Fronius TransPocket 150 Operating Instructions Manual
Rod electrode power source
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- Service manual & spare parts list (120 pages) ,
- Operating instructions manual (56 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 020-26082020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
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Page 3: Table Of Contents
Before commissioning Safety 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 Preparatory work MMA welding MMA welding SoftStart / HotStart function... - Page 4 Welding parameters in the level 2 Setup menu Care, maintenance and disposal Safety General Maintenance 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 5: 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 6: Environmental Conditions
The device is intended solely for the welding processes specified on the rating plate. Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Proper use includes: carefully reading and following all the instructions given in the operating instructions studying and obeying all safety and danger notices carefully performing all stipulated inspection and maintenance work. -
Page 7: Residual Current Protective Device
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 supply company. -
Page 8: Danger From Toxic Gases And Vapours
It is not possible to provide a workplace-related emission value during welding (or cut- ting) as this is influenced by both the process and the environment. All manner of differ- ent welding parameters come into play, including the welding process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc. -
Page 9: Risks From Mains Current And Welding Current
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. Do not carry out welding on containers that are being or have been used to store gases, propellants, mineral oils or similar products. -
Page 10: Meandering Welding Currents
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 ing currents the following consequences: Fire hazard Overheating of parts connected to the workpiece Irreparable damage to ground conductors... -
Page 11: 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 12: Requirement For The Shielding Gas
Observe the information on the coolant safety data sheet when handling coolant. The coolant safety data sheet may be obtained from your service centre or downloaded from the manufacturer's website. Use only suitable load-carrying equipment supplied by the manufacturer when transport- ing devices by crane. -
Page 13: Safety Measures At The Installation Location And During Transport
Close the shielding gas cylinder valve if no welding is taking place. If the shielding gas cylinder is not connected, leave the valve cap in place on the cylin- der. The manufacturer's instructions must be observed as well as applicable national and international regulations for shielding gas cylinders and accessories. -
Page 14: Commissioning, Maintenance And Repair
Only the manufacturer's original coolant is suitable for use with our devices due to its properties (electrical conductibility, anti-freeze agent, material compatibility, flammability, etc.). Only use suitable original coolant from the manufacturer. Do not mix the manufacturer's original coolant with other coolants. Only connect the manufacturer's system components to the cooling circuit. -
Page 15: Safety Symbols
(e.g. relevant product standards of the EN 60 974 series). 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 follow- ing address: http://www.fronius.com... -
Page 16: General
General Device concept The power source has the following properties: 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 17: 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 18: Application Areas
Application areas MMA welding TIG welding, welding torch with gas cut-off valve... -
Page 19: Before Commissioning
Proper use The power source is intended exclusively for MMA welding and TIG welding in conjunc- tion with system components from Fronius. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. - Page 20 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 21: Controls, Connections And Mechanical Components
Controls, connections and mechanical components 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 22: Transpocket 150 Controls, Connections And Mechanical Components
Control panel (-) 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 23: Transpocket 180 Controls, Connections And Mechanical Components
TransPocket 180 controls, connec- tions and mech- anical compon- ents 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 24: 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 25: 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 electrode holder is live. Make sure the electrode does not touch any persons or electrically conductive or earthed parts (e.g. -
Page 26: Mma Welding
Starting current = 100 A Function deactivated 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... -
Page 27: Arc-Force Dynamic
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... -
Page 28: Pulse Welding
Pulse welding Pulse welding is welding with a pulsing welding current. It is used for out-of-position welding of steel pipes or when welding thin sheets. In these applications the welding current set at the start of welding is not always ideal for the whole welding process: if the amperage is too low, the base material will not melt sufficiently if overheating occurs, the liquid weld pool may drip. - Page 29 Turn the adjusting dial until the desired frequency value (Hz) is reached Power source is ready for welding...
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Page 30: 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 31 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.
