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Summary of Contents for Fronius TransSteel 2500c
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions TransSteel 2500c TransSteel 2500c MV MIG/MAG Power source TransSteel 2700c TransSteel 2700c MV TransSteel 3500c 42,0426,0107,EN 034-09012018...
- Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.
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Page 5: Table Of Contents
Contents Safety rules ..............................General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Protecting yourself and others ......................Danger from toxic gases and vapours ....................Danger from flying sparks ........................Risks from mains current and welding current..................Meandering welding currents........................ - Page 6 MIG/MAG welding, water-cooled ......................Manual metal arc welding ........................Before installation and commissioning....................... Safety..............................Utilisation for intended purpose only..................... Setup regulations ..........................Mains connection ..........................Connecting the mains cable........................General ..............................Stipulated mains cables and strain-relief devices ................. Connecting the mains cable........................Fitting the strain-relief device, TSt 2500c MV / TSt 2700c, single-phase operation ......
- Page 7 Safety..............................Preparation ............................MMA welding ............................Corrections during welding ........................HotStart function ........................... Anti-stick function..........................Saving and retrieving operating points....................... General ..............................Saving operating points ........................Retrieving operating points ........................Deleting operating points ........................Retrieving operating points on the Up/Down welding torch ..............Setup settings Setup menu..............................
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Page 9: Safety Rules
Safety rules General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operat- ing company, inefficient operation of the device. -
Page 10: Environmental Conditions
Environmental Operation or storage of the device outside the stipulated area will be deemed conditions as not in accordance with the intended purpose. The manufacturer shall not be held liable for any damage arising from such usage. Ambient temperature range: during operation: -10 °C to + 40 °C (14 °F to 104 °F) during transport and storage: -20 °C to +55 °C (-4 °F to 131 °F) Relative humidity:... -
Page 11: Protecting Yourself And Others
Protecting your- Persons involved with welding expose themselves to numerous risks, e.g.: self and others flying sparks and hot pieces of metal arc radiation, which can damage eyes and skin hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers risk of electrocution from mains current and welding current greater noise pollution... -
Page 12: Danger From Flying Sparks
Otherwise, a protective mask with an air supply must be worn. Close the shielding gas cylinder valve or main gas supply if no welding is tak- ing place. If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values. -
Page 13: Meandering Welding Currents
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Replace loose connections and scorched, damaged or inade- quately dimensioned cables and leads immediately. Use the handle to ensure the power connections are tight before every use. In the case of power cables with a bayonet connector, rotate the power cable around the longitudinal axis by at least 180°... -
Page 14: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is sup- plied from the public low-voltage mains. -
Page 15: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive com- ponents. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. -
Page 16: Factors Affecting Welding Results
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, coun- terbalanced lift truck or other mechanical hoist. All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. -
Page 17: Danger From Escaping Shielding Gas
Danger from es- Risk of suffocation from the uncontrolled escape of shielding gas caping shielding Shielding gas is colourless and odourless and, in the event of a leak, can dis- place the oxygen in the ambient air. Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. -
Page 18: Commissioning, Maintenance And Repair
Commissioning, It is impossible to guarantee that bought-in parts are designed and manufac- maintenance and tured to meet the demands made of them, or that they satisfy safety require- repair ments. Use only original spare and wearing parts (also applies to standard parts). Do not carry out any modifications, alterations, etc. -
Page 19: Safety Symbols
(e.g. relevant product standards 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 following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the rele- vant standards for Canada and the USA. -
Page 21: General Information
General information... -
Page 23: General
General Device concept The TransSteel (TSt) 2500c, 2700c and 3500c power sources are completely digiti- sed, microprocessor-controlled inverter po- wer sources. The modular design and potential for sys- tem add-ons ensure a high degree of flexi- bility. The devices are designed for the welding of steel. -
Page 24: Warning Notices On The Device
Warning notices Warning notices and safety symbols are affixed to the power sources. These warning no- on the device tices and safety symbols must not be removed or painted over. They warn against operat- ing the device incorrectly, as this may result in serious injury and damage. 40,0006,3035 inside Safety symbols on the rating plate... -
Page 25: 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 operation, as necessitated by the particular field of application in which the power source is to be used. - Page 26 TSt 3500c Function Welding torch Gas cylinder holder stabiliser Power source Cooling unit TSt 3500c only Trolley and gas cylinder holder Grounding (earthing) cable and electrode cable...
