Related Manuals for Fronius AccuPocket 150/400 TIG
Summary of Contents for Fronius AccuPocket 150/400 TIG
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions AccuPocket 150/400 TIG Spare parts list ActiveCharger 1000 Rod electrode power source 42,0426,0200,EN 030-18072018...
- 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.
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Page 5: Table Of Contents
Contents Safety rules General ..............................Explanation of safety symbols ......................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 6 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 ........................
- Page 7 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..............................Indicated errors ............................. No function............................Technical data............................Operating environments........................
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Page 9: Safety Rules
Safety rules... -
Page 11: General
General Explanation of DANGER! Indicates immediate and real danger. If it is not avoided, death or se- safety symbols rious injury will result. WARNING! Indicates a potentially dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! Indicates a situation where damage or injury could occur. -
Page 12: 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 13: 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 operat- ing company, inefficient operation of the device. -
Page 14: 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 cardiac pacemakers Risk of electrocution from mains current and welding current Greater noise pollution... -
Page 15: Danger From Toxic Gases And Vapours
Danger from toxic The fumes produced during welding contain harmful gases and vapours. gases and va- Welding fumes contain substances that may, under certain circumstances, pours cause birth defects or cancer. 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. -
Page 16: 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 17: Meandering Welding Currents
Devices with mechanically undamaged rechargeable batteries may be re- turned to the relevant Fronius Service Partner for repair or battery replace- ment. As soon as it becomes evident that the rechargeable battery has been me- chanically damaged (e.g. -
Page 18: 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 19: Danger From Escaping Shielding Gas
If the shielding gas cylinder is not connected, leave the valve cap in place on the cylinder. The manufacturer's instructions must be observed as well as applicable na- tional and international regulations for shielding gas cylinders and accesso- ries. Danger from es- Risk of suffocation from the uncontrolled escape of shielding gas caping shielding Shielding gas is colourless and odourless and, in the event of a leak, can dis-... -
Page 20: 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 rele- vant standards for Canada and the USA. -
Page 21: 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 operat- ing company, inefficient operation of the device. -
Page 22: Dangers From Mains Current And Charging Current
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. NOTE! Ensure that the mains connection is earthed properly Dangers from Anyone working with chargers exposes themselves to numerous dangers e.g.: mains current... -
Page 23: Maintenance And Repair
Maintenance and Under normal operating conditions, the device requires only a minimum of repair care and maintenance. However, it is vital to observe some important points to ensure it remains in a usable condition for many years. Before switching on, always check the mains plug and cable as well as charger leads and charging terminals for any signs of damage. - Page 24 Devices displaying this TÜV test mark and the mark on the rating plate satisfy the requirements of the relevant standards in Australia. Devices displaying this EAC mark of conformity satisfy the requirements of the relevant standards in Russia, Belarus, Kazakhstan, Armenia and Kyrgyzstan.
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Page 25: Power Source
Power source... -
Page 27: 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 28: Application Areas
Application areas MMA welding TIG welding... -
Page 29: Using Rechargeable Devices
WARNING! 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 Ser- vice Partner. Storage and... - Page 30 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% Surrounding air is free from dust and corrosive vapours or gases If the power source is left idle, charge it on a regular basis Fully charge the power source at least every 6 months.
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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 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 32: Temperature Monitoring
Temperature Temperature monitoring prevents the battery from being charged or discharged if the monitoring temperature 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. If the battery is charged, it can be heated until welding is possible. -
Page 33: 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 34: Before Starting For The First Time
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 The power source can be put into operation... -
Page 35: Control Elements And Connections
Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules NOTE! Due to software updates, you may find that your device has certain func- tions that are not described in these operating instructions or vice versa. -
Page 36: Connections And Mechanical Components
(+) 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... -
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 (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 38 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 39: 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 40: Arc-Force Dynamic
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% Starting current = 135 A HotStart 200% Starting current = 180 A HotStart (maximum current limit reached!) Features of SoftStart function: Reduced pore formation with certain... - Page 41 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 42: Tig Modes
TIG modes Symbols and their explanations Pull back and hold the Release the torch trigger Push forward and hold Release the torch trigger torch trigger forwards 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 the base... - Page 43 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. Place the tungsten electrode onto the workpiece and then pull the torch trigger back and hold =>...
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Page 44: Tig Welding
TIG welding General NOTE! Do not use pure tungsten electrodes (colour-coded green) if the TIG weld- ing process has been selected. Connecting the WARNING! There is a high risk of very serious injury and damage if a gas cylin- gas cylinder der falls over. -
Page 45: Setting The Gas Pressure
Setting the gas Welding torch with torch trigger (and pressure TIG Multi Connector plug): Press the torch trigger – Shielding gas flows Set the desired gas flow rate on the pressure regulator Release the torch trigger Welding torch with torch trigger (and TIG Multi Connector plug) TIG welding Select TIG welding with the welding process button... -
Page 46: Tig Comfort Stop
TIG Comfort Stop For more information on activating and setting the TIG Comfort Stop function, see Comfort Stop Sensitivity on 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 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 welding process Setup menu via the "GPo" value, Gas post-flow time (Gas Post flow) 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 weld- ing 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 52. 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 weld pool... -
Page 50: 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 –... -
Page 51: Parameters For Tig Welding
Parameter Description Range Unit 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. - Page 52 Parameter Description Range Unit Final current (I-End) 1 - 100 Percent This parameter is only available in 4-step mode (tri = 4-step). Factory setting: 50% Gas post-flow time (Gas Post flow) 0.2 - 9.9 Seconds Specified period during which gas flows at the end of welding.
