Summary of Contents for Fronius TransSteel 5000 Rob
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/ Perfect Charging / Perfect Welding / Solar Energy Operating Instructions TransSteel 3500 Rob, TransSteel Spare parts list 5000 Rob MIG/MAG Power source 42,0426,0086,EN 023-19042018...
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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.
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........................
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MIG/MAG welding, water-cooled ......................Before installation and commissioning....................... 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 Europe strain-relief device ....................Fitting the strain-relief device for Canada / US and TSt 5000 MV Europe..........
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Entering/exiting the Setup menu......................Setup parameters for MIG/MAG standard manual welding ..............Setup parameters for MIG/MAG standard synergic welding..............Setup parameters for MMA welding...................... Welding parameters for "Special 4-step mode" in the Mode setup menu..........Setup menu - Level 2..........................Level 2 setup menu..........................
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.
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:...
Protecting your- Anyone working with the device exposes 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...
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.
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°...
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.
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.
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.
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.
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material com- patibility, flammability, etc.).
(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.
General Device concept The TransSteel (TSt) 3500 Rob and TSt 5000 Rob power sources are fully-digitised, microprocessor-controlled inverter power 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.
Warning notices Warning notices and safety symbols are affixed to the power source. These warning notic- on the device es and safety symbols must not be removed or painted over. They warn against operating the device incorrectly, as this may result in serious injury and damage. Safety symbols on the rating plate Welding is dangerous.
Options General The options listed below are available with all power source variants. Machine interface The machine interface connects the power source to the machine control. The following signals can be transmitted across the machine interface: Signal input: Start of welding / end of welding Signal input for a floating contact (sensor, relay, etc.) between pin X1:1 and pin X1:2 The machine control signal input is processed by the power source in the same way as a welding torch signal input.
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...
Synergic control panel General The functions on the control panel are all arranged in a logical way. The various welding parameters can easily be selected using buttons and can just as easily be altered using buttons or the adjusting dial displayed on the digital display during welding The synergic function ensures that all other welding parameters are adjusted whenever an individual parameter is changed.
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Function "Parameter selection" button (right) a) for selecting the following welding parameters 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. During welding, the actual value is displayed.
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***) "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"...
Service parame- Various service parameters can be retrieved by pressing the "Parameter selection" buttons ters at the same time. Opening the display Press and hold the "Parameter selection" button (left) Press the "Parameter selection" button (right) Release the "Parameter selection" buttons The first parameter ("Firmware version") is displayed, e.g.
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Press the "Parameter selection" button (right) Release the "Mode" and "Parameter Selection" buttons Keylock activated: The message "CLO | SEd" appears on the displays. Keylock deactivated: The message "OP | En" appears on the displays.
Connections, switches and mechanical components TSt 3500 Rob / 5000 Rob power source Function (-) - 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) Mains switch for switching the power source on and off...
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.
Before installation and commissioning Utilisation for in- The power source may only be used for MIG/MAG and MMA welding. tended purpose Any other form of usage is deemed "not in accordance with the intended purpose". only The manufacturer shall not be held liable for any damages arising from such usage. Utilisation in accordance with the "intended purpose"...
Connecting the mains cable General If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before commissioning. A strain-relief device for the following cable cross-sections is fitted to the power source: Power source Cable cross-section fitted strain-relief device for...
Remove the side panel from the device Push the mains cable in far enough to make it possible to connect the PE conductor and the phase conductors to the block terminal properly. Fit ferrules to the PE conductor and phase conductors Connect the PE conductor and phase conductors to the block terminal Use the strain-relief device to secure the mains cable Fir the side panel of the device...
Fitting the strain- relief device for Canada / US and TSt 5000 MV Eu- rope 3,5 Nm IMPORTANT! Tie the phase conductors near the luster terminal using cable ties.
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:...
Start-up Information on The steps and activities described below include references to various system compo- system compo- nents, including: nents trolley upright console cooling units wire-feed units interconnecting hosepacks welding torches, etc. For more detailed information about installing and connecting the system components, please refer to the appropriate operating instructions.
TSt 3500 Rob / 5000 Rob start-up Fitting the system WARNING! Work that is carried out incorrectly can cause serious injury and dam- components age. The following activities must only be carried out by trained and qualified per- (overview) sonnel. All instructions in the section headed "Safety rules" must be observed. For detailed information about the individual steps, please refer to the operating instruc- tions for the system components.
Connecting the WARNING! If gas cylinders topple over, there is a risk of very serious injury and gas cylinder damage. When using gas cylinders: Place them on a solid, level surface in such a way that they remain stable Secure the gas cylinders to prevent them from falling over Fit the VR holder option Follow the gas cylinder manufacturer's safety rules.
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.
MIG/MAG modes General remarks 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 parameters (e.g.
Special 4-step "Special 4-step mode" is ideal for welding in mode higher power ranges. In special 4-step mo- de, the arc starts at a low power, which ma- kes it easier to stabilise.
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.
MIG/MAG standard synergic welding General The MIG/MAG standard synergic welding process is only available in combination with the Synergic control panel. MIG/MAG stand- On the Synergic control panel: ard synergic welding Press the "Material" button to select the filler metal used. Assignment of the SP position depends on the welding database used for the power source.
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 Set the shielding gas flow rate: If there is a "Gas test"...
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.
