Fronius AccuPocket 150/400 TIG, ActiveCharger 1000 Operating Instruction [EN]

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Operating Instructions

AccuPocket 150/400 TIG ActiveCharger 1000

Operating instructions

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

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

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

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

Safety rules

General

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.

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.

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.

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.

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.

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

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).

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.

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

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.

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

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

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.

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.

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.

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.

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.

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

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

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.

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.

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.

General and electrical risks

KEEP THESE INSTRUCTIONS SAFE- This guide contains important safety

and Operating Instructions for these charger types (for model, see first page of this document)

Do not expose the charger to rain or snow

The use of accessories not sold or recommended by the charger manufac-

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

by pulling the plug rather than the cable

Only use an extension cable if it is absolutely necessary. The use of an incor-

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

cable or plug immediately

Do not use the battery charger if it has been subjected to heavy impact,

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-

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

socket before carrying out any maintenance or cleaning. This risk cannot be reduced by setting controls to the "Off" position

Power source

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.

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.

Application areas

MMA welding TIG welding

Using rechargeable devices

Safety

WARNING!

Danger due to improper handling of the lithium-ion battery.

This can result in severe injury or damage to property.

Never expose the power source to naked ﬂames. Excessive heat can cause

▶

the battery to explode or burst. Do not open the power source or remove the battery. If the battery becomes

▶

damaged due to improper handling, poisonous substances can escape which may be harmful to health. Do not drop the power source into water. This can cause a short circuit, even

▶

if the power source is switched off. This in turn can cause the battery to become hot, ignite or burst.

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in severe injury or damage to property.

Do not open the power source.

▶

The power source may only be opened by a Fronius service technician.

▶

If you need a replacement battery, hand the power source over to a Fronius

▶

Service Partner.

Storage and transport

Service life of the battery

When storing or transporting the power source, observe the environmental conditions in the Technical data section from page 66.

Particularly if the power source is stored for long periods of time, observe the following points:

Only store the power source when it is charged. The state of charge should

ideally be between 50 and 80% Optimum storage temperature: 0 °C to +20 °C (+32 °F to +68 °F)

Recharge the power source at least every six months

When transporting the power source, observe the relevant national guidelines. Note the following safety data for transport:

Dangerous goods class: 9

Classification code: M4

Packaging group: II

NOTE!

The service life of the battery is dependent entirely upon how it is handled.

The way in which the battery is operated and stored and the conditions under which this occurs are therefore extremely important.

The intelligent functions of the power source (see section Battery protection

functions from page 31) play a significant role in increasing the service life of

the battery.

However, the user must observe the following key points in order to guarantee maximum battery life:

Recharge the battery after every discharge

Do not wait until the battery is completely discharged before recharging it.

Protect the power source from extreme inﬂuences

Optimal environmental conditions for operation:

Temperature: +15 °C to +25 °C (+59 °F to +77 °F)

Humidity: 50 %

Surrounding air is free from dust and corrosive vapours or gases

Charge power source regularly when not in use

Check power source at least every 6 months and recharge if necessary

Battery protection functions

General The battery protection functions serve to:

Increase the service life of the battery

Protect the battery from long-term damage

Ensure the reliability of the power source

Deep discharge protector

Automatic switch-off

The power source has a deep discharge protector to warn the user if the state of charge of the battery is too low. If this is the case, the power source switches off.

Function of the deep discharge protector:

When the battery capacity is exhausted

The power source switches off automatically after three seconds

Danger due to prolonged storage of the battery in a discharged state.

This can damage the battery.

If the deep discharge protector is triggered, charge the power source imme-

▶

diately!

Automatic switch-off avoids unnecessary power consumption, thereby extending the effective period of operation with one battery charge.

If the power source is not operated for a specific length of time, it switches off automatically.

all segments of the battery capacity indicator ﬂash

"Lo" is shown on the display

welding is no longer possible

CAUTION!

To reactivate the power source, press the On/Off button for at least two seconds.

NOTE!

The factory setting for the automatic switch-off time is 15 minutes (if no welding is performed for 15 minutes, the power source switches off automatically).

