Download
Share
Print this page
Fronius TransSteel 3000c Pulse Operating Instructions Manual
  1. Manuals
  2. Brands
  3. Fronius Manuals
  4. Welding System
  5. TransSteel 3000c Pulse
  6. Operating instructions manual

Fronius TransSteel 3000c Pulse Operating Instructions Manual

Hide thumbs

Advertisement

Quick Links

Download this manual
/ Perfect Charging / Perfect Welding / Solar Energy
TransSteel 3000c Pulse
42,0426,0354,EA 003-15122020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Operating instructions
MIG/MAG power source

Advertisement

loading
Need help?

Need help?

Do you have a question about the TransSteel 3000c Pulse and is the answer not in the manual?

Questions and answers

Related Manuals for Fronius TransSteel 3000c Pulse

Summary of Contents for Fronius TransSteel 3000c Pulse

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating instructions TransSteel 3000c Pulse MIG/MAG power source 42,0426,0354,EA 003-15122020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
  • Page 3 Table of contents Safety Instructions Explanation of Safety Instructions General Intended Use Environmental Conditions Obligations of the Operating Company Obligations of Personnel Grid Connection Personal Protection and Protection of Others Danger from toxic gases and vapors Danger from Flying Sparks Risks from grid current and welding current Stray welding currents EMC Device Classifications...
  • Page 4 Minimum equipment for welding operations General Gas-cooled MIG/MAG welding Water-cooled MIG/MAG welding Manual metal arc welding TIG DC Welding Before installation and initial operation Safety Intended Use Setup regulations Grid Connection Connecting the Mains Cable Stipulated mains cables and strain-relief devices Safety Connecting the mains cable Fitting the strain-relief device...
  • Page 5 HotStart function Anti-Stick function Easy Documentation General General Documented welding data New CSV file PDF report / Fronius signature Activating / deactivating Easy Documentation Activating Easy Documentation Set the date and time Deactivating Easy Documentation Setup Settings Setup Menu General...
  • Page 6 Special Voltage Explanation of the Term Duty Cycle TransSteel 3000c Pulse TransSteel 3000c Pulse nc Welding program tables Welding program label on the device Welding program tables for TransSteel 3000c Pulse Welding program tables for TransSteel 3000c Pulse - US...
  • Page 7 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 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 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.
  • Page 10 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...
  • Page 11 Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely cover the entire area between the body and the ground potential. All cables and leads must be secured, undamaged, insulated, and adequately dimen- sioned.
  • Page 12 Position the device with sufficient insulation against electrically conductive environments, e.g., insulation against electrically conductive floors or electrically conductive mounts. Observe the following when using electrical distributors, double-headed retainers, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric poten- tial.
  • Page 13 EMF measures Electromagnetic fields may cause health problems that are not yet known: Effects on the health of persons close by, e.g., those with pacemakers and hearing aids Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process Keep distances between welding cables and the head/torso of the welder as large as possible for safety reasons...
  • Page 14 In the event of crane attachment of the wirefeeder during welding, always use a suitable, insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices). If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand.
  • Page 15 Danger Posed by Risk of asphyxiation due to uncontrolled shielding gas leak Shielding Gas Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air Leak in the event of leakage. Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³...
  • Page 16 Always secure the shielding gas cylinder well and remove before transporting by crane. Only the original coolant from the manufacturer is suitable for use in our devices due to its properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.) Only use appropriate original coolant from the manufacturer. Do not mix original coolant from the manufacturer with other coolants.
  • Page 17 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...
  • Page 21 A high degree of reproducibility on all results Excellent weld properties. Application areas The TransSteel 3000c Pulse is used in trade and industry for manual applications with classical steel and galvanized sheet metal. The power source is designed for: Mechanical and equipment engineering...
  • Page 22 40,0006,3035 inside Welding is dangerous. The following basic requirements must be met: Adequate welding qualifications Appropriate protective equipment Exclusion of unauthorized persons 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...
