Fronius TransPocket 2500 Comfort Operating Instructions Manual
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Fronius TransPocket 2500 Comfort Operating Instructions Manual

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Perfect Welding
/ Perfect Charging /
TransPocket 2500 Comfort
TransPocket 3500 Comfort
42,0426,0065,EN 013-13052020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Solar Energy
Operating Instructions
Rod electrode power source
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  • Page 1 Perfect Welding / Perfect Charging / / Solar Energy Operating Instructions TransPocket 2500 Comfort TransPocket 3500 Comfort Rod electrode power source 42,0426,0065,EN 013-13052020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
  • 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 ..............................Explanation of safety notices ........................ General ..............................Proper use ............................Environmental conditions........................Obligations of the operator........................Obligations of personnel ........................Mains connection ..........................Residual current protective device......................Protecting yourself and others ......................Noise emission values .......................... Danger from toxic gases and vapours ....................
  • Page 6 Welding parameters..........................Requirement ............................Preparations............................Setting the shielding gas flow rate for a gas-valve torch............... Setting the shielding gas flow rate for the TTG 2200 TCS torch............TIG welding............................Adjusting welding current, igniting the arc .................... Remote control mode..........................TIG Comfort Stop function ........................Welding job ..............................
  • Page 7 Disposal ..............................Technical data............................Safety..............................Generator-powered operation....................... TP 2500 Comfort........................... TP 2500 Comfort MVm ......................... TP 3500 Comfort........................... TP 3500 Comfort MVm ........................

  • Page 9: 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 10: 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 11: 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 sup- ply company.

  • Page 12: Danger From Toxic Gases And Vapours

    It is not possible to provide a workplace-related emission value during welding (or cutting) as this is influenced by both the process and the environment. All manner of different weld- ing 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 13: 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 14: Meandering Welding Currents

    Meandering weld- If the following instructions are ignored, meandering welding currents can develop with the ing currents following consequences: Fire hazard Overheating of parts connected to the workpiece Irreparable damage to ground conductors Damage to device and other electrical equipment Ensure that the workpiece is held securely by the workpiece clamp.

  • Page 15: 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 16: Requirement For The Shielding Gas

    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 17: 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 18: 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 19: 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 20: General

    TransPocket 2500 Comfort Device concept The TP 2500 / 3500 Comfort power sources have connection sockets with bayonet fixing, a powder-coated sheet steel housing with stainless steel runners and the controls are pro- tected by plastic frames.

  • Page 21: 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 22: Connections

    Left button Navigation in the menu Process button Selects the welding process Rod electrode (MMA) welding MMA welding with CEL electrode Job welding TIG welding The selected welding process remains in memory even after the mains plug is dis- connected. Connections Connections on the front Connections on the back...

  • Page 23: 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 24 NOTE! An inadequately dimensioned electrical installation can cause serious damage. The mains lead and its fuse must be dimensioned to suit the local power supply. The tech- nical data shown on the rating plate applies.

  • Page 25: Changing Mains Voltage (Only Mvm Versions)

    Changing mains voltage (only MVm versions) General remarks MVm machines (MultiVoltage manual) are suitable for operation with a mains voltage of 380 - 460V and a mains voltage of 200 - 240V. NOTE! Machines are supplied with the 380 - 460V setting as standard. If the mains voltage range needs to be reset, this must be done manually.

  • Page 26: Single-Phase Operation

    380V - 460V 200V - 240V Single-phase op- MVm machines can be used in single phase operation (e.g. 1x230V) if required. However, eration this reduces the welding current range. Please see the "Technical Data" section for the rel- evant performance data. Fit the mains cable and mains plug in accordance with the appli- cable national standards.

  • Page 27: Mma Welding

    MMA welding Safety WARNING! Danger from incorrect operation. This can result in serious injury and damage to property. ► Do not use the functions described here until you have fully read and understood the following documents: ► These Operating Instructions ►...

  • Page 28: Welding Parameters

    Welding parame- ters Starting current: Starting current < Main current Starting current: Starting current = Main current (soft start) Starting current: Starting current > Main current (hot start) Unit % (of main current) Setting range 10 - 200 Factory setting Main current: Starting current <...

