Fronius ActiveCharger 1000 Operating Instructions & Parts List Manual
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Fronius ActiveCharger 1000 Operating Instructions & Parts List Manual

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/ Perfect Charging /
Perfect Welding
AccuPocket 150/400
ActiveCharger 1000
42,0426,0176,EN 021-05082016
/ Solar Energy
Operating Instructions
Spare parts list
Rod electrode power source

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Summary of Contents for Fronius ActiveCharger 1000

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions AccuPocket 150/400 Spare parts list ActiveCharger 1000 Rod electrode power source 42,0426,0176,EN 021-05082016...
  • Page 3 Thank you for the trust you have placed in our company and congratulations on buying this high-quality Fronius product. These instructions will help you familiarise yourself with the product. Reading the instructions carefully will enable you to learn about the many different features it has to offer.

  • Page 5: Table Of Contents

    Contents Safety rules General ..............................Explanation of safety symbols ......................Operating environments........................Obligations of the operator........................Obligations of personnel ........................EMC Device Classifications ........................Disposal ..............................Data protection............................Copyright............................... Power source ............................. General ..............................Proper use ............................Protecting yourself and others ......................Noise emission values ..........................
  • Page 6 Before commissioning..........................Safety..............................Proper use ............................Setup regulations ..........................Power connection ..........................Before starting for the first time......................Control elements and connections......................Safety..............................Connections and mechanical components ................... Control panel............................MMA welding ............................. Preparatory work........................... MMA welding ............................SoftStart / HotStart function ........................Arc-force dynamic ..........................
  • Page 7 Safety..............................Commissioning ............................. Operating modes ..........................Options............................... Fitting the wall bracket .......................... Troubleshooting ............................Safety..............................Indicated errors ............................. No function............................Technical data............................Operating environments........................Technical data 230V ..........................Standards 230V ............................ Technical data 120V ..........................Standards 120V ............................ Technical data 100V ..........................Standards 100V ............................

  • Page 9: Safety Rules

    Safety rules...

  • Page 11: General

    General Explanation of DANGER! Indicates immediate and real danger. If it is not avoided, death or se- safety symbols rious injury will result. WARNING! Indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur.

  • Page 12: Obligations Of Personnel

    Obligations of Before using the device, all persons instructed to do so undertake: personnel to observe the basic instructions regarding safety at work and accident prevention to read these operating instructions, especially the "Safety rules" section and sign to confirm that they have understood them and will follow them. Before leaving the workplace, ensure that people or property cannot come to any harm in your absence.

  • Page 13: Power Source

    Power source General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operat- ing company, inefficient operation of the device.

  • Page 14: Protecting Yourself And Others

    Protecting your- Persons involved with welding expose themselves to numerous risks, e.g.: self and others flying sparks and hot pieces of metal arc radiation, which can damage eyes and skin hazardous electromagnetic fields, which can endanger the lives of those using cardiac pacemakers risk of electrocution from mains current and welding current greater noise pollution...

  • Page 15: Danger From Toxic Gases And Vapours

    Danger from toxic The fumes produced during welding contain harmful gases and vapours. gases and va- Welding fumes contain substances that may, under certain circumstances, pours cause birth defects or cancer. Keep your face away from welding fumes and gases. Fumes and hazardous gases must not be breathed in must be extracted from the working area using appropriate methods.

  • Page 16: Dangers From The Battery

    With a faulty battery, liquid may leak out of the device. Avoid contact with the liquid Hand the device over to a Fronius Service Partner for repair Clean and check any parts that have come into contact with the liquid Do not operate or store the device in a potentially explosive atmosphere.

  • Page 17: Meandering Welding Currents

    Devices with mechanically undamaged rechargeable batteries may be re- turned to the relevant Fronius Service Partner for repair or battery replace- ment. As soon as it becomes evident that the rechargeable battery has been me- chanically damaged (e.g.

  • Page 18: Emf Measures

    Welding power leads must be kept as short as possible must run close together (to avoid EMF problems) must be kept well apart from other leads Equipotential bonding Earthing of the workpiece If necessary, establish an earth connection using suitable capacitors. Shielding, if necessary Shield off other nearby devices Shield off entire welding installation...

  • Page 19: Safety Precautions In The Place Of Use And For Storage And Transport

    If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder. The manufacturer's instructions must be observed as well as applicable na- tional and international regulations for shielding gas cylinders and accesso- ries. Safety precau- A toppling device can cause life-threatening injuries.

