Fronius TransPocket 150 Operating Instructions Manual
Rod electrode power source
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Also See for TransPocket 150:
- Service manual & spare parts list (120 pages) ,
- Operating instructions manual (52 pages) ,
- Update procedure (8 pages)
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Summary of Contents for Fronius TransPocket 150
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions TransPocket 150 TransPocket 180 Rod electrode power source 42,0426,0203,EN 017-12022019...
- 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.
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Page 5: Table Of Contents
Proper use ............................Setup regulations ..........................Generator-powered operation....................... Controls, connections and mechanical components.................. Safety..............................TransPocket 150 controls, connections and mechanical components ..........TransPocket 180 controls, connections and mechanical components ..........Control panel............................MMA welding ............................. Preparatory work........................... MMA welding ............................ - Page 6 General ..............................At every start-up............................ Every 2 months ............................. Disposal ..............................Troubleshooting ............................Safety..............................Indicated errors ............................. Service messages..........................No function............................Faulty operation ............................ Technical data............................Explanation of the term "duty cycle" ..................... TransPocket 150........................... TransPocket 180........................... TransPocket 180 MV ..........................
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Page 7: Safety Rules
Safety rules Explanation of DANGER! safety notices Indicates immediate danger. ► If not avoided, death or serious injury will result. WARNING! Indicates a potentially hazardous situation. ► If not avoided, death or serious injury may result. CAUTION! Indicates a situation where damage or injury could occur. ►... -
Page 8: Proper Use
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, rectify any faults that could compromise safety. This is for your personal safety! Proper use The device is to be used exclusively for its intended purpose. -
Page 9: Mains Connection
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connection Devices with a higher rating may affect the energy quality of the mains due to their current consumption. This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement... -
Page 10: Noise Emission Values
Keep all persons, especially children, out of the working area while any devices are in op- eration or welding is in progress. If, however, there are people in the vicinity: Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains current and welding current, etc.) Provide suitable protective equipment... -
Page 11: Risks From Mains Current And Welding Current
Sparks and pieces of hot metal may also get into adjacent areas through small gaps or openings. Take appropriate precautions to prevent any danger of injury or fire. Welding must not be performed in areas that are subject to fire or explosion or near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards. -
Page 12: Meandering Welding Currents
After opening the device: Discharge all live components Ensure that all components in the device are de-energised If work on live parts is required, appoint a second person to switch off the main switch at the right moment. Meandering weld- If the following instructions are ignored, meandering welding currents can develop with the ing currents following consequences:... -
Page 13: Emf Measures
Supporting measures for avoidance of EMC problems: Mains supply If electromagnetic interference arises despite correct mains connection, addition- al measures are necessary (e.g. use a suitable line filter). 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... -
Page 14: Factors Affecting Welding Results
Power sources for work in areas with increased electric risk (e.g. near boilers) must carry the "Safety" sign. However, the power source must not be located in such areas. Risk of scalding from escaping coolant. Switch off cooling unit before disconnecting cool- ant flow or return lines. -
Page 15: Safety Measures At The Installation Location And During Transport
Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). Only use shielding gas cylin- ders and accessories that are in good condition. Turn your face to one side when opening the valve of a shielding gas cylinder. Close the shielding gas cylinder valve if no welding is taking place. -
Page 16: Commissioning, Maintenance And Repair
Always fasten the shielding gas cylinder securely and remove it beforehand if the device is to be transported by crane. Only the manufacturer's original coolant is suitable for use with our devices due to its prop- erties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.). Only use suitable original coolant from the manufacturer. -
Page 17: Disposal
(e.g. relevant product standards of the EN 60 974 se- ries). Fronius International GmbH hereby declares that the device is compliant with Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be found at the following address: http://www.fronius.com... -
Page 18: General
General Device concept The power source has the following proper- ties: Compact dimensions Robust plastic housing Extremely reliable even under harsh operating conditions Carrying strap for easy transport on construction sites, etc. Protected controls Current sockets with bayonet latch In conjunction with the digital resonance inverter, an electronic regulator adapts the power source characteristic to suit the welding electrode during welding. -
Page 19: Warning Notices On The Device
Warning notices The warning notices and safety symbols on the power source must not be removed or on the device painted over. They warn against incorrect operation which can lead to serious injury and damage. Meaning of safety symbols on the device: Welding is dangerous. -
Page 20: Application Areas
Application areas MMA welding TIG welding, welding torch with gas cut-off valve... -
Page 21: Before Commissioning
Proper use The power source is intended exclusively for MMA welding and TIG welding in conjunction with system components from Fronius. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac- cordance with the intended purpose. - Page 22 The maximum apparent power S of the power source can be calculated as follows: 1max 1max 1max See device rating plate or technical data for I and U values 1max The generator apparent power S needed is calculated using the following rule of thumb: x 1.35 1max...