This value can be changed in the Setup menu using the tSd parameter.

Temperature monitoring

Temperature monitoring prevents the battery from being charged or discharged if the temperature of the battery is outside the permitted temperature range.

The battery charger has an internal temperature management function

From 30 °C: Protection against overheating of the charger by automatic re-

duction of the power (derating) From 45 °C: Only standard charging possible to increase battery life

From 70 °C: Power source switched off

Charging is not possible below 0 °C. Welding is conditionally possible de-

pending on the current level. Two additional sensors directly on the power module

Undertemperature

If the battery falls below the permitted temperature range, neither welding nor charging is possible.

Overcharging protection

Overtemperature

Charging is only possible again at a battery temperature of less than +45 °C.

If the battery exceeds the permitted temperature range:

the temperature indicator lights up and „hot“ is shown on the display

neither welding nor charging is possible until the temperature indicator goes

out (when the battery has cooled down)

Once the battery has been fully charged, the charger turns off automatically and switches to conservation charging mode.

More information on how the battery charger and the individual operating modes work can be found in the charger description on page 69.

Before commissioning

Safety

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

▶ ▶

▶

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.

Proper use also includes:

WARNING!

All the work and functions described in this document must only be carried out by technically trained and qualified personnel. Read and understand this document in full.

Read and understand all safety rules and user documentation for this device and all system components.

carefully reading these operating instructions following all the instructions and safety rules in these operating instructions performing all stipulated inspection and maintenance work

Setup regulations

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

The device is tested to IP 23 protection, meaning:

Protection against penetration by solid foreign bodies with diameters > 12.5

mm (0.49 in.) Protected against spraywater at any angle up to 60° to the vertical

Cooling air

The device must be set up in such a way that cooling air can ﬂow freely through the slots in the front and rear panels.

Dust

Ensure that metallic dust is not sucked into the system by the fan, when carrying out grinding for example.

Outdoor operation

The device can be set up and operated outdoors in accordance with IP23 degree of protection. Avoid direct wetting (e.g. from rain).

Power connection

The device is designed to be connected to the mains using the Fronius ActiveCharger 1000 only (= hybrid mode, see Operating modes on page 77).

Before starting for the first time

NOTE!

No warranty claims will be entertained if the device is operated with other chargers.

If the battery is fully charged:

Once connected, the battery capacity indicator on the power source

ﬂashes to indicate the current state of charge; the battery is being 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

Control elements and connections

(1)

(2) (3)

(4)

(5)

(6)

(7)

(8)

Safety

Connections and mechanical components

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

As a result of software updates, you may find that there are functions available on your device that are not described in these Operating Instructions, or vice versa. Certain illustrations may also differ slightly from the actual controls on your device, but these controls function in exactly the same way.

(1) (-) current socket

with bayonet latch

(2) TMC connection (TIG Multi Connector)

(3) (+) current socket

with bayonet latch

(4) Carrying strap

(5) Cable strap

for holding the mains cable and the welding power-leads Do not use to move the device!

(6) Charger connection

(7) Air filter

(8) Shielding gas connection

The use of the current connections depends on the welding process:

MMA welding (depending on electrode type)

(+) 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

Control panel

(10)

(8)

(7)

(3)

(4)

(5)

(6)

(11)

(9)

(1)

(2)

(1) Setting value indicator

shows which setting value is selected:

Arc-force dynamic Welding current SoftStart / HotStart function TIG pulsing / pulse welding

(2) Unit indicator

shows the unit of the value that is currently being changed using the adjusting dial (8):

Percent

Voltage (volts) Frequency (Hertz)

Time (seconds)

(3) Battery capacity indicator

shows the state of charge of the battery:

Battery fully charged Battery capacity 75 % Battery capacity 50 % Battery capacity 25 %

Battery discharged Charge the battery now!

shows the operating mode:

lights up in the following situations:

in pure welding mode

in conservation charging mode

a bar also ﬂashes in the following operating modes:

charging

quick charging

hybrid mode

(4) Display

(5) Welding process indicator

shows which welding process is selected:

MMA welding MMA welding with Cel electrode TIG welding reserved for special programs