  • Page 20: Commissioning, Maintenance And Repair

    (e.g. relevant product standards from the EN 60 974 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 from the following website: http://www.fronius.com Devices with the CSA test mark satisfy the requirements of the relevant stand- ards in Canada and the USA.

  • Page 21: Charger

    Charger General The device is manufactured using state-of-the-art technology and according to recognised safety standards. If used incorrectly or misused, however, it can cause: injury or death to the operator or a third party, damage to the device and other material assets belonging to the operat- ing company, inefficient operation of the device.

  • Page 22: Dangers From Mains Current And Charging Current

    In this case, the plant operator or the person using the device should check whether the device may be connected, where appropriate by discussing the matter with the power supply company. NOTE! Ensure that the mains connection is earthed properly Dangers from Anyone working with chargers exposes themselves to numerous dangers e.g.: mains current...

  • Page 23: Emc Measures

    EMC measures 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).

  • Page 24: Safety Symbols

    Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directives. Devices displaying this TÜV test mark satisfy the requirements of the relevant standards in Canada and USA. Devices displaying this TÜV test mark satisfy the requirements of the relevant standards in Japan.

  • Page 25: Power Source

    Power source...

  • Page 27: General

    General Device concept The power source has the following proper- ties: Operation without mains electricity Compact dimensions Robust plastic housing Extremely reliable even under harsh operating conditions Carrying strap for easy transport on construction sites, etc. Protected controls Connection sockets with bayonet latch During welding, an electronic regulator adapts the power source characteristic to suit the welding electrode.

  • Page 28: Application Areas

    Application areas MMA welding TIG welding with gas-valve torch...

  • Page 29: Using Rechargeable Devices

    WARNING! Improper handling can cause injuries or damage. Do not open the power source. The power source may only be opened by a Fronius service engineer. If you need a replacement battery, hand the power source over to a Fronius Ser- vice Partner. Storage and...
  • Page 30 Protect the power source from extreme influences Optimum environmental conditions for operation and storage: Temperature: +15 °C to +25 °C Humidity: 50% Surrounding air is free from dust and corrosive vapours or gases If the power source is left idle, charge it on a regular basis Charge the power source regularly if it is not used for long periods.

  • Page 31: Battery Protection Functions

    Battery protection functions General The battery protection functions serve to: increase the service life of the battery protect the battery from long-term damage increase the reliability of the power source Deep discharge The power source has a deep discharge protector to warn the user if the state of charge of protector the battery is too low.

  • Page 32: Temperature Monitoring

    Temperature Temperature monitoring prevents the battery from being charged or discharged if the monitoring temperature of the battery is outside the permitted temperature range. Undertemperature: If the battery falls below the permitted temperature range, neither welding nor charging is possible. If the battery is charged, it can be heated until welding is possible.

  • Page 33: Before Commissioning

    Proper use The power source is intended exclusively for MMA welding and TIG welding. The integrated battery must only be charged with the Fronius ActiveCharger 1000. Any other use is deemed improper. The manufacturer is not liable for damage resulting from such use.

  • Page 34: Before Starting For The First Time

    Before starting for the first time Once connected, the battery capacity indicator on the power source flashes to indicate the current state of charge; the battery is being charged If the battery is fully charged: The COMPLETED indicator lights up on the charger On the power source, all segments of the battery capacity indicator are lit The power source can be put into operation...

  • Page 35: Control Elements And Connections

    Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules NOTE! Due to software updates, you may find that your device has certain func- tions that are not described in these operating instructions or vice versa.

  • Page 36: Control Panel

    Control panel (11) (10) Setting value indicator shows which setting value is selected: Arc-force dynamic Welding current SoftStart / HotStart function TIG pulsing (only enabled on TIG version) Unit indicator shows the unit of the value that is currently being changed using the adjusting dial (8): Percent Voltage (volts)
  • Page 37 On/Off button for switching the power source on and off. The button must be pressed for at least two seconds before it responds (to protect against accidental operation) Adjusting dial TAC indicator lights up when the tacking function is activated (only on TIG devices during the TIG welding process) (10) Setting value button...

  • Page 38: Mma Welding

    MMA welding Preparatory work Press the On/Off button for at least two seconds to turn off the power source the indicators go out Plug the grounding cable into the (+) or (-) current socket depending on which type of electrode is to be used and turn it clockwise to latch it in place Use the other end of the grounding cable to establish a connection to the workpiece Plug the electrode holder into the (+) or (-) current socket depending on which type of electrode is to be used and turn it clockwise to latch it in place...

