TransSteel 2700c MP, TransSteel 3500c MP Operating instructions

1. Safety Instructions

1. Safety Instructions

• 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

• 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.

• 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!

1. Safety Instructions

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 responsible for any damage resulting from improper use.

• 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

• 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.

1. Safety Instructions

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.

• 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)

• 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.)

1. Safety Instructions

• 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.

1. Safety Instructions

• 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.

1. Safety Instructions

Devices with a high output can influence the energy quality of the grid due to their current consumption.

• 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!

1. Safety Instructions

• 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

• Flame resistant
• Insulating and dry
• Covering the entire body and in good condition with no damage
• Safety helmet
• Cuffless pants

• 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

• 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.

1. Safety Instructions

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.

• 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 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.

1. Safety Instructions

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 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.

1. Safety Instructions

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.

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 dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180° around the longitudinal axis and pretension.

Do not wrap cables or leads around your body or parts of the body.

• Never immerse it in liquids to cool it
• Never touch it when the power source is switched on.

The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same time may be life-threatening in some cases.

Have the grid and device supply lead regularly inspected by an electrician to ensure that the ground conductor is functioning properly.

Protection class I devices require a grid with a ground conductor and a connector system with ground conductor contact for proper operation.

Operation of the device on a grid without a ground conductor and on a socket without a ground conductor contact is only permitted if all national regulations for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer accepts no liability for any damage resulting from improper use.

Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.

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.

• Discharge all electrically charged components
• Ensure that all components are disconnected from the power supply.

If work is needed on voltage-carrying parts, bring in a second person who will switch off the main switch at the correct time.

1. Safety Instructions

• Fire
• Overheating of parts connected to the workpiece
• Irreparable damage to ground conductors
• Damage to the device and other electrical equipment

Ensure that the workpiece clamp is securely connected to the workpiece.

Secure the workpiece clamp as close to the spot to be welded as possible.

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 power distribution boards, twin-head mounts, etc.: Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.

In automated MIG/MAG applications, only guide the wire electrode from the welding wire drum, large spool, or wirespool to the wirefeeder with insulation.

1. Safety Instructions

• Are only designed for use in industrial settings
• Can cause line-bound and radiated interference in other areas

• Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is supplied from the public low-voltage grid.

EMC device classification as per the rating plate or technical data.

1. Safety Instructions

In certain cases, even though a device complies with the standard limit values for emissions, it may affect the application area for which it was designed (e.g., when there is sensitive equipment at the same location, or if the site where the device is installed is close to either radio or television receivers).
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.

• Safety devices
• Grid power lines, signal lines, and data transfer lines
• IT and telecommunications equipment
• Devices for measuring and calibrating

1. Grid power supply
   • If electromagnetic interference occurs despite a grid connection that complies with regulations, take additional measures (e.g., use a suitable grid filter).

2. Welding power-leads
   • Keep them as short as possible
   • Route them close together (also to avoid EMF problems)
   • Route them far from other lines

3. Equipotential bonding

4. Workpiece grounding
   • If necessary, establish grounding using suitable capacitors.

5. Shield, if necessary
   • Shield other devices in the vicinity
   • Shield the entire welding installation

1. Safety Instructions

• 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 power-leads and the head/torso of the welder as great as possible for safety reasons
• Do not carry welding power-leads and hosepacks over your shoulder or wrap them around your body or body parts

1. Safety Instructions

• Fans
• Gears
• Rollers
• Shafts
• Wirespools and welding wires

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.

• Ensure that all covers are closed, and all side parts have been mounted properly.
• Keep all covers and side parts closed.

The protrusion of welding wire from the welding torch represents a high risk of injury (cuts to the hand, facial and eye injuries, etc.).

Therefore, always hold the welding torch away from the body (devices with wirefeeder) and use suitable protective goggles.

Do not touch the workpiece during or after welding – risk of burns.

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
– follow the appropriate national and international regulations.

Power sources for work in areas with increased electrical hazard (e.g., boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas.

Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting connections for the coolant supply or return.

When handling coolant, observe the information on the coolant safety data sheet. The coolant safety data sheet can be obtained from your service center or via the manufacturer's website.

Only use suitable load-carrying equipment from the manufacturer to transport devices by crane.

• Attach chains or ropes to all designated attachments of the suitable load-carrying equipment.
• Chains or ropes must be the smallest angle possible from vertical.
• Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).

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. The carrier belt is not suitable for transport by crane, counterbalanced lift truck, or other mechanical lifting tools.

All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g., for mechanical damage, corrosion, or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.

There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the shielding gas connection adapter on the device side before installation.

1. Safety Instructions

• Solid particle size < 40 µm
• Pressure condensation point < -20 °C
• Max. oil content < 25 mg/m³

Use filters if necessary.

1. Safety Instructions

Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding gas cylinders are an integral part of the welding equipment, so they must be handled very carefully.

Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.

Mount the shielding gas cylinders vertically and secure them in accordance with instructions 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.

Risk of explosion: Never weld on a compressed shielding gas cylinder.

Always use suitable shielding gas cylinders for the application in question and the correct matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders and accessories that are in good condition.

If a valve on a shielding gas cylinder is open, turn your face away from the outlet.

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

Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.

Follow the manufacturer's instructions and applicable national and international provisions for shielding gas cylinders and accessories.

1. Safety Instructions

Risk of asphyxiation due to uncontrolled shielding gas leak

Shielding gas is colorless and odorless and may suppress the oxygen in the ambient air in the event of leakage.

• Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³ per hour.
• Please observe the safety and maintenance information for the shielding gas cylinder or the main gas supply.
• When no welding is taking place, close the valve of the shielding gas cylinder or the main gas supply.
• Always check the shielding gas cylinder or main gas supply for uncontrolled gas leakage before each start-up.

1. Safety Instructions

• The maximum permitted tilt angle is 10°.

• Follow the appropriate national and international regulations.

Use instructions and checks within the company to ensure that the vicinity of the workplace is always clean and organized.

Only set up and operate the device in accordance with the protection class shown on the rating plate.

When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft. 7.69 in.) to allow cooling air to circulate unhindered.

Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.

Do not lift or transport any active devices. Switch off devices before transport or lifting.

• 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 service technicians before commissioning the device.

1. Safety Instructions

• 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 device

Safety devices that are not fully functional must be repaired before the device is switched on.

