of your machine’s instructionmanual headed “General remarks”.

General remarks

Important!

“DANGER!” indicates an imminently hazardous situation which, if notavoided, will result in death or serious injury. This signal word is to belimited to the most extreme situations. This signal word is not used forproperty damage hazards unless personal injury risk appropriate to thislevel is also involved.

“WARNING!” indicates a potentially hazardous situation which, if notavoided, could result in death or serious injury. This signal word is not usedfor property damage hazards unless personal injury risk appropriate to thislevel is also involved.

“CAUTION!” indicates a potentially hazardous situation which, if not avo-ided, may result in minor or moderate injury. It may also be used to alertagainst unsafe practices that may cause property damage.

“Important!” indicates practical hints and other useful special-information. Itis no signal word for a harmful or dangerous situation.

Whenever you see any of the symbols shown above, you must pay evencloser attention to the contents of the manual!

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Operation or storage of the power source outside the stipulated range isdeemed to be “not in accordance with the intended use”. The manufacturershall not be liable for any damage resulting herefrom.

Temperature range of ambient air:- when operating: - 10 °C to + 40 °C (14 °F to 104 °F)- when being transported or stored: - 25 °C to + 55 °C (-13 °F to 131 °F)

Relative atmospheric 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 substances etc.

Elevation above sea level: Up to 2000 m (6500 ft)

Ambientconditions

The machine may only be used for jobs as defined by the “Intendedpurpose”.

The machine may ONLY be used for the welding processes stated on therating plate.Utilisation for any other purpose, or in any other manner, shall be deemed tobe "not in accordance with the intended purpose". The manufacturer shall notbe liable for any damage resulting from such improper use.

Utilisation in accordance with the “intended purpose” also comprises- complete reading and following of all the instructions given in this manual- complete reading and following of all the safety instructions and danger

warnings- performing all stipulated inspection and servicing work.

The appliance must never be used for the following:- Thawing pipes- Charging batteries/accumulators- Starting engines

The machine is designed to be used in industrial and workshopenvironments. The manufacturer shall not be liable for any damage resultingfrom use of the machine in residential premises.

ikewise the manufacturer will accept no liability for defective or faulty workresults.

Utilisation forintended purposeonly

Any malfunctions which might impair machine safety must be eliminatedimmediately - meaning before the equipment is next switched on.

It’s your safety that’s at stake!

The owner/operator undertakes to ensure that the only persons allowed towork with the machine are persons who- are familiar with the basic regulations on workplace safety and accident

prevention and who have been instructed in how to operate the machine- have read and understood the sections on “safety rules” and the “war-

nings“ contained in this manual, and have confirmed as much with theirsignatures

- be trained in such a way that meets with the requirements of the workresults

Regular checks must be performed to ensure that personnel are still workingin a safety-conscious manner.

Obligations ofowner/operator

General remarks(continued)

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Before starting work, all persons to be entrusted with carrying out work with(or on) the machine shall undertake- to observe the basic regulations on workplace safety and accident

prevention- to read the sections on “safety rules” and the “warnings” contained in this

manual, and to sign to confirm that they have understood these and willcomply with them.

Before leaving the workplace, personnel must ensure that there is no risk ofinjury or damage being caused during their absence.

Obligations ofpersonnel

Protection foryourself andother persons

When welding, you are exposed to many different hazards such as:- flying sparks and hot metal particles- arc radiation which could damage your eyes and skin

- harmful electromagnetic fields which may put the lives of cardiac pace-maker users at risk

- electrical hazards from mains and welding current

- increased exposure to noise

Mains connection High-performance devices can affect the quality of the mains power due totheir current-input.This may affect a number of types of device in terms of:- connection restrictions- criteria with regard to maximum permissible mains impedance *)

- criteria with regard to minimum short-circuit power requirement *)

*) at the interface with the public mains network

see Technical Data

In this case, the plant operator or the person using the device should checkwhether or not the device is allowed to be connected, where appropriatethrough discussion with the power supply company.

- noxious welding fumes and gases.

Anybody working on the workpiece during welding must wear suitable pro-tective clothing with the following characteristics:- flame-retardant- isolating and dry- must cover whole body, be undamaged and in good condition- protective helmet- trousers with no turn-ups

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The fumes given off during welding contain gases and vapors that areharmful to health.

Welding fumes contain substances which may cause birth defects andcancers.

Keep your head away from discharges of welding fumes and gases.

Do not inhale any fumes or noxious gases that are given off.Extract all fumes and gases away from the workplace, using suitable means.

Ensure a sufficient supply of fresh air.

Where insufficient ventilation is available, use a respirator mask with anindependent air supply.

If you are not sure whether your fume-extraction system is sufficiently power-ful, compare the measured pollutant emission values with the permittedthreshold limit values.

Hazards fromnoxious gasesand vapours

Keep other people - especially children - well away from the equipment andthe welding operation while this is in progress. If there are still any otherpersons nearby during welding, you must- draw their attention to all the dangers (risk of being dazzled by the arc or

injured by flying sparks, harmful welding fumes, high noise immissionlevels, possible hazards from mains or welding current ...)

- provide them with suitable protective equipment and/or- erect suitable protective partitions or curtains.

Protection foryourself andother persons(continued)

“Protective clothing” also includes:- protecting your eyes and face from UV rays, heat and flying sparks with

an appropriate safety shield containing appropriate regulation filter glass- wearing a pair of appropriate regulation goggles (with sideguards) behind

the safety shield- wearing stout footwear that will also insulate even in wet conditions- protecting your hands by wearing appropriate gloves (electrically insula-

ting, heat-proof)- To lessen your exposure to noise and to protect your hearing against

injury, wear ear-protectors!