(6) Welding process button

for selecting the welding process

(7) 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)

(8) Adjusting dial

(9) TAC indicator

lights up when the tacking function is activated (only possible on TIG devices during the TIG welding process)

(10) Setting value button

for selecting the desired setting value (1)

(11) Status indicators

display various operating modes of the power source:

VRD - lights up if the (optional) VRD safety device is present

and the reduced safety voltage is present at the welding sockets

Setup - lights up in Setup mode Temperature - power source outside the permitted temperat-

ure range

Error - see also Troubleshooting from page 61

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

Insert the rod electrode into the electrode holder

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

As soon as the power source is switched on, the electrode in the elec-

▶

trode holder is live. Make sure the electrode does not touch any persons or electrically conductive or earthed parts (e.g. the housing, etc.).

Press the On/Off button for at least two seconds to turn on the power

source

the welding current indicator lights up

the display shows the specified welding current

MMA welding

SoftStart / HotStart function

This function is used to set the starting current.

Setting range: 0 - 200%

Operating principle:

At the start of the welding process, the welding current is reduced (SoftStart) or increased (HotStart) for 0.5 seconds, depending on the setting. The change is shown as a percentage from the set welding current.

Use the welding process button to select one of the following processes:

MMA welding - the MMA welding indicator lights up after selection

MMA welding with Cel electrode - the MMA welding with Cel elec-

trode indicator lights up after selection

Press the setting value button until

the welding current indicator lights up

Select the amperage using the adjusting dial

Power source is ready for welding

The duration of the starting current can be changed in the Setup menu using the Hti parameter, see Parameters for MMA welding on page 50.

Setting the starting current:

I (A)

90A

0,5 s 1 s 1,5 s

120A

Press the setting value button until

the SoftStart / HotStart indicator lights up

Turn the adjusting dial until the desired value is reached

Power source is ready for welding

NOTE!

The maximum HotStart current is limited to 180 A.

Examples:

(set welding current = 100 A)

100% Starting current = 100 A Function deactivated

80% 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 cer-

tain electrode types

Example of HotStart function

Features of HotStart function:

Improved ignition properties, even

when using electrodes with poor ignition properties Better fusion of the base material

during the start-up phase, meaning fewer cold-shut defects Largely prevents slag inclusions

Arc-force dynamic

To obtain optimum welding results, it will sometimes be necessary to adjust the arc-force dynamic.

Setting range: 0 - 100 (corresponds to 0 - 200 A current increase)

Operating principle:

At the moment of droplet transfer or in the event of a short circuit, the amperage is brieﬂy increased in order to obtain a stable arc. If the rod electrode threatens to sink into the weld pool, this measure prevents the weld pool solidifying, as well as preventing a prolonged short-circuit of the arc. This largely prevents the rod electrode from sticking.

Setting the arc-force dynamic:

Press the setting value button until

the arc-force dynamic indicator lights up

Turn the adjusting dial until the desired correction value is reached

Power source is ready for welding

NOTE!

The maximum arc-force dynamic current is limited to 180 A.

Examples:

Arc-force dynamic = 0

arc-force dynamic deactivated

soft, low-spatter arc

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!

TIG modes

I-1

GPo

GPr

1 2 3

tdowntup

Symbols and their explanations

Pull back and hold the torch trigger

Release the torch trigger forwards

Push forward and hold the torch trigger

Release 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 material, whose temperature is raised by the continuous heat I-2: Reduced current phase - intermediate lowering of the welding current in

order to prevent any local overheating of the base material

Fixed parameters:

GPr: Gas pre-ﬂow time

tup: UpSlope phase - the welding current is continually increased

Duration = 0.5 seconds

: DownSlope phase - the welding current is continually decreased

down

Duration = 0.5 seconds tS: Starting current duration

tE: Final current duration

2-step mode See the section on page for details on how to activate 2-step mode.

Place the tungsten electrode onto the workpiece and then pull the torch trig-

ger back and hold => shielding gas ﬂows

Raise the tungsten electrode => arc ignites

Release torch trigger => end of welding

I-1

GPr

I-S

I-E

I-2

GPo

I-1

tdown tets

1 2 3 4 5 6 7

tup

4-step mode See the section on page for details on how to activate 4-step mode.

