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Summary of Contents for Fronius TransSteel 5000
- Page 1 TransSteel 3500 / 5000 Operating instructions Spare parts list MIG/MAG Power source 42,0426,0076,EN 012009...
- Page 3 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.
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Page 5: Safety Rules
Safety rules DANGER! “DANGER!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved. -
Page 6: Ambient Conditions
General remarks Any malfunctions which might impair machine safety must be eliminated (continued) immediately - meaning before the equipment is next switched on. It’s your safety that’s at stake! Utilisation for The machine may only be used for jobs as defined by the “Intended intended purpose purpose”. - Page 7 Obligations of Before starting work, all persons to be entrusted with carrying out work with personnel (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 will comply with them.
- Page 8 Protection for “Protective clothing” also includes: yourself and protecting your eyes and face from UV rays, heat and flying sparks with other persons an appropriate safety shield containing appropriate regulation filter glass (continued) 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-...
- Page 9 Hazards from The harmfulness of the welding fumes will depend on e.g. the following noxious gases components: and vapours the metals used in and for the workpiece (continued) the electrodes coatings cleaning and degreasing agents and the like For this reason, pay attention to the relevant Materials Safety Data Sheets and the information given by the manufacturer regarding the components listed above.
- Page 10 Hazards from Do not loop any cables or other leads around your body or any part of your mains and weld- body. ing current (continued) Never immerse the welding electrode (rod electrode, tungsten electrode, welding wire, ...) in liquid in order to cool it, and never touch it when the power source is ON.
- Page 11 Stray welding When using current supply distributors, twin head wire feeder fixtures etc., currents please note the following: The electrode on the unused welding torch/welding (continued) tongs 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 insulated filler wire is routed from the welding wire drum, large wirefeeder spool or wirespool to the wirefeeder.
- Page 12 EMI Precautions 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...
- Page 13 Particular danger When hoisting the machines by crane, only use suitable manufacturer- spots supplied lifting devices. (continued) 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.
- Page 14 Safety precauti- A machine that topples over can easily kill someone! For this reason, always ons at the instal- place the machine on an even, firm floor in such a way that it stands firmly. lation site and An angle of inclination of up to 10° is permissible. when being transported Special regulations apply to rooms at risk from fire and/or explosion.
- Page 15 Safety precauti- If any damage occurs in cases where other coolants have been used, the ons in normal manufacturer shall not be liable for any such damage, and all warranty operation claims shall be null and void. (continued) Under certain conditions, the coolant is flammable. Only transport the coolant in closed original containers, and keep it away from sources of ignition.
- Page 16 Safety markings Equipment with CE-markings fulfils the basic requirements of the Low- Voltage and Electromagnetic Compatibility Guideline (e.g. relevant product standards according to EN 60 974). . Equipment marked with the CSA-Test Mark fulfils the requirements made in the relevant standards for Canada and the USA. Data security The user is responsible for the data security of changes made to factory settings.
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Page 17: Table Of Contents
Table of contents General information General ................................5 Device concept ............................5 Functional principle ............................ 5 Application areas ............................5 System components ............................6 General ..............................6 Overview ..............................6 Control elements and connections Descriptions of the control panels ........................9 General .............................. - Page 18 Troubleshooting and maintenance Troubleshooting ............................25 General ..............................25 Safety ..............................25 Power source - troubleshooting ....................... 25 Care, maintenance and disposal ........................27 General ..............................27 Safety ..............................27 At every start-up ............................27 Every 2 months ............................27 Every 6 months ............................