Information onnoise emissionvalues

The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)when idling and in the cooling phase following operation at the maximumpermissible operating point under maximum rated load conditions according toEN 60974-1.

It is not possible to provide a workplace-related emission value during welding(or cutting) as this is influenced by both the process and the environment. Allmanner of different welding parameters come into play, including the weldingprocess (MIG/MAG, TIG welding), the type of power selected (DC or AC), thepower range, the type of weld metal, the resonance characteristics of theworkpiece, the workplace environment, etc.

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Hazards frommains and weld-ing current

Flying sparks can cause fires and explosions!

Never perform welding anywhere near combustible materials.

Combustible materials must be at least 11 meters (35 feet) away from thearc, or else must be covered over with approved coverings.

Have a suitable, approved fire extinguisher at the ready.

Sparks and hot metal particles may also get into surrounding areas throughsmall cracks and openings. Take suitable measures here to ensure that thereis no risk of injury or fire.

Do not perform welding in locations that are at risk from fire and/or explosion,or in enclosed tanks, barrels or pipes, unless these latter have beenprepared for welding in accordance with the relevant national andinternational standards.

Welding must NEVER be performed on containers that have had gases,fuels, mineral oils etc. stored in them. Even small traces of these substancesleft in the containers are a major explosion hazard.

Hazards fromflying sparks

An electric shock is potentially life-threatening, and can be fatal.

Do not touch any live parts, either inside or outside the machine.

In MIG/MAG and TIG welding, the welding wire, the wire spool, the driverollers and all metal parts having contact with the welding wire are also live.

Always place the wirefeeder on an adequately insulated floor or base, or elseuse a suitable insulating wirefeeder holder.

Ensure sufficient protection for yourself and for other people by means of adry base or cover that provides adequate insulation against the ground/framepotential. The base or cover must completely cover the entire area betweenyour body and the ground/frame potential.

All cables and other leads must be firmly attached, undamaged, properlyinsulated and adequately dimensioned. Immediately replace any looseconnections, scorched, damaged or underdimensioned cables or otherleads.

The harmfulness of the welding fumes will depend on e.g. the followingcomponents:- the metals used in and for the workpiece- the electrodes- coatings- cleaning and degreasing agents and the like

For this reason, pay attention to the relevant Materials Safety Data Sheetsand the information given by the manufacturer regarding the componentslisted above.

Keep all flammable vapors (e.g. from solvents) well away from the arcradiation.

Hazards fromnoxious gasesand vapours(continued)

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If the following instructions are ignored, stray welding currents may occur.These can cause:- fires- overheating of components that are connected to the workpiece- destruction of PE conductors- damage to the machine and other electrical equipment

Ensure that the workpiece clamp is tightly connected to the workpiece.

Attach the workpiece clamp as close as possible to the area to be welded.

On electrically conductive floors, the machine must be set up in such a waythat it is sufficiently insulated from the floor.

Stray weldingcurrents

Hazards frommains and weld-ing current(continued)

Do not loop any cables or other leads around your body or any part of yourbody.

Never immerse the welding electrode (rod electrode, tungsten electrode,welding wire, ...) in liquid in order to cool it, and never touch it when thepower source is ON.

Twice the open-circuit voltage of one single welding machine may occurbetween the welding electrodes of two welding machines. Touching thepotentials of both electrodes simultaneously may be fatal.

Have the mains and the machine supply leads checked regularly by aqualified electrician to ensure that the PE (protective earth) conductor isfunctioning correctly.

Only run the machine on a mains network with a PE conductor, and pluggedinto a power outlet socket with a protective-conductor contact.

If the machine is run on a mains network without a PE conductor andplugged into a power outlet socket without a protective-conductor contact,this counts as gross negligence and the manufacturer shall not be liable forany resulting damage.

Wherever necessary, use suitable measures to ensure that the workpiece issufficiently grounded (earthed).

Switch off any appliances that are not in use.

Wear a safety harness if working at height.

Before doing any work on the machine, switch it off and unplug it from themains.

Put up a clearly legible and easy-to-understand warning sign to stop anybodyinadvertently plugging the machine back into the mains and switching it backon again.

After opening up the machine:- discharge any components that may be storing an electrical charge- ensure that all machine components are electrically dead.

If work needs to be performed on any live parts, there must be a secondperson on hand to immediately switch off the machine at the main switch inan emergency.

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When using current supply distributors, twin head wire feeder fixtures etc.,please note the following: The electrode on the unused welding torch/weldingtongs is also current carrying. Please ensure that there is sufficient insula-ting storage for the unused welding torch/tongs.

In the case of automated MIG/MAG applications, ensure that only insulatedfiller wire is routed from the welding wire drum, large wirefeeder spool orwirespool to the wirefeeder.

Stray weldingcurrents(continued)

EMC deviceclassifications

Devices with emission class A:- are only designed for use in an industrial setting- can cause conducted and emitted interference in other areas.

Devices with emission class B:- satisfy the emissions criteria for residential and industrial areas. This

also applies to residential areas in which power is supplied from thepublic low-voltage grid.

EMC device classification as per the rating plate or technical specifications

EMC measures In certain cases, even though a device complies with the standard limit valuesfor emissions, 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 thedevice is installed is close to either radio or television receivers).If this is the case, then the operator is obliged to take appropriate action torectify the situation.

