Fronius TransPocket 150 Operating Instructions Manual
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Also See for TransPocket 150:
- Service manual & spare parts list (120 pages) ,
- Operating instructions manual (56 pages) ,
- Update procedure (8 pages)
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Summary of Contents for Fronius TransPocket 150
- Page 1 / Perfect Charging / Perfect Welding / Solar Energy Operating Instructions TransPocket 150 TransPocket 180 Rod electrode power source 42,0426,0203,EN 004-26032015...
- 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
Proper use ............................Setup regulations ..........................Generator-powered operation....................... Controls, connections and mechanical components.................. Safety..............................TransPocket 150 control elements, connections and mechanical components ........TransPocket 180 control elements, connections and mechanical components ........Control panel............................MMA welding ............................. Preparations............................MMA welding ............................ - Page 6 On every start-up ..........................Every 2 months ............................. Disposal ..............................Troubleshooting ............................Safety..............................Indicated errors ............................. Service messages..........................No function............................Faulty operation ............................ Technical data............................Explanation of the term "duty cycle" ..................... TransPocket 150........................... TransPocket 180........................... TransPocket 180 MV ..........................
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Page 7: Safety Rules
Safety rules 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 8: 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 manufac- turer 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... -
Page 9: 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 10: Noise Emission Values
harmful welding fumes and gases Anyone working on the workpiece while welding is in progress must wear suit- able protective clothing with the following properties: flame-resistant insulating and dry covers the whole body, is undamaged and in good condition safety helmet trousers with no turn-ups Protective clothing refers to a variety of different items. -
Page 11: Danger From Flying Sparks
If there is any doubt about whether the extraction system is powerful enough, then the measured toxic emission values should be compared with the permis- sible limit values. The following components are responsible, amongst other things, for the de- gree of toxicity of welding fumes: Metals used for the workpiece Electrodes Coatings... -
Page 12: Meandering Welding Currents
Double the open circuit voltage of a power source can occur between the welding electrodes of two power sources. Touching the potentials of both elec- trodes at the same time may be fatal under certain circumstances. Arrange for the mains cable to be checked regularly by a qualified electrician to ensure the ground conductor is functioning properly. -
Page 13: Emc Device Classifications
EMC Device Clas- Devices in emission class A: sifications Are only designed for use in industrial settings Can cause line-bound and radiated interference in other areas Devices in emission class B: Satisfy the emissions criteria for residential and industrial areas. This is also true for residential areas in which the energy is sup- plied from the public low-voltage mains. -
Page 14: Specific Hazards
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example: Fans Cogs Rollers Shafts Wirespools and welding wires Do not reach into the rotating cogs of the wire drive or into rotating drive com- ponents. Covers and side panels may only be opened/removed while maintenance or repair work is being carried out. -
Page 15: Factors Affecting Welding Results
If the device has a carrying strap or handle, this is intended solely for carrying by hand. The carrying strap is not to be used if transporting with a crane, coun- terbalanced lift truck or other mechanical hoist. All lifting accessories (straps, handles, chains, etc.) used in connection with the device or its components must be tested regularly (e.g. -
Page 16: Safety Measures At The Installation Location And During Transport
Safety measures A device toppling over could easily kill someone. Place the device on a solid, at the installation level surface such that it remains stable location and dur- The maximum permissible tilt angle is 10°. ing transport Special regulations apply in rooms at risk of fire or explosion Observe relevant national and international regulations. -
Page 17: Maintenance And Repair
Used coolant must be disposed of properly in accordance with the relevant na- tional and international regulations. The coolant safety data sheet may be ob- tained from your service centre or downloaded from the manufacturer's website. Check the coolant level before starting to weld and while the system is still cool. -
Page 18: Safety Symbols
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage and electromagnetic compatibility directive (e.g. relevant product norms from the EN 60 974 series). Devices with the CSA test mark satisfy the requirements of the relevant stand- ards in Canada and the USA. -
Page 19: General
General Device concept The power source has the following proper- ties: Compact dimensions Robust plastic housing Good reliability even under harsh ope- rating conditions Carrying strap for easy transport on construction sites, etc. Safely protected controls Connection sockets with bayonet latch In conjunction with the digital resonance inverter, an electronic regulator adapts the power source characteristic to suit the welding electrode during welding. -
Page 20: Application Areas
Welding is dangerous. The following basic requirements must be met to ensure the equipment is used properly: Welders must be sufficiently qualified Suitable protective equipment must be used All persons not involved must be kept at a safe distance from the welding process Do not use the functions described here until you have thoroughly read and un- derstood the following documents:... -
Page 21: Before Commissioning
Before commissioning 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 22 The generator apparent power S needed is calculated using the following rule of thumb: x 1.35 1max A smaller generator may be used when not welding at full power. IMPORTANT! The generator apparent power S must always be higher than the maxi- mum apparent power S of the power source.
