Related Manuals for Fronius AccuPocket 150
Summary of Contents for Fronius AccuPocket 150
- Page 1 Service Manual AccuPocket 150 AccuPocket 150 TIG Service Manual 42,0426,0487,EA 007-20042023...
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Page 3: Table Of Contents
Contents General information Foreword and safety instructions Scope of these instructions Safety Protective measures against ESD Fronius Technical Support National (TSN) General Tools and measuring devices Function overview Troubleshooting guide Detailed description Replacing components Terms and abbre-viations used Safety inspection... - Page 4 Removing the AccuPack Installing the AccuPack Packing the AccuPack Replacing the ACCUPLT PC board Removing the ACCUPLT PC board Installing the ACCUPLT PC board Replacing the fan Removing the fan Installing the fan Safety Inspections AccuPocket safety inspection General Responsibility Visual inspections General General conditions...
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Page 5: General Information
General information... -
Page 7: Foreword And Safety Instructions
AccuPocket 150/120V/B (4,075,200,861) AccuPocket 150/100V/nc (4,075,200,864) UTPperform ONE50/230V/EF (4,075,200,865) UTPperform ONE50/120V/B (4,075,200,866) AccuPocket 150/100V/B (4,075,200,867) AccuPocket 150/220V/CN (4,075,200,868) AccuPocket 150 TIG (4,075,201) AccuPocket 150 TIG/230V/Set/EG (4,075,201,850) AccuPocket 150 TIG/120V/Set/B (4,075,201,851) AccuPocket 150 TIG/100V/Set/nc (4,075,201,854) AccuPocket 150 TIG/230V/EF (4,075,201,860) AccuPocket 150 TIG/120V/B (4,075,201,861) -
Page 8: Protective Measures Against Esd
ESD when replacing and installing components. Fronius Technic- If you have any questions about error analysis, your Fronius Technical Support al Support Na- National (TSN) sales team will be able to help. tional (TSN) mailto: welding.techsupport@fronius.com... -
Page 9: Replacing Components
Please also be aware of the requirements and standards relevant to your country, as the measured values or steps taken during the tests may vary. Even if there are no relevant requirements and standards in your country, Fronius recommends that this inspection should still be carried out. -
Page 10: Tools And Measuring Devices
Tools and measuring devices General "Tools and measuring devices" offers an overview and description of all equip- ment needed to service the device professionally. This equipment includes: Tools required Measuring and testing equipment Ancillary materials Tools required Torx screwdriver TX20, 25 Flat spanner, size 13, 17, 22 Small cutting pliers Torque wrench 1 - 6 Nm... -
Page 11: Function Overview
Function overview Principle of the AccuPocket power sources have the AccuPocket following features: Operation without mains electri- city Compact dimensions Robust plastic housing Good reliability even under harsh operating conditions Carrying strap for easy transport on construction sites etc. Safely protected controls Bayonet latching connection sock- During welding, an electronic regulator adapts the power source characteristic to suit the welding electrode. -
Page 12: Software Update
Control panel Welding current sockets DC choke Torch connector - TIG version only Booster choke Output choke Software Update The AccuPocket firmware can be updated when necessary. To update the soft- ware: Download firmware from the DownloadCenter Connect the AccuPocket to a PC with a USB cable (the USB port is behind the control panel) Switch on the power source Select firmware on the PC and double-click to open... -
Page 13: Error Location Aid
Error location aid... -
Page 15: Error Flowchart
Error flowchart Overview The overview will help you to find the relevant sections of the error flowchart from among those listed below. The positions and meanings of the measuring points and LEDs for the compon- ents/PC boards can be found in the "Detailed description" section, which con- tains an "LED checklist"... -
Page 16: No Lights On Control Panel
No lights on con- Start trol panel Voltage present at positive and Revive battery – see Functional negative battery terminals and less description / Reviving deeply than 22 V? discharged batteries Replace battery... -
Page 17: Service Codes
Service codes General Below you will find a description of the faults displayed on the power source, their causes and the corresponding remedies. Indicated errors Overtemperature "hot" appears on the display, the temperature indicator lights up Cause: Device is too hot Remedy: Check/reduce ambient temperature, allow power source to cool down... - Page 18 Battery reports cell undervoltage Remedy Charge / replace battery Cause Battery reports cell overvoltage Remedy Use only original Fronius charger Cause Voltage greater than 110 V DC measured at welding sockets Remedy Check application, replace ACCUPLT / ACCUPLTWIG PC board Cause...
- Page 19 Cause Battery locked, safety feature! Cannot be loaded anymore Remedy New pack required...
