Fronius ActiveCharger 1000 Operating Instructions Manual
Rod electrode power source for fronius accupocket 150/400
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- Operating instructions & parts list manual (76 pages) ,
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- Operating instructions manual (84 pages)
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Summary of Contents for Fronius ActiveCharger 1000
- Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions AccuPocket 150/400 ActiveCharger 1000 Rod electrode power source 42,0426,0176,EN 032-20012020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Contents Safety rules General ..............................Explanation of safety notices ........................ 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 4 Deep discharge protector........................Automatic switch-off..........................Temperature monitoring........................Overcharging protection........................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...........................
- Page 5 Safety..............................Connections and components ......................Control panel............................Start-up ..............................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 ..........................
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Page 7: Safety Rules
Safety rules... -
Page 9: General
General 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 10: 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 11: 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 operating company, inefficient operation of the device. -
Page 12: Protecting Yourself And Others
Protecting your- Anyone working with the device exposes 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 cardi- ac pacemakers Risk of electrocution from mains current and welding current Greater noise pollution... -
Page 13: Danger From Flying Sparks
Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. Otherwise, a protective mask with an air supply must be worn. Close the shielding gas cylinder valve or main gas supply if no welding is taking place. If there is any doubt about whether the extraction capacity is sufficient, the measured toxic emission values should be compared with the permissible limit values. -
Page 14: Dangers From The Battery
(e.g. electrolyte is escaping), dispose of the device at your nearest recycling centre in accordance with national laws and guidelines. If anything is unclear or you have any questions about disposal, contact your Fronius Ser- vice Partner. Only charge the power source using the "C 53 battery charger". Risk of fire when using a different battery charger. -
Page 15: Meandering Welding Currents
Do not use damaged or modified batteries and power sources. Damaged or modified com- ponents and devices may exhibit unpredictable behaviour which can lead to explosions or injury. Do not expose the power source or battery to fire or temperatures exceeding 130 °C (266 °F). -
Page 16: Emf Measures
EMF measures Electromagnetic fields may pose as yet unknown risks to health: effects on the health of others in the vicinity, e.g. wearers of pacemakers and hearing aids wearers of pacemakers must seek advice from their doctor before approaching the de- vice or any welding that is in progress for safety reasons, keep distances between the welding cables and the welder's head/ torso as large as possible... -
Page 17: Safety Precautions In The Place Of Use And For Storage And Transport
Shielding gas is colourless and odourless and, in the event of a leak, can displace the ox- ygen in the ambient air. Ensure an adequate supply of fresh air with a ventilation rate of at least 20 m³/hour. Observe safety and maintenance instructions on the shielding gas cylinder or the main gas supply. -
Page 18: Commissioning, Maintenance And Repair
(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 19: 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 operator Inefficient operation of the device All persons involved in commissioning, operating, maintaining and servicing the device must:... -
Page 20: Dangers From Mains Current And Charging Current
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 at the interface with the public grid see "Technical data" 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 sup- ply company. -
Page 21: Emc Measures
Any safety devices and parts that are not functioning properly or are in imperfect condition must be repaired by a qualified technician before switching on the charger. Never bypass or disable protection devices. After installation, an accessible mains plug is required. EMC measures In certain cases, even though a device complies with the standard limit values for emis- sions, it may affect the application area for which it was designed (e.g. -
Page 22: Safety Symbols
Further details on safety inspections can be obtained from your service centre. They will provide you, on request, with any documents you may require. Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and elec- tromagnetic compatibility directives. -
Page 23: Power Source
Power source... -
Page 25: 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 26: Application Areas
Application areas MMA welding TIG welding with gas-valve torch... -
Page 27: Using Rechargeable Devices
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 Service Part- ner. Storage and... - Page 28 However, the user must observe the following key points in order to guarantee maximum service life of the battery: Recharge the battery after every discharge Do not wait until the battery is completely discharged before recharging it. Protect the power source from extreme influences Optimum environmental conditions for operation and storage: Temperature: +15 °C to +25 °C (+59 °F to +77 °F) Humidity: 50%...
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Page 29: 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 30: Temperature Monitoring
Temperature Temperature monitoring prevents the battery from being charged or discharged if the tem- monitoring perature 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. -
Page 31: 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 32: Before Starting For The First Time
NOTE! No warranty claims will be entertained if the device is operated with other chargers. 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... -
Page 33: Control Elements And Connections
Control elements and connections Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in serious injury and damage to property. ► All the work and functions described in this document must only be carried out by trained and qualified personnel. - Page 34 The use of the current connections depends on the welding process: MMA welding (depending on electrode type) (+) current socket for electrode holder or grounding cable (-) current socket for electrode holder or grounding cable TIG welding (+) current socket for grounding (earthing) cable (-) current socket for welding torch...
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Page 35: 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 36 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...
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Page 37: 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 38: Arc-Force Dynamic
Turn the adjusting dial until the desired value is reached Power source is ready for welding 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%... - Page 39 NOTE! The maximum arc-force dynamic current is limited to 180 A. Examples: Arc-force dynamic = 0 arc-force dynamic deactivated soft, low-spatter arc 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!