Never bypass or disable safety devices.

Before switching on the device, ensure that no one can be put in danger.

The device must be examined at least once a week for externally detectable damage and functionality of the safety devices.

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.

Only connect system components from the manufacturer to the cooling unit circuit.

If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.

Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain conditions. Only transport the coolant in closed original containers and keep away from sources of ignition.

Properly dispose of used coolant according to national and international regulations. The coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.

When the system is cool, always check the coolant level before starting welding.

1. Safety Instructions

It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.

• Use only original spare and wearing parts (also applies to standard parts).
• Do not carry out any modifications, alterations, etc. to the device without the manufacturer's consent.
• Components that are not in perfect condition must be replaced immediately.
• When ordering, please give the exact designation and part number as shown in the spare parts list, as well as the serial number of your device.

The housing screws provide the ground conductor connection for earthing the housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.

1. Safety Instructions

The manufacturer recommends that a safety inspection of the device be performed at least every 12 months.

The manufacturer recommends calibrating power sources within the same 12-month interval.

• After changes
• After alterations
• After repair, care, and maintenance
• At least every 12 months

For the safety inspection, follow the appropriate national and international standards and guidelines.

You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.

1. Safety Instructions

To comply with European directives and national law, waste electrical and electronic equipment must be collected separately and sent for environmentally-friendly recycling. Used devices must be returned to a distributor or an approved collection and recycling facility in your area. Proper disposal of used devices promotes the sustainable recycling of material resources. Ignoring this may have potentially adverse effects on the environment and your health.

Packaging materials
Materials collected separately. Check the regulations in your area. Reduce the volume of cardboard.

1. Safety Instructions

Devices with the CE label satisfy the essential requirements of the low-voltage and electromagnetic compatibility directive (e.g., relevant product standards of the EN 60974 series).

Fronius International GmbH declares that the device complies with Directive 2014/53/EU. The full text of the EU Declaration of Conformity is available on the following website: http://www.fronius.com

Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA.

1. Safety Instructions

The user is responsible for backing up any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal settings.

1. Safety Instructions

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.

1. General information

The TransSteel (TSt) 2700c MP and TSt 3500c MP power sources are fully digitized, microprocessor-controlled inverter power sources.

A modular design and easy ability to extend the system guarantee a high degree of flexibility. The devices are designed for the welding of steel.

1. General information
2. General

The TransSteel (TSt) 2700c MP and TSt 3500c MP power sources are fully digitized, microprocessor-controlled inverter power sources.

A modular design and easy ability to extend the system guarantee a high degree of flexibility. The devices are designed for the welding of steel.

1. General information
2. General

The following welding processes are available on the power sources:

MIG/MAG welding

TSt 2700c MP TSt 3500c MP

Manual metal arc welding

TSt 2700c MP TSt 3500c MP

TIG welding with touchdown ignition

TSt 2700c MP TSt 3500c MP

1. General information
2. General

The central control and regulation unit of the power sources is coupled with a digital signal processor. The central control and regulation unit and signal processor control the entire welding process.
During the welding process, the actual data is measured continuously and the device responds immediately to any changes. Control algorithms ensure that the desired status is maintained.

The device has a "Power limitation" safety feature. This means that the power source can be operated at the power limit without compromising process safety.

• A precise welding process,
• A high degree of reproducibility on all results
• Excellent weld properties.

1. General information
2. General

The devices are used in trade and industry for manual applications with classical steel and galvanized sheets.

The TSt 2700c MP is primarily used in light-gage steel sheet (light steelwork) applications.
Repair, maintenance, and assembly work in shipyards, automotive suppliers, workshops or the furniture construction industry are among the typical application areas. The TSt 2700c MP power source thus positions itself in its power category between the trade/workshop and the industry sector.

• Mechanical and equipment engineering
• Steel construction
• Plant and container construction
• Metal and portal construction
• Rail vehicle construction

1. General information
2. General

There are warning notices and safety symbols on the power sources. These warning 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.

Safety symbols on the rating plate:

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 following documents:

• These Operating Instructions
• All system component Operating Instructions, especially the safety rules

1. General information
2. General

Warning notices are attached to the device for certain device versions.

The arrangement of the symbols may vary.

1. General information

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 operation, depending on the field of application for the power source.

1. General information
2. System components

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 operation, depending on the field of application for the power source.

1. General information
2. System components

1. General information
2. System components

TSt 2700c MP

TSt 3500c MP

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• easily selected using buttons
• changed using buttons or the selection dial
• shown on the digital display during welding

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored expert knowledge is available at all times. All the parameters can be corrected manually. The Synergic control panel also allows entirely manual configuration of parameters.

1. Operating controls and connections

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• easily selected using buttons
• changed using buttons or the selection dial
• shown on the digital display during welding

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored expert knowledge is available at all times. All the parameters can be corrected manually. The Synergic control panel also allows entirely manual configuration of parameters.

1. Operating controls and connections
2. Control Panel

The functions are all arranged in a logical way on the control panel. The individual parameters required for welding can be

• easily selected using buttons
• changed using buttons or the selection dial
• shown on the digital display during welding

The power source uses the Synergic control panel and certain general items of data such as sheet thickness, filler metal, wire diameter and shielding gas to calculate the best welding parameters. As a result, stored expert knowledge is available at all times. All the parameters can be corrected manually. The Synergic control panel also allows entirely manual configuration of parameters.