Examine and evaluate any possible electromagnetic problems that mayoccur on equipment in the vicinity, and the degree of immunity of thisequipment, in accordance with national and international regulations:- safety features- mains, signal and data-transmission leads- IT and telecoms equipment- measurement and calibration devices

Ancillary measures for preventing EMC problems:

a) Mains supply- If electromagnetic interference still occurs, despite the fact that the mains

connection is in accordance with the regulations, take additionalmeasures (e.g. use a suitable mains filter).

b) Welding cables- Keep these as short as possible- Arrange them so that they run close together (to prevent EMI problems

as well)- Lay them well away from other leads.

c) Equipotential bonding

d) Workpiece grounding (earthing)- where necessary, run the connection to ground (earth) via suitable

capacitors.

e) Shielding, where necessary- Shield other equipment in the vicinity- Shield the entire welding installation.

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Power sources for use in spaces with increased electrical danger (e.g.boilers) must be identified by the (for “safety”) mark.However, the power source should not be in such rooms.

Allow welding torches - and other items of equipment that are used at highoperating temperatures - to cool down before doing any work on them.

Special regulations apply to rooms at risk from fire and/or explosion. Observeall relevant national and international regulations.

Risk of scalding from accidental discharge of hot coolant. Before unpluggingthe connectors for coolant forward flow and return flow, switch off the coolingunit.

When the welding wire emerges from the torch, there is a high risk of injury(the wire may pierce the welder’s hand, injure his face and eyes ...). For thisreason, when feeder-inching etc., always hold the torch so that it is pointingaway from your body (machines with wirefeeder).

While the machine is in use:- ensure that all the covers are closed and that all the sideguards are

properly mounted ...- ... and that all covers and sideguards are kept closed.

Do not touch the workpiece during and after welding - risk of injury fromburning!

Slag may suddenly “jump” off workpieces as they cool. For this reason,continue to wear the regulation protective gear, and to ensure that otherpersons are suitably protected, when doing post-weld finishing onworkpieces.

Electromagnetic fields may cause as yet unknown damage to health.- Effects on the health of persons in the vicinity, e.g. users of heart pace-

makers and hearing aids- Users of heart pacemakers must take medical advice before going

anywhere near welding equipment or welding workplaces- Keep as much space as possible between welding cables and head/body

of welder for safety reasons- Do not carrywelding cables and hose pack over shoulder and do not loop

around body or or any part of body

EMI Precautions

Keep your hands, hair, clothing and tools well away from all moving parts,e.g.:- fans- toothed wheels, rollers, shafts- wire-spools and welding wires

Do not put your fingers anywhere near the rotating toothed wheels of thewirefeed drive.0

Covers and sideguards may only be opened or removed for as long as isabsolutely necessary to carry out maintenance and repair work.

Particular dangerspots

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Shielding-gas cylinders contain pressurized gas and may explode if they aredamaged. As shielding-gas cylinders are an integral part of the overallwelding outfit, they also have to be treated with great care.

Protect shielding-gas cylinders containing compressed gas from excessiveheat, mechanical impact, slag, naked flames, sparks and arcs.

Mount the shielding-gas cylinders in the vertical and fasten them in such away that they cannot fall over (i.e. as shown in the instruction manual).

Keep shielding-gas cylinders well away from welding circuits (and, indeed,from any other electrical circuits).

Never hang a welding torch on a shielding-gas cylinder.

Never touch a shielding-gas cylinder with a welding electrode.

Explosion hazard - never perform welding on a pressurized shielding-gascylinder.

Use only shielding-gas cylinders that are suitable for the application inquestion, together with matching, suitable accessories (pressure regulators,hoses and fittings, ...). Only use shielding-gas cylinders and accessories thatare in good condition.

When opening the valve of a shielding-gas cylinder, always turn your faceaway from the outlet nozzle.

Close the shielding-gas cylinder valve when no welding is being carried out.

When the shielding-gas cylinder is not connected up, leave the cap in placeon the shielding-gas cylinder valve.

Observe the manufacturer’s instructions and all relevant national andinternational rules applying to shielding-gas cylinders and accessories.

Danger fromshielding-gascylinders

Particular dangerspots(continued)

When hoisting the machines by crane, only use suitable manufacturer-supplied lifting devices.- Attach the chains and/or ropes to all the hoisting points provided on the

suitable lifting device.- The chains and/or ropes must be at an angle which is as close to the

vertical as possible.- Remove the gas cylinder and the wirefeed unit (from MIG/MAG and TIG

units).

When hoisting the wirefeed unit by crane during welding, always use asuitable, insulating suspension arrangement (MIG/MAG and TIG units).

If a machine is fitted with a carrying strap or carrying handle, remember thatthis strap is ONLY to be used for lifting and carrying the machine by hand.The carrying strap is NOT suitable for transporting the machine by crane,fork-lift truck or by any other mechanical hoisting device.

Danger of colourless and odourless inert gas escaping unnoticed, whenusing an adapter for the inert gas protection. Seal the adapter thread for theinert gas connection using Teflon tape before assembly.

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Only operate the machine if all of its protective features are fully functional. Ifany of the protective features are not fully functional, this endangers:- the life and well-being of the operator or other persons- the equipment and other tangible assets belonging to the owner/operator- efficient working with the equipment.

Any safety features that are not fully functional must be put right before youswitch on the machine.

Never evade safety features and never put safety features out of order.

Before switching on the machine, ensure that nobody can be endangered byyour doing so.