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Page 40: 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 Danger from falling gas cylinders. This can result in serious injury and damage to property. ►... -
Page 41: Setting The Gas Pressure
Setting the gas Open the gas cut-off valve of the wel- pressure ding torch – Shielding gas flows Set the desired gas flow rate on the pressure regulator Close the gas cut-off valve of the wel- ding 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 42: Tig Comfort Stop
TIG Comfort Stop For more information on activating and setting the TIG Comfort Stop function, see Parameters for TIG welding on page 45. 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 43 Gas pre-flow Gas post-flow 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.
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Page 44: 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 After releasing the buttons, the code for the first parameter in the Setup menu is –... -
Page 45: Parameters For Tig Welding
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. Factory setting: 45 volts Software version The full version number of the currently installed software is spread across a number of... - Page 46 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 - 9000 Seconds / OFF If the power source is not operated for the specified length of time, it switches off automat- ically.
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Page 47: 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 48: Care, Maintenance And Disposal
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 Service Part- ner. General Under normal operating conditions, the device requires only a minimum of care and main- tenance. -
Page 49: 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 50: Troubleshooting
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 Service Part- ner. Indicated errors Overtemperature "hot"... -
Page 51: Service Messages
Deep discharge protection "Lo" appears in the display, the "Battery capacity" indicator flashes Cause: Battery discharged, deep discharge protection has been activated Remedy: Charge the battery now Battery operation is possible again above 25% capacity CAUTION! Deep discharge can destroy the battery. Do not store the battery when it is in this state Service messag- When E and a 2 digit error number appear in the display (e.g. -
Page 52: No Function
Cause: Wrong firmware (software) has been loaded Remedy: Contact after-sales service E19 / E22 Cause: Battery fault Remedy: Contact after-sales service Cause: A voltage of > 113 V DC has been measured on the current sockets Remedy: Contact After-Sales Service No function The power source cannot be switched on Cause:... -
Page 53: Faulty Operation
No welding current Power source is switched on, indicator for the selected welding process is lit, overtemper- ature indicator lit Cause: Duty cycle exceeded - power source overloaded - fan running Remedy: Keep within duty cycle Cause: Thermostatic automatic circuit breaker has been tripped Remedy: Wait until the power source comes back on automatically at the end of the cooling phase... - Page 54 Poor weld properties (severe spattering) Cause: Incorrect electrode polarity Remedy: Reverse electrode polarity (refer to manufacturer's instructions) Cause: Poor grounding (earthing) connection Remedy: Fasten earthing clamps directly to workpiece Cause: Setup parameters not ideal for selected welding process Remedy: Select the optimal settings in the Setup menu for the selected welding pro- cess Tungsten electrode melting Tungsten inclusions in base metal during the ignition phase...
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Page 55: Technical Data
Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will be deemed ronments improper. The manufacturer shall not be held liable for any damage arising from such us- age. 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 56: Technical Data
Technical data Rated battery voltage 52.8 V Charging current 10 A Rapid charging current 18 A Battery capacity 7.5 Ah Battery type Li-ion Standard charging 50 min. Rapid charging 30 min. Welding time 2.5 mm Electrode 14 - 18 pc. 3.25 mm Electrode 6 - 8 pc. -
Page 57: Charger
Charger... -
Page 59: 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. A-4600 Wels www.fronius.com ActiveCharger 1000/230V Part No. 4,010,341,xxx Chr. No. xxxxxxxx EMC Emission ~230V 50/60Hz;... -
Page 60: Proper Use
The housing must never be opened by anyone other than a Fronius-trained service engi- neer. 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 61: 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- theTechnical data section on page 68. If quired fuse protection for the mains lead, see there is no mains cable or mains plug on your version of the appliance, fit one that con- forms to national standards. -
Page 62: Space Requirements
Space require- If the charger is installed in a switch cabinet (or a similar sealed area), then forced-air ven- ments tilation must be provided to ensure adequate heat dissipation. There should be an all-round clearance of 10 cm (3.9 in.) around the charger. 275 mm 100 mm 10.8 inch... -
Page 63: Control Elements And Connections
Control elements and connections Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in serious injury and damage to property. ► All the work and functions described in this document must only be carried out by trained and qualified personnel. -
Page 64: Start-Up
Start-up Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in serious injury and damage to property. ► All the work and functions described in this document must only be carried out by trained and qualified personnel. ►... -
Page 65: Operating Modes
Operating modes Charging Starts automatically when the battery charger is connected to the power source and the mains The CHARGING indicator is lit Mains indicator lit The power source is charged at optimum charging power The charging characteristic of this mode maximises the service life of the power source When the COMPLETED indicator lights up, the power source is fully charged and the battery charger switches to conservation charging mode... -
Page 66: Options
Options Fitting the wall NOTE! bracket Depending on the underlying surface, different wall plugs and screws are 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 correct wall plugs and screws. -
Page 67: Troubleshooting
Troubleshooting Safety WARNING! Danger from electric current. An electric shock can be fatal. ► Do not open the device. Indicated errors An error is signalled by the following indica- tors flashing or lighting up: Error indicator QUICK QUICK CHARGE Mains indicator CHARGE Error flashing, mains lit Cause:... -
Page 68: Technical Data
Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will be deemed ronments improper. The manufacturer shall not be held liable for any damage arising from such us- age. 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 69: 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 70: 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 72 FRONIUS INTERNATIONAL GMBH Froniusstraße 1, A-4643 Pettenbach, Austria E-Mail: sales@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...
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