1. Operating controls and connections
2. Control Panel

1. Operating controls and connections
2. Control Panel

(1) "Parameter selection" button (left) For selecting the following welding parameters and for changing parameters in the Setup menu The relevant symbol lights up when a welding parameter is selected.
			Sheet thickness in mm or in. If the welding current to be selected is not known, it is sufficient to enter the sheet thickness. The required welding current and any other parameters marked with *) will then be adjusted automatically.
			Welding current in A *) Before welding begins, the device automatically displays a standard value based on the programmed parameters. The actual value is displayed during welding.
			Wire speed in m/min or ipm *)
(2) SF - spot/stitch welding indicator lights up if a value has been entered for the spot/interval welding time Setup parameter (SPt) (spot or stitch welding operating mode is enabled)
(3) Left digital display
(4) 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.
(5) Intermediate arc indicator A spatter-prone "intermediate arc" occurs between the dip transfer arc and the spray arc. The intermediate arc indicator lights up to alert you to this critical area.
(6) Right digital display
(7) "Parameter selection" button (right) For selecting the following welding parameters and for changing parameters in the Setup menu The relevant symbol lights up when a welding parameter is selected.
			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. The actual value is displayed during welding.
			Arc-force dynamic For influencing the short-circuiting dynamic at the moment of droplet transfer - ... Harder and more stable arc 0 ... Neutral arc + ... Soft and low-spatter arc
			Real Energy Input For displaying the energy applied during the welding operation. **)
(8) Selection dial (left) For changing the sheet thickness, welding current and wire speed parameters and for changing parameters in the Setup menu
(9) Selection dial (right) For changing the arc length correction, welding voltage and arc-force dynamic parameters and for changing parameters in the Setup menu
(10) "Save" buttons (Easy Job) For saving up to 5 operating points
(11) "Process" button For selecting the welding process
			MANUAL - MIG/MAG standard manual welding
			SYNERGIC - MIG/MAG standard synergic welding
			Manual metal arc welding
			TIG welding
(12) "Mode" button For selecting the operating mode
			2 T - 2-step mode
			4 T - 4-step mode
			Special 4-step mode
			Spot welding/stitch welding
(13) "Shielding gas" button For selecting the shielding gas used. The SP parameter is reserved for additional shielding gases. The LED next to the selected shielding gas lights up.
(14) "Wire diameter" button For selecting the wire diameter used. The SP parameter is reserved for additional wire diameters. The LED next to the selected wire diameter lights up.
(15) "Material" button For selecting the filler metal used. The SP parameter is reserved for additional materials. The LED next to the selected filler metal lights up.
(16) "Wire threading" button Press and hold the button: gasless wire threading into the torch hosepack While the button is being held, the wire drive operates at feeder inching speed.
(17) Gas-test button For setting the required gas volume on the gas pressure regulator. Tap button once: shielding gas flows out Tap button again: shielding gas flow stops If the Gas-test button is not tapped again, the shielding gas flow will stop after 30 s.

1. Operating controls and connections
2. Control Panel

Various service parameters can be retrieved by pressing the "Parameter selection" buttons at the same time.

Opening the display

1

The first parameter "Firmware version" will be displayed, e.g., "1.00 | 4.21"

Selecting parameters

2

Use the "Mode" and "Process" buttons or the left-hand selection dial to select the required setup parameter

Available parameters

	Explanation
Example: 1.00 | 4.21	Firmware version
Example: 2 | 491	Welding program configuration
Example: r 2 | 290	Number of the currently selected welding program
Example: 654 | 32.1 = 65,432.1 hours = 65,432 hours 6 mins	Indicates the actual arc time since first use Note: The arc time indicator is not suitable as a basis for calculating hiring fees or for warranty purposes, etc.
Example: iFd | 0.0	Motor current for wire drive in A The value changes as soon as the motor is running.
2nd	Second menu level for service technicians

1. Operating controls and connections
2. Control Panel

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" button was selected when the keylock was enabled

Activating/deactivating the keylock:

1

Keylock activated:
The message "CLO | SEd" appears on the displays.

Keylock deactivated:
The message "OP | En" appears on the displays.

The keylock can also be activated and deactivated using the keylock switch option.

1. Operating controls and connections

* Side panel not shown

1. Operating controls and connections
2. Connections, Switches, and Mechanical Components

* Side panel not shown

1. Operating controls and connections
2. Connections, Switches, and Mechanical Components

* Side panel not shown

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 equipment for welding operations.

1. Installation

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 equipment for welding operations.

1. Installation
2. Minimum equipment for welding operations

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 equipment for welding operations.

1. Installation
2. Minimum equipment for welding operations

• Power source
• Grounding cable
• Gas-cooled MIG/MAG welding torch
• Gas connection (shielding gas supply)
• Wire electrode

1. Installation
2. Minimum equipment for welding operations

• Power source
• Cooling unit including coolant
• Grounding cable
• Water-cooled MIG/MAG welding torch
• Gas connection (shielding gas supply)
• Wire electrode

1. Installation
2. Minimum equipment for welding operations

• Power source
• Grounding cable
• Electrode support
• Rod electrode

1. Installation
2. Minimum equipment for welding operations

• Power source
• Grounding cable
• TIG welding torch with or without rocker switch
• Gas connection (shielding gas supply)
• Filler metal depending on application

1. Installation

1. Installation
2. Before installation and initial operation

1. Installation
2. Before installation and initial operation

The power source is only intended for MIG/MAG, MMA and TIG welding. Any other use is deemed to be "not in accordance with the intended purpose." The manufacturer shall not be liable for any damage resulting from such improper use.

• Following all instructions in the Operating Instructions
• Carrying out all the specified inspection and maintenance work

1. Installation
2. Before installation and initial operation

• Protection against penetration by solid foreign bodies with diameters > 12 mm (0.49 in.)
• Protection against spraywater at any angle up to 60° from the vertical

The device can be set up and operated outdoors in accordance with degree of protection IP 23.
Direct moisture (e.g., from rain) must be avoided.

The ventilation channel is a very important safety device. When selecting the setup location, 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.

1. Installation
2. Before installation and initial operation

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.

1. Installation

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated as follows:

Three-phase devices: S_1max = I_1max x U₁ x √3

Single-phase devices: S_1max = I_1max x U₁

I_1max and U₁ according to the device rating plate and technical data

The generator apparent power S_GEN needed is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the power source!

When single phase devices are being operated with a 3-phase generator, note that the stated apparent power of the generator is often just the total that can be present across all three phases of the generator. If necessary, obtain further information about the single-phase power of the generator from the generator manufacturer.

1. Installation
2. Generator-Powered Operation

The power source is generator-compatible.

The maximum apparent power S_1max of the power source must be known in order to select the correct generator output.
The maximum apparent power S_1max of the power source is calculated as follows:

Three-phase devices: S_1max = I_1max x U₁ x √3

Single-phase devices: S_1max = I_1max x U₁

I_1max and U₁ according to the device rating plate and technical data

The generator apparent power S_GEN needed is calculated using the following rule of thumb:

S_GEN = S_1max x 1.35

A smaller generator can be used when not welding at full power.

IMPORTANT! The generator apparent power S_GEN must not be less than the maximum apparent power S_1max of the power source!