  • Page 29: Preparations

    (e.g. the housing etc.) Move the mains switch to the - I - position The Fronius logo appears on the display for roughly 1 second. Press the Process button to select one of the following processes:...
  • Page 30 NOTE! MMA welding with hot start is recommended for welding rutile electrodes. MMA welding with soft start is recommended for welding basic electrodes. The MMA welding process with CEL electrode should always be selected for welding cellulose electrodes. The graphic for the MMA welding parameters appears on the display, e.g.: Press the Right button to select the individual welding parameters Turn the dial to change the value of the welding parameter Turn the dial to change the value of the welding parameter:...

  • Page 31: Hotstart Function (Used With Rutile And Cel Processes)

    HotStart function Benefits: (used with rutile Improved ignition properties, even and Cel process- when using electrodes with poor igniti- I (A) on properties 117A Better fusion of the base material du- ring the start-up phase, meaning fewer cold-shut defects Largely prevents slag inclusions 1,5 s Example of HotStart function Mode of operation:...

  • Page 32: Remote Control Mode

    Remote control If there is a remote control unit connected to the remote control socket or if the TP09 wire- mode less remote control unit is used, the symbol „EXT“ appears on the display: All the possible welding parameter settings are made via the remote control unit.

  • Page 33: Tig Welding

    TIG welding Safety WARNING! Danger from incorrect operation. Operating the equipment incorrectly can cause serious injury and damage. ► Do not use the functions described here until you have read and completely under- stood these Operating Instructions. ► Do not use the functions described here until you have fully read and understood all of the Operating Instructions for the system components, in particular the safety rules.

  • Page 34: Requirement

    TP 3500: 10 - 350 Factory setting Requirement The full range of functions for TIG welding can only be guaranteed if the Fronius TTG 2200 TCS welding torch is used. Preparations Move the mains switch to the - O - position...

  • Page 35: Setting The Shielding Gas Flow Rate For A Gas-Valve Torch

    LIVE. Make sure that the tungsten electrode does not touch any persons or electrically conducting or earthed parts (e.g. housing etc.) Move the mains switch to the - I - position The Fronius logo appears on the display for roughly 1 second. Press and hold the Process button Press the Setup button The power source is now in the Service menu: Turn the dial to select ‘Sol.ValveTest’...
  • Page 36 Press the dial to set the parameter You can now change the parameter value. Turn the dial to set the ‘Sol.ValveTest’ parameter to ‘On’ Press the dial to accept the set parameter value The gas solenoid valve picks up Set the shielding gas flow rate on the pressure controller Press the Setup button A graphic of the welding parameters appears on the display, e.g.:...

  • Page 37: Tig Welding

    TIG welding Press the Process button to select the TIG welding process The graphic for the TIG welding parameters appears on the display: Press the Right button to select the individual welding parameters Turn the dial to change the value of the welding parameter Set any other parameters in the Setup menu: Press the Setup button The relevant menu is displayed, e.g.:...

  • Page 38: Remote Control Mode

    IMPORTANT! As long as the torch is touching the workpiece, the gas pre-flow takes place auto- matically. If the torch and workpiece remain in contact for more than 3 seconds, the welding current switches off automatically. Place the gas nozzle on the ignition location again. Raise the torch and tilt it into the normal position - the arc now ignites Carry out welding Placing the gas nozzle down Arc ignites when electrode is...
  • Page 39 Keep the welding torch at the same height The welding current continuously decreases until it reaches the minimum welding current (10 A) (downslope) The minimum welding current is held constant for 0.2 seconds Arc goes out Wait for the gas post-flow time to finish, and lift the torch off the workpiece Welding Raise torch Lower torch...
  • Page 40 0.2 s 0.4 s Gas pre-flow 4.8 s 10 s Gas post-flow TIG Comfort Stop: Welding current and gas flow...

  • Page 41: Welding Job

    (e.g. housing etc.) Move the mains switch to the - I - position The Fronius logo appears on the display for roughly 1 second. Press the Process button to select the job welding process: The display shows the last selected job, e.g.:...
  • Page 42 Use the Left and Right buttons to select the job You can change the job using the Job correction function in the Service menu, e.g.: NOTE! Before starting job welding, make sure that the power source is set up and installed to suit the job.

