Operating
Instructions
AccuPocket 150/400 TIG
ActiveCharger 1000
Operating instructions
EN
42,0426,0200,EN 034-16082022
Contents
Safety rules 7
General 9
Explanation of safety notices 9
Environmental conditions 9
Obligations of the operator 9
Obligations of personnel 10
EMC Device Classifications 10
Disposal 10
Data protection 10
Copyright 10
Power source 11
General 11
Proper use 11
Protecting yourself and others 12
Noise emission values 12
Danger from toxic gases and vapours 12
Danger from flying sparks 13
Dangers from welding current 13
Dangers from the battery 14
Meandering welding currents 15
EMC measures 15
EMF measures 16
Requirement for the shielding gas 16
Danger from shielding gas cylinders 16
Danger from escaping shielding gas 17
Safety precautions in the place of use and for storage and transport 17
Safety measures in normal operation 18
Safety inspection 18
Commissioning, maintenance and repair 18
Safety symbols 19
Charger 20
General 20
Environmental conditions 20
Intended use 20
Mains connection 20
Dangers from mains current and charging current 21
Protecting yourself and others 21
Safety measures in normal operation 21
EMC measures 22
Maintenance 22
Maintenance and repair 22
Warranty and liability 22
Safety inspection 22
Markings on the device 23
General and electrical risks 23
EN
Power source 25
General 27
Device concept 27
Warning notices on the device 27
Application areas 28
Using rechargeable devices 29
Safety 29
Storage and transport 29
Service life of the battery 29
Battery protection functions 31
3
General 31
Deep discharge protector 31
Automatic switch-off 31
Temperature monitoring 32
Overcharging protection 32
Before commissioning 33
Safety 33
Proper use 33
Setup regulations 33
Power connection 33
Before starting for the first time 34
Control elements and connections 35
Safety 35
Connections and mechanical components 35
Control panel 37
MMA welding 39
Preparatory work 39
MMA welding 39
SoftStart / HotStart function 39
Arc-force dynamic 41
TIG modes 42
Symbols and their explanations 42
2-step mode 42
4-step mode 43
TIG welding 44
General 44
Connecting the gas cylinder 44
Preparation 44
Setting the gas pressure 45
TIG welding 45
TIG Comfort Stop 46
TIG pulsing 48
Tacking function 49
The Setup menu 50
Accessing the Setup menu 50
Changing welding parameters 50
Exiting the Setup menu 50
Parameters for MMA welding 50
Parameters for TIG welding 52
VRD safety device (optional) 54
General 54
Function 54
Care and maintenance 55
Safety 55
General 55
At every start-up 55
Every 2 months 56
Disposal 57
General 57
Safety 57
Removing the rechargeable battery pack 58
Troubleshooting 61
Safety 61
Indicated errors 61
Service messages 62
No function 63
Faulty operation 64
Technical data 66
Environmental conditions 66
Explanation of the term "duty cycle" 66
Technical data 67
4
Charger 69
General 71
Warning notices on the device 71
Warning notices inside the device 72
Intended use 72
Before commissioning 73
Mains connection 73
Generator-powered operation 73
Setup regulations 73
Space requirements 74
Control elements and connections 75
Safety 75
Connections and components 75
Control panel 75
Start-up 76
Safety 76
Commissioning 76
Operating modes 77
Options 78
Fitting the wall bracket 78
Troubleshooting 79
Safety 79
Indicated errors 79
No function 79
Technical data 80
Environmental conditions 80
Technical data 230V 81
Standards 230V 81
Technical data 120V 82
Standards 120V 82
Technical data 100V 83
Standards 100V 83
EN
5
6
Safety rules
7
8
General
EN
Explanation of
safety notices
DANGER!
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.
If not avoided, minor injury and/or damage to property may result.
▶
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
Environmental
conditions
Transport, storage or operation of the device outside the stipulated range will be
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)
Recommended temperature range during storage:
-
0 °C to + 20 °C (+ 32 °F to + 68 °F)
When placing in storage, the state of charge should ideally be at 50 - 80%
(corresponds to approx. 2 to 3 bars on the charging status indication).
Relative humidity:
Up to 50% at 40 °C (104 °F)
-
Up to 90 % at 20 °C (68 °F)
-
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes up to 2000 m (6561 ft.)
