Fronius TransSteel 2200 Operating Instructions Manual
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Fronius TransSteel 2200 Operating Instructions Manual

Mig/mag power source
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/ Perfect Charging / Perfect Welding / Solar Energy
TransSteel 2200
42,0426,0241,EA 014-29042021
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Operating instructions
MIG/MAG power source

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Summary of Contents for Fronius TransSteel 2200

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions TransSteel 2200 MIG/MAG power source 42,0426,0241,EA 014-29042021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Table of contents Safety Instructions Explanation of Safety Instructions General Intended Use Grid Connection Environmental Conditions Obligations of the Operating Company Obligations of Personnel Residual current circuit breaker Personal Protection and Protection of Others Data regarding Noise Emission Values Danger from toxic gases and vapors Danger from Flying Sparks Risks from grid current and welding current Stray welding currents...
  • Page 4 Required generator output Mains Fuse Protection Adjustable mains fuse protection Adjustable mains fuse protection Fitting the Carrying Strap Fitting the carrying strap to the power source MIG/MAG Commissioning Connecting a MIG/MAG welding torch Inserting the feed rollers Inserting the D100 wirespool Inserting the D200 wirespool Feeding in the wire electrode Selecting the desired country-specific setting...
  • Page 5 Laying the hosepacks correctly Functions for Optimizing the Welding Process Arc-Force Dynamic HotStart (Hti) function Anti-stick (Ast) function EasyJobs Saving and Retrieving EasyJobs General Saving an EasyJob Retrieving an EasyJob Deleting an EasyJob Setup Menu Setup Menu Level 1 Accessing and exiting the Setup menu, changing parameters Parameters for MIG/MAG Standard Manual Welding Parameters for MIG/MAG standard synergic welding Parameters for TIG welding...
  • Page 6 Special voltage Explanation of the Term Duty Cycle TransSteel 2200 TransSteel 2200 MV Welding program tables TSt 2200 welding program table...

  • Page 7: Safety Instructions

    Safety Instructions Explanation of DANGER! Safety Instruc- tions Indicates an immediate danger. ▶ Death or serious injury may result if appropriate precautions are not taken. WARNING! Indicates a possibly dangerous situation. ▶ Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur.

  • Page 8: Grid Connection

    The device is intended exclusively for the welding process specified on the rating plate. Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage resulting from improper use.

  • Page 9: Obligations Of The Operating Company

    Obligations of the The operating company must only allow persons to work with the device if they Operating Com- Are familiar with the basic occupational safety and accident prevention regulations pany and are trained in handling the device Have read and understood these Operating Instructions, especially the section "Safety Rules,"...

  • Page 10: Data Regarding Noise Emission Values

    Keep persons, especially children, away during the operation of the devices and during the welding process. If persons are in the vicinity, however: Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying sparks, welding fumes hazardous to health, noise exposure, possible hazard due to grid current or welding current, etc.) Provide suitable protective equipment or Construct suitable protective walls and curtains.

  • Page 11: Danger From Flying Sparks

    Danger from Fly- Flying sparks can cause fires and explosions. ing Sparks Never undertake welding near flammable materials. Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or pro- tected with a certified cover. Keep suitable, tested fire extinguishers on hand.

  • Page 12: Stray Welding Currents

    Use suitable equipment to ensure that the workpiece is sufficiently grounded if neces- sary. Switch off unused devices. When working at elevated heights, wear a safety harness to prevent falls. Before working on the device, switch off the device and remove the grid plug. Secure the device to prevent the grid plug from being connected and switched on again by applying a clearly legible and understandable warning sign.

  • Page 13: Emf Measures

    Test and assess the immunity of equipment in the vicinity of the device in accordance with national and international provisions. Examples of interference-prone equipment that could be affected by the device: Safety devices Grid power lines, signal lines and data transfer lines EMC and telecommunications equipment Devices for measuring and calibrating Supporting measures to avoid EMC problems:...