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Page 19: General Information
General information... -
Page 21: General
General Device concept The TransSteel (TSt) 3500 and TSt 5000 power sources are completely digitised, microprocessor-controlled inverter power sources. The modular design and potential for system add-ons ensure a high degree of flexibility. The devices are designed for the welding of steel. All devices are suitable for: MIG/MAG welding MMA welding... -
Page 22: System Components
System components General The power sources can be operated with various system components and options. This makes 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 to be used. -
Page 23: Control Elements And Connections
Control elements and connections... -
Page 25: Descriptions Of The Control Panels
Descriptions of the control panels General The functions on the control panels are all arranged in a very logical way. The various parameters 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, appropriate changes will automatically be made to all the other parameters. -
Page 26: Remote" Control Panel
“Remote” control panel General The “Remote” control panel is fitted as standard as part of the power source. The power source 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 “Remote”... -
Page 27: Connections, Switches And Mechanical Components
Connections, switches and mechanical components TSt 3500/5000 Front view Rear view power source TSt 3500/5000 power source No. Function (1) (-) - current socket with bayonet latch used for 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. -
Page 29: Installation
Installation... -
Page 31: Minimum Equipment Needed For Welding Task
Minimum equipment needed for welding task General Depending on which welding process you intend to use, a certain minimum equipment level will be needed in order to work with the power source. The welding processes and the minimum equipment levels required for the welding task are then described. -
Page 32: Before Installation And Commissioning
Before installation and commissioning Safety 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 safety rules The power source may only be used for MIG/MAG and MMA welding. -
Page 33: Connecting Up The Mains Cable On Mv Power Sources
Connecting up the mains cable on MV power sources General If there is no mains cable attached to the power source, a mains cable appropriate for the 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. - Page 34 Connecting the Important! Push the mains cable in far enough to make it possible to connect the PE mains cable conductor and the phase conductors to the block terminal properly. (continued)
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Page 35: Commissioning
Commissioning Safety WARNING! An electric shock can be fatal. If the device is plugged into the mains electricity supply during installation, there is a high risk of very serious injury and damage. Only carry out work on the device when the mains switch is in the „O“... -
Page 36: Commissioning A Tst 3500/5000 Power Source
Commissioning a TSt 3500/5000 power source General Commissioning a TSt 3500/5000 power source is described by reference to a manual water-cooled MIG/MAG application. Fitting the sys- WARNING! Operating the equipment incorrectly can cause serious injury and tem components damage. The following activities must only be carried out by trained and (overview) qualified personnel. -
Page 37: Fixing The Strain-Relief Device In Place
Fixing the strain- relief device in place Connecting the Important! There is no cooling unit present in the case of gas-cooled systems. There is interconnecting no need to attach the water connections in the case of gas-cooled systems. hosepack black... -
Page 38: Connecting Up The Gas Cylinder
Connecting up WARNING! There is a high risk of very serious injury and damage from the gas cylinder toppling gas cylinders. Place gas cylinders on a solid, level surface in such a way that they remain stable. Secure gas cylinders to prevent them from toppling over. -
Page 39: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 41: Troubleshooting
Troubleshooting General The power sources are equipped with an intelligent safety system. This means that apart from 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 put back into normal operation again without any fuses having to be replaced. - Page 42 Power source - No welding current troubleshooting Mains switch is ON and indicators are lit up (continued) Cause: Grounding (earthing) connection is wrong Remedy: Check the earth (ground) connection and clamp for correct polarity Cause: There is a break in the current cable in the welding torch Remedy: Replace the torch Nothing happens when the torch trigger is pressed...
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Page 43: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions the power source requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the welding system remains in a usable condition for many years. Safety WARNING! An electric shock can be fatal. -
Page 45: Annex
Annex... -
Page 47: Technical Data
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 plug allows the user to operate with a mains voltage of up to 400 V. For mains voltages up to 460 V fit a mains plug permitted for such use or install the mains supply directly. - Page 49 Ersatzteilliste Spare Parts List Liste de pièces de rechange Lista parti di ricambio Lista de repuestos Lista de peças sobresselentes Onderdelenlijst Reservdelsliste Seznam náhradních dílů Ñïèñîê çàïàñíûõ ÷àñòåé SK Zoznam náhradných dielov ud_fr_st_tb_00150 012008...
- Page 50 TransSteel 3500 43,0001,1368 TransSteel 5000 43,0001,1369 42,0201,2966 42,0401,1116 (4x) 42,0405,0691 42,0401,1118 (4x) BU2,0201,3002 45,0200,1320 45,0200,1319 42,0401,1118 (6x) 42,0405,0690 42,0400,0132 TSt 5000 42,0405,0692 33,0010,0383 43,0001,1333 40,0006,3001 (TSt 3500) 40,0006,3002 (TSt 5000) 42,0405,0754 41,0005,0288 TSt 5000 43,0006,0242 TSt 5000 42,0201,2991 42,0405,0689 43,0006,0204 TSt 3500...
- Page 51 43,0004,0507 -4G2,5mm² 5m 43,0004,0881 -4G2,5mm² 5m E5 32A 43,0004,4044 -4G2,5mm² 5m E4 32A 43,0004,0586 -4G4mm² 5m 43,0004,0987 -4G4mm² 5m E5 32A 43,0004,4045 -4G4mm² 5m E4 32A 43,0004,2323 -AWG 12 43,0004,2955 -AWG 10 43,0004,0664 -4G10mm² 43,0004,2324 - AWG6 44,0450,1214 32,0405,0229 4,100,608 (BRTSFMAG 50) 43,0004,4035 43,0003,1071 42,0407,0481...
- Page 52 FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, 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 our Sales & service partners and Locations. ud_fr_st_so_00082 012008...
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