Obligations of
the operator
The operator must only allow persons to work with the device who:
are familiar with the fundamental instructions regarding safety at work and
-
accident prevention and have been instructed in how to use the device
have read and understood these operating instructions, especially the sec-
-
tion "safety rules", and have confirmed as much with their signatures
are trained to produce the required results.
-
9
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
EMC Device
Classifications
Disposal Waste electrical and electronic equipment must be collected separately and re-
Before using the device, all persons instructed to do so undertake:
to observe the basic instructions regarding safety at work and accident pre-
-
vention
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.
Devices in emission class A:
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 supplied from the public lowvoltage mains.
EMC device classification as per the rating plate or technical data.
cycled in an environmentally-friendly way, in accordance with the European Directive and national legislation. Used equipment must be returned to the distributor or disposed of via an approved local collection and disposal facility. Correct
disposal of used equipment promotes the sustainable recycling of material resources. Failing to dispose of used equipment correctly can lead to adverse
health and/or environmental impacts.
Packaging materials
Separate collection according to material. Check your local authority regulations.
Crush containers to reduce size.
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. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any mistakes that you have found in the instructions, we will be most grateful for your
comments.
10
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.
-
All persons involved in commissioning, operating, maintaining and servicing the
device must:
be suitably qualified,
-
have sufficient knowledge of welding and
-
read and follow these operating instructions carefully.
-
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
must be in a legible state,
-
must not be damaged,
-
must not be removed,
-
must not be covered, pasted or painted over.
-
EN
For the location of the safety and danger notices on the device, refer to the section headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
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
studying and obeying all safety and danger notices carefully
-
performing all stipulated inspection and maintenance work.
-
Never use the device for the following purposes:
Thawing out pipes
-
Charging batteries
-
Starting engines
-
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic setting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
11
Protecting yourself and others
Anyone working with the device exposes themselves to numerous risks, e.g.
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
-
Harmful welding fumes and gases
-
Suitable protective clothing must be worn when working with the device. The
protective clothing must have 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. Operators should:
Protect eyes and face from UV rays, heat and sparks using a protective visor
-
and regulation filter
Wear regulation protective goggles with side protection behind the protect-
-
ive visor
Wear stout footwear that provides insulation even in wet conditions
-
Protect the hands with suitable gloves (electrically insulated and providing
-
protection against heat)
Wear ear protection to reduce the harmful effects of noise and to prevent in-
-
jury
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 vicinity:
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 current and welding current, etc.)
Provide suitable protective equipment
-
Alternatively, erect suitable safety screens/curtains.
-
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum permissible operating point under maximum rated load conditions according to EN
60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the workpiece, the workplace environment, etc.
Danger from toxic gases and vapours
12
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
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 per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:
Metals used for the workpiece
-
Electrodes
-
Coatings
-
Cleaners, degreasers, etc.
-
Welding process used
-
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Association website under Health & Safety (https://european-welding.org).
EN
Danger from fly-
ing sparks
Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radiation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or
fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accordance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store
gases, propellants, mineral oils or similar products. Residues pose an explosive
hazard.
Dangers from
welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
13
Make sure that you and others are protected with an adequately insulated, dry
temporary backing or cover for the earth or ground potential. This temporary
backing or cover must extend over the entire area between the body and the
earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched, damaged or inadequately dimensioned
cables and leads must be replaced immediately.
Do not sling cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
never be immersed in liquid for cooling
-
never be touched when the power source is switched on.
-
Double the open circuit voltage of a power source can occur between the welding
electrodes of two power sources. Touching the potentials of both electrodes at
the same time may be fatal under certain circumstances.
If necessary, provide an adequate earthing connection for the workpiece.
Switch off unused devices.
Dangers from
the battery
The substances contained in the battery used in this device can be harmful to
the environment and to human and animal health.
If the device becomes damaged, please observe the following points:
Make sure that leaking fluids cannot get into the soil or groundwater
-
If pollution has already occurred, it must be removed in accordance with rel-
-
evant national regulations
Liquid may leak from the battery if used or stored under improper conditions.
The liquid may cause irritation or burns.
-
Avoid contact with this liquid.
-
In case of accidental contact, clean the affected area immediately with wa-
-
ter.
In case of eye contact, also consult a doctor.
-
The battery can catch fire if overheated. Do not expose the device to heat
(e.g. a permanent heat source or fire)
If the battery is damaged or subjected to improper use, dangerous vapours may
be given off which can irritate the airways.