- At least once a week, check the machine for any damage that may bevisible from the outside, and check that the safety features all functioncorrectly.

- Always fasten the shielding-gas cylinder firmly, and remove it altogetherbefore hoisting the machine by crane.

- Owing to its special properties (in terms of electrical conductivity, frost-proofing, materials-compatibility, combustibility etc.), only original coolantof the manufacturer is suitable for use in our machines.

- Only use suitable original coolant of the manufacturer.- Do not mix original coolant of the manufacturer with other coolants.

Safety precau-tions in normaloperation

Safety precauti-ons at the instal-lation site andwhen beingtransported

A machine that topples over can easily kill someone! For this reason, alwaysplace the machine on an even, firm floor in such a way that it stands firmly.- An angle of inclination of up to 10° is permissible.

Special regulations apply to rooms at risk from fire and/or explosion. Observeall relevant national and international regulations.

By means of internal instructions and checks, ensure that the workplace andthe area around it are always kept clean and tidy.

The appliance must only be installed and operated in accordance with theprotection type stated on the specifications plate.

When installing the appliance, please ensure a clearance radius of 0.5 m(1.6ft.) , so that cool air can circulate freely.

When transporting the appliance, please ensure that the valid national andregional guidelines and accident protection regulations are followed. Thisapplies in particular to guidelines in respect of dangers during transportationand carriage.

Before transportation, completely drain any coolant and dismantle the follo-wing components:- Wire feed- Wire wound coil- Gas bottle

Before commissioning and after transportation, a visual check for damagemust be carried out. Any damage must be repaired by trained service per-sonnel before commissioning.

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With parts sourced from other suppliers, there is no certainty that these partswill have been designed and manufactured to cope with the stressing andsafety requirements that will be made of them. Use only original spares andwearing parts (this also applies to standard parts).

Do not make any alterations, installations or modifications to the machinewithout getting permission from the manufacturer first.

Replace immediately any components that are not in perfect condition.

When ordering spare parts, please state the exact designation and therelevant part number, as given in the spare parts list. Please also quote theserial number of your machine.

Preventive andcorrective main-tenance

- If any damage occurs in cases where other coolants have been used, themanufacturer shall not be liable for any such damage, and all warrantyclaims shall be null and void.

- Under certain conditions, the coolant is flammable. Only transport thecoolant in closed original containers, and keep it away from sources ofignition.

- Used coolant must be disposed of properly in accordance with therelevant national and international regulations. A safety data sheet isavailable from your service centre and on the manufacturer’s homepage.

- Before starting welding - while the machine is still cool - check thecoolant level.

Safety precauti-ons in normaloperation(continued)

The owner/operator is obliged to have a safety inspection performed on themachine at least once every 12 months.

The manufacturer also recommend the same (12-month) interval for regularcalibration of power sources.

A safety inspection, by a trained and certified electrician, is prescribed:- after any alterations- after any modifications or installations of additional components- following repairs, care and maintenance- at least every twelve months.

Observe the relevant national and international standards and directives inconnection with the safety inspection.

More detailed information on safety inspections and calibration is availablefrom your regional or national service centre, who will be pleased to provideyou with copies of the necessary documents upon request.

Safety inspection

Do not dispose of this device with normal domestic waste!To comply with the European Directive 2002/96/EC on Waste Electrical andElectronic Equipment and its implementation as national law, electricalequipment that has reached the end of its life must be collected separatelyand returned to an approved recycling facility Any device that you no longerrequire must be returned to our agent, or find out about the approved collec-tion and recycling facilities in your area.Ignoring this European Directive may have potentially adverse affects on theenvironment and your health!

Disposal

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Copyright to this instruction manual remains the property of themanufacturer.

The text and illustrations are all technically correct at the time of going toprint. The right to effect modifications is reserved. The contents of the in-struction manual shall not provide the basis for any claims whatever on thepart of the purchaser. If you have any suggestions for improvement, or canpoint out to us any mistakes which you may have found in the manual, weshould be most grateful for your comments.

Copyright

Equipment with CE-markings fulfils the basic requirements of the Low-Voltage and Electromagnetic Compatibility Guideline (e.g. relevant productstandards according to EN 60 974). .

Safety markings

Equipment marked with the CSA-Test Mark fulfils the requirements made inthe relevant standards for Canada and the USA.

The user is responsible for the data security of changes made to factorysettings. The manufacturer is not liable, if personal settings are deleted.

Data security

1

Table of contents

General information 3

General .......................................................................................................................................................... 5Device concept .......................................................................................................................................... 5Functional principle .................................................................................................................................... 5Application areas ....................................................................................................................................... 5

System components ....................................................................................................................................... 6General ..................................................................................................................................................... 6Overview ................................................................................................................................................... 6

Control elements and connections 7

Descriptions of the control panels ................................................................................................................... 9General ..................................................................................................................................................... 9Safety ........................................................................................................................................................ 9Overview ................................................................................................................................................... 9

“Remote” control panel ................................................................................................................................. 10General ................................................................................................................................................... 10“Remote” control panel ............................................................................................................................ 10

Connections, switches and mechanical components ..................................................................................... 11TSt 3500/5000 power source .................................................................................................................... 11

Installation 13

Minimum equipment needed for welding task ............................................................................................... 15General ................................................................................................................................................... 15MIG/MAG welding, gas-cooled ................................................................................................................ 15MIG/MAG welding, water-cooled ............................................................................................................. 15MMA welding ........................................................................................................................................... 15

Before installation and commissioning .......................................................................................................... 16Safety ...................................................................................................................................................... 16Utilisation for intended purpose only ........................................................................................................ 16Mains connection .................................................................................................................................... 16Setup regulations .................................................................................................................................... 16

Connecting up the mains cable on MV power sources ................................................................................. 17General ................................................................................................................................................... 17Stipulated mains cables and strain-relief devices .................................................................................... 17Safety ...................................................................................................................................................... 17Connecting the mains cable .................................................................................................................... 17

Commissioning ............................................................................................................................................. 19Safety ...................................................................................................................................................... 19Information on system components ......................................................................................................... 19Overview ................................................................................................................................................. 19

Commissioning a TSt 3500/5000 power source ........................................................................................... 20General ................................................................................................................................................... 20Fitting the system components (overview) ............................................................................................... 20Fixing the strain-relief device in place ...................................................................................................... 21Connecting the interconnecting hosepack ............................................................................................... 21Connecting up the gas cylinder ............................................................................................................... 22Creating a ground earth connection, connecting the welding torch .......................................................... 22Other activities ......................................................................................................................................... 22

2

Troubleshooting and maintenance 23

Troubleshooting ............................................................................................................................................ 25General ................................................................................................................................................... 25Safety ...................................................................................................................................................... 25Power source - troubleshooting ............................................................................................................... 25

Care, maintenance and disposal .................................................................................................................. 27General ................................................................................................................................................... 27Safety ...................................................................................................................................................... 27At every start-up ...................................................................................................................................... 27Every 2 months ....................................................................................................................................... 27Every 6 months ....................................................................................................................................... 27Disposal .................................................................................................................................................. 27

Annex 29

Technical data .............................................................................................................................................. 31Special voltages....................................................................................................................................... 31TSt 3500 .................................................................................................................................................. 31TSt 5000 .................................................................................................................................................. 31

3

General information

4

5

The TransSteel (TSt) 3500 and TSt 5000power sources are completely digitised,microprocessor-controlled inverter powersources.

The modular design and potential forsystem add-ons ensure a high degree offlexibility. The devices are designed for thewelding of steel.

All devices are suitable for:- MIG/MAG welding- MMA welding

TSt 3500/5000 power source

The devices are used in workshops and industry: manual and automated applicationswith classical steel and galvanised sheets.

The TSt 3500/5000 power sources are designed for:- machine and equipment construction- steelwork- plant and container construction- shipyards and the offshore industry- metal and gantry construction- rolling stock construction

General

Functional prin-ciple

Device concept

Application areas

The central control and regulation unit of the power sources is coupled with a digitalsignal processor. The central control and regulation unit and signal processor control theentire welding process.During the welding process, the actual data is measured continuously and the deviceresponds immediately to any changes. Control algorithms ensure that the specifiedtarget status is maintained.

This results in:- a precise welding process,- high reproducibility of all results- excellent weld properties.

6

System components

General The power sources can be operated with various system components and options. Thismakes it possible to optimise procedures and to simplify machine handling and operati-on, as necessitated by the particular field of application in which the power source is tobe used.

Overview

Wire-feed unit

Interconnectinghosepacks

Trolleys and gas-cylinder holders

Wire-feed unitholder

Overview of system components

Welding torch

Power sources

Cooling unit

Grounding (earthing) cable and electrode cable

7

Control elements and connections

8

9

Descriptions of the control panels

General The functions on the control panels are all arranged in a very logical way. The variousparameters needed for welding are easy to select, by pressing the appropriate button,and can easily be- altered with buttons (“Standard”) or the adjusting dial (“Comfort”), and- displayed during welding on the digital display

Thanks to the synergic function, whenever you alter any one parameter, appropriatechanges will automatically be made to all the other parameters.

NOTE! Owing to software updates, you may find that your device has certainfunctions that are not described in these operating instructions, or vice versa.Certain illustrations may also differ slightly from the actual control elements onyour device. However, these control elements function in exactly the same way.

WARNING! Operating the equipment incorrectly can cause serious injury anddamage. Do not use the functions described until you have thoroughly readand understood the following documents:- these operating instructions- All the operating instructions for the system components, especially the

safety rules

Safety

Overview „Description of the control panels“ is composed of the following sections:- “Remote” control panel

10

R EMOTE

(3)

(2)

(1)

“Remote” control panel

The “Remote” control panel is fitted as standard as part of the power source. The powersource is operated from the control panel on the wire-feed unit.

The remote power source can be operated via the following system add-ons:- remote control units

No. Function(1) Overtemperature indication

lights up if the power source overheats (e.g. because the duty cycle has beenexceeded). For more information, refer to the „Troubleshooting“ section.

(2) Error indicationlights up if an error has occurred. All the units which are connected to the LocalNet,and which have a digital display, support the display of the relevant error message.