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Page 21: Detailed Description
Detailed description... -
Page 23: Detailed Description
Detailed description General The "Detailed description" section contains a detailed description of the elec- tronic modules with regard to the following points: General (designation, item number) Overview Functional description Plugs and connections LED checklist Measuring points Overview The "Detailed description" is composed of the following subsections: ACCUPLT PC board... -
Page 24: Accuplt Pc Board
ACCUPLT PC board General The ACCUPLT PC board is the power module board for the AccuPocket and is available in the following versions: ACCUPLT PC board, Item number 4,071,211,Z ACCUPLT TIG PC board Item number 4,071,389,Z Overview Functional de- Power module for generating welding current scription Control and regulating unit for power source CAN bus interface for communication with battery... -
Page 25: Led Checklist
Pin 1 +15 V Pin 2 Fan GND X 11 Solenoid valve Pin 1 +15 V Pin 3 Pin 2 GND valve Pin 4 X 12 16 pin Molex - battery control LED checklist Function -15V green Lights up when the -15 V supply voltage is present 15V - S5 green Lights up when the +15 V supply voltage is present S5 red... -
Page 27: Replacing Modules
Replacing modules... -
Page 29: Replacing Modules
Replacing modules Safety WARNING! Work that is carried out incorrectly can cause serious injury or damage. All activities described in the service manual must only be carried out by Froni- us-trained service technicians. Take note of the "Safety rules" section in the power source operating instructions. -
Page 30: Opening/Closing The Housing
Opening/closing the housing Opening the Disconnect the power source from housing the battery charging system NOTE! When removing the control panel, en- sure that the ribbon cable is not trapped or damaged. Undo the two TX25 screws (1) and fold the control panel forwards PDisconnect the positive lead of the AccuPack (3) Remove two TX25 screws (2) -
Page 31: Closing The Housing
Closing the NOTE! housing Ensure that the casing (2) lies in the grooves of the front and back panels Place the casing (1) on the power source with the tab (2) pointing to- wards the front panel Fit the carrying handle Fit two TX25 screws (4) Torque 3.0 Connect the positive lead of the Accu- Pack (3), making sure it en-... - Page 32 Place the control panel on the front panel and attach with two TX25 screws (5). Torque: 3.0 Nm...
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Page 33: Replacing The Accupack
Replacing the AccuPack Removing the Open housing as described in the AccuPack "Opening the housing" section Remove the TX25 screw (1) of the negative lead of the AccuPack Insulate the negative lead with the insulating sleeve from the new Ac- cuPack and secure the sleeve with a cable tie Remove the cable tie (a) -
Page 34: Installing The Accupack
Installing the NOTE! AccuPack Check all screw locations (3) of the AccuPack for obstruction or blockage BE- FORE mounting on the function carrier — perform a visual inspection! NOTE! Ensure that the positive and negative leads of the AccuPack are routed in the required position. -
Page 35: Packing The Accupack
Packing the Ac- NOTE! cuPack The AccuPack of the AccuPocket is in hazard class 9. It is therefore recommended to pack the AccuPack in the original packaging of the new AccuPack as described be- low for shipping. Place the used AccuPack in the in- ner carton and tape it shut with fil- ament tape (40,0005,0059) by winding the tape around the entire... -
Page 36: Replacing The Accuplt Pc Board
Replacing the ACCUPLT PC board Removing the Open housing as described in the ACCUPLT PC "Opening the housing" section board Disconnect plugs (6), (8), (9) and (10) Remove six TX20 screws (2, 3, 4, 5, Remove six TX25 screws (1) Remove ACCUPLT board Installing the NOTE! -
Page 37: Replacing The Fan
Replacing the fan Removing the Open housing as described in the "Opening the housing" section Remove the AccuPack as de- scribed in the "Replacing the Accu- Pack" section Disconnect the fan leads (1) Remove two TX25 screws (2) Fold the back cover (3) away to the side Feed the fan leads through the opening and remove the fan... - Page 38 Fit the back cover (3) and device feet on the housing Fit two TX25 screws (2). Torque: 3.0 Nm Install the AccuPack as described in the "Installing the AccuPack" section Close housing as described in the "Closing the housing" section...
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Page 39: Safety Inspections
Safety Inspections... -
Page 41: Accupocket Safety Inspection
This section outlines the safety inspection of the welding systems described in this service manual. This section is fully compliant with IEC 60974-4. Extracts of the requisite measuring methods are documented in Fronius work instruction PMÜ-01. Please also be aware of the requirements and standards relevant to your country, as the measured values or steps taken during the tests may vary. -
Page 42: Visual Inspections
Visual inspections General The following must be visually inspected without any further dismantling of the device. Obvious defects in any safety-related device components are unaccept- able. Defects that could pose a risk during the visual inspection must also be re- corded. -
Page 43: Electrical Tests
Electrical tests Insulation resist- Test voltage for insulation meas- ance urement 500 V DC Insulation resistance must be at least 2.5 MΩ Must be measured from the cur- rent sockets to the tab on the cas- ing (behind the control panel) The lowest measured value must be entered in the test record Measuring device... -
Page 44: Function Tests
Function tests General Under normal circumstances, function tests are only mandatory following repair work. However, we recommend that the following function tests are carried out on a regular basis to ensure that the welding system is safe and working properly at all times. -
Page 45: Documentation
Any device that fails a test must be clearly marked as unsafe and the operat- or informed. The device may no longer be used. Once a device passes the test, an inspection sticker (42,0409,3688) must be affixed to it. The "Safety inspection" test record is available from the Fronius DownloadCen- ter.