  • Page 14: Requirement For The Shielding Gas

    Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective equipment when reworking workpieces and ensure that other persons are sufficiently protected. Leave the welding torch and other parts with a high operating temperature to cool before working on them. Special regulations apply in areas at risk of fire or explosion –...

  • Page 15: Danger Posed By Shielding Gas Leak

    Mount the shielding gas cylinders vertically and secure them in accordance with instruc- tions so they cannot fall over. Keep shielding gas cylinders away from welding or other electrical circuits. Never hang a welding torch on a shielding gas cylinder. Never touch a shielding gas cylinder with an electrode.

  • Page 16: Safety Measures In Normal Operation

    Before transporting the device, completely drain the coolant and dismantle the following components: wirefeeder wirespool shielding gas cylinder It is essential to conduct a visual inspection of the device to check for damage after it has been transported but before commissioning. Have any damage repaired by trained ser- vice technicians before commissioning the device.

  • Page 17: Safety Inspection

    Copyright Copyright of these Operating Instructions remains with the manufacturer. Text and illustrations were accurate at the time of printing. Fronius reserves the right to make changes. The contents of the Operating Instructions shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the Operating Instructions, we will be most grateful for your comments.

  • Page 19: General Information

    General information...

  • Page 21: General

    General Device concept The TransSteel (TSt) 2200 power source is a completely digitized, microprocessor- controlled power source. This power source is designed for the welding of steel and can be used for the following welding processes: MIG/MAG welding SMAW TIG welding with touch-down ignition The central control and regulation unit of the power source is coupled with a digital signal processor.

  • Page 22: Application Areas

    Application areas MIG/MAG welding TIG welding Manual metal arc welding...

  • Page 23: Warning Notices On The Device

    Warning notices Warning notices and safety symbols are affixed to the power source. These warning on the device notices and safety symbols must not be removed or painted over. They warn against incorrect operation, as this may result in serious injury and property damage. Steel: 3-4 CrNi: 3-4 FCW: 3...

  • Page 24: Warning Notices On The Device

    Do not use the functions described here until you have fully read and understood the fol- lowing documents: These Operating Instructions All system component Operating Instructions, especially the safety rules Dispose of old devices in accordance with safety rules and not in normal domestic waste.
  • Page 25 Steel: 3-4 CrNi: 3-4 FCW: 3 .023 Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk Kasjf;laksf;lkasdf’l;aksdf;lkasd;flksadflkasd;lk Welding is dangerous. To ensure that this device can be used correctly and safely, the following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Keep unauthorized people away from the power source and the welding process Do not use the functions described here until you have fully read and understood the fol- lowing documents: These Operating Instructions...
  • Page 26 Keep hands, hair, loose clothing, and tools away from moving parts, such as: Gears Feed rollers Wirespools and wire electrodes Do not reach into rotating gears of the wire drive or into rotating drive parts. Covers and side panels must only be opened/removed during maintenance and repair work.

  • Page 27: Description Of The Warnings On The Device

    Description of the Warning notices are attached to the device for certain device versions. warnings on the device The arrangement of the symbols may vary. Warning! Caution! The symbols represent possible dangers. Drive rollers can injure fingers. The welding wire and drive parts are under welding voltage during operation. Keep hands and metal objects away! An electric shock can be fatal.
  • Page 28 Welding sparks can cause an explosion or fire. Keep flammable materials away from the welding process. Do not perform weld- ing near flammable materials. Welding sparks can cause a fire. Have fire extinguishers ready. If necessary, have a supervisor ready who can operate the fire extinguisher. Do not weld on drums or closed containers.

  • Page 29: Operating Controls And Connections

    Operating controls and connections...