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Page 27: Options
Options VRD: safety func- A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. It tion is recommended for environments in which the risk of an electric shock or electrical acci- dent is increased considerably during arc welding: Due to a low human body resistance of the welder If the welder is exposed to a clear risk of touching the workpiece or other parts of the welding circuit... - Page 28 In MMA welding mode: Within 0.3 seconds of end of welding: VRD is active again The output voltage is limited to 35 V once more...
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Page 29: Control Elements And Connections
Control elements and connections... -
Page 31: Synergic Central Control Panel
Synergic Central control panel General The functions on the control panel are all arranged in a logical way. The individual param- eters required for welding can be selected easily using buttons altered using buttons or the adjusting dial displayed on the digital display during welding The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best weld- ing parameters. - Page 32 Function "Parameter selection" button (right) for selecting the following welding parameters and for changing parameters in the Setup menu The relevant symbol lights up when a welding parameter is selected. Arc length correction for correcting the arc length Welding voltage in V *) Before the start of welding, the system automatically displays a standard val- ue based on the programmed parameters.
- Page 33 ***) "Process" button for selecting the welding process MANUAL - MIG/MAG standard manual welding SYNERGIC - MIG/MAG standard synergic welding STICK - manual metal arc welding "Mode" button for selecting the operating mode 2 T - 2-step mode 4 T - 4-step mode S 4 T - Special 4-step mode "Shielding gas"...
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Page 34: Service Parameters
If one of these parameters is selected in the MIG/MAG standard synergic welding process, then the synergic function ensures that all other parameters, including the welding voltage parameter, are adjusted automatically. The Real Energy Input display must be activated in level 2 of the Setup menu – EnE parameter. -
Page 35: Keylock
Keylock A keylock can be selected to prevent the settings from being inadvertently changed on the control panel. As long as the keylock is active no settings can be made on the control panel only parameter settings can be retrieved any assigned "Save"... -
Page 36: Connections, Switches And Mechanical Components
Connections, switches and mechanical components Front and rear sides, TSt 2500c / TSt 2700c TSt 2500c / TSt 2700c Function Welding torch connection for connecting the welding torch (-) - Current socket with bayonet latch used for connecting the grounding (earthing) cable during MIG/MAG welding connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used) LocalNet connection... -
Page 37: Front And Rear Sides, Tst 3500C
Front and rear (3) (4) (5) sides, TSt 3500c TSt 3500c Function Welding torch connection for connecting the welding torch (-) - Current socket with bayonet latch used for connecting the grounding (earthing) cable during MIG/MAG welding connecting the electrode cable or grounding (earthing) cable during MMA welding (depending on the type of electrode used) (+) - Current socket with bayonet latch used for... -
Page 38: Side View
Side view Function Wirespool holder with brake for holding standard wirespools with a max. diameter of 300 mm (11.81 in.) and a max. weight of up to 19 kg (41.89 lbs.) 4-roller drive LED wirespool interior lighting (TSt 2500c, TSt 2700c only) with the setup parameter LED the turn-off time is adjustable... -
Page 39: Installation And Commissioning
Installation and commissioning... -
Page 41: 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 lev- el 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 42: 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 safe- ty rules WARNING! An electric shock can be fatal. - Page 43 NOTE! Inadequately dimensioned electrical installations can cause serious dam- age. The incoming mains lead and its fuse must be dimensioned to suit the local power supply. The technical data shown on the rating plate applies.