- Page 53 Parameter Description Range Unit Factory setting (FACtory) The power source can be reset to its factory set- tings here. Cancel reset Reset the parameters for the selected weld- ing process to their factory settings Reset the parameters for all welding process- es to their factory settings Resetting of the selected value to its factory set- ting must be confirmed by pressing the adjusting...
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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 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 55: Care, Maintenance And Disposal
WARNING! 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 Ser- vice Partner. General Under normal operating conditions, the device requires only a minimum of care and main- tenance. -
Page 56: 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 57: Troubleshooting
WARNING! 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 Ser- vice Partner. Indicated errors Overtemperature "hot"... -
Page 58: Service Messages
Service messag- When E and a 2 digit error number appear in the display (e.g. E02) and the "Error" indicator lights up, this is an internal power source service code. Example: It is also possible that several error numbers are present. These appear when turning the adjusting dial. -
Page 59: No Function
No function The power source cannot be switched on Cause: The battery has entered a state of deep discharge as it has been stored for too long without being charged Remedy: Charge the battery now Battery operation is possible again above 25% capacity. If charging is no longer possible, contact After-Sales Service. -
Page 60: Faulty Operation
No welding current Power source is switched on, indicator for the selected welding process is lit, overtemper- ature indicator lit Cause: Power module error Remedy: Turn off the power source, then turn it on again. If the error occurs frequently, contact After-Sales Service Faulty operation Poor ignition properties during MMA welding Cause:... - Page 61 Tungsten electrode melting Tungsten inclusions in base metal during the ignition phase Cause: Incorrect tungsten electrode polarity Remedy: Connect the TIG welding torch to the (-) current socket Cause: Incorrect (or no) shielding gas Remedy: Use inert shielding gas (argon) VRD does not light up even though no welding process is taking place Cause: VRD option not present...
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Page 62: Technical Data
Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will ronments be deemed improper. The manufacturer shall not be held liable for any dam- age arising from such usage. 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 63: Technical Data
Technical data Battery nominal voltage 52.8 V Charging current 10 A Rapid charging current 18 A Battery capacity 7,5 Ah Battery type Li-ion Welding current range Electrode DC 10 -140 A TIG DC 3 - 150 A Welding current in hybrid mode, MMA welding 40 °C (104 °F) 18% D.C. -
Page 65: Charger
Charger... -
Page 67: General
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. Do not use the functions described here until you have fully read and understood the following documents: these operating instructions all the operating instructions for the system components of the power... -
Page 68: Warning Notices Inside The Device
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 69: 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- quired fuse protection for the mains lead, see the Technical data section on page 76. - Page 70 275 mm 100 mm 10.8 inch 3.9 inch...
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Page 71: Control Elements And Connections
Control elements and connections Safety WARNING! Operating the equipment incorrectly can cause serious injury and damage. Do not use the functions described until you have thoroughly read and understood the following documents: these operating instructions all the operating instructions for the system components, especially the safe- ty rules NOTE! Due to software updates, you may find that your device has certain func- tions that are not described in these operating instructions or vice versa. -
Page 72: Start-Up
Start-up Safety WARNING! Incorrect operation or shoddy workmanship can cause serious injury or damage. All activities described in these operating instructions may only be carried out by trained and qualified personnel. All functions described in these op- erating instructions may only be used by trained and qualified personnel. Do not carry out any of the work or use any of the functions described until you have fully read and understood the following documents: these operating instructions... -
Page 73: Operating Modes
Operating modes Operating mode Activation/deactivation Features Charging Starts automatically when The CHARGING indi- the charger is connected to cator is lit the power source and the Mains indicator lit mains The power source is charged at optimum charging power The charging characteristic of this mode maximises the ser- vice life of the power source When the COMPLET-... -
Page 74: Options
Options Fitting the wall NOTE! Depending on the underlying surface, different wall plugs and screws are bracket 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 right wall plugs and screws. -
Page 75: Troubleshooting
Troubleshooting Safety WARNING! An electric shock can be fatal. Do not open the device. Indicated errors An error is signalled by the following indi- cators flashing or lighting up: Error indicator QUICK QUICK CHARGE CHARGE Mains indicator Error flashing, mains lit Cause: Battery fault Remedy:... -
Page 76: Technical Data
Technical data Operating envi- Transport, storage or operation of the charger outside the stipulated area will ronments be deemed improper. The manufacturer shall not be held liable for any dam- age arising from such usage. 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 77: 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 78: 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 79: Appendix
Appendix... -
Page 80: Spare Parts List: Accupocket
Spare parts list: AccuPocket... -
Page 81: Spare Parts List: Activecharger
Spare parts list: ActiveCharger... - Page 84 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations...