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Summary of Contents for Fronius AccuPocket 150/400 TIG
- Page 1 Operating Instructions AccuPocket 150/400 TIG ActiveCharger 1000 Operating instructions 42,0426,0200,EN 034-16082022...
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Page 3: Table Of Contents
Contents Safety rules General Explanation of safety notices Environmental conditions 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 Danger from toxic gases and vapours Danger from flying sparks Dangers from welding current Dangers from the battery... - Page 4 General 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 MMA welding SoftStart / HotStart function Arc-force dynamic...
- Page 5 Charger General Warning notices on the device Warning notices inside the device Intended use Before commissioning Mains connection Generator-powered operation Setup regulations Space requirements Control elements and connections Safety Connections and components Control panel Start-up Safety Commissioning Operating modes Options Fitting the wall bracket Troubleshooting Safety...
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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
Checks must be carried out at regular intervals to ensure that operators are working in a safety-conscious manner. 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 pre- vention to read these operating instructions, especially the "Safety rules"... -
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 us- ing cardiac pacemakers Risk of electrocution from mains current and welding current Greater noise pollution... -
Page 13: Danger From Flying Sparks
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. Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of at least 20 m³... -
Page 14: 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 15: Meandering Welding Currents
Devices with mechanically undamaged rechargeable batteries may be returned to the relevant Fronius Service Partner for repair or battery replacement. As soon as it becomes evident that the rechargeable battery has been mechanic- ally damaged (e.g. -
Page 16: Emf Measures
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). If this is the case, then the operator is obliged to take appropriate action to recti- fy the situation. -
Page 17: Danger From Escaping Shielding Gas
Keep the shielding gas cylinders well away from any welding or other electrical circuits. Never hang a welding torch on a shielding gas cylinder. Never touch a shielding gas cylinder with an electrode. Risk of explosion - never attempt to weld a pressurised shielding gas cylinder. Only use shielding gas cylinders suitable for the application in hand, along with the correct and appropriate accessories (regulator, hoses and fittings). -
Page 18: Safety Measures In Normal Operation
Odourless and colourless shielding gas may escape unnoticed if an adapter is used for the shielding gas connection. Prior to assembly, seal the device-side thread of the adapter for the shielding gas connection using suitable Teflon tape. Safety measures Only operate the device if all safety devices are fully functional. If the safety in normal opera- devices are not fully functional, there is a risk of tion... -
Page 19: 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 following address: http://www.fronius.com Devices marked with the CSA test mark satisfy the requirements of the relevant standards for Canada and the USA. -
Page 20: Charger
Charger General The device has been manufactured in line with the state of the art and according to recognized safety standards. If used incorrectly or misused, however, it can cause: Serious or fatal injury to the operator or third parties Damage to the device and other material assets belonging to the operating company Inefficient operation of the device... -
Page 21: 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 mat- ter with the power supply company. -
Page 22: Emc Measures
After installation, an accessible mains plug is required. 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 23: Markings On The Device
Markings on the Devices with the CE marking satisfy the essential requirements of the applicable device guidelines. Devices displaying the EAC mark of conformity satisfy the requirements of the relevant standards in Russia, Belarus, Kazakhstan, Armenia and Kyrgyzstan. General and KEEP THESE INSTRUCTIONS SAFE- This guide contains important safety electrical risks and Operating Instructions for these charger types (for model, see first page... -
Page 25: Power Source
Power source... -
Page 27: General
General Device concept The power source has the following properties: Operation without mains electri- city 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... -
Page 29: Using Rechargeable Devices
▶ The power source may only be opened by a Fronius service technician. ▶ If you need a replacement battery, hand the power source over to a Fronius Service Partner. Storage and When storing or transporting the power source, observe the environmental con-... - Page 30 However, the user must observe the following key points in order to guarantee maximum battery life: 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 Optimal environmental conditions for operation: Temperature: +15 °C to +25 °C (+59 °F to +77 °F) Humidity: 50 %...