  • Page 23 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 24 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 25 Welding processes, procedures, and welding char- acteristics for MIG/MAG welding General In order to process a wide range of materials effectively, various welding processes, pro- cedures, and welding characteristics are available on the power source. Brief description MIG/MAG standard synergic of MIG/MAG standard syner- MIG/MAG standard synergic welding is a MIG/MAG welding process covering the entire...
  • Page 26 System components General The power sources can be operated with various system components and options. This makes it possible to optimize procedures and to simplify machine handling and opera- tion, depending on the field of application for the power source. Safety WARNING! Danger due to incorrect operation.
  • Page 27 Operating controls and connections...
  • Page 29 Control Panel General The functions are all arranged in a logical way on the control panel. The individual para- meters required for welding can be Selected by means of buttons Changed using buttons or the selection dial Shown on the digital display during welding. Due to the synergic function, all other parameters are also adjusted if a single parameter is changed.
  • Page 30 Control panel (13) (14) (15)(16) (17) (12) (11) (10) Function "Parameter selection" button (right) a) for selecting the following parameters Arc length correction For correcting the arc length Welding voltage in V *) Before welding begins, the device automatically displays a standard value based on the programmed parameters.
  • Page 31 Pulse / arc-force dynamic correction For continuously correcting the droplet detachment force in MIG/MAG pulsed synergic welding - ... reduced droplet detachment force 0 ... neutral droplet detachment force + ... increased droplet detachment force For influencing the short-circuiting dynamic at the instant of droplet transfer in MIG/MAG standard synergic welding, MIG/MAG standard manual welding, and manual metal arc welding - ...
  • Page 32 Selection dial (left) For changing the sheet thickness, welding current, and wire speed parameters For selecting parameters in the Setup menu EasyJob save buttons For saving up to 5 operating points "Process" button For selecting the welding process MIG/MAG standard manual welding MIG/MAG standard synergic welding MIG/MAG pulsed synergic welding TIG welding...
  • Page 33 "Shielding gas" button For selecting the shielding gas used. The SP parameter is reserved for additional shielding gases. When the shielding gas is selected, the LED behind the corresponding shielding gas lights up. "Wire diameter" button For selecting the wire diameter used. The SP parameter is reserved for addi- tional wire diameters.
  • Page 34 EnE parameter. The value continuously rises during welding in line with the per- manently increasing energy input. The final value is stored after the end of weld- ing until welding starts again or the power source is switched back on - the HOLD indicator lights up.
  • Page 35 Service paramet- Various service parameters can be retrieved by pressing the "Parameter selection" but- tons 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" and "Process" buttons or the left-hand selection dial to select the required setup parameter Available parameters...
  • Page 36 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: Settings cannot be adjusted on the control panel Only parameter settings can be retrieved Any assigned "Save" button can be retrieved provided that an assigned "Save" but- ton was selected when the keylock was enabled Activating/deactivating the keylock: Keylock activated:...
  • Page 37 Connections, Switches, and Mechanical Compon- ents Front and back (10) (11) Welding torch connection For connecting the welding torch Polarity reverser For selecting the welding potential on the MIG/MAG welding torch (-) Current socket with bayonet latch Used for Connecting the grounding cable or polarity reverser for MIG/MAG welding (depending on the wire electrode used) Connecting the electrode cable or grounding cable for manual metal arc welding (depending on the type of electrode used)
  • Page 38 (10) EASY DOCUMENTATION label (11) TIG shielding gas connection socket For the shielding gas supply for the (-) current socket (5) 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 19 kg (41.89 lbs.) 4-roller drive Side panel not shown...
  • Page 39 Installation and Startup...
  • Page 41 Minimum equipment for welding operations General Depending on the welding process, a minimum level of equipment is required to work with the power source. The following describes the welding processes and the corresponding minimum equip- ment for welding operations. Gas-cooled Power source MIG/MAG welding Grounding cable...
  • Page 42 Before installation and initial operation Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
  • Page 43 The ventilation channel is a very important safety device. When selecting the setup loca- tion, ensure that the cooling air can enter or exit unhindered through the vents on the front and back. Any electrically conductive dust (e.g., from grinding work) must not be allowed to be sucked into the device.