When single phase devices are being operated with a 3-phase generator, note that the stated apparent power of the generator is often just the total that can be present across all three phases of the generator. If necessary, obtain further information about the single-phase power of the generator from the generator manufacturer.

1. Installation

As an alternative to three-phase operation, the multivoltage variant (MV) of the power source enables a welding operation with limited power or duration from just a single-phase supply. The maximum possible welding power is limited by the dimensioning of the mains fuse protection, which determines the safety cut-out of the power source.

If the grid lead has a 20 A or 30 A fuse, the FUS parameter may be changed to 20 A or 30 A. Welding with a higher maximum power or for longer periods is therefore possible. The FUS welding parameter can be found in the Setup menu 2nd level and can be set when the US setting is enabled or a single-phase supply is being used (SEt welding parameter set to US).

In order to use the power source in single-phase operation, the following prerequisite must be fulfilled:

• Correct single-phase power source supply in accordance with the chapter "Installation" section "Connecting the mains cable" from page (→).

The following table shows which grid voltages and fuse ratings limit the welding current in single-phase operation:

The welding current data applies at an ambient temperature of 40 °C (104 °F).

At a grid voltage of 240 V and a fuse rating of 30 A, the maximum value of 220 A is possible for MIG/MAG welding with a duty cycle of 40% for example.

In single-phase operation, a safety cut-out prevents the fuse from tripping at higher welding powers. The safety cut-out is active at fuse ratings of 15 A, 16 A and 20 A and determines the possible welding duration, without the fuse being tripped. If the precalculated weld time is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immediately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again. After this time, the message disappears, and the power source is ready for operation again.

At a fuse rating of 30 A, the temperature monitoring for the power source ensures the welding current is promptly switched off. A service code from "to1" to "to7" is displayed. Detailed information on the service codes "to1" to "to7" can be found in the "Troubleshooting" chapter under "Displayed service codes". If there is no fault or the cooling components are not dirty, then the device will be ready for welding again after an appropriate welding pause.

1. Installation
2. TSt 2700c MV MP - Single-Phase Operation

As an alternative to three-phase operation, the multivoltage variant (MV) of the power source enables a welding operation with limited power or duration from just a single-phase supply. The maximum possible welding power is limited by the dimensioning of the mains fuse protection, which determines the safety cut-out of the power source.

If the grid lead has a 20 A or 30 A fuse, the FUS parameter may be changed to 20 A or 30 A. Welding with a higher maximum power or for longer periods is therefore possible. The FUS welding parameter can be found in the Setup menu 2nd level and can be set when the US setting is enabled or a single-phase supply is being used (SEt welding parameter set to US).

In order to use the power source in single-phase operation, the following prerequisite must be fulfilled:

• Correct single-phase power source supply in accordance with the chapter "Installation" section "Connecting the mains cable" from page (→).

The following table shows which grid voltages and fuse ratings limit the welding current in single-phase operation:

The welding current data applies at an ambient temperature of 40 °C (104 °F).

At a grid voltage of 240 V and a fuse rating of 30 A, the maximum value of 220 A is possible for MIG/MAG welding with a duty cycle of 40% for example.

In single-phase operation, a safety cut-out prevents the fuse from tripping at higher welding powers. The safety cut-out is active at fuse ratings of 15 A, 16 A and 20 A and determines the possible welding duration, without the fuse being tripped. If the precalculated weld time is exceeded, thus causing the welding current to switch off, the service code "toF" is displayed. A countdown immediately appears next to the "toF" indicator, which shows the remaining time until the power source is ready for welding again. After this time, the message disappears, and the power source is ready for operation again.

At a fuse rating of 30 A, the temperature monitoring for the power source ensures the welding current is promptly switched off. A service code from "to1" to "to7" is displayed. Detailed information on the service codes "to1" to "to7" can be found in the "Troubleshooting" chapter under "Displayed service codes". If there is no fault or the cooling components are not dirty, then the device will be ready for welding again after an appropriate welding pause.

1. Installation
2. TSt 2700c MV MP - Single-Phase Operation

For single-phase operation, the "Technical Data" chapter specifies duty cycle values as a function of the fuse rating and the welding current. Although the percentages of these duty cycle values are also based on the ten-minute cycle explained in the "Technical Data" chapter for general duty cycles, the cooling phase of the fuse, however, is calculated at approx. 60 s only. Afterwards, the power source is once again ready for use.

Due to technical standards, in single-phase operation, the duty cycle is only specified up to the end (switch off) of the first welding cycle. If the relationship to the ten-minute cycle normally used when specifying the duty cycle was also established with respect to the cooling phases, in practice there would be longer welding phases than those stated. The values are actually based on cooling phases of approx. 60 s only, after which the power source is ready for further use.

The following example shows the welding and pause cycles as defined in the relevant standards, with a welding current of 180 A and a duty cycle of 15%.

1. Installation
2. TSt 2700c MV MP - Single-Phase Operation

The following diagram shows the possible welding time in accordance with standards, depending on the fuse rating and welding current.

(1) 10 A mains fuse protection (2) 13 A mains fuse protection (3) 15 A mains fuse protection
(4) 16 A mains fuse protection (5) 20 A mains fuse protection

1. Installation

1. Installation
2. Connecting the Mains Cable

1. Installation
2. Connecting the Mains Cable

A strain-relief device for the following cable cross-sections is fitted to the power source:

Strain-relief devices for other cable cross-sections must be designed accordingly.

1. Installation
2. Connecting the Mains Cable

The item numbers of the different cables can be found in the Spare Parts List.

American Wire Gauge

1. Installation
2. Connecting the Mains Cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before start-up.

The ground conductor (PE) should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductor (L1) and neutral conductor (N).

1

2

3

4

5

To connect the mains cable:

• Connect phase conductor L1 to L1 according to the imprint on the switch
• Connect neutral conductor N to L2 according to the imprint on the switch
• Connect the ground conductor PE to the block terminal inside the device
  

IMPORTANT! Tie the phase conductor, neutral conductor, and ground conductor together near the strain-relief device using a cable tie.

6

1. Installation
2. Connecting the Mains Cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before start-up.

The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

1

2

3

4

5

To connect the mains cable:

• Connect phase conductor L1 to L1 according to the imprint on the switch
• Connect phase conductor L2 to L2 according to the imprint on the switch
• Connect phase conductor L3 to L3 according to the imprint on the switch
• Connect the ground conductor PE to the block terminal inside the device
  

IMPORTANT! Tie the phase conductors near the strain-relief device using cable ties.