If this happens:
Ensure an adequate supply of fresh air
-
Seek medical attention in case of discomfort
-
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
-
14
Do not operate or store the device in a potentially explosive atmosphere.
Special regulations apply in rooms at risk of fire or explosion.
Observe relevant national and international regulations.
To comply with European Directive 2006/66/EC on batteries and accumulators
and its implementation in national law, batteries and rechargeable batteries that
have reached the end of their life must be collected separately and returned to
an approved recycling facility. Be sure to return any device that you no longer require to your distributor, or find out about the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse effects on the environment and your health!
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 mechanically damaged (e.g. electrolyte is escaping), dispose of the device at your nearest
recycling centre in accordance with national laws and guidelines.
If anything is unclear or you have any questions about disposal, contact your
Fronius Service Partner.
Use only the "ActiveCharger 1000" battery charger to charge the power source.
Use of a different charger poses a fire risk.
Only operate the power source using the battery provided. Use of a different battery could result in the risk of injury and/or fire.
If the battery is disconnected, keep it away from metal objects such as paperclips, coins, keys, nails, screws or other small metal objects that could establish a
connection between the battery terminals. Short circuiting of the battery poles
could result in a burn injury or a fire.
Do not use damaged or modified batteries and power sources. Damaged or modified components and devices may exhibit unpredictable behaviour that could result in an explosion or injury.
EN
Meandering
welding currents
Do not expose the power source and the battery to fire or temperatures exceeding 130 °C (266 °F). This could result in an explosion.
Follow the charging instructions contained in these Operating Instructions. Do
not charge the battery outside of the permitted temperature range - see sectionEnvironmental conditions on page 20. Improper charging or exposure to
unauthorised temperatures could damage the battery and increase the risk of
fire.
If the following instructions are ignored, meandering welding currents can develop with the following consequences:
Fire hazard
-
Overheating of parts connected to the workpiece
-
Irreparable damage to ground conductors
-
Damage to device and other electrical equipment
-
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
If the floor is electrically conductive, the device must be set up with sufficient
insulating material to insulate it from the floor.
If distribution boards, twin-head mounts, etc., are being used, note the following:
The electrode of the welding torch / electrode holder that is not used is also live.
Make sure that the welding torch / electrode holder that is not used is kept sufficiently insulated.
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
15
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 rectify the situation.
Check and evaluate the immunity to interference of nearby devices according to
national and international regulations. Examples of equipment that may be susceptible to interference from the device include:
Safety devices
-
Network, signal and data transfer lines
-
IT and telecommunications devices
-
Measuring and calibrating devices
-
Supporting measures for avoidance of EMC problems:
Mains supply
1.
If electromagnetic interference arises despite the correct mains connec-
-
tion, additional measures are necessary (e.g. use of a suitable line filter)
Welding power-leads
2.
must be kept as short as possible
-
must be laid close together (to avoid EMF problems)
-
must be kept well apart from other leads
-
Equipotential bonding
3.
Earthing of the workpiece
4.
If necessary, establish an earth connection using suitable capacitors.
-
Shield, if necessary
5.
Shield other devices nearby
-
Shield the entire welding installation
-
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
Effects on the health of persons in the vicinity, e.g. those with pacemakers
-
and hearing aids
Individuals with pacemakers must seek advice from their doctor before ap-
-
proaching the device or any welding that is in progress
For safety reasons, maintain as large a distance as possible between the
-
welding power-leads and the head/torso of the welder
Do not carry welding power-leads and hosepacks over the shoulders or wind
-
them around any part of the body
Requirement for
the shielding gas
Danger from
shielding gas cylinders
Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
Solid particle size < 40 µm
-
Pressure condensation point < -20 °C
-
Max. oil content < 25 mg/m³
-
Use filters if necessary.
Shielding gas cylinders contain gas under pressure and can explode if damaged.
As the shielding gas cylinders are part of the welding equipment, they must be
handled with the greatest of care.
16
Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions
to prevent them falling over.
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). Only use
shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
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 national
and international regulations for shielding gas cylinders and accessories.
EN
Danger from escaping shielding
gas
Safety precautions in the place
of use and for
storage and
transport
Risk of suffocation from the uncontrolled escape of shielding gas
Shielding gas is colourless and odourless and, in the event of a leak, can displace
the oxygen in the ambient air.