  • Page 44 Connecting the Mains Cable Stipulated mains The following mains cables are required to operate the power source: cables and strain- relief devices Europe: Cable cross-section 4G2.5 USA/Canada: Cable cross-section AWG 12, extra-hard usage Depending on the version, a strain-relief device corresponding to the cable cross-section is fitted on the power source.
  • Page 45 Fitting the strain- relief device 1,2 Nm IMPORTANT! Tie the phase conductors near the block terminal using cable ties. Fitting the strain- relief device for Canada / US...
  • Page 46 IMPORTANT! Tie the phase conductors near the block terminal using cable ties.
  • Page 47 Generator-Powered Operation Generator- The power source is generator-compatible. powered opera- tion 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 for 3-phase 1max devices as follows: x √3...
  • Page 48 Commissioning Safety WARNING! An electric shock can be fatal. If the power source is connected to the grid during installation, there is a danger of seri- ous personal injury and property damage. ▶ Only carry out work on the device when the power source's power switch is in the - O - position.
  • Page 49 Assembling sys- WARNING! tem components Work performed incorrectly can cause serious injury and damage. ▶ The following activities must only be carried out by trained and qualified personnel. ▶ Please note the information in the "Safety instructions" chapter! The following diagram shows an overview of how the individual system components are put together.
  • Page 50 Inserting/chan- CAUTION! ging feed rollers Danger due to feed roller holders shooting upwards. Serious injuries may result. ▶ When unlocking the clamping lever, keep fingers away from the area to the left and right of the clamping lever. CAUTION! Danger due to open feed rollers. Serious injuries may result.
  • Page 51 Inserting the CAUTION! wirespool Risk of injury due to springiness of spooled wire electrode. ▶ When inserting the wirespool, hold the end of the wire electrode firmly to avoid injur- ies caused by the wire electrode springing back. CAUTION! Risk of injury from falling wirespool. ▶...
  • Page 52 Installing the bas- CAUTION! ket-type spool Risk of injury due to springiness of spooled wire electrode. ▶ When inserting the basket-type spool, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. CAUTION! Risk of injury from falling basket-type spool.
  • Page 53 Feed in the wire CAUTION! electrode Risk of injury due to springiness of spooled wire electrode. ▶ When inserting the wire electrode into the 4-roller drive, hold the end of the wire electrode firmly to avoid injuries caused by the wire electrode springing back. CAUTION! Risk of damage to the welding torch from sharp end of wire electrode.
  • Page 54 Hold the button for up to one second ... the wire speed stays at 1 m/min or 39.37 ipm for the first (m/min, ipm) second. Hold the button for up to 2.5 seconds ... after one second, the wire speed increases evenly within the next 1.5 seconds.
  • Page 55 Setting the con- CAUTION! tact pressure Risk of contact pressure being too high. This can result in severe damage to property and poor weld properties. ▶ Set the contact pressure in such a way that the wire electrode is not deformed but nevertheless ensures proper wirefeeding.
  • Page 56 Adjust the brake NOTE! After releasing the wire threading button, the wirespool must stop unreeling. ▶ If it continues unreeling, readjust the brake. STOP STOP Design of the WARNING! Brake Danger from incorrect installation. Serious personal injury and damage to property may result.
  • Page 57 Setting the date After switching on the power source for the first time, the date and time must be set. For and time when this purpose, the power source changes to the second level of the service menu; the starting for the yEA parameter is selected.
  • Page 59 MIG/MAG welding...
  • Page 61 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 speed is a determining parameter for welding power. If it is too high, the arc gets smaller and smaller and may be extinguished.
  • Page 62 MIG/MAG Operating Modes General WARNING! Operating the device incorrectly can cause serious injury and damage to property. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
  • Page 63 2-step mode "2-step mode" is suitable for Tacking work Short weld seams Automatic and robot operation 4-step mode "4-step mode" is suitable for longer weld seams.
  • Page 64 Special 2-step mode "Special 2-step mode" is ideal for welding in higher power ranges. In special 2-step mode, the arc starts at a lower power, which makes it easier to stabilize. To activate special 2-step mode: Select 2-step mode In the Setup menu, set the t-S (starting current duration) and t-E (final current dura- tion) parameters to a value >...
  • Page 65 Spot welding < SPt The "Spot welding" mode is suitable for welded joints on overlapped sheets. Start by pressing and releasing the torch trigger - GPr gas pre-flow time - welding current phase over the SPt spot welding time duration - GPo gas post-flow time. If the torch trigger is pressed again before the end of the spot welding time (<...