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Page 23: Controls, Connections And Mechanical Components
Controls, connections and mechanical components 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 fol- lowing documents: ► these operating instructions ► all the operating instructions for the system components, especially the safety rules NOTE! Due to software updates, you may find that your device has certain functions that are not described in these operating instructions or vice versa. -
Page 24: Transpocket 150 Controls, Connections And Mechanical Components
(-) current socket with bayonet latch TMC connection (TIG Multi Connector) TransPocket 150 RC only - for connecting a remote control NOTE! If a remote control is connected to the power source: ► "rc" appears on the power source display ►... -
Page 25: Transpocket 180 Controls, Connections And Mechanical Components
TransPocket 180 controls, connec- tions and me- chanical components Control panel (-) current socket with bayonet latch TMC connection (TIG Multi Connector) TransPocket 180 RC only - for connecting a remote control NOTE! If a remote control is connected to the power source: ►... -
Page 26: Control Panel
Control panel Setting value indicator shows which setting value is selected: Arc-force dynamic Welding current SoftStart / HotStart function Pulse welding (only available for manual metal arc welding) Unit indicator shows the unit of the value that is currently being changed with the adjusting dial (7): Time (seconds) Percent... -
Page 27: Mma Welding
MMA welding Preparatory work CAUTION! Risk of injury and damage from electric shock. As soon as the power source is switched on, the electrode in the electrode holder is live. Make sure the electrode does not touch any persons or electrically conductive or earthed parts (e.g. -
Page 28: Mma Welding
SoftStart / HotStart indicator lights up Turn the adjusting dial until the desired value is reached Power source is ready for welding NOTE! The maximum HotStart current is limited as follows: ► TransPocket 150 to 160 A ► TransPocket 180 to 200 A... -
Page 29: Arc-Force Dynamic
Starting current = 80 A SoftStart 135% Starting current = 135 A HotStart 200% Starting current, for TransPocket 150 = 160 A HotStart (maximum current limit reached!) 200% Starting current, for TransPocket 180 = 200 A HotStart Features of SoftStart function:... -
Page 30: Pulse Welding
Arc-force dynamic = 60, set welding current = 100 A for the TransPocket 150: actual increase is just 80 A as the maximum current limit is reached! for the TransPocket 180: arc-force dynamic with 120 A current increase Pulse welding Pulse welding is welding with a pulsing welding current. - Page 31 1/F-P Pulse welding - welding current curve Adjustable parameters: F-P = Pulse frequency (1/F-P = time I-P = Pulse current interval between two pulses) SoftStart / HotStart Fixed parameters: I-G = Base current dcY = Duty cycle To use pulse welding: Press the setting value button until the pulse welding indicator lights up Turn the adjusting dial until the desired frequency value (Hz) is reached...
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Page 32: Tig Welding
TIG welding General NOTE! Do not use pure tungsten electrodes (colour-coded green) if the TIG welding pro- cess has been selected. Connecting the WARNING! gas cylinder There is a high risk of very serious injury and damage if a gas cylinder falls over. Place gas cylinders on a solid, level surface so that they remain stable. -
Page 33: Preparatory Work
Preparatory work CAUTION! Risk of injury and damage from electric shock. As soon as the power source is switched on, the electrode in the welding torch is live. Make sure the electrode does not touch any persons or electrically conductive or earthed parts (e.g. -
Page 34: Setting The Gas Pressure - On The Welding Torch With Gas Cut-Off Valve
Setting the gas Open the gas cut-off valve pressure - on the – Shielding gas flows welding torch with gas cut-off Set the desired gas flow rate on the valve pressure regulator Close the gas cut-off valve Welding torch with gas cut-off valve... -
Page 35: Tig Welding
TIG welding Select TIG welding with the welding process button the TIG welding indicator lights up Press the setting value button until the welding current indicator lights up Adjust the welding current using the adjusting dial Place the gas nozzle down on the ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece Actuate the gas cut-off valve Shielding gas flows... - Page 36 Keep the welding torch at the same height The welding current continually decreases (DownSlope) until the arc goes out Wait for the gas post-flow time to finish and lift the welding torch away from the work- piece Max. A 70 A down Welding current and gas flow curve with TIG Comfort Stop function activated Gas pre-flow...