6

 

1. Installation
2. Connecting the Mains Cable

If no mains cable is connected, a mains cable that is suitable for the connection voltage must be fitted before start-up.

The ground conductor should be approx. 10 - 15 mm (0.4 - 0.6 in.) longer than the phase conductors.

1

2

3

L1, L2, L3 = phase conductor, PE = ground conductor

IMPORTANT! Tie the phase conductors near the block terminal using a cable tie.

4

1. Installation

The steps and activities described below include references to various system components, such as

• Trolley
• Cooling units (TSt 3500c only)
• Welding torches, etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate Operating Instructions for the system components.

1. Installation
2. Fitting/Connecting the System Components

The steps and activities described below include references to various system components, such as

• Trolley
• Cooling units (TSt 3500c only)
• Welding torches, etc.

For more detailed information about installing and connecting the system components, please refer to the appropriate Operating Instructions for the system components.

1. Installation
2. Fitting/Connecting the System Components

The following diagram shows an overview of how the individual system components are put together.
For detailed information about the individual steps, please refer to the corresponding Operating Instructions for the system components.

TSt 2700c MP

TSt 3500c MP

1. Installation
2. Fitting/Connecting the System Components

TSt 2700c MP

TSt 3500c MP

The device is started up by pressing the torch trigger (for manual applications).

1. MIG/MAG

The device is started up by pressing the torch trigger (for manual applications).

1. MIG/MAG
2. Commissioning

The device is started up by pressing the torch trigger (for manual applications).

1. MIG/MAG
2. Commissioning

1

*	The TSt 3500c MP can be optionally equipped with a cooling unit. Coolant hoses are only available on water-cooled welding torches.

1. MIG/MAG
2. Commissioning

In order to achieve optimum wire electrode feed, the feed rollers must be suitable for the diameter and alloy of the wire being welded.

An overview of the available feed rollers can be found in the Spare Parts Lists.

1

2

3

4

1. MIG/MAG
2. Commissioning

Inserting the wirespool

1

Inserting the basket-type spool

1

2

1. MIG/MAG
2. Commissioning

1

2

1. MIG/MAG
2. Commissioning

Connecting the Polarity Reverser

1

TSt 2700c MP

2

TSt 3500c MP

Establishing a Ground Earth Connection

Connect grounding cable to the free current socket

1

TSt 2700c MP: Example of ground connection to the (+) current socket

2

TSt 3500c MP: Example of ground connection to the
(-) current socket

3

1. MIG/MAG
2. Commissioning

1

2

IMPORTANT! To facilitate wire threading, the following procedure is possible when the "Wire threading" button is pressed and held down.

• Hold the button for up to one second ...the wire speed stays at 1 m/min or 39.37 ipm for the first second.
• Hold the button for up to 2.5 seconds ... after one second, the wire speed increases over the next 1.5 seconds.
• Hold the button for more than 2.5 seconds ... after 2.5 seconds, the wire is fed at a constant rate equal to the wire speed set for the Fdi welding parameter.

If you release the "Wire threading" button and press it again before one second has elapsed, the sequence starts again from the beginning. This makes it possible to continuously position the wire at a low wire speed of 1 m/min or 39.37 ipm where necessary.

If there is no "Wire threading" / "Gas-test" button, the torch trigger can be used in a similar way. Before using the torch trigger for wire threading, proceed as follows:

IMPORTANT! If the torch trigger is pressed instead of the "Wire threading"/"Gas-test" button, the welding wire runs at the feeder creep speed (depending on the welding program) for the first 3 seconds. After these 3 seconds, wirefeeding is briefly interrupted.

The welding system detects that the welding process should not start, but that the wire is to be threaded in. At the same time, the gas solenoid valve closes, and the welding voltage on the wire electrode is switched off.

If the torch trigger is kept pressed, wirefeeding restarts immediately without shielding gas and welding voltage, and the process continues as described above.

3

4

1. MIG/MAG
2. Commissioning

Standard values for the U-groove rollers:

Steel: 4 - 5

CrNi: 4 - 5

Tubular covered electrodes: 2 - 3

1. MIG/MAG
2. Commissioning

1

2

3

1. MIG/MAG
2. Commissioning

WARNING!

Danger from incorrect installation.

This can result in severe personal injury and damage to property.

Do not dismantle the brake.

Maintenance and servicing of brakes is to be carried out by trained, qualified personnel only.

The brake is only available as a complete unit.
The illustration of the brake is for information purposes only.

1. MIG/MAG

"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. In order to prevent this, the welding power is lowered.

If the "MIG/MAG standard synergic welding" process is selected, the symbol for the "Wire speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire speed is displayed.

1. MIG/MAG
2. Power Limitation

"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. In order to prevent this, the welding power is lowered.

If the "MIG/MAG standard synergic welding" process is selected, the symbol for the "Wire speed" parameter flashes as soon as the safety function trips. The flashing continues until the next welding start-up, or until the next parameter change.

If the "Wire speed" parameter is selected, for example, the reduced value for wire speed is displayed.

1. MIG/MAG

For details of the meaning, settings, setting range and units of the available welding parameters (e.g., gas pre-flow time), please refer to the "Setup parameters" chapter.

1. MIG/MAG
2. MIG/MAG Operating Modes

For details of the meaning, settings, setting range and units of the available welding parameters (e.g., gas pre-flow time), please refer to the "Setup parameters" chapter.

1. MIG/MAG
2. MIG/MAG Operating Modes

Press the torch trigger | Hold the torch trigger | Release the torch trigger

1. MIG/MAG
2. MIG/MAG Operating Modes

• Tacking work
• Short weld seams
• Automatic and robot operation

1. MIG/MAG
2. MIG/MAG Operating Modes

"4-step mode" is suitable for longer weld seams.

1. MIG/MAG
2. MIG/MAG Operating Modes

Special 4-step mode allows the starting and final current to be configured in addition to the advantages of 4-step mode.

1. MIG/MAG
2. MIG/MAG Operating Modes

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 (< SPt), the process is canceled immediately.