  • Page 66 4-step stitch welding 4-step stitch welding The "4-step stitch welding" mode is suitable for welding longer weld seams on thin sheets, to prevent the weld seams from dropping through the parent material.
  • Page 67 MIG/MAG welding Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
  • Page 68 MIG/MAG synergic welding MIG/MAG syner- Press the "Material" button to select the filler metal to be used. gic welding Press the "Wire diameter" button to select the diameter of the wire electrode used. 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 69 Use the appropriate selection dial to set the welding parameter. The value of the parameter is displayed on the digital display located above. The sheet thickness, welding current, wire speed, and welding voltage parameters are directly linked. It is sufficient to change one of the parameters, as the remaining paramet- ers are immediately adjusted accordingly All welding parameter set values remain stored until the next time they are changed.
  • Page 70 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 Pulse / arc-force dynamic correction For continuous correction of the droplet detachment force in MIG/MAG pulsed synergic welding reduced droplet detachment force...
  • Page 71 How SynchroPulse works when used in "Special 4-step" mode I-S = starting-current phase, SL = Slope, I-E = crater-fill phase, v = wire speed Al.2 SynchroPulse mode of operation...
  • Page 72 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 of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.
  • Page 73 IMPORTANT! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component - such as remote control or wirefeeder - on the control panel of the power source. Press the "Parameter selection"...
  • Page 74 Spot and Stitch Welding General The spot welding and stitch welding modes are MIG/MAG welding processes. The spot welding and stitch welding modes are activated on the control panel. Spot welding is used on welded joints on overlapping sheets that are only accessible on one side.
  • Page 75 CAUTION! Danger of injury and damage from electric shock and from the wire electrode emerging from the torch. When you press the torch trigger: ▶ Keep the welding torch away from your face and body ▶ Wear suitable protective goggles ▶...
  • Page 76 Depending on the welding process selected, select the desired welding parameters and adjust them using the appropriate selection dial Open the gas cylinder valve Adjust quantity of shielding gas CAUTION! Danger of injury and damage from electric shock and from the wire electrode emerging from the torch.
  • Page 77 EasyJob mode General The "Save" buttons allow up to five EasyJob operating points to be saved. Each operat- ing point corresponds to the settings made on the control panel. EasyJobs can be stored for each welding process. IMPORTANT! Setup parameters are not saved at this time. Saving EasyJob Press and hold one of the "Save"...
  • Page 78 Retrieving Easy- Press one of the "Save" buttons on the control panel to retrieve the saved settings using Job operating the Up/Down welding torch. points on the Up/ Down welding Press one of the "Save" buttons on the control panel, e.g.: torch The control panel will show the saved settings.
  • Page 79 TIG welding...
  • Page 81 TIG welding Safety WARNING! Danger due to incorrect operation. This can result in severe personal injury and damage to property. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
  • Page 82 TIG welding CAUTION! Danger of injury and damage from electric shock. When the power switch is switched to position - I -, the tungsten electrode of the welding torch is live. ▶ Ensure that the tungsten electrode is not touching any people or electrically conduct- ive or grounded parts (housing, etc.).
  • Page 83 Igniting the arc When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting): Position the gas nozzle at the ignition point so that there is a distance of approxim- ately 2 to 3 mm (0.078 to 0.118 in.) between the tungsten electrode and the work- piece Gradually tilt the welding torch up until the tungsten electrode touches the workpiece Pull back the torch trigger and hold it in this position...
  • Page 84 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 85 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 105.
  • Page 87 Manual Metal Arc Welding...
  • Page 89 Manual Metal Arc Welding Safety WARNING! Operating the device incorrectly can cause serious injury and damage to property. ▶ Do not use the functions described here until you have fully read and understood the Operating Instructions. ▶ Do not use the functions described here until you have fully read and understood all of the Operating Instructions of the system components, especially the safety rules.
  • Page 90 Manual metal arc CAUTION! welding Danger of injury and damage from electric shock. When the power switch is switched to position - I -, the rod electrode in the electrode holder is live. ▶ Ensure that the rod electrode is not touching any people or electrically conductive or grounded parts (housing, etc.).