  • Page 31: Control Panel

    Control Panel General As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.
  • Page 32 Hold indicator At the end of each welding operation, the actual values for welding current and welding voltage are stored - the "HOLD" indicator lights up Intermediate arc indicator A spatter-prone intermediate arc occurs between the dip transfer arc and the spray arc.
  • Page 33 "Parameter selection" button (left) For selecting the parameters listed below The relevant symbol lights up when a welding parameter is selected. Sheet thickness in mm or inch (synergic parameter) If, for example, the welding current to be selected is not known, entering the sheet thickness alone is sufficient.
  • Page 34 "Parameter selection" button (right) For selecting the parameters listed below The relevant symbol lights up when a welding parameter is selected. Arc length correction For correcting the arc length Welding voltage in V (synergic parameter) Before welding begins, the device automatically displays a standard value based on the programmed parameters.
  • Page 35 (10) (11) "Gas-test" button For setting the required gas flow rate on the gas pressure regulator/for filling the torch hosepack with shielding gas. When the "Gas-test" button is pressed, shielding gas will flow for 30 seconds. Press the button again to stop the gas flow prematurely. Selection dial (left) For changing the sheet thickness, welding current, and wire speed parameters, and for changing parameters in the Setup menu...
  • Page 36 (12) (18) (13) (14) (15) (16) (17) (12) "Material" button For selecting the filler metal to be used (13) "Save" button 1 For saving an EasyJob (14) "Mode" button For selecting the operating mode 2 T = 2-step mode 4 T = 4-step mode S 4 T = Special 4-step mode Spot welding/stitch welding (15)

  • Page 37: Keylock

    Keylock A keylock can be activated to prevent the settings from being inadvertently changed on the control panel. As long as the keylock is active: Settings cannot be adjusted on the control panel Parameter settings can be displayed It is possible to switch between EasyJobs if an EasyJob was selected before the keylock was activated Activating/deactivating the keylock: Keylock activated:...

  • Page 38: Connections, Switches, And Mechanical Components

    Connections, Switches, and Mechanical Compon- ents Safety WARNING! Danger from incorrect operation and work that is not carried out properly. Serious personal injury and damage to property may result. ▶ Read and understand this document. ▶ Read and understand all the Operating Instructions for the system components, especially the safety rules.

  • Page 39: Side View

    MIG/MAG shielding gas connec- (7) (8) tion socket For the shielding gas supply to the welding torch connection (1) Power switch For switching the power source on and off Ventilation openings (air inlet vents) For device cooling, the air filter is located behind these vents (11) (10)

  • Page 41: Before Installation And Initial Operation

    Before installation and initial opera- tion...

  • Page 43: General

    General Safety WARNING! Danger from incorrect operation and work that is not carried out properly. Serious personal injury and damage to property may result. ▶ All the work and functions described in this document must only be carried out by trained and qualified personnel.

  • Page 44: Grid Connection

    Grid Connection The devices are designed for the grid voltage stated on the rating plate. If the mains cable or mains plug has not been attached to your version of the appliance, these must be installed according to national standards. Fuse protection for the grid lead can be found in the technical data.

  • Page 45: Generator-Powered Operation

    Generator-Powered Operation Required gener- The power source is generator-compatible. ator output The maximum apparent power S of the power source must be known in order to 1max select the correct generator output. The maximum apparent power S of the power source is calculated as follows: 1max 1max 1max...

  • Page 46: Mains Fuse Protection

    Mains Fuse Protection Adjustable mains The mains fuse protection selected on the power source limits the power drawn in from fuse protection the grid and in turn the possible welding current. This prevents the automatic circuit breaker (e.g., in the fuse box) from tripping straight away. The desired mains fuse protection can be selected on the power source depending on the grid voltage and automatic circuit breaker used.
  • Page 47 Grid voltage Welding current limitation Country-specific setting Power source fuse rating 120 V MIG/MAG welding: max. 105 A; 80 A at 100%* 15 A SMAW: max. 90 A; 70 A at 100%* TIG welding: max. 135 A; 105 A at 100%* 120 V MIG/MAG welding: max.