(3) Power source ON indicationlights up when the mains cable is plugged into the mains and the mains switch is inthe - I - position

“Remote” control panel

General

“Remote” controlpanel

11

Connections, switches and mechanical components

TSt 3500/5000power source

TSt 3500/5000 power source

No. Function(1) (-) - current socket with bayonet latch

usedfor connecting the grounding (earthing) cable in MIG/MAG welding- for connecting the electrode (or grounding/earthing) cable in MMA welding,

depending on the type of electrode being used(2) Mains switch

for switching the power source on and off.(3) (+) - Current socket with bayonet latch

usedfor connecting the current cable from the interconnecting hosepack in MIG/

MAG welding- for connecting the electrode (or grounding/earthing) cable in MMA welding,

depending on the type of electrode being used(4) Gas preheater (option)(5) Blanking cover(6) Gas test button (option)(7) Mains cable with strain relief(8) LocalNet connection

Standardised connection socket for the wire-feed unit (intermediary hosepack)

Rear viewFront view

(1) (2)

(3)

(4)

(5)

(6)

(7)

(8)

12

13

Installation

14

15

Minimum equipment needed for welding task

Depending on which welding process you intend to use, a certain minimum equipmentlevel will be needed in order to work with the power source.The welding processes and the minimum equipment levels required for the welding taskare then described.

General

- Power source- Grounding (earthing) cable- MIG/MAG welding torch, gas-cooled- Gas connection (shielding gas supply)- Wire-feed unit- Interconnecting hosepack- Wire electrode

MIG/MAG wel-ding, gas-cooled

- Power source- Cooling unit- Grounding (earthing) cable- MIG/MAG welding torch, water-cooled- Gas connection (shielding gas supply)- Wire-feed unit- Interconnecting hosepack- Wire electrode

MIG/MAG wel-ding, water-cooled

- Power source- Grounding (earthing) cable- Electrode holder- Rod electrodes

MMA welding

16

Before installation and commissioning

Safety

The power source may only be used for MIG/MAG and MMA welding.Utilisation for any other purpose, or in any other manner, shall be deemed to be „not inaccordance with the intended purpose“. The manufacturer shall not be liable for anydamage resulting from such improper use.

Utilisation in accordance with the „intended purpose“ also includes- following all the instructions in this manual- carrying out all the specified inspection and servicing work

Utilisation forintended purposeonly

Setup regulations

Mains connection

The device is tested to “Degree of protection IP23”, meaning:- Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49

in.)- Protection against direct sprays of water up to 60° from the vertical

The device can be set up and operated outdoors in accordance with IP23. Direct wetting(e.g. from rain) should be avoided.

The devices are designed to run on the mains voltage shown on the respective ratingplates. If your version of the device does not come with mains cables and plugs ready-fitted, these must be fitted in accordance with national regulations and standards. Fordetails of fuse protection of the mains lead, please see the Technical Data.

NOTE! An inadequately dimensioned electrical installation can cause seriousdamage. The incoming mains lead and its fuse must be dimensioned to suit thelocal power supply. The technical data shown on the rating plate applies.

WARNING! Operating the equipment incorrectly can cause serious injury anddamage. Do not use the functions described until you have thoroughly readand understood the following documents:- These operating instructions- All the operating instructions for the system components, especially the

safety rules

The venting duct is a very important safety feature. When choosing the location for thedevice, ensure that the cooling air can enter and exit unhindered through the air ducts onthe front and back of the device. Any electroconductive metallic dust from e.g. grindingwork must not be allowed to get sucked into the device.

WARNING! If one of these machines topples over or falls it could causeserious or even fatal injury. Place device on a solid, level surface in such away that it remains stable.

17

Connecting up the mains cable on MV power sources

Safety

Important! The PE conductor (green, or green with yellow stripes) should be approx. 10- 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

NOTE! If wire end ferrules are not used, there is a risk of short circuits betweenthe phase conductors or between phase conductors and the PE conductor. Fitwire-end ferrules to all phase conductors and the PE conductor of the strippedmains cable.

Connecting themains cable

Stipulated mainscables andstrain-reliefdevices

Power source Mains voltage Cable cross-sectionUS Europe

TSt 3500 MV 3 x 460 V AWG 10 4G43 x 230 V AWG 8

TSt 5,000 MV 3 x 460 V AWG 10 4G103 x 230 V AWG 63 x 400 V - 4G2,5

AWG ... American wire gauge

General If there is no mains cable attached to the power source, a mains cable appropriate forthe connection voltage must be fitted prior to putting the unit into service.A strain-relief device for a cable cross-section AWG 10 is installed on the power source.Strain-relief devices for other cable cross-sections must be designed accordingly.

WARNING! Operating the equipment incorrectly can cause serious injury anddamage. The following activities must only be carried out by trained andqualified personnel. Pay particular attention to the „Safety rules“ section.

1

3

1

2

5

4

7

2

2

3

4

100mm

(4inch)

PE

1

18

Connecting themains cable(continued)

Important! Push the mains cable in far enough to make it possible to connect the PEconductor and the phase conductors to the block terminal properly.

3

1

2

3

4x

4

1

4

3

2

5

6

19

WARNING! An electric shock can be fatal. If the device is plugged into themains electricity supply during installation, there is a high risk of very seriousinjury and damage. Only carry out work on the device when- the mains switch is in the „O“ position,- the device is unplugged from the mains.

„Commissioning“ comprises the following sections:- Commissioning a TSt 3500/5000 power source

The steps and activities described below include references to various system compon-ents, including- Trolleys- Cooling units- Wire-feed unit holders- Wire-feed units- Interconnecting hosepacks- Welding torch- etc.

For more detailed information about installing and connecting the system components,please refer to the appropriate operating instructions.

Commissioning

Safety

Information onsystem compon-ents

Overview

20

The diagram below is intended to show you how to fit the individual system components.For detailed information about the individual steps, please refer to the operating instruc-tions for the system components.

Fitting the sys-tem components(overview)

Commissioning a TSt 3500/5000 power source

General Commissioning a TSt 3500/5000 power source is described by reference to a manualwater-cooled MIG/MAG application.

