Fronius TransPocket 2500 Operating Instructions Manual
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Summary of Contents for Fronius TransPocket 2500
- Page 1 Operating Instructions TransPocket 2500/3500 TransPocket 2500/3500 RC TransPocket 2500/3500 TIG Operating Instructions 42,0426,0041,EN 011-28082023...
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Page 3: 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 Danger from flying sparks Risks from mains current and welding current Meandering welding currents EMC Device Classifications... - Page 4 Average shielding gas consumption during TIG welding Technical data Safety Generator-powered operation TransPocket 2500, 2500 RC, 2500 TIG TransPocket 2500 MVm, 2500 TIG MVm TransPocket 3500, 3500 RC, 3500 TIG TransPocket 3500 MVm, 3500 TIG MVm Overview with critical raw materials, year of production of the device...
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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: Proper Use
Proper use The device is to be used exclusively for its intended purpose. 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 in- structions... -
Page 7: Mains Connection
Before leaving the workplace, ensure that people or property cannot come to any harm in your absence. Mains connec- Devices with a higher rating may affect the energy quality of the mains due to tion their current consumption. This may affect a number device types in terms of: Connection restrictions Criteria with regard to the maximum permissible mains impedance Criteria with regard to the minimum short-circuit power requirement... -
Page 8: Noise Emission Values
Keep all persons, especially children, out of the working area while any devices are in operation or welding is in progress. If, however, there are people in the vi- cinity: Make them aware of all the dangers (risk of dazzling by the arc, injury from flying sparks, harmful welding fumes, noise, possible risks from mains cur- rent and welding current, etc.) Provide suitable protective equipment... -
Page 9: Danger From Flying Sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi- ation area. Close the shielding gas cylinder valve or main gas supply if no welding is taking place. Danger from fly- Flying sparks may cause fires or explosions. ing sparks Never weld close to flammable materials. -
Page 10: Meandering Welding Currents
Protection class I devices require a mains supply with ground conductor and a connector system with ground conductor contact for proper operation. Operation of the device on a mains supply without ground conductor and on a socket without ground conductor contact is only permitted if all national regula- tions for protective separation are observed. -
Page 11: Emc Measures
EMC device classification as per the rating plate or technical data. 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 12: Requirement For The Shielding Gas
During operation Ensure that all covers are closed and all side panels are fitted properly. Keep all covers and side panels closed. The welding wire emerging from the welding torch poses a high risk of injury (piercing of the hand, injuries to the face and eyes, etc.). Therefore, always keep the welding torch away from the body (devices with wirefeeder) and wear suitable protective goggles. -
Page 13: Danger From Shielding Gas Cylinders
Use filters if necessary. Danger from Shielding gas cylinders contain gas under pressure and can explode if damaged. shielding gas cyl- As the shielding gas cylinders are part of the welding equipment, they must be inders handled with the greatest of care. Protect shielding gas cylinders containing compressed gas from excessive heat, mechanical impact, slag, naked flames, sparks and arcs. -
Page 14: Safety Measures In Normal Operation
Before transporting the device, allow coolant to drain completely and detach the following components: Wirefeeder Wirespool Shielding gas cylinder After transporting the device, the device must be visually inspected for damage before commissioning. Any damage must be repaired by trained service techni- cians before commissioning the device. -
Page 15: Safety Inspection
(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 16: Data Protection
Data protection The user is responsible for the safekeeping of any changes made to the factory settings. The manufacturer accepts no liability for any deleted personal settings. Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of printing. We reserve the right to make changes. -
Page 17: General
General Principle The TP 2500 and TP 3500 power sources are a further highlight of the new generation of inverter power sources. Using powerful electronics, a unique high-performance, lightweight welding system has been created. The power source works on resonance inverter principles and therefore offers a number of advantages: Intelligent control for stable arc... -
Page 18: 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 19: Operating Elements
Rod electrode or grounding cable for manual metal arc (MMA) weld- ing, depending on the type of electrode being used Grounding cable for TIG welding (-) current socket with bayonet latch For connecting the: Rod electrode or grounding cable for manual metal arc (MMA) weld- ing, depending on the type of electrode being used Welding torch in TIG welding (current connection) Remote control connection socket... - Page 20 Lights up red when the Voltage Reduction Device (VRD) is active and the open circuit voltage is greater than 35 V Does not light up if an open circuit voltage outside the VRD range is...
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Page 21: Before Commissioning
Proper use The power source is intended exclusively for MMA welding and TIG welding in conjunction with system components from Fronius. Utilisation for any other purpose, or in any other manner, shall be deemed to be not in accordance with the intended purpose. - Page 22 section. If there is no mains cable or mains plug on your device, fit one that con- forms to national standards. 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 technical data shown on the rating plate applies.