  • Page 43: Saving Settings As A Job

    Saving settings as a job General remarks You can save settings and welding parameters in 20 jobs within the individual welding pro- cesses. You save settings as a job in the Setup menu for the process. Storing settings Press the Process button to select the process to be saved as a job The graphic shows the welding parameters.
  • Page 44 Turn the dial to select the job number under which you want to save the set- tings NOTE! If you select an existing job, it will be overwritten without a prompt when you save. Press the dial The second screen for saving a job is displayed: Turn the dial to select the letters for the job name Press the dial to accept the letters To change a letter:...
  • Page 45 Press the dial The required letter is deleted: Turn the dial to select ‘OK’ Press the dial The settings are saved, and the graphic showing the welding parameters is displayed.

  • Page 46: The Setup Menu

    The Setup menu General remarks On the TP 2500 Comfort and TP 3500 Comfort power sources, there is a separate Setup menu for each welding process. Opening a Setup Press the Process button to select the process menu For the MMA welding, MMS welding with CEL electrode and TIG weld- ing processes, the graphic is displayed with the welding parameters.

  • Page 47: Exiting A Setup Menu

    Turn the dial to change the value of the parameter Press the dial to accept the set parameter value IMPORTANT! Set parameters remain in memory even if the mains plug is disconnected. Exiting a Setup Press the Setup button menu Turn the dial to select the arrow symbol Press the dial The graphic shows the welding parameters.

  • Page 48: Easy Mode

    Easy Mode General remarks Easy Mode is a simplified way to operate the power source. The following functions and controls are not available in Easy Mode: The job welding process Navigation with the Left and Right buttons The Setup button The dial press function Activating Easy Open the Service menu...

  • Page 49: Selecting The Welding Process In Easy Mode

    Press the Setup button The power source switches to Easy Mode and the last selected process is displayed: E.g.: Easy Mode for the Hot start process with MMA welding Selecting the In Easy Mode, it is generally the Process button that is used to select the welding process. welding process The following welding processes are available in Easy Mode: in Easy Mode...
  • Page 50 MMA welding MMA welding with CEL electrodes TIG welding TIG pulsed arc weld- Turn the dial to set the parameter Set the parameters by pressing and holding the Process button: The values of the Dynamic, TCS and Pulsing frequency parameters are shown as bar dis- plays in Easy Mode.

  • Page 51: Deactivating Easy Mode

    Deactivating Easy Press and hold the Process button Mode Press the Setup button The Service menu is displayed: Turn the dial to select ‘Easy Mode’ Press the dial You can now deactivate ‘Easy Mode’ Turn the dial to select ‘Off’...
  • Page 52 Press the dial to deactivate ‘Easy Mode’ Press the Setup button The power source switches to Comfort Mode and the graph with welding pa- rameters for the last selected process is displayed:...

  • Page 53: Mma Setup

    MMA setup MMA setup MMA setup pa- Starting duration rameters Duration of the starting current for a hot or soft start Unit Setting range 0,1 - 5,0 Factory setting To obtain optimum welding results, it will sometimes be necessary to adjust the hot or soft start function.

  • Page 54: Cel Electrode Setup (Cel-Elec.-Setup)

    CEL electrode setup (Cel-elec.-Setup) CEL setup Cel setup param- Starting duration eters Duration of the starting current for a hot start Unit Setting range 0,1 - 5,0 Factory setting To obtain optimum welding results, it will sometimes be necessary to adjust the Hot start function.
  • Page 55 CEL char. slope CEL characteristic slope Unit Setting range 0 - 5 Factory setting The CEL char. slope parameter sets the U (V) gradient for the falling welding current cha- racteristic. When welding cellulose electro- des, the characteristic slope is one of the most important criteria for the welding pro- Pre-set welding current...

  • Page 56: Job Setup

    Job setup Job setup The job setup is used to fine-tune and copy jobs. There are different job setups available to suit the process used in the saved jobs: Job setup for MMA and CEL jobs Job setup for TIG jobs Opening the job Press the Process button to select the job welding process:: setup for a saved...