  • Page 48: Adjustable Mains Fuse Protection

    circuit breaker tripping. If the precalculated weld time is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immedi- ately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again.
  • Page 49 Grid Country- Power source fuse Welding current limitation voltage specific set- rating ting 230 V 16 A MIG/MAG welding: max. 210 A; 150 A at 100%* SMAW: max. 180 A; 130 A at 100%* 240 V 15 A MIG/MAG welding: max.

  • Page 50: Fitting The Carrying Strap

    Fitting the Carrying Strap Fitting the carry- ing strap to the power source...

  • Page 51: Mig/Mag

    MIG/MAG...

  • Page 53: Commissioning

    Commissioning Connecting a Before connecting the welding torch to the power source, equip the welding torch MIG/MAG welding according to the welding torch Operating Instructions: Fit wearing parts to the torch torch body, fit the inner liner. Unscrew the knurled screw (1) slightly so that the welding torch can be easily pushed into the welding torch connection.

  • Page 54: Inserting The Feed Rollers

    CAUTION! Danger if welding torch is not screwed tight. The device may be damaged. ▶ Always tighten the welding torch to the specified tightening torque. 3 Nm Inserting the feed In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the rollers diameter and alloy of the wire being welded.

  • Page 55: Inserting The D100 Wirespool

    Inserting the D100 wirespool Inserting the D200 wirespool...

  • Page 56: Feeding In The Wire Electrode

    Feeding in the CAUTION! wire electrode Danger from springiness of spooled wire electrode. It can cause injuries. ▶ When inserting the wire electrode into the wire drive, hold the end of the wire elec- trode firmly. Adjust the contact pressure as shown below Doing so will prevent deformation of the wire electrode and ensure that the...
  • Page 57 It is only necessary to connect the mains cable to the power source for multivoltage power sources. CAUTION! Danger from wire electrode emerging unexpectedly as it is being threaded. It can cause injuries. ▶ Wear suitable protective goggles ▶ Keep the tip of the welding torch away from your face and body ▶...

  • Page 58: Selecting The Desired Country-Specific Setting

    Wire threading process (press the "Wire threading" button on the control panel): Hold down the button for up to one (m/min, ipm) second (briefly press the button): the wire speed stays at 1 m/min (39.37 ipm) for the first second Hold down the button for up to 2.5 seconds: after one second, the wire speed increases over the next 1.5...

  • Page 59: Connecting The Polarity Reverser And Establishing A Ground Earth Connection

    Connecting the NOTE! polarity reverser and establishing Risk from incorrectly connected polar- a ground earth ity reverser. This can result in poor-quality weld proper- connection ties. ▶ Connect the polarity reverser accord- ing to the wire electrode being used. Check the wire electrode packaging to determine whether the wire electrode is for (+) or (-) welding Laying the...

  • Page 60: Adjusting The Brake Of The Wirespool Holders

    Adjusting the Brake of the Wirespool Holders General D200 wirespool holder: Adjust the brake when using the wirespool holder for the first time and after changing the wirespool. To do so, proceed as described in the following section Adjusting the brake of the D200 wirespool holder.

  • Page 61: Adjusting The Brake Of The D200 Wirespool Holder

    Adjusting the CAUTION! brake of the D200 wirespool holder Danger from emerging wire electrode and moving parts. Personal injury and damage to property may result. ▶ Before starting work, turn the mains switch of the power source to - O - and discon- nect the power source from the mains ▶...

  • Page 62: Description Of Mig/Mag Operating Modes

    Description of MIG/MAG Operating Modes 2-step mode "2-step mode" is suitable for Tacking work Short weld seams 2-step mode Explanation of symbols: Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations used: Gas pre-flow time Welding current Gas post-flow time...

  • Page 63: 4-Step Mode

    4-step mode "4-step mode" is suitable for longer weld seams. 4-step mode Explanation of symbols: Press the torch trigger Release the torch trigger Abbreviations used: Gas pre-flow time Welding current Gas post-flow time...

