FRONIUS TransSteel 3000c Pulse Bedienungsanleitung

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TransSteel 3000c Pulse

EN-US

Operating instructions

MIG/MAG power source

42,0426,0354,EA 003-15122020

Table of contents

Safety Instructions 7

Explanation of Safety Instructions 7

General 7

Intended Use 7

Environmental Conditions 8

Obligations of the Operating Company 8

Obligations of Personnel 8

Grid Connection 8

Personal Protection and Protection of Others 9

Danger from toxic gases and vapors 9

Danger from Flying Sparks 10

Risks from grid current and welding current 10

Stray welding currents 11

EMC Device Classifications 12

EMC Measures 12

EMF measures 13

Particular Hazard Areas 13

Requirement for the shielding gas 14

Danger from Shielding Gas Cylinders 14

Danger Posed by Shielding Gas Leak 15

Safety Measures at the Setup Location and During Transport 15

Safety Measures in Normal Operation 15

Maintenance and repair 16

Safety Inspection 16

Disposal 16

Safety Symbols 17

Data backup 17

General information 19

General 21

Device concept 21

Operating principle 21

Application areas 21

Warning notices on the device 21

Description of the warnings on the device 23

Welding processes, procedures, and welding characteristics for MIG/MAG welding 25

General 25

Brief description of MIG/MAG standard synergic welding 25

Brief description of MIG/MAG pulsed synergic welding 25

Brief description of SynchroPulse welding 25

System components 26

General 26

Safety 26

Overview 26

Operating controls and connections 27

Control Panel 29

General 29

Safety 29

Control panel 30

Service parameters 35

Keylock 36

Connections, Switches, and Mechanical Components 37

Front and back 37

Side view 38

Installation and Startup 39

EN-US

Minimum equipment for welding operations 41

General 41

Gas-cooled MIG/MAG welding 41

Water-cooled MIG/MAG welding 41

Manual metal arc welding 41

TIG DC Welding 41

Before installation and initial operation 42

Safety 42

Intended Use 42

Setup regulations 42

Grid Connection 43

Connecting the Mains Cable 44

Stipulated mains cables and strain-relief devices 44

Safety 44

Connecting the mains cable 44

Fitting the strain-relief device 45

Fitting the strain-relief device for Canada / US 45

Generator-Powered Operation 47

Generator-powered operation 47

Commissioning 48

Safety 48

General 48

Information on system components 48

Assembling system components 49

Establishing a ground earth connection 49

Inserting/changing feed rollers 50

Inserting the wirespool 51

Installing the basket-type spool 52

Feed in the wire electrode 53

Setting the contact pressure 55

Adjust the brake 56

Design of the Brake 56

Setting the date and time when starting for the first time 57

MIG/MAG welding 59

Power Limitation 61

Safety function 61

MIG/MAG Operating Modes 62

General 62

Symbols and explanations 62

2-step mode 63

4-step mode 63

Special 2-step mode 64

Special 4-step mode 64

Spot welding 65

2-step stitch welding 65

4-step stitch welding 66

MIG/MAG welding 67

Safety 67

Preparation 67

Overview 67

MIG/MAG synergic welding 68

Corrections during welding 70

SynchroPulse welding 70

MIG/MAG Standard Manual Welding 72

General 72

Available parameters 72

MIG/MAG standard manual welding 72

Corrections during welding 73

Spot and Stitch Welding 74

General 74

Spot welding 74

Stitch welding 75

EasyJob mode 77

General 77

Saving EasyJob operating points 77

Retrieving EasyJob operating points 77

Deleting EasyJob operating points 77

Retrieving EasyJob operating points on the Up/Down welding torch 78

TIG welding 79

TIG welding 81

Safety 81

Preparation 81

TIG welding 82

Igniting the arc 83

Ending the welding process 83

Pulse welding 84

Applications 84

Operating principle 84

Activating pulse welding 85

Manual Metal Arc Welding 87

Manual Metal Arc Welding 89

Safety 89

Preparation 89

Manual metal arc welding 90

Corrections during welding 90

HotStart function 91

Anti-Stick function 91

Easy Documentation 93

General 95

Documented welding data 95

New CSV file 96

PDF report / Fronius signature 96

Activating / deactivating Easy Documentation 97

Activating Easy Documentation 97

Set the date and time 97

Deactivating Easy Documentation 98

Setup Settings 99

Setup Menu 101

General 101

Operation 101

Setup parameters for MIG/MAG synergic welding 102