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Page 44: Connecting The Mains Cable
Connecting the mains cable General A strain-relief device for the following cable cross-sections is fitted to the power source: Power source Cable cross-section Canada / US Europe TSt 2500c / TSt 2700c AWG 14 to AWG 6 *) 4G2.5 TSt 3500c AWG 12 *) 4G2.5 Canada / US cable type: Extra-hard usage... -
Page 45: Fitting The Strain-Relief Device, Tst 2500C Mv / Tst 2700C, Single-Phase Operation
Connect the ground conductor and phase conductors to the block terminal Use the strain-relief device to secure the mains cable Fit the side panel of the device Fitting the strain- relief device, TSt 2500c MV / TSt 3,5 Nm 2700c, single- phase operation IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties. -
Page 46: Fitting The Strain-Relief Device, Tst 2500C / Tst 2700C
Fitting the strain- relief device, TSt 2500c / TSt 2700c 1,2 Nm IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties. -
Page 47: Fitting The Strain-Relief Device, Tst 2500C Mv / Tst 2700C Mv
Fitting the strain- relief device, TSt 2500c MV / TSt 3,5 Nm 2700c MV IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties. -
Page 48: Fitting The Strain-Relief Device, Tst 3500C
Fitting the strain- relief device, TSt 3500c 1,2 Nm IMPORTANT! Tie the phase conductors near the luster terminal using cable ties. Fitting the Cana- da / U S strain-re- lief device, TSt 3500c... - Page 49 IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
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Page 50: Generator-Powered Operation
Generator-powered operation Generator-pow- The power source is generator-compatible. ered operation The maximum apparent power S of the power source must be known in order to select 1max the correct generator output. The maximum apparent power S of the power source is calculated as follows: 1max 3-phase devices: Single-phase devices:... -
Page 51: Single-Phase Operation
Single-phase operation Single-phase op- As an alternative to three-phase operation, the multivoltage variant (MV) of the power eration source enables a welding operation with limited power or duration from just a single-phase supply. The maximum possible welding power is limited due to the dimensioning of the mains fuse protection, upon which the safety cut-out of the power source is dependant. -
Page 52: Explanation Of The Term „Duty Cycle" In Single-Phase Operation
In single-phase operation a safety cut-out function prevents a triggering of the fuse at high- er welding power values. The safety cut-out function is active at fuse values of 15 A, 16 A and 20 A and determines the possible welding time, without triggering of the fuse. If a cut- out of the welding current results due to exceeding the pre-calculated welding time, the ser- vice code „toF“... - Page 53 t (min) I2 (A) Legend Mains fuse protection 10 A Mains fuse protection 13 A Mains fuse protection 15 A Mains fuse protection 16 A Mains fuse protection 20 A...
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Page 54: Fitting/Connecting The System Components
Fitting/connecting the system components Information on The steps and activities described below include references to various system compo- system compo- nents, such as nents Trolley Cooling units (TSt 3500c only) Welding torches, etc. For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions. -
Page 55: Connecting A Mig/Mag Welding Torch
TSt 2500c / TSt 2700c TSt 3500c Secure the gas cylinder with a belt Briefly open the gas cylinder valve to remove any dust or dirt Check the seal on the pressure regulator NOTE! US devices (TSt 3500c only) are supplied with an adapter for the gas hose: Seal male thread spacers on the gas solenoid valve using suitable means be- fore screwing on the adapter. -
Page 56: Establishing A Ground (Earth) Connection
Establishing a ground (earth) connection Inserting/replac- CAUTION! Risk of injury if the feed roller holders fly upwards. When unlocking ing feed rollers the lever, keep fingers away from the area to the left and right of the lever. In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded. -
Page 57: Inserting The Wirespool/Basket-Type Spool
Inserting the wire- CAUTION! Risk of injury from springiness of spooled wire electrode. When insert- spool/basket-type ing the wirespool / basket-type spool, hold the end of the wire electrode firmly to spool avoid injuries caused by the wire electrode springing back. CAUTION! Risk of injury from falling wirespool/basket-type spool. -
Page 58: Feeding In The Wire Electrode
Feeding in the CAUTION! Risk of injury from springiness of spooled wire electrode. When insert- wire electrode ing the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire springing back. CAUTION! Risk of damage to the welding torch from sharp end of wire electrode. - Page 59 Hold the button for up to one second ... the wire feed speed stays at 1 m/ min or 39.37 ipm for the first second. Hold the button for up to 2.5 seconds (m/min, ipm) ... after one second, the wire feed speed increases over the next 1.5 seconds.