  • Page 64: Special 4-Step Mode

    Special 4-step "Special 4-step mode" is ideal for welding in higher power ranges. In special 4-step mode mode, the arc starts at a lower power, which makes it easier to stabilize. Special 4-step mode Explanation of symbols: Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations used:...

  • Page 65: Spot Welding

    Spot welding The "Spot welding" mode is suitable for welded joints on overlapped sheets. Spot welding Explanation of symbols: Press the torch trigger Release the torch trigger Abbreviations used: Gas pre-flow time Welding current Spot welding time / stitch welding time Gas post-flow time...

  • Page 66: 2-Step Stitch Welding

    2-step stitch The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets, welding to prevent the weld seams from dropping through the parent material. 2-step stitch welding Explanation of symbols: Press the torch trigger Hold the torch trigger Release the torch trigger Abbreviations used: Gas pre-flow time...

  • Page 67: 4-Step Stitch Welding

    4-step stitch The "4-step stitch welding" mode is suitable for welding longer weld seams on thin welding sheets, to prevent the weld seams from dropping through the parent material. 4-step stitch welding Explanation of symbols: Press the torch trigger Release the torch trigger Abbreviations used: Gas pre-flow time Welding current...

  • Page 68: 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 para- meters – all variable parameters must be adjusted individually. Adjustable weld- The following parameters are available for MIG/MAG manual welding: ing parameters:...

  • Page 69: Mig/Mag Standard Synergic Welding

    MIG/MAG Standard Synergic Welding MIG/MAG stand- Press the "Process" button to select SYNERGIC ard synergic welding Press the "Mode" button to select the desired MIG/MAG mode: 2-step mode 4-step mode S 4 T = Special 4-step mode Spot welding/stitch welding Under certain circumstances, it may not be possible to change welding parameters that have been set for a system component (remote control, etc.) on the control panel of the power source.

  • Page 70: Corrections During Welding

    Corrections dur- The arc length correction and arc-force dynamic parameters can be used to optimize the ing welding welding result. Arc length correction: = shorter arc, reduced welding voltage = neutral arc = longer arc, increased welding voltage Arc-force dynamic: For influencing the short-circuiting dynamic at the instant of droplet transfer = hard, stable arc = neutral arc...

  • Page 71: Spot Welding And Stitch Welding

    Spot welding and stitch welding General The spot and stitch welding modes are MIG/MAG welding processes. Spot welding is used on welded joints on overlapping sheets that are only accessible on one side. Stitch welding is used for light-gage sheets. As the wire electrode is not fed continuously, the weld pool can cool down during the intervals.
  • Page 72 Ensure that the ground earth connection has been established Ensure that the shielding gas supply has been established Power source is ready for welding...

  • Page 75: Commissioning

    Commissioning Start-Up...

  • Page 76: Tig Welding

    It is only necessary to connect the mains cable to the power source for multivoltage power sources. CAUTION! Danger due to welding processes start- ing unintentionally. Personal injury and damage to property may result. ▶ As soon as the power source is switched on, ensure that the tungsten electrode does not accidentally, or in an uncontrolled manner, touch any...

  • Page 77: Selecting The Desired Country-Specific Setting

    Selecting the The country-specific setting of the power source defines the unit (cm + mm or inch) desired country- in which the set welding parameters are displayed specific setting The country-specific setting can be changed in the Setup menu 2nd level (Para- meter SEt) •...

  • Page 78: Description Of Tig Operating Modes

    Description of TIG Operating Modes 2-step mode down Welding with 2-step mode: Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold => shielding gas flows Raise the tungsten electrode => arc ignites Release torch trigger => end of welding Explanation of symbols: Pull back the torch trigger and hold it in this position Release the torch trigger forwards...