Setup parameters for MIG/MAG standard manual welding 104

Setup parameters for MMA welding 105

Parameters for TIG welding 105

Setup Menu 2nd Level 107

Limitations 107

Operation (Setup Menu 2nd Level) 107

Parameters for MIG/MAG synergic welding in Setup menu 2nd level 108

Parameters for MIG/MAG standard manual welding in Setup menu 2nd level 109

Parameters for manual metal arc welding in Setup menu 2nd level 111

Parameters for TIG welding (Setup menu 2nd level) 111

Measuring the Welding Circuit Resistance r 112

General 112

Measuring the welding circuit resistance (MIG/MAG welding) 112

EN-US

Measuring the welding circuit resistance (MMA welding) 113

Displaying the welding circuit Inductivity L 114

General 114

Displaying the welding circuit inductivity 114

Laying the hosepacks correctly 114

Troubleshooting and Maintenance 115

Troubleshooting 117

General 117

Safety 117

Displayed Service Codes 117

Displayed service codes in connection with OPT Easy Documentation 122

Service, maintenance and disposal 123

General 123

Safety 123

At every start-up 123

Whenever required 123

Every 2 Months 123

Every 6 Months 124

Disposal 124

Appendix 125

Average consumption values during welding 127

Average wire electrode consumption during MIG/MAG welding 127

Average shielding gas consumption during MIG/MAG welding 127

Average shielding gas consumption during TIG welding 127

Technical data 128

Overview with critical raw materials, year of production of the device 128

Special Voltage 128

Explanation of the Term Duty Cycle 128

TransSteel 3000c Pulse TransSteel 3000c Pulse nc 130

Welding program tables 132

Welding program label on the device 132

Welding program tables for TransSteel 3000c Pulse 133

Welding program tables for TransSteel 3000c Pulse - US 135

Safety Instructions

Explanation of

Safety Instruc-

tions

DANGER!

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.

▶Minor injury or damage to property may result if appropriate precautions are not

taken.

NOTE!

Indicates the possibility of flawed results and damage to the equipment.

General The device has been manufactured using state-of-the-art technology and according to

recognized 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 operating company

- Inefficient operation of the equipment

All persons involved in the commissioning, operation, maintenance, and servicing of the

device must

- Be suitably qualified

- Have knowledge of welding

- Have completely read and followed these Operating Instructions

The Operating Instructions must always be at hand wherever the device is being used. In

addition to the Operating Instructions, all applicable local rules and regulations regarding

accident prevention and environmental protection must also be followed.

All safety and danger notices on the device must

- Be kept in a legible state

- Not be damaged/marked

- Not be removed

- Not be covered, pasted, or painted over

For the location of the safety and danger notices on the device, refer to the section

headed "General" in the Operating Instructions for the device.

Before switching on the device, remove any faults that could compromise safety.

Your personal safety is at stake!

Intended Use The device is to be used exclusively for its intended purpose.

EN-US

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.

Proper use also means

- Completely reading and obeying all instructions in the Operating Instructions

- Completely reading and obeying all safety instructions and danger notices

- Carrying out all the specified inspection and servicing work

Never use the device for the following applications:

- Thawing pipes

- Charging batteries

- Starting motors

The device is designed for operation in industry and business. The manufacture shall not

be liable for any damage resulting from use in a living area.

The manufacture shall also not be liable for faulty or incorrect work results.

Environmental

Conditions

Operation or storage of the device outside the stipulated area will be deemed as not in

accordance with the intended purpose. The manufacturer accepts no liability for any

damage resulting from improper use.

Temperature range of the ambient air:

- 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:

- Up to 50% at 40°C (104°F)

- Up to 90% at 20°C (68°F)

Ambient air: free of dust, acids, corrosive gases or substances, etc.

Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)

Obligations of the

Operating Com-

pany

The operating company must only allow persons to work with the device if they

- Are familiar with the basic occupational safety and accident prevention regulations

and are trained in handling the device

- Have read and understood these Operating Instructions, especially the section

"Safety Rules," and have confirmed this with their signature

- Are trained according to the requirements for the work results

The safety-conscious work of the personnel must be checked regularly.

Obligations of

Personnel

All persons who are assigned to work with the device must do the following before begin-

ning the work:

- Follow the basic regulations for occupational safety and accident prevention

- Read these Operating Instructions, especially the section "Safety Rules," and con-

firm that they have understood and will follow them by signing

Before leaving the workplace, ensure that no personal injury or property damage can

occur in one's absence.

Grid Connection Devices with a high output can influence the energy quality of the grid due to their cur-

rent consumption.

This may affect a number of device types in terms of:

- connection restrictions

-criteria regarding maximum permissible grid impedance *)

-criteria regarding the minimum required short-circuit power *)

*) both at the interface with the public grid

See technical data

In this case, the operator or the person using the device should check whether or not the

device is allowed to be connected, where appropriate through discussion with the power

supply company.

IMPORTANT! Ensure secure grounding of the grid connection!

Personal Protec-

tion and Protec-

tion of Others

You are exposed to numerous hazards while handling the device, for example:

- Flying sparks and pieces of hot metal

- Arc radiation that poses a risk of injury to the eyes and skin

- Hazardous electromagnetic fields that pose a risk of death for individuals with pace-

makers

- Electrical risks from grid current and welding current

- Increased noise exposure

- Harmful welding fumes and gases

Wear suitable protective clothing when dealing with the device. The protective clothing

must have the following properties:

- Flame resistant

- Insulating and dry

- Covering the entire body and in good condition with no damage

- Safety helmet

- Cuffless pants

Protective clothing involves the following:

- Protecting the face and eyes from UV radiation, heat and flying sparks with a face

guard featuring a regulation-compliant filter

- Wearing regulation-compliant protective goggles with side protection behind the face

guard

- Wearing rigid, wet-insulating footwear

- Protecting hands with appropriate gloves (featuring electrical insulation and thermal

protection)

- Wearing ear protection to reduce noise exposure and protect against injury

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.

Danger from

toxic gases and

vapors

The fumes produced during welding contain toxic gases and vapors.

Welding fumes contain substances that cause cancer, as stated in monograph 118 from

the International Agency for Research on Cancer.

Use at-source extraction source and a room extraction system.

If possible, use a welding torch with an integrated extraction device.

Keep your head out of the welding fumes and gases.

EN-US

Take the following precautionary measures for fumes and harmful gases:

- Do not breathe them in.

- Extract them from the work area using appropriate equipment.

Ensure that there is a sufficient supply of fresh air. Ensure that there is a ventilation flow

rate of at least 20 m³ per hour.

Use a welding helmet with air supply if there is insufficient ventilation.

If there is uncertainty as to whether the extraction capacity is sufficient, compare the

measured toxic emission values against the permissible limit values.

The following components are factors that determine how toxic the welding fumes are:

- The metals used for the workpiece

- Electrodes

- Coatings

- Cleaning agents, degreasers, and the like

- The welding process used

Consult the corresponding material safety data sheets and manufacturer's instructions

for the components listed above.

Recommendations for exposure scenarios, risk management measures and identifying

working conditions can be found on the European Welding Association website under

Health & Safety (https://european-welding.org).

Keep flammable vapors (such as solvent vapors) out of the arc radiation range.

When no welding is taking place, close the valve of the shielding gas cylinder or the main

gas supply.

Danger from Fly-

ing Sparks

Flying sparks can cause fires and explosions.

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.

Sparks and pieces of hot metal may also get into surrounding areas through small cracks

and openings. Take appropriate measures to ensure that there is no risk of injury or fire.

Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks,

drums, or pipes if these have not been prepared in accordance with corresponding

national and international standards.

Do not undertake welding on containers in which gases, fuels, mineral oils, and the like

are/were stored. Residues pose a risk of explosion.

Risks from grid

current and weld-

ing current

An electric shock can be fatal.

Do not touch voltage-carrying parts inside or outside the device.

During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed

rollers, as well as all pieces of metal that are in contact with the welding wire, are live.

Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating

wirefeeder holder.

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