  • Page 57: Copying A Job

    Copying a job Press the Process button to select the job welding process: The display shows the last selected job, e.g.: The LED on the process symbol for the process of the selected job lights up. Use the Left and Right buttons to select the job to be copied Press the Setup button The display shows the job setup for the selected job, e.g.: Turn the dial to select ‘Save job’:...
  • Page 58 Turn the dial to select the job number under which you want to save the job to be copied NOTE! If you select an existing job, it will be overwritten without a prompt when you save. Press the dial The second screen for saving a job is displayed: Turn the dial to select the letters for the job name Press the dial to accept the letters To change a letter:...

  • Page 59: Job Setup Parameters For Mma And Cel Jobs

    Press the dial The required letter is deleted: Turn the dial to select ‘OK’ Press the dial The display shows the copied job, e.g.: Job setup param- Main current eters for MMA Set target welding current and CEL jobs Unit Setting range 10 - 250 for TP 2500 10 - 350 for TP 3500...
  • Page 60 Starting current for hot or soft start Unit % (of main current) Setting range 10 - 200 Factory setting Startind duration Duration of the starting current for a hot or soft start Unit Setting range 0,1 - 5,0 Factory setting To obtain optimum welding results, it will sometimes be necessary to adjust the Hot start function.

  • Page 61: Job Setup Parameters For Tig Jobs

    The CEL char. slope parameter sets the U (V) gradient for the falling welding current cha- racteristic. When welding cellulose electro- des, the characteristic slope is one of the most important criteria for the welding pro- Pre-set welding current perties.If the cellulose electrode tends to (constant current) stick, adjust the CEL char.
  • Page 62 Base current Unit % (of main current) Setting range 10 - 100 Facory setting TIG-Comfort Stop The TIG-ComfortStop parameter determines how high the torch must be raised tempo- rarily to trigger the TIG-Comfort Stop function. If the welding process is frequently stopped unintentionally, increase the value of the TIG-Comfort Stop parameter.

  • Page 63: Tig Setup

    TIG setup TIG setup TIG setup param- Gas post-flow eters Gas post-flow timet. Unit Setting range 0 - 25 Factory setting Pulsing frequency For setting the frequency of the pulsed arc. The pulsed arc frequency is an important criterion for the TIG pulsed arc welding proper- ties.

  • Page 64: The Service Menu

    The Service menu General remarks The TP 2500 Comfort and TP 3500 Comfort power sources have a separate Service menu in which you can make the various basic settings. Opening the Ser- You always open the Service menu in the same way, regardless of which process is cur- vice menu rently selected.

  • Page 65: Exiting The Service Menu

    Turn the dial to change the value of the parameter Press the dial to accept the set parameter value IMPORTANT! Set parameters remain in memory even if the mains plug is disconnected. Exiting the Ser- Exiting the Service menu vice menu Turn the dial to select the arrow symbol Press the dial The graphic shows the welding parameters.

  • Page 66: Parameters In The Service Menu

    Parameters in the Language Service menu for setting the display language Unit Setting range D / GB / F / E Factory setting D = German GB = English F = French E = Spanish Anti-stick Unit Setting range On / Off Factory setting As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will tend to “stick”.
  • Page 67 Easy Mode Switches the simple display on or off Unit Setting range On / Off Factory setting The functions of and how to use the power source in Easy Mode are described in the ‘Easy Mode’ section Inverse Display Switches the inverse display on or off Unit Setting range On / Off...

  • Page 68: Setting The Language

    Setting the lan- Turn the dial to select ‘Language’ guage Press the dial to set the language You can now change the language: Turn the dial to change the language. Press the dial to accept the language The texts on the display appear in the selected language...

  • Page 69: Resetting The Power Source Factory Settings

    Resetting the Turn the dial to select ‘Factory’ power source fac- tory settings Press the dial Turn the dial to select ‘YES’ and reset the power source Press the dial The power source is reset to the factory settings and the Service menu is dis- played.

  • Page 70: Opening The Info Screen

    Opening the Info Turn the dial to select ‘Info’ screen Press the dial The Info screen is displayed: The Info screen contains the following data: Op. circt. hrs. (open-circuit hours) ArcBurningTime (total arc burning time) Version of PCB FPA25 and STTP2 Press the dial to exit the Info screen The Service menu is displayed...