1. MIG/MAG
2. MIG/MAG Operating Modes

2-step stitch welding

The "2-step stitch welding" mode is suitable for welding short weld seams on thin sheets, to prevent the weld seams from dropping through the parent material.

1. MIG/MAG
2. MIG/MAG Operating Modes

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.

1. MIG/MAG

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press 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.

4Press the "Process" button to select the "MIG/MAG standard synergic" welding process:   

5Press the "Mode" button to select the desired MIG/MAG mode:  2-step mode  4-step mode  Special 4-step mode

NOTE!

Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000 remote control) on the control panel of the power source.

6Use the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power in Synergic operation:  Sheet thickness
or  Welding current
or  Wire speed
or  Welding voltage

7Use the appropriate selection dial to set the welding parameterThe welding parameter values are shown in the digital display located above.

All welding parameter set values remain stored until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime. To display the actual welding current during welding, select the welding current parameter.

1. MIG/MAG
2. MIG/MAG Standard Synergic Welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press 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.

4Press the "Process" button to select the "MIG/MAG standard synergic" welding process:   

5Press the "Mode" button to select the desired MIG/MAG mode:  2-step mode  4-step mode  Special 4-step mode

NOTE!

Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000 remote control) on the control panel of the power source.

6Use the "Parameter selection" buttons to select the welding parameters to be used to specify the welding power in Synergic operation:  Sheet thickness
or  Welding current
or  Wire speed
or  Welding voltage

7Use the appropriate selection dial to set the welding parameterThe welding parameter values are shown in the digital display located above.

All welding parameter set values remain stored until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime. To display the actual welding current during welding, select the welding current parameter.

1. MIG/MAG
2. MIG/MAG Standard Synergic Welding

To obtain the best possible welding results, the arc length correction and arc-force dynamic welding parameters will sometimes need to be corrected.

1. MIG/MAG

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 parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

1. MIG/MAG
2. MIG/MAG Standard Manual Welding

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 parameters. All of the variable parameters must therefore be adjusted individually, as dictated by the welding process in question.

1. MIG/MAG
2. MIG/MAG Standard Manual Welding

The following parameters are available for MIG/MAG manual welding:

	Wire speed 1 m/min (39.37 ipm.) - maximum wire speed, e.g., 25 m/min (984.25 ipm.)
	Welding voltage TSt 2700c MP: 14.4–34.9 V TSt 3500c MP: 14.5–38.5 V
	Arc-force dynamic For influencing the short-circuiting dynamic at the instant of droplet transfer
	Welding current Only the actual value is displaye

1. MIG/MAG
2. MIG/MAG Standard Manual Welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press 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.

4Press the "Process" button to select the "MIG/MAG standard manual" welding process:   

5Press the "Mode" button to select the desired MIG/MAG mode:  2-step mode  4-step mode
In MIG/MAG standard manual welding, special 4-step mode corresponds to conventional 4-step mode.

NOTE!

Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000 remote control) on the control panel of the power source.

6Use the "Parameter selection" buttons to    select the welding parameter (wire speed)

7Use the appropriate selection dial to set the wire speed

8Use the "Parameter selection" buttons to    select the welding parameter (welding voltage)

9Use the appropriate selection dial to set the welding voltage

The welding parameter values are shown in the digital display located above

All welding parameter set values remain stored until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime. To display the actual welding current during welding, select the welding current parameter.

To display the actual welding current during welding:

• Press the "Parameter selection" button to select the welding current parameter
• The actual welding current is shown on the digital display during welding.

1. MIG/MAG
2. MIG/MAG Standard Manual Welding

To obtain the best possible welding results, the arc-force dynamic parameter will sometimes need to be adjusted.

1. MIG/MAG

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. Local overheating leading to the parent material being melted through is largely avoided.

1. MIG/MAG
2. Spot welding and stitch welding

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. Local overheating leading to the parent material being melted through is largely avoided.

1. MIG/MAG
2. Spot welding and stitch welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press 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.

4Press the "Process" button to select the desired welding process:      

5Press the "Mode" button to select the spot welding/stitch welding mode:  (spot welding/stitch welding)

6Set the SPt parameter in the Setup menu (spot welding time/interval welding time) to the desired value

7Ensure that the ground earth connection has been established

8Ensure that the shielding gas supply has been established

The power source is ready for welding.

1. MIG/MAG
2. Spot welding and stitch welding

1Press the "Material" button to select the filler metal to be used.

2Press the "Wire diameter" button to select the diameter of the wire electrode used.

3Press 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.

4Press the "Process" button to select the desired welding process:      

5Press the "Mode" button to select the spot welding/stitch welding mode:  (spot welding/stitch welding)

6Set the SPt parameter in the Setup menu (spot welding time/interval welding time) to the desired value

7Set the SPb parameter in the Setup menu (spot welding/stitch pause time) to the desired value

8Set the Int parameter (interval) in the Setup menu to the desired value

9Ensure that the ground earth connection has been established

10Ensure that the shielding gas supply has been established

The power source is ready for welding.

1. Rod Electrode

1. Rod Electrode
2. Commissioning

1. Rod Electrode
2. Commissioning

1

Check the rod electrode packaging to determine whether the rod electrode is for (+) or (-) welding.

2

3

CAUTION!

Danger due to welding processes starting unintentionally.

Personal injury and damage to property may result.

As soon as the power source is switched on, ensure that the rod electrode does not unintentionally/accidentally touch electrically conductive or grounded parts (such as housing).

4Plug the grid cable into the grid

5Switch on the power source

1. Rod Electrode

1Press the "Process" button to select the MMA welding process:
	The welding voltage is applied to the welding socket with a three second time lag.
	NOTE! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000) on the control panel of the power source.
2Press the "Parameter selection" button to select the amperage parameter.
3Use the selection dial to set the desired amperage.
	The amperage value is displayed on the left-hand digital display.
	All welding parameter set values remain stored until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime.
4Initiate welding process
	To display the actual welding current during welding:
	Press the "Parameter selection" button to select the welding current parameter
	The actual welding current is shown on the digital display during welding.