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Page 60: Setting The Contact Pressure
Setting the con- NOTE! Set the contact pressure in such a way that the wire electrode is not de- tact pressure formed but nevertheless ensures proper wirefeed. Standard values U-grooved rollers Steel 4 - 5 CrNi 4 - 5 Tubular cored elec- 2 -3 trodes Adjusting the... -
Page 61: Design Of The Brake
STOP Design of the WARNING! Fitting the equipment brake incorrectly can cause serious inju- ry and damage. Do not dismantle the brake. Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only. The brake is only available as a complete unit. -
Page 62: Start-Up
Start-up General 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 The device is started up by pressing the torch trigger (for manual applications). -
Page 63: Welding
Welding... -
Page 65: Power Limitation
Power limitation Safety function "Power limitation" is a safety function for MIG/MAG welding. This means that the power source can be operated at the power limit whilst maintaining process safety. Wire feed speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished. -
Page 66: Mig/Mag Modes
MIG/MAG modes General 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 For details of the meaning, settings, setting range and units of the available welding pa- rameters (e.g. -
Page 67: 2-Step Mode
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. Special 4-step Special 4-step mode allows the starting and mode final current to be configured in addition to the advantages of 4-step mode. -
Page 68: 2-Step Stitch Welding
2-step stitch The "2-step stitch welding" mode is suitable welding for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the base material. 4-step stitch The "4-step stitch welding" mode is suitable welding for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the base material. -
Page 69: Mig/Mag Welding
MIG/MAG welding 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 safe- ty rules WARNING! An electric shock can be fatal. -
Page 70: Mig/Mag Standard Synergic Welding
MIG/MAG standard synergic welding MIG/MAG stand- Press the "Material" button to select the filler metal to be used. ard synergic Press the "Wire diameter" button to select the diameter of the wire electrode used. welding Press the "Shielding gas" button to select the shielding gas to be used. The assignment of the SP position is in the welding program tables in the appendix. - Page 71 Press the "Parameter selection" buttons to select the parameters you wish to correct. Use the adjusting dials to set the selected welding parameters to the required values. Welding parameter values are shown in the indicators located above them.
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Page 72: Mig/Mag Standard Manual Welding
MIG/MAG standard manual welding General The MIG/MAG standard manual welding process is a MIG/MAG welding process with no synergic function. Changing one parameter does not result in any automatic adjustments to the other param- eters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question. -
Page 73: Corrections During Welding
To display the actual welding current during welding: Press the "Parameter selection" button to select the welding current parameter The actual welding current is shown on the digital display during welding. Open the gas cylinder valve Setting the shielding gas flow rate: Tap the "Gas-test"... -
Page 74: Mma Welding
MMA welding 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 safe- ty rules WARNING! An electric shock can be fatal. -
Page 75: Corrections During Welding
Start welding To display the actual welding current during welding: Press the "Parameter selection" button to select the welding current parameter The actual welding current is shown on the digital display during welding. Corrections dur- To obtain the best possible welding results, the arc-force dynamic parameter will some- ing welding times need to be adjusted. -
Page 76: Saving And Retrieving Operating Points
Saving and retrieving operating points General The "Save" buttons allow up to 5 operating points to be saved. Every operating point matches the settings on the control panel. IMPORTANT! Setup parameters are not saved at this time. Saving operating Press and hold one of the "Save" buttons to save the current settings on the control points panel, e.g.: The left indicator displays "Pro"... - Page 77 Number 3 Number 4 Number 5...
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Page 79: Setup Settings
Setup settings... -
Page 81: Setup Menu
Setup menu General remarks The Setup menu provides simple access to expert knowledge in the power source and to additional functions. The Setup menu can be used to make simple adjustments of the pa- rameters to suit the various job settings. Configuring the Configuring the setup parameters is described here with reference to the "MIG/MAG stand- setup parameters... -
Page 82: Setup Parameters For Mig/Mag Standard Manual Welding
Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, welding for MIG/MAG program, etc. standard manual Gas pre-flow time welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9 Factory setting: 0.5... - Page 83 Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94) Factory setting: OFF NOTE! The "Ignition time-out" function (ito) is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the preset wire length, particularly when the wire is being fed at high speeds.
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Page 84: Setup Parameters For Mig/Mag Standard Synergic Welding
Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, welding for MIG/MAG program, etc. standard syner- Gas pre-flow time gic welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9 Factory setting: 0.1... - Page 85 NOTE! The "Ignition time-out" function (ito) is a safety function. The length of wire that is fed before the safety cut-out trips may differ from the preset wire length, particularly when the wire is being fed at fast wire feed speeds. The "Ignition time-out"...