  • Page 39: Arc-Force Dynamic

    NOTE! The maximum HotStart current is limited to 180 A. Examples: (set welding current = 100 A) 100% Starting current = 100 A Function deactivated Starting current = 80 A SoftStart 135% Starting current = 135 A HotStart 200% Starting current = 180 A HotStart (maximum current limit reached!) Features of SoftStart function: Reduced pore formation with certain...
  • Page 40 Arc-force dynamic = 20 arc-force dynamic with 40 A current increase harder, more stable arc Set welding current = 100 A / arc-force dynamic = 60 arc-force dynamic theoretically with 120 A current increase actual increase is just 80 A as the maximum current limit has been reached!

  • Page 41: Tig Welding

    TIG welding General NOTE! Do not use pure tungsten electrodes (colour-coded green) if the TIG weld- ing process has been selected. Connecting the WARNING! There is a high risk of very serious injury and damage if a gas cylin- gas cylinder der falls over.

  • Page 42: Setting The Gas Pressure

    Setting the gas Open the gas cut-off valve of the pressure welding torch – Shielding gas flows Set the desired gas flow rate on the pressure regulator Close the gas cut-off valve of the welding torch Welding torch with gas cut-off valve TIG welding Select TIG welding with the welding process button the TIG welding indicator lights up...

  • Page 43: Tig Comfort Stop

    TIG Comfort Stop For more information on activating and setting the TIG Comfort Stop function, see Comfort Stop Sensitivity on page 46. Function and application of TIG Comfort Stop: Welding During welding, raise the welding torch The arc length is increased significantly Lower the welding torch The arc length is decreased significantly This triggers the TIG Comfort Stop function...
  • Page 44 Downslope: The downslope time t is 0.5 seconds and cannot be adjusted. down Gas post-flow: The gas post-flow must be carried out manually.

  • Page 45: The Setup Menu

    The Setup menu Accessing the Use the welding process button to select the process for which the Setup param- Setup menu eters are to be changed: MMA welding MMA welding with Cel electrode TIG welding Press the setting value and welding process buttons together –...

  • Page 46: Parameters For Tig Welding

    Parameter Description Range Unit Break voltage (U cut off) 25 - 80 Volts Used to specify at which arc length the welding process is to be completed. The welding voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here.
  • Page 47 Parameter Description Range Unit Software version The full version number of the currently installed software is spread across a number of displays and can be retrieved by turning the adjusting dial. Automatic switch-off (time Shut down) 300 - 900 Seconds If the power source is not operated for the speci- fied length of time, it switches off automatically.

  • Page 48: Vrd Safety Device (Optional)

    VRD safety device (optional) General VRD is an additional safety device that prevents, as far as possible, output voltages that may pose a danger to persons. VRD = Voltage Reduction Device. Function The welding circuit resistance is greater than the minimum human body resistance (greater than or equal to 200 Ohm): VRD is active Open circuit voltage is limited to 14 V...

  • Page 49: Care, Maintenance And Disposal

    WARNING! Improper handling can cause injuries or damage. Do not open the power source. The power source may only be opened by a Fronius service engineer. If you need a replacement battery, hand the power source over to a Fronius Ser- vice Partner. General Under normal operating conditions, the device requires only a minimum of care and main- tenance.

  • Page 50: Every 2 Months

    Every 2 months Clean the air filter (if fitted): Disposal Dispose of in accordance with the applicable national and local regulations.

  • Page 51: Troubleshooting

    WARNING! Improper handling can cause injuries or damage. Do not open the power source. The power source may only be opened by a Fronius service engineer. If you need a replacement battery, hand the power source over to a Fronius Ser- vice Partner. Indicated errors Overtemperature "hot"...

  • Page 52: Service Messages

    Service messag- When E and a 2 digit error number appear in the display (e.g. E02) and the "Error" indicator lights up, this is an internal power source service code. Example: It is also possible that several error numbers are present. These appear when turning the adjusting dial.

  • Page 53: No Function

    No function The power source cannot be switched on Cause: The battery has entered a state of deep discharge as it has been stored for too long without being charged Remedy: Charge the battery now Battery operation is possible again above 25% capacity. If charging is no longer possible, contact After-Sales Service.