1. Rod Electrode
2. Manual Metal Arc Welding

1Press the "Process" button to select the MMA welding process:
	The welding voltage is applied to the welding socket with a three second time lag.
	NOTE! Under certain circumstances, it may not be possible to change welding parameters that have been set on the control panel of a system component (TR 2000 or TR 3000) on the control panel of the power source.
2Press the "Parameter selection" button to select the amperage parameter.
3Use the selection dial to set the desired amperage.
	The amperage value is displayed on the left-hand digital display.
	All welding parameter set values remain stored until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime.
4Initiate welding process
	To display the actual welding current during welding:
	Press the "Parameter selection" button to select the welding current parameter
	The actual welding current is shown on the digital display during welding.

1. Rod Electrode

 Arc-force dynamic:
For influencing the short-circuiting dynamic at the instant of droplet transfer

1. Rod Electrode
2. Functions for Optimizing the Welding Process

 Arc-force dynamic:
For influencing the short-circuiting dynamic at the instant of droplet transfer

1. Rod Electrode
2. Functions for Optimizing the Welding Process

This function is activated at the factory.

• Improved ignition properties, even when using electrodes with poor ignition properties
• Better fusion of the parent material during the start-up phase, meaning fewer cold-shut defects
• Slag inclusions largely avoided

Key

Hti	Hot-current time, 0 - 2 s, factory setting 0.5 s
HCU	HotStart current, 100 - 200%, factory setting 150%
IH	Main current = set welding current

The Hti and HCU parameters can be set in the Setup menu. For a parameter description see section Parameters for MMA Welding from page (→).

Function
During the specified hot-current time (Hti), the welding current is increased to a certain value. This value (HCU) is higher than the selected welding current (I_H).

1. Rod Electrode
2. Functions for Optimizing the Welding Process

This function is activated at the factory.

As the arc becomes shorter, the welding voltage may also fall so that the rod electrode is more likely to stick to the workpiece. This may also cause the rod electrode to burn out.

Electrode burn-out is prevented by activating the anti-stick function. If the rod electrode begins to stick, the power source immediately switches the welding current off. The welding process can be resumed without problems once the rod electrode has been detached from the workpiece.

For a parameter description see section Anti-stick function from page (→).

1. TIG

1

2

3

4

5

CAUTION!

Danger due to welding processes starting 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 unintentionally/accidentally touch electrically conductive or grounded parts (such as housing).

6Plug the grid cable into the grid

7Switch on the power source

1. TIG
2. Commissioning

1

2

3

4

5

CAUTION!

Danger due to welding processes starting 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 unintentionally/accidentally touch electrically conductive or grounded parts (such as housing).

6Plug the grid cable into the grid

7Switch on the power source

1. TIG

1Press the "Process" button to select the TIG welding process:  

2Press the "Parameter selection" button to select the amperage parameter.

3Use the selection dial to set the desired amperage.
The amperage value is shown on the left-hand digital display.

All the parameter set values are saved until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime.

When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting):

1. TIG
2. TIG Welding

1Press the "Process" button to select the TIG welding process:  

2Press the "Parameter selection" button to select the amperage parameter.

3Use the selection dial to set the desired amperage.
The amperage value is shown on the left-hand digital display.

All the parameter set values are saved until the next time they are changed. This is still true if the power source has been turned off and on again in the meantime.

When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting):

1. TIG

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.

• 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.

1. TIG
2. Pulse welding

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.

• 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.

1. TIG
2. Pulse welding

• A low base current I-G rises steeply to the significantly higher pulse current I-P and drops back to the base current I-G after the Duty cycle dcY time.
• This results in an average current that is lower than the set pulse current I-P.
• During pulse welding, small sections of the welding location melt quickly and then rapidly re-solidify.

The power source controls the "Duty cycle dcY" and "Base current I-G" parameters according to the set pulse current (welding current) and pulse frequency.

Welding current progression curve

Adjustable parameters:

Fixed parameters:

1. TIG
2. Pulse welding

For a parameter description see section Parameters for TIG welding from page (→).

The "Save" buttons allow five EasyJobs to be saved. The adjustable parameters on the control panel are saved as EasyJobs.

1. EasyJobs

The "Save" buttons allow five EasyJobs to be saved. The adjustable parameters on the control panel are saved as EasyJobs.

1. EasyJobs
2. Saving and Retrieving EasyJobs

The "Save" buttons allow five EasyJobs to be saved. The adjustable parameters on the control panel are saved as EasyJobs.

1. EasyJobs
2. Saving and Retrieving EasyJobs

1Press 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"
• After a short time, the left indicator switches to the original value

2Release the "Save" button

1. EasyJobs
2. Saving and Retrieving EasyJobs

1To retrieve saved settings, press the corresponding "Save" button briefly, e.g., Number 1

• The control panel will show the saved settings

1. EasyJobs
2. Saving and Retrieving EasyJobs

1Press and hold the relevant "Save" button to delete the memory content of that "Save" button, e.g., Number 1

• The left indicator displays "Pro"
• After a short time, the left indicator switches to the original value

2Keep the "Save" button held down

• The left indicator displays "CLr"
• After a while, both indicators display "---"

3Release the "Save" button

1. EasyJobs
2. Saving and Retrieving EasyJobs

Press one of the "Save" buttons on the control panel to retrieve the saved settings using the Up/Down welding torch.

1Press one of the "Save" buttons on the control panel, e.g.: The control panel will show the saved settings

The "Save" buttons can now be selected using the buttons on the Up/Down welding torch. Vacant "Save" buttons are skipped.

In addition to the "Save" button number lighting up, a number is displayed directly on the Up/Down welding torch:

	Number 1
	Number 2
	Number 3
	Number 4
	Number 5

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a 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.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation (TransSteel 3500c MP)

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a 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.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation (TransSteel 3500c MP)
2. General

If the Easy Documentation option is available on the power source, the most important welding data for each welding operation can be documented and saved as a 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.

Easy Documentation is activated / deactivated by plugging / unplugging the supplied Fronius USB thumb drive with FAT32 formatting into the back of the power source.

IMPORTANT! To document the welding data, the date and time must be set correctly.

1. Easy Documentation (TransSteel 3500c MP)
2. General

The following data are documented:

Device type
File name
Part number
Serial number
Firmware version of power source
Firmware of PC board DOCMAG (Easy Documentation)
Document version
https://www.easydocu.weldcube.com (A PFDF report of selected welding data can be created under this link)

The welding data are documented as average values in the main process phase and for each welding operation.