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Page 86: Setup Parameters For Mma Welding
Setup parameters IMPORTANT! If you reset the power source using the FAC factory setup parameter, the for MMA welding hot-current time (Hti) and HotStart current (HCU) setup parameters are also reset. HotStart current Unit: % Setting range: 100 - 200 Factory setting: 150 Hot-current time Unit: s... -
Page 87: Setup Menu - Level 2
Setup menu - Level 2 Restrictions In conjunction with the level 2 of the Setup menu, the following restrictions occur: Level 2 of the Setup menu cannot be selected: during welding if the "Gas test" function is active if the "Wire threading" function is active if the "Wire withdrawal"... - Page 88 Changing welding parameters Use the "Mode" and "Process" buttons or the left-hand adjusting dial to select the required setup parameter Change the value of the setup parameter using the "Parameter selection" buttons or the right-hand adjusting dial Exiting the Level 2 Setup menu Press and hold the "Mode"...
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Page 89: Parameters For Mig/Mag Welding In The Setup Menu Level 2
Parameters for Cooling unit Control MIG/MAG welding (only with connected cooling unit) in the Setup menu level 2 Unit: - Setting range: Aut, On, OFF Factory setting: Aut Aut: The cooling unit cuts out after a 2-minute welding off-time. IMPORTANT! If the coolant temperature and flow monitoring options have been installed in the cooling unit, the cooling unit cuts out as soon as the return-flow temperature drops below 50 °C, but at the earliest after a 2-minute welding off- time. -
Page 90: Parameters For Manual Metal Arc (Mma) Welding In The Setup Menu Level 2
Real Energy Input – electrical energy of the arc relative to the welding speed Unit: kJ Setting range: ON / OFF Factory setting: OFF Since the full range of values (1 kJ - 99999 kJ) cannot be displayed on the three- digit display, the following display format has been selected: Value in kJ / indicator on display: 1 to 999 / 1 to 999... -
Page 91: Measuring Welding Circuit Resistance R
Measuring welding circuit resistance r General Measuring the welding circuit resistance r makes it possible to have a constant welding re- sult at all times, even with hosepacks of different lengths. The welding voltage at the arc is then always precisely regulated, regardless of the length and cross-sectional area of the hosepack. -
Page 92: Displaying Welding Circuit Inductivity L
Displaying welding circuit inductivity L General Laying of the hosepacks has a significant effect on welding circuit inductivity and therefore affects the welding process. It is important to lay the hosepacks correctly in order to obtain the best possible welding result. Displaying weld- The setup parameter "L"... -
Page 93: Troubleshooting And Maintenance
Troubleshooting and maintenance... -
Page 95: Troubleshooting
Troubleshooting General The devices are equipped with an intelligent safety system. This means that to a large ex- tent it has been possible to dispense with melting-type fuses. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the device is ready for use again. - Page 96 Nothing happens when the torch trigger is pressed Power source mains switch is on, power source ON indication is lit up on the power source, indications on wire-feed unit are not lit up Cause: The interconnecting hosepack is faulty or not connected properly Remedy: Check interconnecting hosepack No welding current...
- Page 97 Irregular wire feed speed Cause: Braking force has been set too high Remedy: Loosen the brake Cause: Hole in the contact tip is too narrow Remedy: Use a suitable contact tip Cause: Faulty inner liner in welding torch Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary Cause: The feed rollers are not suitable for the wire electrode being used Remedy:...
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Page 98: Displayed Service Codes
Poor weld properties Cause: Incorrect welding parameters Remedy: Check the settings Cause: Poor ground earth connection Remedy: Ensure good contact to workpiece Cause: Inadequate or no protective gas shield Remedy: Check the pressure regulator, gas hose, gas solenoid valve, torch gas con- nection, etc. - Page 99 ELn | 8 Cause: The connected wire-feed unit is not supported Remedy: Connect supported wire-feed unit ELn | 12 Cause: Different control panels for selecting materials are in the system Remedy: Connect similar control panels to select materials ELn | 13 Cause: Illegal change of welding process during welding Remedy:...
- Page 100 E-Stop Cause: "External stop" has tripped Remedy: Remedy the event that triggered the external stop -St | oP- Cause: At the robot interface the flag was not deleted by the robot Remedy: Delete the signal robot ready at the robot interface PHA | SE Cause: Phase failure...
- Page 101 EFd | 81, EFd | 83 Cause: Fault in the wire feed system (overcurrent in wire-feed unit drive) Remedy: Arrange the hosepack in as straight a line as possible; check that there are no kinks or dirt in the inner liner; check the contact pressure on the 4 roller drive Cause: Wire-feed unit motor is sticking or defective...