  • Page 71: Voltage Reduction Device (Somente Variações Vrd)

    Voltage Reduction Device (somente variações VRD) General A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage. As far as possible, VRD prevents output voltages at the current sockets that may pose a danger to persons. Safety principle Welding circuit resistance is greater than the minimum human body resistance (grea-...
  • Page 72 VRD active VRD inactive VRD active (VRD symbol on the display) VRD inactive (VRD symbol crossed out on the dis- play) The open-circuit voltage is limited No voltage limitation (e.g.: when to 12 V. welding) or VRD is defective...

  • Page 73: Diagnóstico De Erro, Eliminação De Erro

    Diagnóstico de erro, eliminação de erro Safety WARNING! An electric shock can be fatal. Before opening the device ► Turn the mains switch to the "O" position ► Unplug the device from the mains ► Ensure the device cannot be switched back on ►...
  • Page 74 No welding current Device switched on, indicator for the selected welding process is lit, error indicator lit Cause: Duty cycle exceeded - device overloaded - fan running Remedy: Keep within duty cycle Cause: Thermostatic automatic circuit breaker has switched off the device Remedy: Wait until the power source comes back on automatically at the end of the cooling phase (do not switch off the device - the fan will cool it down)
  • Page 75 LED for set process is flashing Cause: Single-phase operation with a welding current greater than 140A Remedy: Select a welding current less than 140A and continue welding Cause: Phase failure Remedy: Check the mains lead Poor weld properties (severe spattering) Cause: Incorrect electrode polarity Remedy:...

  • Page 76: Service Codes

    Service codes Open circuit (Leerlauf) Cause: Output voltage is greater than 110 V Remedy: Switch machine off and on again; if error keeps re- curring, have machine serviced Mains undervoltage or overvoltage (OVUV) Cause: The mains voltage is outside the tolerance range Remedy: Check mains voltage, switch machine off and on again;...
  • Page 77 Asymmetrie (Asym. Init.) (on switching on) Cause: Internal error Remedy: Switch machine off and on again; if error keeps re- curring, have machine serviced Primary current (IP) Cause: Internal error Remedy: Switch machine off and on again; if error keeps re- curring, have machine serviced Current transformer polarity (I prim.

  • Page 78: Care, Maintenance And Disposal

    Care, maintenance and disposal General Under normal operating conditions, the power source requires only a minimum of care and maintenance. However, some important points must be noted to ensure that the welding system remains in a usable condition for many years. WARNING! An electric shock can be fatal.

  • Page 79: Technical Data

    Technical data Safety NOTE! An inadequately dimensioned electrical installation can cause serious damage. The mains lead and its fuse protection must be rated accordingly. The technical data shown on the rating plate applies. Generator-pow- The TP 2500 Comfort and TP 3500 Comfort power sources are totally generator-compat- ered operation ible, provided that the maximum apparent power delivered by the generator is at least 14 kVA for the TP 2500 Comfort and 22 kVA for the TP 3500 Comfort.

  • Page 80: Tp 2500 Comfort Mvm

    TP 2500 Comfort Mains voltage (U 200 V 230 V Max. effective primary current (I 16.2 A 15.9 A 1eff Max. primary current (I 27.4 A 26.8 A 1max Mains fuse protection 20 A slow-blow Mains voltage (U 380 V 400 V 460 V Max.

  • Page 81: Tp 3500 Comfort Mvm

    Welding current range (I Rod electrode 10 - 350 A 10 - 350 A Welding current at 10 min / 40 °C (104 °F) 40 % 60 % 100 % 350 A 280 A 230 A Output voltage range according to standard characteristic (U Rod electrode 20.4 - 34 V 10.4 - 24 V...
  • Page 82 Degree of protection IP 23 Type of cooling Overvoltage category Pollution level according to IEC60664 Safety symbols S, CE, CSA Dimensions l x w x h 500 x 190 x 380 mm 19.68 x 7.48 x 14.96 in. Weight 20,1 kg 44.3 lb.
  • Page 84 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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