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 trig-

ger back and hold => shielding gas ﬂows

Raise the tungsten electrode => start of welding with starting current I-S

Release torch trigger => welding with main current I-1

Push forward and hold the torch trigger => activation of intermediate lower-

ing with reduced current I-2

Release torch trigger => welding with main current I-1

Pull back and hold the torch trigger => lowering to final current I-E

Release torch trigger => end of welding

TIG welding

max. 5 bar (72 psi)

General

Connecting the gas cylinder

NOTE!

Do not use pure tungsten electrodes (colour-coded green) if the TIG welding process has been selected.

WARNING!

Danger from falling gas cylinders.

This can result in severe personal injury and damage to property.

Place gas cylinders on a solid, level surface so that they remain stable. Se-

▶

cure gas cylinders to prevent them from falling over. Observe the safety rules of the gas cylinder manufacturer.

▶

Preparation

Press the On/Off button for at least two seconds to turn off the power

source

the indicators go out

Plug the TIG welding torch into the (-) current socket and turn it clockwise to latch it in place

Plug the TIG Multi Connector plug of the TIG welding torch into the TMC connection of the power source

Set up the welding torch in accordance with the welding torch Operating Instructions

Plug the grounding cable into the (+) current socket and turn it clockwise to latch it in place

Use the other end of the grounding cable to establish a connection to the

workpiece

WARNING!

Danger from electric shocks.

This can result in serious injury and damage to property.

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 conductive or earthed parts (e.g. the housing, etc.).

Setting the gas pressure

Press the On/Off button for at least two seconds to turn on the power

source

Welding torch with torch trigger (and TIG Multi Connector plug)

the welding current indicator lights up

the display shows the specified welding current

Welding torch with torch trigger (and 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

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

When using a welding torch with a torch trigger and TIG Multi Connector plug (with 2-step mode factory setting):

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 Gap exists

Gradually tilt the welding torch up until the tungsten electrode touches the

workpiece

Pull back and hold the torch trigger

Shielding gas ﬂows

Raise the welding torch and rotate it into its normal position

The arc ignites

Carry out welding

4 6 7

1 2 3 4 5

TIG Comfort Stop

For more information on activating and setting the TIG Comfort Stop function see Parameters for TIG welding from 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

Keep the welding torch at the same height

The welding current continually decreases (downslope) until the arc goes

out

Wait for the gas post-ﬂow time to finish and lift the welding torch away from

the workpiece

tdown

Max. A

70 A

(1)

(2)

1 2

3 4 5+

Welding current and gas ﬂow curve with TIG Comfort Stop function activated

(1) Gas pre-ﬂow (2) Gas post-ﬂow

Downslope:

The downslope time t

Gas post-ﬂow:

The gas post-ﬂow can be changed in the Setup menu via the "GPo" value, see

Parameters for TIG welding on page 52.

is 0.5 seconds and cannot be adjusted.

down

TIG pulsing TIG pulsing is TIG welding with a pulsing welding current. It is used for out-of-

1/F-P

I-P

I-G

down

I-S

I-E

dcY

position welding 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

Setting range: 0.5 - 990 Hz

Operating principle:

A low base current I-G rises steeply to the significantly higher pulse current I-P and, depending on the set dcY (duty cycle) time, drops back to the base current I-G. This results in an average for the main current of I-1. During TIG pulsing, small sections of the welding location melt quickly and then solidify again quickly.

Activating TIG pulsing / setting the pulse frequency:

Press the setting value button until

the TIG pulsing indicator lights up

Turn the adjusting dial until the desired frequency value (Hz) is reached

power source is ready for welding

TIG pulsing - welding current curve

Legend: I-P Pulse current

I-S Starting current F-P Pulse frequency *)

I-E Final current dcY Duty cycle

Down

*) (1/F-P = time interval between two pulses)

UpSlope I-G Base current

DownSlope I-1 Main current

Tacking function Activating and setting the tacking function is described in the Tacking function

tAC

I-1

down

I-S

I-E

(tACking) section on page 53.