Fitting the system components


21

1

2

34

1

1

Fixing the strain-relief device inplace

Connecting theinterconnectinghosepack

Important! There is no cooling unit present in the case of gas-cooled systems. There isno need to attach the water connections in the case of gas-cooled systems.

red

black

2

1

2

34

1

2

2 3

6

7

4

5

22

Creating aground earthconnection,connecting thewelding torch

Other activities Carry out the following steps in accordance with the wire-feed unit operating instructions:

1. Insert the feed rollers in the wire-feed unit2. Insert the wirespool or basket-type spool and basket spool adapter in the wire-feed

unit3. Feeding in the wire electrode4. Setting the contact pressure

Connecting upthe gas cylinder WARNING! There is a high risk of very serious injury and damage from

toppling gas cylinders. Place gas cylinders on a solid, level surface in such away that they remain stable. Secure gas cylinders to prevent them fromtoppling over.Follow the gas cylinder manufacturer’s safety instructions.

- Briefly open the gas cylinder valve toblow off any dust or dirt

- Inspect the seal on the pressureregulator

NOTE! US machines are supplied with an adapter for the gas hose:- Glue in or seal the adapter- Test the adapter to ensure that it is gas-tight.

3

1

2

3

4

5

5

1

2

1

3

1

23

Troubleshooting and maintenance

24

25

The power sources are equipped with an intelligent safety system. This means that apartfrom the fuse for the coolant-pump, it has been possible to dispense with fuses entirely.After a possible malfunction or error has been remedied, the power source can be putback into normal operation again without any fuses having to be replaced.

Troubleshooting

General

WARNING! An electric shock can be fatal. Before opening the device- Turn the mains switch to the „O“ position- Unplug the device from the mains- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again- Using a suitable measuring instrument, check to make sure that electri-

cally charged components (e.g. capacitors) have discharged

CAUTION! Inadequate PE conductor connections can cause serious injuryand damage. The housing screws provide a suitable PE conductor connectionfor earthing (grounding) the housing and must NOT be replaced by any otherscrews which do not provide a reliable PE conductor connection.

Safety

Power source -troubleshooting

tSt | xxxRemark: xxx stands for a temperature value

Cause: Overtemperature in the control circuitRemedy: Allow the power source to cool downPower source inoperativeMains switch is on, power source ON indication not lit up

Cause: There is a break in the mains lead; the mains plug is not plugged inRemedy: Check the mains supply lead, make sure that the mains plug is

plugged in

Cause Mains outlet socket or plug is faultyRemedy: Replace faulty componentsPower source inoperativeMains switch is on, power source ON indication not lit up

Cause: Mains fuse is faultyRemedy: Change the mains fuseNo welding currentMains switch is ON, overtemperature indication is lit up

Cause: Overload; the duty cycle has been exceededRemedy: Do not exceed the duty cycle

Cause: Thermostatic cut-out system has been trippedRemedy: Wait until the power source automatically comes back on after the

end of the cooling phase

Cause: The fan in the power source is defectiveRemedy: Change the fan

26

No welding currentMains switch is ON and indicators are lit up

Cause: Grounding (earthing) connection is wrongRemedy: Check the earth (ground) connection and clamp for correct polarity

Cause: There is a break in the current cable in the welding torchRemedy: Replace the torchNothing happens when the torch trigger is pressedMains switch is on, power source ON indication is lit up, indications on wire-feed unit notlit up

Cause: The interconnecting hosepack is faulty or not connected properlyRemedy: Check interconnecting hosepackNo shielding gasAll other functions are OK

Cause: The gas cylinder is emptyRemedy: Change the gas cylinder

Cause: Gas pressure regulator is faultyRemedy: Change the gas pressure regulator

Cause: The gas hose is not connected, or is damagedRemedy: Mount/change the gas hose

Cause: The welding torch is defectiveRemedy: Change the welding torch

Cause: Gas solenoid valve is defectiveRemedy: Replace gas solenoid valvePoor weld properties

Cause: Incorrect welding parametersRemedy: Check the settings

Cause: Poor ground earth connectionRemedy: Ensure good contact to workpiece

Cause: Not enough protective gas shield, or none at allRemedy: Check the pressure regulator, gas hose, gas solenoid valve, torch

gas connection, etc.

Cause: Welding torch is leakingRemedy: Change the welding torch

Cause: Wrong contact tube, or contact tube is worn outRemedy: Change the contact tube

Cause: Wrong wire alloy or wrong wire diameterRemedy: Check the wire spool that has been inserted

Cause: Wrong wire alloy or wrong wire diameterRemedy: Check the weldability of the base material

Cause: The protective gas shield is not suitable for this wire alloyRemedy: Use the correct protective gas shieldThe welding torch becomes very hot

Cause: The design dimensions of the welding torch are not sufficient for thistask

Remedy: Observe the duty cycle and loading limits

Cause: Only on water-cooled machines: Coolant flow is insufficientRemedy: Check the water level, water flowrate, its cleanliness, etc.

Power source -troubleshooting(continued)

27

Care, maintenance and disposal

Under normal operating conditions the power source requires only a minimum of careand maintenance. However, it is vital to observe some important points to ensure thewelding system remains in a usable condition for many years.

- Check mains plug, mains cable, welding torch, interconnecting hosepack andgrounding (earthing) connection for damage

- Check whether the all-round clearance of 0.5 m (1 ft 8 in.) is kept to ensure that thecooling air can easily flow and escape.