  • Page 79: 4-Step Mode

    4-step mode down 4-step mode with intermediate lowering I-2 Intermediate lowering means that the welder uses the torch trigger during the main cur- rent phase to lower the welding current to the specified reduced current I-2. Welding with 4-step mode: Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold =>...
  • Page 80 Final current phase: to prevent crater cracks or shrink holes Reduced current phase: intermediate lowering of the welding current in order to prevent any local overheating of the parent material Starting current duration UpSlope phase: the welding current is continually increased Duration: 0.5 seconds Final current duration DownSlope phase: the welding current is continuously reduced...

  • Page 81: Pulse Welding

    Pulse welding Applications Pulsed welding is welding with a pulsing welding current. It is used to weld steel pipes out-of-position or to weld thin sheet metal. In these applications, the welding current set at the start of welding is not always optimum for the entire welding process: If the amperage is too low, the parent material will not be melted enough If overheating occurs, there is a danger that the liquid weld pool may drip.

  • Page 82: Activating Pulse Welding

    Activating pulse Set a value for the F-P setup parameter (pulse frequency) welding Setting range: 1 - 990 Hz For a parameter description see section Parameters for TIG welding from page 98.

  • Page 83: Rod Electrode

    Rod Electrode...

  • Page 85: Commissioning

    Commissioning Preparation Check the rod electrode packaging to determine whether the rod electrode is for (+) or (-) welding. It is only necessary to connect the mains cable to the power source for multivoltage power sources.

  • Page 86: Selecting The Desired Country-Specific Setting

    CAUTION! Danger due to welding processes start- ing unintentionally. Personal injury and damage to property may result. ▶ As soon as the power source is switched on, ensure that the rod elec- trode does not unintentionally touch electrically conductive or grounded parts (such as housing).

  • Page 87: Functions For Optimizing The Welding Process

    Functions for Optimizing the Welding Process Arc-Force Arc-force dynamic: Dynamic For influencing the short-circuiting dynamic at the instant of droplet transfer = hard, stable arc = neutral arc = soft, low-spatter arc HotStart (Hti) This function is activated at the factory. function Advantages Improved ignition properties, even when using electrodes with poor ignition proper-...
  • Page 88 For a parameter description see section Parameters for MMA Welding from page 99.

  • Page 89: Easyjobs

    EasyJobs...

  • Page 91: Saving And Retrieving Easyjobs

    Saving and Retrieving EasyJobs General The "Save" buttons allow two EasyJobs to be saved The adjustable parameters on the control panel are saved Setup parameters are not saved at this time Saving an Easy- Press and hold one of the "Save" buttons to save the current settings on the control panel, e.g., Number 1 The left indicator displays "Pro"...

  • Page 93: Setup Menu

    Setup Menu...

  • Page 95: Setup Menu Level 1

    Setup Menu Level 1 Accessing and Accessing the Setup menu is described with reference to the MIG/MAG standard syner- exiting the Setup gic (SYNERGIC) welding process. menu, changing Access is the same for the other welding processes. parameters Accessing the Setup menu: Press the "Process"...

  • Page 96: Parameters For Mig/Mag Standard Synergic Welding

    Length of wire that is fed before the safety cut-out trips Unit: mm (in.) Setting range: OFF, 5 - 100 (OFF, 0.2 - 3.94) Factory setting: OFF The ignition time-out function (Ito) is a safety feature. If the power source determines that no ignition has occurred after the preset wire length has been fed, wirefeeding is stopped.
  • Page 97 Setting range: 0 - 200 Factory setting: 100 Final current Unit: % of welding current Setting range: 0 - 200 Factory setting: 50 Start current duration Unit: seconds Setting range: 0 - 9.9 Factory setting: 0 Final current duration Unit: seconds Setting range: 0 - 9.9 Factory setting: 0 Feeder inching speed...

  • Page 98: Parameters For Tig Welding

    When the power source is reset, the majority of the applied settings are deleted. The following values remain: Welding circuit resistance and welding circuit inductivity Country-specific setting Second level of the Setup menu (see "Setup Menu 2nd Level") Parameters for Pulse frequency TIG welding Unit: Hertz...