  • Page 91 HotStart function To obtain the best possible welding result, the HotStart function will sometimes need to be adjusted. Advantages Improved ignition properties, even when using electrodes with poor ignition proper- ties Better fusion of the parent material during the start-up phase, meaning fewer cold- shut defects Slag inclusions largely avoided The setting of the available parameters is described in the section "Setup settings",...
  • Page 93 Easy Documentation...
  • Page 95 CSV file on a USB thumb drive. A Fronius signature is stored with the welding data, which can be used to check and guarantee the authenticity of the data.
  • Page 96 By scanning this link... Fronius signature A PDF report of the selected welding data can be created The authenticity of the welding data can be checked and guaran- teed via the Fronius signature read out with the welding data. https://easydocu.weldcube.com...
  • Page 97 Activating / deactivating Easy Documentation Activating Easy The power source display shows: Documentation USB 3.1 FAT32 Easy Documentation is activated. doc | on is also displayed when the power source is switched off and on again with the USB thumb drive connected. Easy Documentation remains activated.
  • Page 98 To set the date and time: Left-hand selection dial: select parameter Right-hand selection dial: change values Setting ranges: Year (20yy; 0 - 99) Month (mm; 1 -1 12) Day (dd; 1 - 31) Hour (hh; 0 - 24) Minute (mm; 0 - 59) NOTE! If the power source is reset to factory settings via setup parameter FAC, the date and time remain stored.
  • Page 99 Setup Settings...
  • Page 101 Setup Menu General The Setup menu offers easy access to expert knowledge related to the power source, as well as additional functions. The Setup menu makes it possible to easily adjust the para- meters for various tasks. Operation Accessing the Setup menu is described with reference to the MIG/MAG standard syner- gic welding process.
  • Page 102 Setup parameters The specifications "min." and "max." are used for setting ranges that vary according to for MIG/MAG syn- the power source, welding program, etc. ergic welding Gas pre-flow time Unit: s Setting range: 0 - 9.9 Factory setting: 0.1 Gas post-flow time Unit: s Setting range: 0 - 9.9...
  • Page 103 NOTE! The Ito function (length of wire fed until safety cut-out trips) is a safety function. At high wire speeds in particular, the length of wire fed until the safety cut-out trips can deviate from the set wire length. Spot welding time / interval welding time Unit: s Setting range: 0.3 - 5 Factory setting: 1...
  • Page 104 Setup parameters The specifications "min." and "max." are used for setting ranges that vary according to for MIG/MAG the power source, welding 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...
  • Page 105 Factory setting: 2T (2-step) Reset power source to factory settings Press and hold one of the "Parameter selection" buttons for two seconds to restore the factory settings - when "PrG" appears on the digital display, the power source has been reset IMPORTANT! If the power source is reset, all the personal settings in the Setup menu are lost.
  • Page 106 Factory setting: OFF UpSlope Unit: seconds Setting range: 0.01 - 9.9 Factory setting: 0.5 DownSlope Unit: seconds Setting range: 0.01 - 9.9 Factory setting: 1 Starting current Unit: % of main current Setting range: 1 - 200 Factory setting: 35 Lowering current Unit: % of main current Setting range: 1 - 100...
  • Page 107 Setup Menu 2nd Level Limitations The following restrictions occur in relation to the Setup menu 2nd level: Setup menu 2nd level cannot be selected: during welding if the "Gas test" function is active if the "Wire threading" function is active if the "Wire withdrawal"...
  • Page 108 MANUAL STD SYNERGIC PULSE SYNERGIC Parameters for Country-specific setting (Standard/USA) ... Hour/US MIG/MAG syner- Unit: gic welding in Setting range: Std, US (Standard/USA) Setup menu 2nd Factory setting: level Standard version: Std (dimensions: cm / mm) USA version: US (dimensions: in.) Synergic programs/characteristics Standards EN / AWS Unit:...
  • Page 109 Unit: s Setting range: 5 - 25 Factory setting: 10 IMPORTANT! Every time the power source is switched on, the cooling unit car- ries out a test run for 180 seconds. Welding circuit resistance (in mOhm) See the section "Measuring the welding circuit resistance r" from page 112. Welding circuit inductivity (in microhenrys) See the section "Displaying the welding circuit inductivity L"...
  • Page 110 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 111 Parameters for Country-specific setting (Standard/USA) ... Hour/US manual metal arc Unit: welding in Setup Setting range: Std, US (Standard/USA) menu 2nd level Factory setting: Standard version: Std (dimensions: cm / mm) USA version: US (dimensions: in.) r (resistance) - welding circuit resistance (in mOhm) See the section "Measuring the welding circuit resistance r"...