- Page 102 to7 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the power source Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on toF | xxx Cause: With the TSt 2500c MV / TSt 2700c MV power source operating in single- phase mode, the power source safety cut-out has tripped in order to prevent the mains fuse from tripping.
- Page 103 tu7 | xxx Note: xxx stands for a temperature value Cause: Undertemperature in the power source Remedy: Place power source in a heated room and allow it to warm up no | H2O Cause: Coolant flow rate too low Remedy: Check coolant flow rate and cooling unit, including cooling circuit (for mini- mum coolant flow, see "Technical Data"...
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Page 104: Care, Maintenance And Disposal
Care, maintenance and disposal General Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, it is vital to observe some important points to ensure the weld- ing system remains in a usable condition for many years. Safety WARNING! An electric shock can be fatal. -
Page 105: Disposal
Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 106: 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 107: Tst 2500C
TSt 2500c Mains voltage (U 380 V 400 V 460 V Max. effective primary current (I 6.7 A 5.6 A 1eff Max. primary current (I 11.8 A 11.2 A 9.7 A 1max Mains fuse 16 A slow-blow Mains voltage tolerance -15 / +15% Mains frequency 50 / 60 Hz... -
Page 108: Tst 2500C Mv
TSt 2500c MV Mains voltage (U 200 V 230 V Max. effective primary current (I 16.8 A 14.5 A 1eff Max. primary current (I 26.0 A 22.4 A 1max Mains fuse protection (slow-blow) 25 A Mains voltage (U 380 V 400 V 460 V Max. - Page 109 MIG / MAG 14.5- 24 V Rod electrode 20.4 - 27.2 V Open circuit voltage (U peak / U r.m.s) 42 V Apparent power at 400 V AC 7,76 kVA Protection class IP 23 Insulation class Overvoltage category Pollution level according to IEC60664 Safety symbols S, CE, CSA Efficiency at 220 A and 25.0 V...
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Page 110: Tst 2700C
TSt 2700c Mains voltage (U 380 V 400 V 460 V Max. effective primary current (I 6.6 A 5.8 A 1eff Max. primary current (I 13.1 A 12.5 A 10.8 A 1max Mains fuse 16 A slow-blow Mains voltage tolerance -15 / +15% Mains frequency 50 / 60 Hz... -
Page 111: Tst 2700C Mv
TSt 2700c MV Mains voltage (U 200 V 230 V Max. effective primary current (I 13.3 A 11.6 A 1eff Max. primary current (I 25.7 A 22.41A 1max Mains fuse protection (slow-blow) 25 A Mains voltage (U 380 V 400 V 460 V Max. - Page 112 Output voltage range according to standard characteristic (U ) in single-phase operation MIG / MAG 14.5- 24 V Rod electrode 20.4 - 27.2 V Open circuit voltage (U peak / U r.m.s) 42 V Protection class IP 23 Insulation class Overvoltage category Pollution level according to IEC60664 Safety symbols...
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Page 113: Tst 3500C
29.4 x 11.8 x 19.6 in. Weight 36 kg / 79.4 lb. Max. shielding gas pressure 5 bar / 72.52 psi Coolant Original Fronius Wire feed speed 1 - 25 m/min / 40 - 980 ipm Wire drive 4-roller drive Wire diameter 0.8 - 1.6 mm / 0.03 - 0.06 in. -
Page 114: Appendix
Appendix Quick reference... -
Page 116: Tst 2500C / Tst 2700C Welding Program Table
TSt 2500c / TSt Welding program database: 2700c welding TSt 2500c / TSt 2700c Pos. program table VAT ID 3474 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘... -
Page 117: Tst 2500C Usa / Tst 2700C Usa Welding Program Table
TSt 2500c USA / Welding program database: TSt 2700c USA TSt 2500c USA / TSt 2700c USA Pos. welding program VAT ID 3475 table Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. -
Page 118: Transsteel 3500 Euro Welding Program Tables
TransSteel 3500 Welding program database: Euro welding pro- TransSteel 3500 Euro Pos. gram tables VAT ID 3431 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘... -
Page 119: Transsteel 3500 Us Welding Program Tables
TransSteel 3500 Welding program database: US welding pro- TransSteel 3500 US Pos. gram tables VAT ID 3431 Pos. Standard Programs Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm Pos. Pos. .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘... - Page 120 FRONIUS INTERNATIONAL GMBH Froniusplatz 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 our Sales & service partners and Locations...
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