NOTE! Air inlets and outlets must never be covered, not even partially.

- Clean air filter

- Dismantle device side panels and clean inside of device with dry reduced com-pressed air

NOTE! Risk of damage to electronic components. Do not bring air nozzle tooclose to electronic components.

- If a lot of dust has accumulated, clean the cooling air ducts.

Dispose of in accordance with the applicable national and local regulations.

WARNING! An electric shock can be fatal. Before opening the device- Turn the mains switch to the „O“ position- Unplug the device from the mains- Put up an easy-to-understand warning sign to stop anybody inadvertently

switching it back on again- Using a suitable measuring instrument, check to make sure that electri-

cally charged components (e.g. capacitors) have discharged

General

Safety

At every start-up

Every 2 months

Every 6 months

Disposal


28

29

Annex

30

31

Technical data

Special voltages For devices designed for special voltages, the technical data on the rating plate applies.

For all machines with a permitted mains voltage of up to 460 V: The standard mains plugallows the user to operate with a mains voltage of up to 400 V. For mains voltages up to460 V fit a mains plug permitted for such use or install the mains supply directly.

TSt 3500 Mains voltage +- 10% 380 V / 400 V / 460 VWelding current range 10 – 350 AWelding current at 10 min / 40°C (104°F) 40 % d.c.* 350 A

100 % d.c.* 250 AOpen circuit voltage 60 VWorking voltage 15.5 – 31.5 VMaximum impedance value on the PCC 22.5 mOhmDegree of protection IP 23Dimensions l x w x h 747 x 300 x 497 mmWeight 26.5 kg

* d.c. = duty cycle

TSt 5000 Mains voltage +- 10% 380 V / 400 V / 460 VWelding current range 10 – 500 AWelding current at 10 min / 40°C (104°F) 40 % d.c.* 500 A

100 % d.c.* 360 AOpen circuit voltage 65 VWorking voltage 14.5 – 39 VMaximum impedance value on the PCC 29.6 mOhmDegree of protection IP 23Dimensions l x w x h 747 x 300 x 497 mmWeight 30.15 kg

* d.c. = duty cycle

32

ud_fr_st_tb_00150 012008

Liste de pièces de rechange

ErsatzteillisteD

Lista parti di ricambio

Lista de repuestos

Lista de peças sobresselentes

GB

F

I

E

P

NL

N

CZ

RUS

Spare Parts List

Onderdelenlijst

Reservdelsliste

Seznam náhradních dílů

Ñïèñîê çàïàñíûõ ÷àñòåé

SK Zoznam náhradných dielov

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei RicambiTransSteel 3500/5000

1/2

el_fr_st_mi_01585 012009

43,0006,0204 TSt 3500

42,0405,0689

42,0405,0690

42,0405,0691

45,0200,132045,0200,1319

BU2,0201,3002

42,0201,2991

42,0405,0692

42,0405,0692

42,0201,2966

33,0010,0383

43,0001,1333

42,0401,1118 (6x)

42,0401,1118 (4x)

42,0400,0132 TSt 5000

41,0005,0288 TSt 5000

42,0401,1116 (4x)

40,0006,3002 (TSt 5000)

43,0006,0242 TSt 5000

TransSteel 3500 43,0001,1368TransSteel 5000 43,0001,1369

40,0006,3001 (TSt 3500)

42,0405,0754

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei RicambiTransSteel 3500/5000

2/2

el_fr_st_mi_01585 012009

43,0002,0405

41,0009,0255

42,0406,0294

41,0002,0060

42,0407,0440

41,0003,0320

33,0005,4148 (TSt 3500)33,0005,4149 (TSt 5000)

32,0405,0229

45,0200,1321

42,0300,1511 -PVC PG16 SW42,0407,0532 -M25AWG1242,0407,0534 -M25AWG1042,0407,0437 -M3242,0407,0533 -M40

4,100,61142,0409,3272 -PG1642,0409,5112 -M2542,0409,5113 -M3242,0409,5114 -M40

42,0200,9158

44,0450,1214

43,0004,0507 -4G2,5mm² 5m43,0004,0881 -4G2,5mm² 5m E5 32A43,0004,4044 -4G2,5mm² 5m E4 32A43,0004,0586 -4G4mm² 5m43,0004,0987 -4G4mm² 5m E5 32A43,0004,4045 -4G4mm² 5m E4 32A43,0004,2323 -AWG 1243,0004,2955 -AWG 1043,0004,0664 -4G10mm²43,0004,2324 - AWG6

43,0001,1187

43,0001,1186

4,0401,1120 (2x)

42,0401,1120 (3x)

42,0401,1115 (2x)

4,070,989

33,0024,0046

40,0009,0043

40,0009,0043

4,071,144,Z (LST MAG 35/50)4,071,134,Z (LST MAG 50,Z)

4,071,067,Z (NT2500)

43,0003,0031

43,0004,4035

43,0003,1072

43,0003,0031

42,0407,0481

43,0001,1084

4,070,955 (GPR MAG50)

43,0010,0350

4,100,608 (BRTSFMAG 50)

4,070,991 (NF MAG50)

4,070,627,Z 42,0400,0105

43,0003,1071

ud_fr_st_so_00082 012008

FRONIUS INTERNATIONAL GMBH

Buxbaumstraße 2, A-4600 Wels, Austria

Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940

E-Mail: [email protected]

www.fronius.com

www.fronius.com/addresses

Under http://www.fronius.com/addresses you will find all addresses

of our Sales & service partners and Locations.

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