  • Page 112 Measuring the Welding Circuit Resistance r 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 113 Fit the gas nozzle back onto the welding torch Measuring the NOTE! welding circuit resistance (MMA Incorrect measurement of the welding circuit resistance can have a negative effect welding) on the welding result. ▶ Ensure that the workpiece has an optimum contact surface in the area of the earth- ing clamp (clean surface, no rust, etc.).
  • Page 114 Displaying the welding circuit Inductivity L 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 115 Troubleshooting and Maintenance...
  • Page 117 Troubleshooting General The devices are equipped with an intelligent safety system, which largely negates the need for 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. Safety WARNING! Work that is performed incorrectly can cause serious injury and damage to prop-...
  • Page 118 ESr | 20 Cause: The cooling unit used is not compatible with the power source Remedy: Connect compatible cooling unit ELn | 8 Cause: The connected wirefeeder is not supported Remedy: Connect supported wirefeeder ELn | 12 Cause: Different control panels for selecting materials are in the system Remedy: Connect similar control panels to select materials ELn | 13...
  • Page 119 Err | 52 Cause: Mains overvoltage: the grid voltage has risen above the tolerance range Remedy: Check the grid voltage. If the service code persists, contact the After-Sales Service team EFd 5 Cause: Incorrect wirefeeder connected Remedy: Connect correct wirefeeder EFd 8 Cause: Wirefeeder overtemperature...
  • Page 120 to5 | xxx Note: xxx stands for a temperature value Cause: Overtemperature in cooling unit Remedy: Allow cooling unit to cool down, check that fan is on to6 | xxx Note: xxx stands for a temperature value Cause: Overtemperature on the power source transformer Remedy: Allow power source to cool down, check air filter and clean if necessary, check that fan is on...
  • Page 121 tu6 | xxx Note: xxx stands for a temperature value Cause: Undertemperature on the power source transformer Remedy: Place power source in a heated room and allow it to warm up tu7 | xxx Note: xxx stands for a temperature value Cause: Undertemperature in power source Remedy:...
  • Page 122 Displayed service no | dAt codes in connec- Welding is not possible tion with OPT Easy Documenta- Cause: Date and time are not set on the power source tion Remedy: To reset the service code, press the arrow key; Set date and time in the 2nd level of the service menu: see page bAt | Lo Welding is possible...
  • Page 123 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! An electric shock can be fatal.
  • Page 124 Every 6 Months CAUTION! Danger due to the effect of compressed air. This can result in damage to property. ▶ Do not bring the air nozzle too close to electronic parts. Dismantle device side panels and blow the inside of the device clean with dry, reduced compressed air Also clean the cooling air ducts if there is a large accumulation of dust WARNING!
  • Page 125 Appendix...
  • Page 127 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 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 To use the device without interruptions: Search for a 100% D.C. value in the technical data, which corresponds to the exist- ing ambient temperature. Reduce the power or amperage value correspondingly so that the device can oper- ate without a cool-down phase.
  • Page 130 Pollution degree according to IEC60664 Safety markings S, CE, CSA Dimensions l x w x h 747 x 300 x 497 mm / 29.4 x 11.8 x 19.6 Weight 36 kg / 79.4 lb. Max. shielding gas pressure 5 bar/72.52 psi Coolant Original Fronius...
  • Page 131 Wire 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. Wirespool diameter max. 300 mm / max. 11.81 in. Wirespool weight max. 19.0 kg / max. 41.9 lb. Max.
  • Page 132 Welding program tables Welding program A label with the most common welding programs is affixed to the power source: label on the device Standard welding characteristics Configuration [mm / inch] Tst - 3000 Pulse KL-DB: 3992 .030 .035 .040 .045 .052 1/16 Steel ER 70-120...
  • Page 133 Welding program The welding programs are active if the tables for "SEt" setup parameter is set to "Std" TransSteel 3000c (Standard) Pulse Welding program database: DB 3992 Standard welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm .030‘‘...
  • Page 134 Additional welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘ 1/16‘‘ S2423 S2424 CrNi/Stainless Ar + 18% CO P4014 P4013 S2440 S2441 S2442 S2443 CrNi/Stainless root Ar + 18% CO S2471 S2472 Rutil...
  • Page 135 Welding program The welding programs are active if the tables for "SEt" setup parameter is set to "US" TransSteel 3000c (USA). Pulse - US Welding program database: UID 3992 Standard welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm...
  • Page 136 Additional welding characteristics Material Configuration Diameter 0,8 mm 0,9 mm 1,0 mm 1,2 mm 1,4 mm 1,6 mm .030‘‘ .035‘‘ .040‘‘ .045‘‘ .052‘‘ 1/16‘‘ S2423 S2424 CrNi/Stainless Ar + 15-25% CO P4014 P4013 S2440 S2441 S2442 S2443 CrNi/Stainless root Ar + 2,5% CO S2471 S2472 Rutil...
  • Page 140 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...