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Page 23: Controls, Connections And Mechanical Components
Individ- ual illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way. TransPocket 150 control elements, connections and... -
Page 24: Transpocket 180 Control Elements, Connections And Mechanical Components
TransPocket 180 control elements, connections and mechanical com- ponents Control panel (-) current socket with bayonet latch (+) current socket with bayonet latch Mains switch Air filter The use of the current connections depends on the welding process: MMA welding (depending on electrode type) (+) current socket for electrode holder or grounding (earthing) cable (-) current socket for electrode holder or grounding (earthing) cable TIG welding... -
Page 25: Control Panel
Control panel Setting value indicator shows which setting value is selected: Arc-force dynamic Welding current SoftStart / HotStart function TIG pulsing (only with TIG version) Unit indicator shows the unit of the value that is currently being changed with the adjusting dial (7): Time (seconds) Percent... -
Page 26: Mma Welding
MMA welding Preparations CAUTION! Risk of injury and damage from electric shock. As soon as the power source is switched on, the electrode in the welding torch is live. Make sure the electrode does not touch any persons or electrically conducting or earthed parts (e.g. -
Page 27: Mma Welding
= 80 A SoftStart 135% starting current = 135 A HotStart 200% starting current, for TransPocket 150 = 160 A HotStart (maximum cur- rent limit reached!) 200% starting current, for TransPocket 180 = 200 A HotStart... -
Page 28: Arc-Force Dynamic
Arc-force dynamic = 60, set welding current = 100 A for the TransPocket 150: actual increase is just 80 A as the maximum current limit is reached! for the TransPocket 180: arc-force dynamic with 120 A current increase... -
Page 29: 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! If gas cylinders topple over, there is a risk of very serious injury and gas cylinder damage. -
Page 30: Setting The Gas Pressure - On The Welding Torch With Gas Cut-Off Valve
CAUTION! Risk of injury and damage from electric shock. As soon as the power source is switched on, the electrode in the welding torch is live. Make sure the electrode does not touch any persons or electrically conducting or earthed parts (e.g. -
Page 31: Tig Welding
TIG welding Select TIG welding with the welding process button the TIG welding indicator lights up Press the setting value button until the welding current indicator lights up Adjust the welding current using the adjusting dial Place the gas nozzle down on the ignition location, ensuring there is a gap of approx. 2 to 3 mm (5/64 to 1/8 in.) between the tungsten electrode and the workpiece Actuate the gas cut-off valve Shielding gas flows... - Page 32 Wait for the gas post-flow time to finish and lift the welding torch away from the work- piece 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.