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Page 37: Welding Process Setup Menu
Welding process Setup menu Accessing the Use the Welding Process button to select the process whose Setup parameters Setup menu are to be changed: MMA welding MMA welding with Cel electrode TIG welding Press the Setting Value and Welding Process buttons together The code for the first parameter in the Setup menu is displayed on the control panel Changing weld-... -
Page 38: Parameters For Tig Welding
Comfort Stop Sensitivity (Comfort Stop Sensi- Volts tivity) 0.5 - 2.5 Factory setting on TransPocket 150: 1.6 volts Factory setting on TransPocket 180: 1.5 volts For details, see section „TIG Comfort Stop“ Break voltage (U cut off) 12 - 22 Volts Used to specify at which arc length the welding process is completed. - Page 39 Parameter Description Range Unit Factory setting (FACtory) This can be used to reset the device to its factory settings Cancel reset Reset the parameters for the selected weld- ing process to their factory settings Reset the parameters for all welding process- es to their factory settings Resetting of the selected value to its factory set- ting must be confirmed by pressing the adjusting...
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Page 40: Setup Menu - Level 2
15 / 16 / This prevents the circuit breaker from tripping im- 20 / OFF mediately (TP 180 MV only) TransPocket 150 - Ratio between set fuse and welding current: Mains voltage Welding cur- TIG welding Duty cycle fuse rent electrode... - Page 41 TransPocket 180 - Ratio between set fuse and welding current: Mains voltage Set fuse Welding cur- TIG welding Duty cycle rent electrode current 230 V 10 A 125 A 180 A 13 A 150 A 200 A 16 A 180 A 220 A OFF (TP 180 180 A...
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Page 42: Care, Maintenance And Disposal
Care, maintenance and disposal Safety WARNING! Work that is carried out incorrectly can cause serious injury and damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: ►... -
Page 43: Every 2 Months
Every 2 months Clean air filter: Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 44: Troubleshooting
Troubleshooting Safety WARNING! Work that is carried out incorrectly can cause serious injury and damage. All the work described below must only be carried out by trained and qualified personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: ►... - Page 45 E01 - E03 / E11 / E15 / E21 / E33 - E35 / E37 - E40 / E42 - E44 / E46 - E52 Cause: Fault in power module Remedy: Contact After-Sales Service Cause: Open circuit voltage is not being reached: electrode in contact with workpiece / hardware fault Remedy: Remove electrode holder from workpiece.
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Page 46: No Function
E65 - E75 Cause: Communication error with welding torch/remote control Remedy: Check TIG Multi Connector plug connection / switch device off and on again / contact after-sales service if a repeated occurrence No function The device cannot be switched on Cause: Mains switch is faulty Remedy:... -
Page 47: Faulty Operation
Faulty operation Poor ignition properties during MMA welding Cause: Incorrect welding process selected Remedy: Select "MMA welding" or "MMA welding with Cel electrode" process Cause: Starting current too low; electrode sticking during ignition Remedy: Increase starting current using HotStart function Cause: Starting current too high;... -
Page 48: Technical Data
Technical data Explanation of Duty cycle (D.C.) is the proportion of time in a 10-minute cycle at which the device may be the term "duty cy- operated at its rated output without overheating. cle" NOTE! The D. C. values specified on the rating plate are based on an ambient temperature of 40°C. If the ambient temperature is higher, either the D.C. -
Page 49: Transpocket 150
TransPocket Mains voltage (U 1 x 230 V Max. effective primary current (I 15 A 1eff Max. primary current (I 24 A 1max Max. apparent power (S 5.52 kVA 1max Mains fuse protection 16 A slow-blow Mains voltage tolerance -20%/+15% Mains frequency 50 / 60 Hz Cos phi... -
Page 50: Transpocket 180
TransPocket Mains voltage (U 1 x 230 V Max. effective primary current (I 16 A 1eff Max. primary current (I 25 A 1max Max. apparent power (S 5.75 kVA 1max Mains fuse protection 16 A slow-blow Mains voltage tolerance -20%/+15% Mains frequency 50 / 60 Hz Cos phi... -
Page 51: Transpocket 180 Mv
TransPocket Mains voltage (U 1 x 230 V 180 MV Max. effective primary current (I 16 A 1eff Max. primary current (I 25 A 1max Max. apparent power (S 5.75 kVA 1max Mains fuse protection 16 A slow-blow Mains voltage (U 1 x 120 V Max. - Page 52 Welding current for 10 min/40 °C (104 °F) 100% MMA welding 120 A 100 A 90 A = 120 V, fuse = 20 A) Welding current for TIG 10 min/40 °C (104 °F) 100% welding 170 A 130 A 100 A = 120 V, fuse = 20 A) Welding current for 10 min/40 °C (104 °F)
- Page 56 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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