Fronius TransSteel 5000 Syn - Troubleshooting and Maintenance

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Troubleshooting and maintenance

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Parameters for Manual Metal Arc (MMA) Welding in the Setup Menu Level2
Table of Contents3
Safety Rules7
Explanation of Safety Notices7
General7
Proper Use8
Environmental Conditions8
Obligations of the Operator8
Obligations of Personnel8
Mains Connection9
Protecting Yourself and Others9
Danger from Toxic Gases and Vapours10
Danger from Flying Sparks10
Risks from Mains Current and Welding Current11
Meandering Welding Currents12
EMC Device Classifications12
EMC Measures12
EMF Measures13
Specific Hazards13
Requirement for the Shielding Gas14
Danger from Shielding Gas Cylinders14
Danger from Escaping Shielding Gas15
Safety Measures at the Installation Location and During Transport15
Safety Measures in Normal Operation16
Commissioning, Maintenance and Repair16
Safety Inspection17
Disposal17
Safety Symbols17
Data Protection17
Copyright17
General Information19
General21
Device Concept21
Functional Principle21
Application Areas21
Warning Notices on the Device21
Welding Processes, Procedures and Welding Characteristics for MIG/MAG Welding23
General23
Welding Characteristics23
Summary of MIG/MAG Standard Synergic Welding23
Short Description of Arc Air Gouging23
System Components24
General24
Safety24
Overview24
Options26
General26
Machine Interface26
Gas Preheater CO2 Connection26
Keylock Switch27
VRD: Safety Function27
VRD: Safety Principle28
Control Elements and Connections29
Synergic Control Panel31
General31
Safety31
Synergic Control Panel32
Service Parameters35
Keylock36
Connections, Switches and Mechanical Components37
Tst 3500/5000 Syn Power Source37
Installation and Commissioning39
Minimum Equipment Needed for Welding Task41
General41
Gas-Cooled MIG/MAG Welding41
MIG/MAG Welding, Water-Cooled41
MMA Welding41
Before Installation and Commissioning42
Safety42
Utilisation for Intended Purpose Only42
Setup Regulations42
Mains Connection43
Connecting the Mains Cable44
Safety44
General44
Stipulated Mains Cables and Strain-Relief Devices44
Connecting the Mains Cable45
Fitting the Europe Strain-Relief Device45
Fitting the Canada/Us Strain-Relief Device46
Generator-Powered Operation48
Start-Up49
General49
Information on System Components49
Assembling the System Components (Overview)49
Placing the Wirefeeder on the Power Source50
Fitting the Interconnecting Hosepack Strain-Relief Device51
Connecting the Interconnecting Hosepack51
Connecting the Gas Cylinder52
Establishing a Ground Earth Connection53
Connecting MIG/MAG Welding Torches54
Inserting/Replacing Feed Rollers54
Inserting the Wirespool55
Inserting the Basket-Type Spool56
Feeding in the Wire Electrode57
Setting the Contact Pressure59
Adjusting the Brake59
Design of the Brake60
Welding61
Power Limitation63
Safety Function63
MIG/MAG Modes64
General64
Symbols and Their Explanations64
2-Step Mode65
Special 4-Step Mode66
Spot Welding66
2-Step Stitch Welding67
MIG/MAG Welding68
Safety68
Preparatory Work68
Overview68
MIG/MAG Standard Synergic Welding69
Corrections During Welding70
MIG/MAG Standard Manual Welding71
General71
Available Parameters71
Corrections During Welding72
Spot and Stitch Welding73
General73
Spot Welding73
Stitch Welding74
Easyjob Mode76
General76
Storing Easyjob Operating Points76
Retrieving Easyjob Operating Points76
Deleting Easyjob Operating Points76
Retrieving Easyjob Operating Points on the Up/Down Welding Torch76
MMA Welding78
Safety78
Preparation78
Corrections During Welding79
Hotstart Function80
Anti-Stick Function80
Arc Air Gauging (Tst 5000 Syn)81
Safety81
Preparation81
Arc Air Gouging82
Easy Documentation85
General87
Documented Welding Data87
New CSV File88
PDF Report / Fronius Signature88
Activating / Deactivating Easy Documentation89
Setting the Date and Time89
Deactivating Easy Documentation89
Setup Settings91
Setup Menu93
General Remarks93
Operation93
Setup Parameters for MIG/MAG Standard Manual Welding93
Setup Parameters for MIG/MAG Standard Synergic Welding95
Setup Parameters for MMA Welding96
Setup Menu - Level 298
Operation (Level 2 Setup Menu)98
Measuring Welding Circuit Resistance R102
General102
Measuring Welding Circuit Resistance (MIG/MAG Welding)102
Retrieving the Welding Circuit Inductivity L104
General104
Displaying Welding Circuit Inductivity104
Laying the Hosepacks Correctly104
Troubleshooting and Maintenance105
Troubleshooting107
General107
Safety107
Fault Diagnosis107
Displayed Service Codes110
Displayed Service Codes in Connection with OPT Easy Documentation115
Care, Maintenance and Disposal117
General117
Safety117
At Every Start-Up117
Every 2 Months117
Every 6 Months118
Disposal118
Appendix119
Average Consumption Values During Welding121
Average Wire Electrode Consumption During MIG/MAG Welding121
Average Shielding Gas Consumption During MIG/MAG Welding121
Average Shielding Gas Consumption During TIG Welding121
Technical Data122
Special Voltages122
Explanation of the Term "Duty Cycle122
Tst 3500 Syn123
Tst 3500 MV Syn124
Tst 5000 Syn125
Tst 5000 MV Syn126
Welding Program Tables128
Transsteel 3500 Syn - Euro Welding Program Tables128
Transsteel 5000 Syn - Euro Welding Program Tables130
Transsteel 3500 Syn - US Welding Program Tables132
Transsteel 5000 Syn - US Welding Program Tables134
Transsteel 3500 Yard Welding Program Tables136
Transsteel 5000 Yard Welding Program Tables137
Standard Value Tables for MIG/MAG Standard Manual Welding138
Settings Tables138

Fronius TransSteel 5000 Syn - Troubleshooting and Maintenance

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