Open the gas cylinder valve Set the shielding gas flow rate: If there is a "Gas test" button: Press and release the "Gas test" button Turn the adjusting screw on the underside of the pressure regulator until the pres- sure gauge shows the required gas flow rate Press and release the "Gas test"...
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.
The amperage value is shown in the left-hand digital display. All welding parameter set values that have been set using the adjusting dial remain stored until the next time they are changed. This applies even if the power source is switched on and off again in the meantime.
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Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode be- gins to stick, the power source immediately switches the welding current off. After the rod electrode has been detached from the workpiece, the welding operation can be continued without difficulty.
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"...
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. Entering/exiting Setting the setup parameters is described here with reference to the "MIG/MAG standard the Setup menu...
Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, wire- for MIG/MAG feed unit, welding program, etc. standard manual Gas pre-flow time welding Unit: s Setting range: 0 - 9.9 Factory setting: 0.5 Gas post-flow time Unit: s Setting range: 0 - 9.9...
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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 fast wire feed speeds. The "Ignition time-out"...
Setup parameters "Min." and "max." are used for setting ranges that differ according to power source, wire- for MIG/MAG feed unit, welding 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...
Spot break - stitch pause time Unit: s Setting range: OFF, 0.1 - 10 (in 0.1 s increments) Factory setting: OFF Factory - Reset power source to factory setting Press and hold down the "Dynamic" (manual control panel) or "Parameter selec- tion"...
Welding parame- I (current) - Starting: Starting current ters for "Special Unit: % (of welding current) 4-step mode" in Setting range: 0 - 200 the Mode setup Factory setting: 100 menu Slope: 0 - 9.9 s Unit: s Setting range: 0 - 9.9 Factory setting: 0 I (current) - End: Final current Unit: % of welding current...
Setup menu - Level 2 Level 2 setup Accessing the setup menu menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons The control panel is now in the setup menu - the last setup parameter that was selected is displayed.
Exiting the setup menu Press and hold the "Mode" button Press the "Process" button Release the "Mode" and "Process" buttons Welding parame- Cooling unit control ters for MIG/MAG welding in the Unit: - Setup menu level Setting range: Aut, On, Off Factory setting: Aut Aut: The cooling unit cuts out after a 2-minute welding off-time.
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 / indication on display: 1 to 999 / 1 to 999...
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.
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"...
Troubleshooting General The power sources are equipped with an intelligent safety system. This means that it has been possible to dispense with melting-type fuses entirely. Melting-type fuses therefore no longer need to be replaced. After a possible malfunction has been remedied, the power source is ready for use again.
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No welding current Mains switch is on, one of the overtemperature service codes "to" is displayed. Detailed information on the service codes "to0" to "to6" can be found in the section "Displayed ser- vice codes". Cause: Overload Remedy: Take the duty cycle into account Cause: Thermostatic safety cut-out has tripped Remedy:...
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.
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ESr | 20 Cause: The selected cooling unit is not compatible with the power source Remedy: Connect compatible cooling unit ----- Cause: An invalid welding process was called up on the robot interface (no. 37) or an empty flag was selected (no. 32) Remedy: Call up a valid welding process or select assigned "Save"...
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no | UrL Cause: The VRD option has tripped too early. Remedy: Check whether all welding power-leads and control lines are connected. Switch off the power source Wait 10 seconds and switch the power source back on again If the error occurs again - contact After Sales Service. E-Stop Cause: "External stop"...
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to0 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the primary circuit of the power source Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on to1 | xxx Note: xxx stands for a temperature value Cause: Overtemperature on the booster located in the power source...
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tu0 | xxx Remark: xxx stands for a temperature value Cause: Undertemperature in the power source primary circuit Remedy: Place power source in a heated room and allow to warm up tu1 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the booster located in the power source Remedy:...
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hot | H2O Cause: The coolant temperature is too high Remedy: Allow cooling unit and cooling circuit to cool down, until "hot | H2O" is no longer displayed. Open the cooling unit and clean the cooler, check fan is working properly. Robot interface or field bus coupler: before resuming weld- ing, set the "Source error reset"...
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.
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.
Cos phi (1) 0.99 Max. permitted mains impedance Z at PCC 77 mOhm Recommended earth-leakage circuit breaker Type B Welding current range (I MIG/MAG 10 - 350 A Rod electrode 10 - 350 A Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 %...
MIG/MAG 10 - 500 A Rod electrode 10 - 500 A Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 % 500 A 420 A 360 A Output voltage range according to standard characteristic (U MIG/MAG 14.3 - 39 V Rod electrode...
Rod electrode 10 - 350 A Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 % : 200 - 460 V 350 A 300 A 250 A Output voltage range according to standard characteristic (U MIG/MAG 14.5 - 31.5 V Rod electrode...
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Rod electrode 10 - 500 A Welding current at 10 min / 40 °C (104 °F) 100% : 200 V 500 A 420 A 360 A Welding current at 10 min / 40 °C (104 °F) 100% : 208 - 460 V 500 A 420 A 360 A...
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‘‘...
TransSteel 5000 Welding program database: Euro welding pro- TransSteel 5000 Euro Pos. gram tables VAT ID 2546 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‘‘...
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‘‘...
TransSteel 5000 Welding program database: US welding pro- TransSteel 5000 US Pos. gram tables VAT ID 2539 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‘‘...
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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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