  • Page 99: Parameters For Mma Welding

    When the power source is reset, the majority of the applied settings are deleted. The following values remain: Welding circuit resistance and welding circuit inductivity Country-specific setting Second level of the Setup menu (see "Setup Menu 2nd Level") Parameters for HotStart current MMA Welding Unit: %...

  • Page 100: Setup Menu 2Nd Level

    Setup Menu 2nd Level Accessing and Accessing the 2nd level of the Setup menu: exiting the 2nd level of the Setup Press the "Process" button to select the menu, changing "MIG/MAG standard synergic welding" parameters process The control panel is now located in the Setup menu of the "MIG/MAG standard synergic welding"...

  • Page 101: Parameters For Mig/Mag Standard Synergic Welding

    USA device: US (measurements: inches) Mains fuse protection The maximum possible welding power is limited by the rating of the mains fuse protection used. Unit: A The available mains fuse ratings are determined by the SEt parameter setting: SEt parameter set as Std: OFF / 10 / 13 / 16 SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage) Factory setting: OFF Welding circuit resistance (in mOhm)

  • Page 102: Parameters For Tig Welding

    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: 1 to 999 / indicator on display: 1 to 999 Value in kJ: 1000 to 9999 / indicator on display: 1.00 to 9.99 (without unit digit, e.g., 5270 kJ ->...
  • Page 103 Welding circuit inductivity (in microhenrys) See section Displaying the welding circuit inductivity from page Mains fuse protection The maximum possible welding power is limited by the rating of the mains fuse protection used. Unit: A The available mains fuse ratings are determined by the SEt parameter setting: SEt parameter set as Std: OFF / 10 / 13 / 16 SEt parameter set as US: OFF / 15 / 20 (only for 120 V grid voltage) Factory setting: OFF...

  • Page 105: Optimizing Weld Quality

    Optimizing Weld Quality...

  • Page 107: Measuring The Welding Circuit Resistance

    Measuring the welding circuit resistance General Measuring the welding circuit resistance makes it possible to have a constant welding result 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 108: Measuring The Welding Circuit Resistance (Stick Welding)

    Fit the gas nozzle back onto the welding torch Measuring the NOTE! welding circuit Risk of incorrect measurement of the welding circuit resistance. resistance (stick welding) This can have a negative effect on the welding results. ▶ Ensure that the workpiece has an optimum contact surface in the area of the earth- ing clamp (clean surface, no rust, etc.).

  • Page 109: Displaying The Welding Circuit Inductivity

    Displaying the welding circuit inductivity General The way that the hosepack is arranged has a very significant effect on the 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 the The setup parameter "L"...

  • Page 111: Troubleshooting And Maintenance

    Troubleshooting and Maintenance...

  • Page 113: Displaying Service Parameters

    Displaying Service Parameters Service paramet- Various service parameters can be retrieved by pressing the left and right-hand "Para- meter selection" buttons at the same time. Opening the display: The first parameter "Firmware version" will be displayed, e.g., "1.00 | 4.21" Selecting parameters: Use the "Mode"...

  • Page 114: Troubleshooting

    Troubleshooting Safety WARNING! Danger from incorrect operation and work that is not carried out properly. Serious personal injury and damage to property may result. ▶ All the work and functions described in this document must only be carried out by trained and qualified personnel.
  • Page 115 No welding current Power 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 Service Codes from page 117. Cause: Overloading Remedy: Observe the duty cycle Cause: Thermal automatic circuit breaker has tripped...
  • Page 116 Irregular wire speed Cause: Braking force has been set too high Remedy: Loosen the brake Cause: Contact tip hole too narrow Remedy: Use suitable contact tip Cause: Faulty inner liner in welding torch Remedy: Check the inner liner for kinks, dirt, etc. and replace if necessary Cause: Feed rollers not suitable for wire electrode used Remedy:...