Ensure an adequate supply of fresh air with a ventilation rate of at least
-
20 m³/hour.
Observe safety and maintenance instructions on the shielding gas cylinder or
-
the main gas supply.
Close the shielding gas cylinder valve or main gas supply if no welding is tak-
-
ing place.
Check the shielding gas cylinder or main gas supply for uncontrolled gas
-
leakage before every start-up.
A toppling device can cause life-threatening injuries. Place the device on a solid,
level surface so that it remains stable
The maximum permissible tilt angle is 10°.
-
Do not operate or store the device in a potentially explosive atmosphere.
Special regulations apply in rooms at risk of fire or explosion.
Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is
always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection
shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regarding the risks arising during transport.
After transporting the device, it must be visually inspected for damage before
commissioning. Any damage must be repaired by trained service technicians before commissioning the device.
17
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
in normal operation
Safety inspection
Only operate the device if all safety devices are fully functional. If the safety
devices are not fully functional, there is a risk of
injury or death to the operator or a third party,
-
damage to the device and other material assets belonging to the operator,
-
inefficient operation of the device.
-
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper functioning of safety devices.
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
after any changes are made
-
after any additional parts are installed, or after any conversions
-
after repair, care and maintenance has been carried out
-
at least every twelve months.
-
Commissioning,
maintenance and
repair
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may require.
It is impossible to guarantee that bought-in parts are designed and manufactured to meet the demands made of them, or that they satisfy safety requirements.
Use only original spare and wearing parts (also applies to standard parts).
-
Do not carry out any modifications, alterations, etc. to the device without the
-
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
-
When ordering, please give the exact designation and part number as shown
-
in the spare parts list, as well as the serial number of your device.
The housing screws provide the ground conductor connection for earthing the
housing parts.
Only use original housing screws in the correct number and tightened to the specified torque.
18
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (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.
EN
19
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
-
All persons involved in commissioning, operating, maintaining and servicing the
device must:
Be suitably qualified
-
Read and follow these Operating Instructions carefully
-
The Operating Instructions must always be at hand wherever the device is being
used. In addition to the Operating Instructions, attention must also be paid to
any generally applicable and local regulations regarding accident prevention and
environmental protection.
All safety and danger notices on the device:
Must be kept in a legible state
-
Must not be damaged/marked
-
Must not be removed
-
Must not be covered, pasted, or painted over
-
For the location of the safety and danger notices on the device, refer to the section headed "General information" in the Operating Instructions for your device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
Environmental
conditions
Intended use The device is to be used exclusively for its intended purpose. Any use above and
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
For exact information on permitted environmental conditions, please refer to the
"Technical data" section.
beyond this purpose is deemed improper. The manufacturer is not liable for any
damage, or unexpected or incorrect results arising out of such misuse.
Proper use also includes:
Carefully reading and following all Operating Instructions, safety and danger
-
notices
Performing all stipulated inspection and servicing work
-
Following all instructions from the battery and vehicle manufacturers
-
Mains connection
20
Proper handling of the device is essential for it to function correctly. Never pull
on the cable when handling the device.
Devices with a higher rating may affect the energy quality of the mains due to
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
*)
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 matter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
EN
Dangers from
mains current
and charging
current
Protecting yourself and others
Anyone working with chargers exposes themselves to numerous dangers e.g.:
risk of electrocution from mains current and charging current
-
hazardous electromagnetic fields, which can risk the lives of those using car-
-
diac pacemakers
An electric shock can be fatal. Every electric shock is potentially life threatening.
To avoid electric shocks while using the charger:
do not touch any live parts inside or on the outside of the charger.
-
do not short-circuit the charger lead
-
All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched, damaged or inadequately dimensioned
cables and leads must be immediately repaired by authorised personnel.
While the charger is in operation, keep all persons, especially children, out of the
working area. If, however, there are people in the vicinity,
warn them of all the dangers,
-
provide suitable protective equipment.
-
Before leaving the work area, ensure that people or property cannot come to any
harm in your absence.
Safety measures
in normal operation
Chargers with a ground conductor must only be operated on a mains supply with
a ground conductor and a socket with a ground conductor contact. If the charger
is operated on a mains supply without a ground conductor or in a socket without
a ground conductor contact, this will be deemed gross negligence. The manufacturer shall not be held liable for any damage arising from such usage.
Only operate the charger in accordance with the degree of protection shown on
the rating plate.