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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 Ensure the reliability of the power source Deep discharge The power source has a deep discharge protector to warn the user if the state of protector charge of the battery is too low. -
Page 32: Temperature Monitoring
Temperature Temperature monitoring prevents the battery from being charged or discharged monitoring if the temperature of the battery is outside the permitted temperature range. The battery charger has an internal temperature management function From 30 °C: Protection against overheating of the charger by automatic re- duction of the power (derating) From 45 °C: Only standard charging possible to increase battery life From 70 °C: Power source switched off... -
Page 33: Before Commissioning
The device can be set up and operated outdoors in accordance with IP23 degree of protection. Avoid direct wetting (e.g. from rain). Power connec- The device is designed to be connected to the mains using the Fronius Act- tion iveCharger 1000 only (= hybrid mode, see Operating modes on page 77). -
Page 34: Before Starting For The First Time
NOTE! No warranty claims will be entertained if the device is operated with other char- gers. 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... -
Page 35: Control Elements And Connections
Control elements and connections Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel. - Page 36 (+) current socket for electrode holder or grounding cable (-) current socket for electrode holder or grounding cable TIG welding (+) current socket for grounding cable (-) current socket for welding torch TMC connection for control connection on the Fronius welding torch...
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Page 37: 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 / pulse welding Unit indicator shows the unit of the value that is currently being changed using the adjusting dial (8): Percent Voltage (volts) - Page 38 Welding process button for selecting the welding process 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 possible on TIG devices during the TIG welding process) (10)
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Page 39: Mma Welding
MMA welding Preparatory Press the On/Off button for at least two seconds to turn off the power work 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... - Page 40 Setting the starting current: Press the setting value button until the 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 to 180 A. Examples: (set welding current = 100 A) 100%...
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Page 41: Arc-Force Dynamic
Arc-force dy- To obtain optimum welding results, it will sometimes be necessary to adjust the namic arc-force dynamic. Setting range: 0 - 100 (corresponds to 0 - 200 A current increase) Operating principle: At the moment of droplet transfer or in the event of a short circuit, the amper- age is briefly increased in order to obtain a stable arc. -
Page 42: Tig Modes
TIG modes Symbols and Pull back and hold the torch trigger their explana- tions Release the torch trigger forwards Push forward and hold the torch trigger Release the torch trigger backwards Adjustable parameters: GPo: Gas post-flow time I-S: Starting-current phase - the temperature is raised gently at low welding current, so that the filler metal can be positioned correctly I-E: Final current phase - to prevent crater cracks or cavitations I-1: Main current phase (welding-current phase) - uniform thermal input into... -
Page 43: 4-Step Mode
Release torch trigger => end of welding 4-step mode See the section on page for details on how to activate 4-step mode. down 4-step mode with intermediate lowering I-2 Intermediate lowering means that the welder uses the torch trigger during the main current phase to lower the welding current to the specified reduced current I-2. -
Page 44: Tig Welding
TIG welding General NOTE! Do not use pure tungsten electrodes (colour-coded green) if the TIG welding process has been selected. Connecting the WARNING! gas cylinder Danger from falling gas cylinders. This can result in severe personal injury and damage to property. ▶... -
Page 45: Setting The Gas Pressure
Use the other end of the grounding cable to establish a connection to the workpiece WARNING! Danger from electric shocks. This can result in serious injury and damage to property. ▶ As soon as the power source is switched on, the electrode in the welding torch is live. -
Page 46: Tig Comfort Stop
Carry out welding TIG Comfort For more information on activating and setting the TIG Comfort Stop function Stop Parameters for TIG welding from page 52. 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 47 Max. A 70 A down Welding current and gas flow curve with TIG Comfort Stop function activated 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 can be changed in the Setup menu via the "GPo" value, see Parameters for TIG welding on page 52.