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Page 32: 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 Set the desired gas flow rate on with gas cut-off the pressure regulator valve Close the gas cut-off valve Welding torch with gas cut-off valve TIG welding Select TIG welding with the welding process button the TIG welding indicator lights up... - Page 33 Operating principle and use of the 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 The TIG Comfort Stop function is activated 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...
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Page 34: Pulse Welding
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. Pulse welding Pulse welding is welding with a pulsing welding current. It is used for out-of-position welding of steel pipes or when welding thin sheets. In these applications the welding current set at the start of welding is not always ideal for the whole welding process: if the amperage is too low, the base material will not melt sufficiently... - Page 35 1/F-P down Pulse welding - welding current curve Adjustable parameters: I-S = Starting current F-P = Pulse frequency (1/F-P = time interval between two pulses) I-E = Final current I-P = Pulse current Fixed parameters: UpSlope dcY = Duty cycle DownSlope I-G = Base current...
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Page 36: 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 37: Parameters For Tig Welding
For details, see section "Level 2 Setup menu" Parameters for Parameter Description Range Unit TIG welding Comfort Stop Sensitivity (Comfort Stop Volts Sensitivity) 0.6 - 3.5 Factory setting on TransPocket 150: 1.5 volts Factory setting on TransPocket 180: 1.5 volts For details, see section „TIG Comfort Stop“... - Page 38 Parameter Description Range Unit Break voltage (U cut off) 10 - 45 Volts Used to specify at which arc length the welding process is 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: 35 V (for 2-step and 4-step mode and operation with a foot-operated...
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Page 39: Setup Menu - Level 2
This prevents the circuit breaker from tripping 120 V: immediately 15 / 16 / 20 / (TP 180 only) TransPocket 150 - Ratio between set fuse and welding current: Mains voltage Welding cur- TIG welding Duty cycle fuse rent electrode... - Page 40 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 41: Care, Maintenance And Disposal
Care, maintenance and disposal 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 42: Disposal
Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 43: Troubleshooting
Troubleshooting 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 44 Make a note of the error numbers shown in the display, and of the serial number and configuration of the power source, and contact our after-sales service team with a detailed description of the error. E01 - E03 / E11 / E15 / E21 / E33 - E35 / E37 - E40 / E42 - E44 / E46 - E52 Cause: Fault in power module Remedy:...
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Page 45: No Function
E36, E41, E45 Cause: Mains voltage outside tolerance or maximum load of grid is too low Remedy: Ensure that the power source is being operated on the correct mains voltage; ensure that the correct fuse is set; E65 - E75 Cause: Communication error with welding torch/remote control Remedy:... -
Page 46: 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 47: 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 the term "duty be operated at its rated output without overheating. cycle" 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 48: Transpocket 180
Max. permissible mains impedance Z 32 mOhm Recommended earth-leakage circuit breaker Type B Welding current range (I 10 - 150 A 10 - 150 A Welding current for 10 min/40 °C (104 °F) 100% MMA welding 150 A 110 A Welding current for 10 min/40 °C (104 °F) 100%... -
Page 49: Transpocket 180 Mv
Recommended earth-leakage circuit breaker Type B Welding current range (I 10 -180 A 10 - 220 A Welding current for 10 min/40 °C (104 °F) 100% MMA welding 180 A 150 A 120 A Welding current for 10 min/40 °C (104 °F) 100% TIG welding 220 A... - Page 50 Mains voltage (U 1 x 120 V Max. effective primary current (I 15 A 1eff Max. primary current (I 19 A 1max Max. apparent power (S 2.28 kVA 1max Mains fuse protection 15 A slow-blow Mains voltage tolerance -20%/+15% Mains frequency 50 / 60 Hz Cos phi 0.99...
- Page 51 Welding current for 10 min/40 °C (104 °F) 100% MMA welding 85 A 70 A 65 A = 120 V, fuse = 15 A) Welding current for 10 min/40 °C (104 °F) 100% TIG welding 140 A 110 A 100 A = 120 V, fuse = 15 A) Output voltage range according to standard characteristic 20.4 - 27.2 V...
- Page 52 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@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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