1. Easy Documentation (TransSteel 3500c MP)
2. General

• When the USB thumb drive is disconnected and reconnected with the power source switched on
• When the date and time are changed
• From 1000 welding operations
• During a firmware update
• When the USB thumb drive is disconnected and reconnected to another power source
  (= change of serial number).

1. Easy Documentation (TransSteel 3500c MP)
2. General

By scanning this link... A PDF report of the selected welding data can be created The authenticity of the welding data can be checked and guaranteed via the Fronius signature read out with the welding data. https://easydocu.weldcube.com

1. Easy Documentation (TransSteel 3500c MP)

Setting the date and time is carried out in the 2nd level of the service menu.

1

The first parameter in the service menu is displayed.

2

Select the "2nd" setup parameter using the left-hand selection dial

3

The first parameter in the 2nd level of the service menu is displayed.

4

Select the "yEA" (= year) setup parameter using the left-hand selection dial

5

To set the date and time:

• Left-hand selection dial:
  Select parameter
• Right-hand selection dial:
  Change values
  

Setting ranges:

yEA	Year (20yy; 0 - 99)
Mon	Month (mm; 1 -1 12)
dAY	Day (dd; 1 - 31)
Hou	Hour (hh; 0 - 24)
Min	Minute (mm; 0 - 59)

1. Easy Documentation (TransSteel 3500c MP)
2. Activating / deactivating Easy Documentation

Setting the date and time is carried out in the 2nd level of the service menu.

1

The first parameter in the service menu is displayed.

2

Select the "2nd" setup parameter using the left-hand selection dial

3

The first parameter in the 2nd level of the service menu is displayed.

4

Select the "yEA" (= year) setup parameter using the left-hand selection dial

5

To set the date and time:

• Left-hand selection dial:
  Select parameter
• Right-hand selection dial:
  Change values
  

Setting ranges:

yEA	Year (20yy; 0 - 99)
Mon	Month (mm; 1 -1 12)
dAY	Day (dd; 1 - 31)
Hou	Hour (hh; 0 - 24)
Min	Minute (mm; 0 - 59)

1. Easy Documentation (TransSteel 3500c MP)
2. Activating / deactivating Easy Documentation

The power source display shows:

Easy Documentation is deactivated.

2Acknowledge the display by pressing the arrow key

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 parameters for various tasks.

1. Setup Settings

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 parameters for various tasks.

1. Setup Settings
2. Setup Menu

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 parameters for various tasks.

1. Setup Settings
2. Setup Menu

Accessing the Setup menu is described with reference to the MIG/MAG standard synergic welding process.
Access is the same for the other welding processes.

Accessing the Setup menu

1

Press the "Process" button to select the "MIG/MAG standard synergic welding" process

2

The control panel is now located in the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

Adjusting parameters

1

Select the desired setup parameter using the left-hand selection dial

Change the setup parameter value using the right-hand selection dial

Exiting the Setup menu

1

1. Setup Settings
2. Setup Menu

1. Setup Settings
2. Setup Menu

1. Setup Settings
2. Setup Menu

1. Setup Settings
2. Setup Menu

1. Setup Settings

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" function is active
• if the "Gas purging" function is active

If level 2 of the Setup menu is selected, the following functions are not available, even in robot mode:

• Welding start-up - the "Power source ready" signal will not be emitted for robot mode
• Gas test
• Wire inching
• Wire withdrawal
• Gas purging

1. Setup Settings
2. Setup Menu 2nd Level

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" function is active
• if the "Gas purging" function is active

If level 2 of the Setup menu is selected, the following functions are not available, even in robot mode:

• Welding start-up - the "Power source ready" signal will not be emitted for robot mode
• Gas test
• Wire inching
• Wire withdrawal
• Gas purging

1. Setup Settings
2. Setup Menu 2nd Level

To access the 2nd level of the Setup menu:

1

Press the "Process" button to select the "MIG/MAG standard synergic welding" process

2

The control panel is now located in the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

3

Select the "2nd" setup parameter using the left-hand selection dial

4

The control panel is now located in the 2nd level of the Setup menu of the "MIG/MAG standard synergic welding" process - the last selected setup parameter is displayed.

Adjusting parameters

1

Select the desired setup parameter using the left-hand selection dial

Change the setup parameter value using the right-hand selection dial

Exiting the Setup menu

1

A parameter is displayed in the first level of the Setup menu.

2

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings
2. Setup Menu 2nd Level

1. Setup Settings

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. The use of arc length correction is no longer required.

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

If the welding circuit resistance has been measured correctly, the set welding voltage will correspond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.

• If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
• Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads

1. Setup Settings
2. Measuring the Welding Circuit Resistance r

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. The use of arc length correction is no longer required.

The calculated welding circuit resistance is shown on the display.

r = welding circuit resistance in milliohm (mOhm)

If the welding circuit resistance has been measured correctly, the set welding voltage will correspond exactly to the welding voltage at the arc. If you manually measure the voltage on the output jacks of the power source, this voltage will be higher than the welding voltage at the arc - that is, higher by the same amount as the voltage drop of the hosepack.

• If the length or cross-sectional area of the hosepack has changed, measure the welding circuit resistance again
• Measure the welding circuit resistance for every welding process separately with the appropriate welding power-leads

1. Setup Settings
2. Measuring the Welding Circuit Resistance r

The measurement is finished when the welding circuit resistance is shown on the display in mOhm (for example 11.4).

1. Setup Settings

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.

1. Setup Settings
2. Displaying the Welding Circuit Inductivity L

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.

1. Setup Settings
2. Displaying the Welding Circuit Inductivity L

The setup parameter "L" is used to display the most recently calculated welding circuit inductivity. The welding circuit inductivity is adjusted when the welding circuit resistance is measured. Detailed information in this regard can be found under the "Welding circuit resistance" chapter.

The most recently calculated welding circuit inductivity L is shown on the right-hand digital display.

L ... Welding circuit inductivity (in microhenrys)

1. Setup Settings
2. Displaying the Welding Circuit Inductivity L

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.

1. Troubleshooting and Maintenance

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.

1. Troubleshooting and Maintenance
2. Troubleshooting

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.

1. Troubleshooting and Maintenance
2. Troubleshooting

1. Troubleshooting and Maintenance
2. Troubleshooting

Make a note of the serial number and configuration of the device, and provide the service team with a detailed error description if:

• Errors occur that are not covered in this document
• The troubleshooting measures provided in this document are unsuccessful