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Page 33: Welding Process Setup Menu
Welding process Setup menu Accessing the Use the Welding Process button to select the process whose Setup parameters Setup menu are to be changed: MMA welding MMA welding with Cel electrode TIG welding Press the Setting Value and Welding Process buttons together The code for the first parameter in the Setup menu is displayed on the control panel Changing weld-... -
Page 34: Parameters For Tig Welding
Parameter Description Range Unit Factory setting (FACtory) This can be used to reset the device to its factory settings. 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... -
Page 35: Setup Menu - Level 2
Setup menu - Level 2 Welding parame- Parameter Description Range Unit ters in the level 2 Software version Setup menu The full version number of the currently installed software is contained in a number of displays and can be retrieved by turning the adjusting dial. Automatic switch-off (time Shut down) 5 - 60 Minutes... -
Page 36: Care, Maintenance And Disposal
Care, maintenance and disposal Safety WARNING! Work that is carried out incorrectly can cause serious injury and dam- age. All the work described below must only be carried out by trained and quali- fied personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: This document all the operating instructions for the system components, especially the safe-... -
Page 37: Every 2 Months
Every 2 months Clean air filter: Disposal Dispose of in accordance with the applicable national and local regulations. -
Page 38: Troubleshooting
Troubleshooting Safety WARNING! Work that is carried out incorrectly can cause serious injury and dam- age. All the work described below must only be carried out by trained and quali- fied personnel. Do not carry out any of the work described below until you have fully read and understood the following documents: This document all the operating instructions for the system components, especially the safe-... -
Page 39: No Function
E09 / E10 Cause: Impedance load too high on power source output Remedy: Use power source correctly (welding) Cause: No communication with the control panel Remedy: Contact after-sales service E018 Cause: Wrong firmware (software) has been loaded Remedy: Contact after-sales service Cause: A voltage of >... -
Page 40: Faulty Operation
No welding current Device switched on, indicator for the selected welding process is lit, overtemperature indi- cator lit Cause: Duty cycle exceeded - device overloaded - fan running Remedy: Keep within duty cycle Cause: Thermostatic automatic circuit breaker has been tripped Remedy: Wait until the power source automatically comes back on after the end of the cooling phase... - Page 41 Poor weld properties (severe spattering) Cause: Incorrect electrode polarity Remedy: Reverse electrode polarity (refer to manufacturer's instructions) Cause: Poor grounding (earthing) connection Remedy: Fasten earthing clamps directly to workpiece Cause: Set-up parameters not ideal for selected welding process Remedy: Select best setting in set-up menu for selected welding process Tungsten electrode melting Tungsten inclusions in base metal during the ignition phase Cause:...
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Page 42: Technical Data
Technical data Explanation of Duty cycle (D.C.) is the proportion of time in a 10-minute cycle at which the device may be the term "duty cy- operated at its rated output without overheating. cle" NOTE! The D.C. values specified on the rating plate are based on an ambient temperature of 40°C. -
Page 43: Transpocket 150
TransPocket Mains voltage (U 1 x 230 V Max. effective primary current (I 13 A 1eff Max. primary current (I 21 A 1max Mains fuse 16 A slow-blow Mains voltage tolerance -20%/+20% Mains frequency 50/60 Hz Cos phi 0.99 Max. permissible mains impedance Z 75 mOhm Recommended RCCB Type B... -
Page 44: Transpocket 180
TransPocket Mains voltage (U 1 x 230 V Max. effective primary current (I 15 A 1eff Max. primary current (I 25 A 1max Mains fuse 16 A slow-blow Mains voltage tolerance -30%/+35% Mains frequency 50/60 Hz Cos phi 0.99 Max. permissible mains impedance Z 75 mOhm Recommended RCCB Type B... -
Page 45: Transpocket 180 Mv
TransPocket Mains voltage (U 1 x 230 V 180 MV Max. effective primary current (I 15 A 1eff Max. primary current (I 25 A 1max Mains fuse 16 A slow-blow Mains voltage (U 1 x 120 V Max. effective primary current (I 20 A 1eff Max. - Page 46 Welding current for TIG 10 min/40°C (104°F) 100% welding 150 A 140 A 130 A = 120 V, fuse = 20 A) Welding current for 10 min/40°C (104°F) 100% MMA welding 85 A 70 A 65 A = 120 V, fuse = 15 A) Welding current for TIG 10 min/40°C (104°F) 100%...
- Page 48 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...
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