  • Page 117: Displayed Service Codes

    Displayed Ser- If an error message that is not described here appears on the displays, first try to resolve vice Codes the problem as follows: Switch the power source power switch to the -O- position Wait ten seconds Switch the power switch to the -I- position If the error occurs again despite several attempts to eliminate it, or if the troubleshooting measures listed here are unsuccessful: Make a note of the error message displayed...
  • Page 118 to2 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in the secondary circuit of the power source Remedy: Allow power source to cool down, check air filter and clean if necessary (see section Maintenance as required, at least every two months page 122), check whether the fan is running to3 | xxx Note: xxx stands for a temperature value...
  • Page 119 tu0 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the PC board (secondary circuit) Remedy: Place power source in a heated room and allow it to warm up tu2 | xxx Note: xxx stands for a temperature value Cause: Undertemperature in the power source secondary circuit Remedy:...
  • Page 120 no | IGn Cause: "Ignition time-out" function is active; current did not start flowing before the length of wire specified in the Setup menu had been fed. The power source safety cut-out has tripped Remedy: Shorten the wire stick-out; press the torch trigger again; clean the surface of the workpiece;...

  • Page 121: Service, Maintenance And Disposal

    Service, maintenance and disposal General Under normal operating conditions, the welding system requires only a minimum of care and maintenance. However, several points must be observed in order for the welding system to remain operational for years to come. Safety WARNING! Danger from incorrect operation and work that is not carried out properly.

  • Page 122: Maintenance As Required, At Least Every Two Months

    Maintenance as required, at least every two months CAUTION! Danger from wet air filter. This can result in damage to property. ▶ Ensure that the air filter is dry when it is fitted. Maintenance CAUTION! every 6 months Danger due to the effect of compressed air. This can result in damage to property.

  • Page 123: Removing Stiff Drive Rollers

    Removing Stiff Drive Rollers Removing a stiff If a drive roller is difficult to remove by hand, the knurled screw on the D100 brake can drive roller be used to remove it.

  • Page 125: Appendix

    Appendix...

  • Page 127: Average Consumption Values During Welding

    Average consumption values during welding Average wire Average wire electrode consumption at a wire speed of 5 m/min electrode con- 1.0 mm wire 1.2 mm wire 1.6 mm wire sumption during electrode dia- electrode dia- electrode dia- MIG/MAG welding meter meter meter Steel wire electrode...

  • Page 128: Technical Data

    An overview of which critical raw materials are contained in this device can be found at materials, year of the following Internet address. production of the www.fronius.com/en/about-fronius/sustainability. device To calculate the year of production of the device: Each device is provided with a serial number...
  • Page 129 Reduce the power or amperage value correspondingly so that the device can oper- ate without a cool-down phase. TransSteel 2200 Grid voltage (U 230 V Max. effective primary current (I 16 A 1eff Max. primary current (I 26 A 1max...
  • Page 130 A device in emissions class A is not intended for use in residential areas in which the electrical power is supplied via a public low-voltage grid. The electromagnetic compatibility may be influenced by conducted or radiated radio frequencies. TransSteel 2200 Grid voltage (U 120 V Max. effective primary current (I...
  • Page 131 Mains fuse protection 16 A slow-blow Max. apparent power (S 5.98 kVA 1max Grid voltage (U 240 V Max. effective primary current (I 15 A 1eff Max. primary current (I 26 A 1max Mains fuse 20 A time-delay fuse Max. apparent power (S 6.24 kVA 1max Mains voltage tolerance...
  • Page 132 Type of cooling Overvoltage category Pollution degree according to IEC60664 EMC device class Safety markings S, CE, CSA Dimensions l x w x h 560 x 215 x 370 mm 22.05 x 8.46 x 14.57 in. Weight 15.2 kg 33.51 lb. Max.
  • Page 133 Welding program tables TSt 2200 welding Welding program database: DB 3815 program table Material Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 0,6 mm .025“ .030“ .035“ .040“ .045“ Steel CO 100% 3814 3813 3812 3811 Steel Ar + 15-20% CO 3810 3810 3809...
  • Page 136 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...

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