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Welding System
TransSteel 5000 Syn
Fronius TransSteel 5000 Syn User Manual
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Op
erating
in
s
tr
uction
s
T
r
ansSteel 3500 Syn
T
r
ansSteel 5000 Syn
42,0426,0258,EN
017-02052022
EN
Opera
ting instructions
2
Table of Contents
Parameters for Manual Metal Arc (MMA) Welding in the Setup Menu Level
2
Table of Contents
3
Safety Rules
7
Explanation of Safety Notices
7
General
7
Proper Use
8
Environmental Conditions
8
Obligations of the Operator
8
Obligations of Personnel
8
Mains Connection
9
Protecting Yourself and Others
9
Danger from Toxic Gases and Vapours
10
Danger from Flying Sparks
10
Risks from Mains Current and Welding Current
11
Meandering Welding Currents
12
EMC Device Classifications
12
EMC Measures
12
EMF Measures
13
Specific Hazards
13
Requirement for the Shielding Gas
14
Danger from Shielding Gas Cylinders
14
Danger from Escaping Shielding Gas
15
Safety Measures at the Installation Location and During Transport
15
Safety Measures in Normal Operation
16
Commissioning, Maintenance and Repair
16
Safety Inspection
17
Disposal
17
Safety Symbols
17
Data Protection
17
Copyright
17
General Information
19
General
21
Device Concept
21
Functional Principle
21
Application Areas
21
Warning Notices on the Device
21
Welding Processes, Procedures and Welding Characteristics for MIG/MAG Welding
23
General
23
Welding Characteristics
23
Summary of MIG/MAG Standard Synergic Welding
23
Short Description of Arc Air Gouging
23
System Components
24
General
24
Safety
24
Overview
24
Options
26
General
26
Machine Interface
26
Gas Preheater CO2 Connection
26
Keylock Switch
27
VRD: Safety Function
27
VRD: Safety Principle
28
Control Elements and Connections
29
Synergic Control Panel
31
General
31
Safety
31
Synergic Control Panel
32
Service Parameters
35
Keylock
36
Connections, Switches and Mechanical Components
37
Tst 3500/5000 Syn Power Source
37
Installation and Commissioning
39
Minimum Equipment Needed for Welding Task
41
General
41
Gas-Cooled MIG/MAG Welding
41
MIG/MAG Welding, Water-Cooled
41
MMA Welding
41
Before Installation and Commissioning
42
Safety
42
Utilisation for Intended Purpose Only
42
Setup Regulations
42
Mains Connection
43
Connecting the Mains Cable
44
Safety
44
General
44
Stipulated Mains Cables and Strain-Relief Devices
44
Connecting the Mains Cable
45
Fitting the Europe Strain-Relief Device
45
Fitting the Canada/Us Strain-Relief Device
46
Generator-Powered Operation
48
Start-Up
49
General
49
Information on System Components
49
Assembling the System Components (Overview)
49
Placing the Wirefeeder on the Power Source
50
Fitting the Interconnecting Hosepack Strain-Relief Device
51
Connecting the Interconnecting Hosepack
51
Connecting the Gas Cylinder
52
Establishing a Ground Earth Connection
53
Connecting MIG/MAG Welding Torches
54
Inserting/Replacing Feed Rollers
54
Inserting the Wirespool
55
Inserting the Basket-Type Spool
56
Feeding in the Wire Electrode
57
Setting the Contact Pressure
59
Adjusting the Brake
59
Design of the Brake
60
Welding
61
Power Limitation
63
Safety Function
63
MIG/MAG Modes
64
General
64
Symbols and Their Explanations
64
2-Step Mode
65
Special 4-Step Mode
66
Spot Welding
66
2-Step Stitch Welding
67
MIG/MAG Welding
68
Safety
68
Preparatory Work
68
Overview
68
MIG/MAG Standard Synergic Welding
69
Corrections During Welding
70
MIG/MAG Standard Manual Welding
71
General
71
Available Parameters
71
Corrections During Welding
72
Spot and Stitch Welding
73
General
73
Spot Welding
73
Stitch Welding
74
Easyjob Mode
76
General
76
Storing Easyjob Operating Points
76
Retrieving Easyjob Operating Points
76
Deleting Easyjob Operating Points
76
Retrieving Easyjob Operating Points on the Up/Down Welding Torch
76
MMA Welding
78
Safety
78
Preparation
78
Corrections During Welding
79
Hotstart Function
80
Anti-Stick Function
80
Arc Air Gauging (Tst 5000 Syn)
81
Safety
81
Preparation
81
Arc Air Gouging
82
Easy Documentation
85
General
87
Documented Welding Data
87
New CSV File
88
PDF Report / Fronius Signature
88
Activating / Deactivating Easy Documentation
89
Setting the Date and Time
89
Deactivating Easy Documentation
89
Setup Settings
91
Setup Menu
93
General Remarks
93
Operation
93
Setup Parameters for MIG/MAG Standard Manual Welding
93
Setup Parameters for MIG/MAG Standard Synergic Welding
95
Setup Parameters for MMA Welding
96
Setup Menu - Level 2
98
Operation (Level 2 Setup Menu)
98
Measuring Welding Circuit Resistance R
102
General
102
Measuring Welding Circuit Resistance (MIG/MAG Welding)
102
Retrieving the Welding Circuit Inductivity L
104
General
104
Displaying Welding Circuit Inductivity
104
Laying the Hosepacks Correctly
104
Troubleshooting and Maintenance
105
Troubleshooting
107
General
107
Safety
107
Fault Diagnosis
107
Displayed Service Codes
110
Displayed Service Codes in Connection with OPT Easy Documentation
115
Care, Maintenance and Disposal
117
General
117
Safety
117
At Every Start-Up
117
Every 2 Months
117
Every 6 Months
118
Disposal
118
Appendix
119
Average Consumption Values During Welding
121
Average Wire Electrode Consumption During MIG/MAG Welding
121
Average Shielding Gas Consumption During MIG/MAG Welding
121
Average Shielding Gas Consumption During TIG Welding
121
Technical Data
122
Special Voltages
122
Explanation of the Term "Duty Cycle
122
Tst 3500 Syn
123
Tst 3500 MV Syn
124
Tst 5000 Syn
125
Tst 5000 MV Syn
126
Welding Program Tables
128
Transsteel 3500 Syn - Euro Welding Program Tables
128
Transsteel 5000 Syn - Euro Welding Program Tables
130
Transsteel 3500 Syn - US Welding Program Tables
132
Transsteel 5000 Syn - US Welding Program Tables
134
Transsteel 3500 Yard Welding Program Tables
136
Transsteel 5000 Yard Welding Program Tables
137
Standard Value Tables for MIG/MAG Standard Manual Welding
138
Settings Tables
138
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Quick Guides
2 pages
4
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Fronius TransSteel 5000 Syn Specifications
General
Brand
Fronius
Model
TransSteel 5000 Syn
Category
Welding System
Language
English
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