FRONIUS TransSteel 2700c Manual de usuario

Operating

instructions

TransSteel 2700c MultiProzess

TransSteel 2700c MV MultiProzess

TransSteel 3500c MultiProzess

42,0426,0322,EA 012-04052022

EN-US Operating instructions

Table of contents

Safety Instructions 7

Explanation of Safety Instructions 7

General 7

Intended Use 8

Environmental Conditions 8

Obligations of the Operating Company 8

Obligations of Personnel 8

Grid Connection 9

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 12

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 16

Maintenance and repair 16

Safety Inspection 17

Disposal 17

Safety symbols 17

Data backup 17

General information 19

General 21

Device Concept 21

Available welding processes 21

Operating Principle 22

Applications 23

Warning notices on the device 23

Description of the warnings on the device 25

System components 27

General 27

Safety 27

Overview 27

Operating controls and connections 29

Control Panel 31

General 31

Safety 31

Synergic control panel 32

Service parameters 35

Keylock 36

Connections, Switches, and Mechanical Components 37

TSt 2700c MP 37

TSt 3500c MP 38

Installation 41

Minimum equipment for welding operations 43

General 43

Gas-cooled MIG/MAG welding 43

Water-cooled MIG/MAG welding 43

EN-US

Manual metal arc welding 43

TIG DC Welding 43

Before installation and initial operation 44

Safety 44

Intended Use 44

Setup regulations 44

Grid Connection 45

Generator-Powered Operation 46

TSt 2700c MV MP - Single-Phase Operation 47

Single-phase operation 47

Explanation of the Term "Duty Cycle" in Single-Phase Operation 48

Welding time in single-phase operation 50

Connecting the Mains Cable 51

Safety 51

General 51

Stipulated Grid Cables and Strain-Relief Devices 51

Connecting the Grid Cable, TSt 2700c MV, Single-Phase Operation 52

Connecting the Grid Cable, TSt 2700c MP MV 53

Connecting the Grid Cable, TSt 3500c nc MP 54

Fitting/Connecting the System Components 56

Information on System Components 56

Mounting on the Trolley 56

Connecting the Gas Cylinder 57

MIG/MAG 59

Commissioning 61

General 61

Connecting MIG/MAG Welding Torches 61

Inserting/changing feed rollers 62

Inserting the wirespool/basket-type spool 63

Connecting the Gas Cylinder 64

Connecting the Polarity Reverser and Establishing a Ground Earth Connection 65

Feeding in the wire electrode 66

Setting the contact pressure 68

Adjusting the brake 69

Design of the brake 69

Power Limitation 70

Safety function 70

MIG/MAG Operating Modes 71

General 71

Symbols and explanations 71

2-step mode 72

4-step mode 72

Special 4-step mode 73

Spot welding 73

2-step stitch welding 74

4-step stitch welding 74

MIG/MAG Standard Synergic Welding 75

Corrections During Welding 76

MIG/MAG Standard Manual Welding 77

General 77

Available parameters 77

MIG/MAG Standard Manual Welding 77

Corrections During Welding 78

Spot welding and stitch welding 79

General 79

Spot Welding 79

Stitch Welding 80

Rod Electrode 81

Commissioning 83

Safety 83

Preparation 83

Manual Metal Arc Welding 85

Functions for Optimizing the Welding Process 86

Arc-Force Dynamic 86

HotStart (Hti) function 86

Anti-stick (Ast) function 86

TIG 89

Commissioning 91

Start-up 91

TIG Welding 93

Pulse welding 94

Applications 94

Operating principle 94

Activating pulse welding 95

EasyJobs 97

Saving and Retrieving EasyJobs 99

General 99

Saving an EasyJob 99

Retrieving an EasyJob 99

Deleting an EasyJob 99

Retrieving operating points on the Up/Down welding torch 100

Easy Documentation (TransSteel 3500c MP) 101

General 103

Documented welding data 103

New CSV file 104

PDF report / Fronius signature 104

Activating / deactivating Easy Documentation 105

Setting the date and time 105

Deactivating Easy Documentation 105

Setup Settings 107

Setup Menu 109

General 109

Operation 109

Parameters for MIG/MAG standard synergic welding 109

Parameters for MIG/MAG Standard Manual Welding 111

Parameters for MMA Welding 112

Parameters for TIG welding 112

Setup Menu 2nd Level 114

Limitations 114

Operation (Setup Menu 2nd Level) 114

Parameters for MIG/MAG Standard Synergic Welding (Setup Menu 2nd Level) 115

Parameters for MIG/MAG Standard Manual Welding (Setup Menu 2nd Level) 117

Parameters for stick welding (SMAW) 119

Parameters for TIG Welding (Setup Menu 2nd Level) 120

Measuring the Welding Circuit Resistance r 121

General 121

Measuring the welding circuit resistance (MIG/MAG welding) 121

Displaying the Welding Circuit Inductivity L 123

General 123

EN-US

Displaying the welding circuit inductivity 123

Laying the hosepacks correctly 123

Troubleshooting and Maintenance 125

Troubleshooting 127

General 127

Safety 127

Troubleshooting 127

Displayed Service Codes 130

Displayed service codes in connection with OPT Easy Documentation 136

Service, maintenance and disposal 137

General 137

Safety 137

At every start-up 137

Whenever Required 137

Every 2 Months 138

Every 6 Months 138

Disposal 138

Appendix 139

Average consumption values during welding 141

Average wire electrode consumption during MIG/MAG welding 141

Average shielding gas consumption during MIG/MAG welding 141

Average shielding gas consumption during TIG welding 141

Technical data 142

Special Voltage 142

Explanation of the term duty cycle 142

TSt 2700c MP 143

TransSteel 2700c MV MP 145

TSt 3500c MP 148

Overview with critical raw materials, year of production of the device 149

Welding program tables 150

TSt 2700c MP welding program table 150

TSt 2700c MP USA welding program table 151

TSt 3500c MP welding program table 152

TSt 3500c MP USA welding program table 153

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 ac-

cording 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 reg-

ulations 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 sec-

tion 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!

EN-US

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

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 respons-

ible for any damage resulting from improper use.

Proper use also means

-Completely reading and obeying all instructions in the Operating Instruc-

tions

-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 liab-

ility 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

Company

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

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

lations and are trained in handling the device

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

tion "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 be-

fore beginning the work:

-Follow the basic regulations for occupational safety and accident prevention

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

confirm 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 current 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 pacemakers

-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, pos-

sible hazard due to grid current or welding current, etc.)

-Provide suitable protective equipment or

-Construct suitable protective walls and curtains.

Danger from tox-

ic gases and va-

pors

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.

EN-US

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.

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 ventila-

tion 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, com-

pare 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 in-

structions for the components listed above.

Recommendations for exposure scenarios, risk management measures and

identifying working conditions can be found on the European Welding Associ-

ation 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 protected 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 cor-

responding 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

welding current

An electric shock can be fatal.

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

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