Under no circumstances operate the charger if there is any evidence of damage.
Arrange for the mains cable to be checked regularly by a qualified electrician to
ensure the ground conductor is functioning properly.
Any safety devices and parts that are not functioning properly or are in imperfect
condition must be repaired by a qualified technician before switching on the
charger.
Never bypass or disable protection devices.
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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).
If this is the case, then the operating company is obliged to take appropriate action to rectify the situation.
Maintenance Before switching on, always check the mains plug and cable as well as charger
leads and charging terminals for any signs of damage.
If the surface of the device housing is dirty, clean with a soft cloth and solventfree cleaning agent only.
Maintenance and
repair
Warranty and liability
Safety inspection
Maintenance and repair work must only be carried out by authorised personnel.
Use only original spare and wearing parts (also applies to standard parts). It is
impossible to guarantee that bought-in parts are designed and manufactured to
meet the demands made on them, or that they satisfy safety requirements.
Modifications, installations or conversions are only permitted with the approval
of the manufacturer.
The warranty period for the charger is 2 years from the date of invoice.
However, the manufacturer will not accept any liability if the damage was caused
by one or more of the following:
Use of the charger "not in accordance with the intended purpose"
-
Improper installation and operation.
-
Operating the charger with faulty protection devices.
-
Non-compliance with the operating instructions.
-
Unauthorised modifications to the charger.
-
Catastrophes caused by the activities of third parties and force majeure.
-
The manufacturer recommends that a safety inspection of the device is performed at least once every 12 months.
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The safety inspection may only be performed by an appropriately qualified electrician
After any changes have been made
-
After any additional parts are installed, or after any conversions
-
After repair, care and maintenance are carried out
-
At least every twelve months
-
For safety inspections, follow the appropriate national and international standards and directives.
Further details on safety inspections can be obtained from your service centre.
They will provide you on request with any documents you may require.
Markings on the
device
Devices with the CE marking satisfy the essential requirements of the applicable
guidelines.
Devices displaying the EAC mark of conformity satisfy the requirements of the
relevant standards in Russia, Belarus, Kazakhstan, Armenia and Kyrgyzstan.
EN
General and
electrical risks
KEEP THESE INSTRUCTIONS SAFE- This guide contains important safety
1
and Operating Instructions for these charger types (for model, see first page
of this document)
Do not expose the charger to rain or snow
2
The use of accessories not sold or recommended by the charger manufac-
3
turer can lead to fire, electric shock or personal injury
Minimum AWG size of an extension cable
25 ft (7.6 m) 50 ft (15.2 m) 100 ft (30.5 m) 150 ft (45.6 m)
AWG 16 AWG 12 AWG 10 AWG 8
To reduce the risk of damage to plugs and cables, always unplug the charger
4
by pulling the plug rather than the cable
Only use an extension cable if it is absolutely necessary. The use of an incor-
5
rect extension cable can lead to fire and electric shock. If an extension cable
must be used, make sure that
The pins of the extension cable plug are of the same number, size and
-
shape as those of the battery charger
The extension cable is correctly wired and in good electrical condition
-
The cable size is large enough for the AC amperage of the battery char-
-
ger, see section Technical data on page 80
Do not use the battery charger with a damaged cable or plug - replace the
6
cable or plug immediately
Do not use the battery charger if it has been subjected to heavy impact,
7
dropped or otherwise damaged; hand it over to a qualified service technician
Do not dismantle the battery charger; hand it over to a qualified service tech-
8
nician if maintenance or repair is required. Incorrect reassembly can result in
fire and electric shock
To reduce the risk of an electric shock, unplug the battery charger from the
9
socket before carrying out any maintenance or cleaning. This risk cannot be
reduced by setting controls to the "Off" position
23
24
Power source
25
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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. The result is a lightweight and compact device with
excellent ignition and weld properties.
When cellulose electrodes (CEL) are used, a special operating mode can be selected to ensure perfect welding results.
EN
Warning notices
on the device
TIG welding with touchdown ignition greatly extends the range of applications.
The warning notices and safety symbols on the power source must not be removed or painted over. They warn against incorrect operation which can lead to
serious injury and damage.
Meaning of safety symbols on the device:
Risk of serious injury and damage due to incorrect operation.
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
-
source, especially the safety rules
Do not dispose of used devices with domestic waste. Dispose of them according
to the safety rules.
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