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Page 23: 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 24: Single-Phase Operation
380V - 460V 200V - 240V Single-phase op- MVm machines can be used in single phase operation (e.g. 1x230V) if required. eration However, this reduces the welding current range. Please see the "Technical Data" section for the relevant performance data. Fit the mains cable and mains plug in accordance with the applicable national standards. -
Page 25: 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 under- stood the following documents: ▶ These Operating Instructions ▶... -
Page 26: Hotstart Function (Used With Rutile And Cel Processes)
HotStart func- Benefits: tion (used with Improved ignition properties, even I (A) rutile and Cel when using electrodes with poor 117A processes) ignition properties Better fusion of the base material during the start-up phase, meaning fewer cold-shut defects Largely prevents slag inclusions 1,5 s Example of HotStart function Mode of operation:... -
Page 27: 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 understood these Operating Instructions. ▶ Do not use the functions described here until you have fully read and under- stood all of the Operating Instructions for the system components, in partic- ular the safety rules. -
Page 28: Setting The Shielding Gas Flow Rate
Setting the CAUTION! shielding gas flow rate Risk of injury and damage from electric shock. As soon as the mains switch is in the "I" position, the tungsten electrode of the welding torch is LIVE. Make sure that the tungsten electrode does not touch any persons or electrically conductive or earthed parts (e.g. -
Page 29: Tig Comfort Stop Function
Raise the torch and tilt it into the normal position - the arc now ignites Carry out welding TIG Comfort The "TIG Comfort Stop" function (TCS) is only available with the TP 2500/3500 Stop function TIG power source. The TIG-Comfort-Stop function is deactivated as standard. Activating and setting the TIG Comfort Stop function is described in the "The Setup menu"... - Page 30 The downslope depends on the welding current selected and cannot be adjusted. The duration of the downslope between the following values must be extrapol- ated. Downslope with low welding current (10 A): 0.4 seconds Downslope with maximum welding current (250 A): 10 seconds Gas post-flow time: The gas post-flow time depends on the welding current selected and cannot be adjusted.
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Page 31: The Setup Menu
The Setup menu Setting options Welding process Settable parameters Factory setting Arc-force dynamic Level 2 Arc-force dynamic Level 2 Cel characteristic and arc-force dynamic Level 2 TIG Comfort Stop Level 0 Pulse frequency (TP 2500/3500 TIG Level 1 only) Functional prin- The parameters can be set at 4 levels (TP 2500/3500) or 5 levels (TP 2500/3500 ciple TIG). -
Page 32: Arc-Force Dynamic Parameter
Arc-force dy- The purpose of the arc-force dynamic namic parameter parameter is to influence the short-cir- I (A) or U (V) cuit amperage at the moment of droplet transfer. Level: 5 4 3 2 1 5 4 3 2 1 If the rod electrode has a tendency to stick, adjust the arc-force dynamic parameter to a higher level. -
Page 33: Pulsing Frequency Parameter
Level Increase in arc size before function is triggered Small increase required Very small increase required TIG Comfort Stop deactivated (factory setting) Pulsing fre- The frequency parameter is only available on the TP 2500/3500 TIG power quency paramet- source and is used to set the frequency of the pulsed arc. The pulsed arc frequency is one of the most important criterion for the TIG pulsed arc welding properties. -
Page 34: Voltage Reduction Device (Vrd Versions Only)
Voltage Reduction Device (VRD versions only) 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 resist-... -
Page 35: Troubleshooting
Troubleshooting Safety WARNING! Danger from electrical current. This can result in serious personal injury and damage to property. ▶ Before starting work, switch off all devices and components involved, and disconnect them from the grid. ▶ Secure all devices and components involved so they cannot be switched back ▶... - Page 36 No welding current Device switched on, indicator for the selected welding process is lit, error indicat- or 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...
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Page 37: Status Indicators
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 38 Ground current (earth current watchdog option only) Indicators shown on the right light up, VRD indicator flashes red Cause: Current flowing via device earth Remedy: Check ground earth connection to workpiece, switch machine off and on again; if error keeps recurring, have machine serviced Short circuit after switching on the machine Indicators shown on the right light up, VRD indicator flashes red...
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Page 39: 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 40: Average Consumption Values During Welding
Average consumption values during welding Average wire Average wire electrode consumption at a wire speed of 5 m/min electrode con- 1.0 mm wire 1.2 mm wire 1.6 mm wire sumption during electrode dia- electrode dia- electrode dia- MIG/MAG weld- meter meter meter Steel wire electrode... -
Page 41: 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- The power sources in the TP 2500/3500 series are totally generator-compatible, powered opera- provided that the maximum apparent power delivered by the generator is at least tion... -
Page 42: Transpocket 2500 Mvm, 2500 Tig Mvm
Weight 12.5 kg 27.5 lb. Max. shielding gas pressure 12.5 bar kg (TIG) 72.5 psi. Max. noise emission (LWA) 74 dB (A) Idle state power consumption at 400 V 23.4 W Power source efficiency at 250 A / 30 V TransPocket Mains voltage (U 200 V... -
Page 43: Transpocket 3500, 3500 Rc, 3500 Tig
Dimensions l x w x h 430 x 180 x 320 mm 16.9 x 7.1 x 12.6 in. Weight 12.5 kg 27.5 lb. Max. shielding gas pressure 12.5 bar kg (TIG) 72.5 psi. Max. noise emission (LWA) 74 dB (A) Idle state power consumption at 400 V 23.4 W Power source efficiency at 250 A / 30 V... -
Page 44: Transpocket 3500 Mvm, 3500 Tig Mvm
Max. shielding gas pressure 12.5 bar kg (TIG) 72.5 psi. Max. noise emission (LWA) 70 dB (A) Idle state power consumption at 400 V 25.5 W Power source efficiency at 350 A / 34 V TransPocket 230 V Mains voltage (U 200 V 3500 MVm, 3500 Max. -
Page 45: Overview With Critical Raw Materials, Year Of Production Of The Device
An overview of which critical raw materials are contained in this device can be terials, year of found at the following Internet address. production of www.fronius.com/en/about-fronius/sustainability. the device To calculate the year of production of the device: Each device is provided with a serial number...
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