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Page 48: Tig Pulsing
TIG pulsing TIG pulsing is TIG 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 49: Tacking Function
Tacking function Activating and setting the tacking function is described in the Tacking function (tACking) section on page 53. The tacking function is only available for the TIG DC welding process. When a time period is specified for the tAC (tacking) setup parameter, the tacking function is assigned to all operating modes The basic operating sequence of each of these modes remains unchanged During the specified period, there is a pulsed welding current that makes the... -
Page 50: The Setup Menu
The Setup menu Accessing the Use the welding process button to select the process for which the Setup Setup menu parameters are to be changed: MMA welding MMA welding with Cel electrode TIG welding 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... - Page 51 Starting current duration 0,1 - 1,5 seconds for the SoftStart / HotStart function Factory setting: 0.5 seconds Anti-Stick On / OFF When the anti-stick function is active, the arc is extinguished after 1.5 seconds in the event of a short circuit (sticking of the electrode) Factory setting: ON (activated) Break voltage (U cut off) 25 - 80 Volts...
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Page 52: Parameters For Tig Welding
Parameters for TIG welding Operating mode (trigger mode) OFF / 2t / 4t Operation using welding torch without a torch trigger 2-step mode 4-step mode Factory setting: 2t Starting current (I-Start) 1 - 200 percent This parameter is only available in 4-step mode (tri = 4t). Factory setting: 50 % Reduced current 1 - 200 percent... - Page 53 Break voltage (U cut off) 12 - 35 V Used to specify at which arc length the welding process is completed. The weld- ing voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here. This parameter is only available when the tri and CSS parameters are set to OFF.
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Page 54: 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 great- er than the minimum human body res- istance (greater than or equal to 200 Ohm): VRD is active... -
Page 55: Care And Maintenance
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 Partner. General Under normal operating conditions, the device requires only a minimum of care and maintenance. -
Page 56: Every 2 Months
Every 2 months Clean the air filter (if fitted):... -
Page 57: Disposal
Disposal General Dispose of in accordance with the applicable national and local regulations. Always dispose of the device separately from the installed battery. The following section explains how to remove the battery. Safety WARNING! Danger due to incorrect operation and incorrectly performed work. This can result in serious injury and damage to property. -
Page 58: Removing The Rechargeable Battery Pack
Removing the re- NOTE! chargeable bat- The following steps on removing the rechargeable battery pack must only be tery pack used when disposing of the device! ▶ If the rechargeable battery pack needs to be repaired or replaced, contact After-Sales Service. NOTE! Before removing the rechargeable battery pack, the power source must be dis- connected from the battery charger! - Page 59 Remove 2 TX25 screws, remove device feet, fold Press front and rear outwards, remove carrying rear to one side handle Press front and rear outwards, remove device casing CAUTION! Fire hazard due to short circuit of the battery! If the battery is short-circuited, sparks may be generated and the battery may catch fire.
- Page 60 Remove TX25 screw and terminate (-) power Disconnect 16-pin connector X1 from the bat- cable of the rechargeable battery back; tery pack, remove 6 TX 20 screws, remove the IMPORTANT! Insulate the terminated cable lug rechargeable battery pack well! Dispose of the device and rechargeable battery pack separately according to the local guidelines...
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Page 61: Troubleshooting
▶ 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 Partner. Indicated errors Overtemperature "hot" appears on the display, the temperature indicator lights up... -
Page 62: Service Messages
Deep discharge protector "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! Danger due to prolonged storage of the battery in a discharged state. This can damage the battery. -
Page 63: No Function
Cause: Communication error between battery and ACCUPLT / ACCUPLT- TIG PC board Remedy: Contact after-sales service Cause: Wrong firmware (software) has been loaded Remedy: Contact after-sales service E19 / E22 / E30 / E53 / E83 Cause: Battery fault Remedy: Contact After-Sales Service Cause: A voltage of >... -
Page 64: Faulty Operation
No welding current Power source is switched on, indicator for the selected welding process is lit Cause: Welding power-lead connections have been disconnected Remedy: Establish proper welding power-lead connections Cause: Poor or no earth Remedy: Establish a connection to the workpiece Cause: There is a break in the power cable in the welding torch or electrode holder... - Page 65 In some cases, arc breaks during welding Cause: Electrode (e.g. grooved electrode) voltage too high Remedy: If possible, use alternative electrode or a power source with more welding power Cause: Comfort Stop Sensitivity (CSS) setting is too sensitive Remedy: Increase or deactivate the CSS value in the Setup menu Cause: Break voltage (Uco) set too low Remedy:...