  • Page 54: Faulty Operation

    No welding current Power source is switched on, indicator for the selected welding process is lit, overtemper- ature indicator lit Cause: Power module error Remedy: Turn off the power source, then turn it on again. If the error occurs frequently, contact After-Sales Service Faulty operation Poor ignition properties during MMA welding Cause:...
  • Page 55 VRD does not light up even though no welding process is taking place Cause: VRD option not present or internal device fault Remedy: Contact after-sales service...

  • Page 56: Technical Data

    Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will ronments be deemed improper. The manufacturer shall not be held liable for any dam- age arising from such usage. Ambient temperature range: 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) recommended temperature range during charging: + 4 °C to + 40 °C (+ 39,2 °F to + 104 °F)

  • Page 57: Technical Data

    Technical data Battery nominal voltage 52.8 V Charging current 10 A Rapid charging current 18 A Battery capacity 7,5 Ah Battery type Li-ion Welding current range Electrode DC 10 -140 A TIG DC 3 - 150 A Welding current in hybrid mode, MMA welding 40 °C (104 °F) 18% D.C.

  • Page 59: Charger

    Charger...

  • Page 61: General

    General Warning notices A number of safety symbols can be seen on the charger's rating plate. The safety symbols on the device must not be removed or painted over. Do not use the functions described here until you have fully read and understood the following documents: these operating instructions all the operating instructions for the system components of the power...

  • Page 62: Warning Notices Inside The Device

    An electric shock can be fatal. Do not open the device! The housing must never be opened by anyone other than a Fronius-trained ser- vice engineer. The device must be disconnected from the mains before starting any work with the housing open. A suitable measuring instrument must be used to ensure that electrically charged components (e.g.

  • Page 63: Before Commissioning

    Before commissioning Mains connection The rating plate, which is located on the housing, contains information about the permitted mains voltage. The device is designed for this mains voltage only. For details on the re- quired fuse protection for the mains lead, see the Technical data section on page 70.
  • Page 64 275 mm 100 mm 10.8 inch 3.9 inch...

  • Page 65: Control Elements And Connections

    Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules NOTE! Due to software updates, you may find that your device has certain func- tions that are not described in these operating instructions or vice versa.

  • Page 66: Start-Up

    Start-up Safety WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op- erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents: these operating instructions...

  • Page 67: Operating Modes

    Operating modes Operating mode Activation/deactivation Features Charging Starts automatically when The CHARGING indi- the charger is connected to cator is lit the power source and the Mains indicator lit mains The power source is charged at optimum charging power The charging characteristic of this mode maximises the ser- vice life of the power source When the COMPLET-...

  • Page 68: Options

    Options Fitting the wall NOTE! Depending on the underlying surface, different wall plugs and screws are bracket needed to fit the wall bracket. Wall plugs and screws are therefore not included in the scope of supply. The installer is responsible for selecting the right wall plugs and screws.

  • Page 69: Troubleshooting

    Troubleshooting Safety WARNING! An electric shock can be fatal. Do not open the device. Indicated errors An error is signalled by the following indi- cators flashing or lighting up: Error indicator QUICK QUICK CHARGE CHARGE Mains indicator Error flashing, mains lit Cause: Battery fault Remedy:...

  • Page 70: Technical Data

    Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will ronments be deemed improper. The manufacturer shall not be held liable for any dam- age arising from such usage. Ambient temperature range: 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) recommended temperature range during charging: + 4 °C to + 40 °C (+ 39,2 °F to + 104 °F)

  • Page 71: Standards 230V

    Standards 230V EN 62477-1 EN 60974-10 (Class A) Technical data Mains voltage ~ 120 V AC, ±15% 120V Mains frequency 50/60 Hz Mains current max. 15 A eff. Mains fuse max. 20 A Efficiency max. 94 % Effective power max. 1100 W Apparent power max.

  • Page 72: Standards 100V

    Apparent power max. 1600 VA Power consumption (standby) max. 1.6 W Protection class I (with ground conductor) Maximum permitted mains impedance at the inter- none face (PCC) to the public grid EMC device class Mark of conformity Output voltage range 30 - 58 V DC Output current max.

  • Page 73: Appendix

    Appendix...

  • Page 74: Spare Parts List: Accupocket

    Spare parts list: AccuPocket...

  • Page 75: Spare Parts List: Activecharger

    Spare parts list: ActiveCharger...
  • Page 76 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...

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