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Page 66: Technical Data
Technical data Environmental Transport, storage or operation of the device outside the stipulated range will be conditions deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Ambient air temperature range: During operation: -10 °C to + 40 °C (14 °F to 104 °F) During transport: -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 67: Technical Data
60 % 6 Min. 4 Min. 150 A 0 Min. 6 Min. 10 Min. If the device is to be continuously operated without stopping: Look in the technical data for a ED value of 100% for the current ambient temperature. Reduce the output or amperage in line with this value so that the device can remain in use without observing a cooling phase. - Page 68 Protection class IP 23 Type of cooling Dimensions L x W x H 435 x 160 x 310 mm 17.1 x 6.3 x 12.2 in. Weight 11.4 kg (25.1 lb) Max. shielding gas pressure 5 bar (72 psi) D.C. = Duty cycle...
- Page 69 Charger...
- Page 71 General Warning notices A number of safety symbols can be seen on the charger's rating plate. The safety on the device symbols 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 72 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 73 Before commissioning Mains connec- The rating plate, which is located on the housing, contains information about the tion permitted mains voltage. The device is designed for this mains voltage only. For details on the required fuse protection for the mains lead, see theTechnical data section on page 80.
- Page 74 Space require- If the charger is installed in a switch cabinet (or a similar sealed area), then ments forced-air ventilation 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 75 Control elements and connections Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
- Page 76 Start-up Safety WARNING! Danger from incorrect operation and work that is not carried out properly. This can result in serious personal injury and damage to property. ▶ All the work and functions described in this document must only be carried out by technically trained and qualified personnel.
- Page 77 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 78 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 in- staller is responsible for selecting the correct wall plugs and screws.
- Page 79 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 indicators flashing or lighting up: QUICK QUICK Error indicator CHARGE CHARGE Mains indicator Error flashing, mains lit Cause: Battery fault...
- Page 80 Technical data Environmental Transport, storage or operation of the device outside the stipulated range will be conditions deemed improper. The manufacturer shall not be held liable for any damage arising from such usage. Ambient air temperature range: During operation: -10 °C to + 40 °C (14 °F to 104 °F) During transport: -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)
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Page 81: Technical Data 230V
Technical data Mains voltage ~ 230 V AC, ±15% 230V Grid frequency 50/60 Hz Mains current max. 9.5 A eff. Mains fuse protection max. 16 A Efficiency max. 95 % Effective power max. 1100 W Apparent power max. 2370 VA Power input (stand-by) max. -
Page 82: Technical Data 120V
Technical data Mains voltage ~ 120 V AC, ±15% 120V Grid frequency 50/60 Hz Mains current max. 15 A eff. Mains fuse protection max. 20 A Efficiency max. 94 % Effective power max. 1100 W Apparent power max. 1900 VA Power input (stand-by) max. -
Page 83: Technical Data 100V
Technical data Mains voltage ~ 100 - 110 V AC, +10% / 100V -15% Grid frequency 50/60 Hz Mains current max. 15.7 A eff. Mains fuse protection max. 16 A Efficiency max. 92 % Effective power max. 940 W Apparent power max. - Page 88 SPAREPARTS ONLINE Fronius International GmbH Froniusstraße 1 4643 Pettenbach Austria contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the adresses of all Fronius Sales & Service Partners and locations.
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