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 run together better when two components are being tacked.

Tacking function - welding current curve

Key:

tAC Duration of pulsed welding current for the tacking process

I-S Starting current

I-E Final current

Down

UpSlope

Downslope

I-1 Main current

NOTE!

The following points apply to the pulsed welding current:

The power source automatically regulates the pulsing parameters depending

▶

on the specified main current I-1 There is no need to set any pulsing parameters

▶

The pulsed welding current begins

after the end of the starting-current phase I-S

with the UpSlope phase t

After the tAC time has elapsed, welding continues at a constant welding current, and any pulsing parameters that may have been set are available.

The Setup menu

Accessing the Setup menu

Changing welding parameters

Use the welding process button to select the process for which the Setup

parameters are to be changed:

MMA welding

MMA welding with Cel electrode

TIG welding

MMA welding

MMA welding with Cel electrode

TIG welding

+ Press the setting value and welding process buttons together

After releasing the buttons, the code for the first parameter in the Setup

menu is displayed

Turn the adjusting dial to select the required parameter

Exiting the Setup menu

Parameters for MMA welding

Press the adjusting dial to display the preset value of the parameter

Turn the adjusting dial to change the value

the new value becomes effective immediately

exception: when restoring the factory settings, press the adjust-

ing dial after changing the value to activate the new value.

Press the adjusting dial to return to the list of parameters

Press the setting value or

welding process button to exit the Setup menu

Starting current duration

0,1 - 1,5 seconds for the SoftStart / HotStart function Factory setting: 0.5 seconds

Anti-Stick

On / OFF When the anti-stick function is active, the arc is extinguished after 1.5 seconds in the event of a short circuit (sticking of the electrode) Factory setting: ON (activated)

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. Factory setting: 45 volts

Software version

The full version number of the currently installed software is spread across a number of displays and can be retrieved by turning the adjusting dial.

Automatic switch-off (time Shut down)

300 - 900 Seconds / OFF If the power source is not operated for the specified length of time, it switches off automatically. Factory setting: 900 seconds

Factory setting (FACtory)

The power source can be reset to its factory settings here. no / YES / ALL

Cancel reset

Reset the parameters for the selected welding process to their factory set-

tings Reset the parameters for all welding processes to their factory settings

Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.

Parameters for TIG welding

Operating mode (trigger mode)

OFF / 2t / 4t

Operation using welding torch without a torch trigger

2-step mode

4-step mode

Factory setting: 2t

Starting current (I-Start)

1 - 200 percent This parameter is only available in 4-step mode (tri = 4t). Factory setting: 50 %

Reduced current

1 - 200 percent This parameter is only available in 4-step mode (tri = 4t). Factory setting: 50 %

Final current (I-End)

1 - 100 percent This parameter is only available in 4-step mode (tri = 4t). 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. Factory setting: 9.9 seconds

Comfort Stop Sensitivity (Comfort Stop Sensitivity)

0.3 - 2.0 V / OFF This parameter is only available when the tri parameter is set to OFF. Factory setting: OFF

For details see the TIG Comfort Stop section from page 46.

Break voltage (U cut off)

12 - 35 V Used to specify at which arc length the welding process is completed. The welding voltage increases as the length of the arc increases. The arc is extinguished when it reaches the voltage specified here. This parameter is only available when the tri and CSS parameters are set to OFF. Factory setting: 15 volts

Tacking function (tACking)

0.1 - 9.9 seconds / OFF Factory setting: ON

For details see the Tacking function section on page 49.

Software version

The full version number of the currently installed software is spread across a number of displays and can be retrieved by turning the adjusting dial.

Automatic shutdown (time Shut down)

300 - 900 seconds / OFF If the power source is not operated for the specified length of time, it switches off automatically. Factory setting: 900 seconds

Factory setting (FACtory)

no / YES / ALL The power source can be reset to its factory settings here.

cancel reset

reset the parameters for the selected welding process to their factory set-

tings reset the parameters for all welding processes to their factory settings

Resetting of the selected value to its factory setting must be confirmed by pressing the adjusting dial.

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

VRD is active

VRD is not active

NOTE!

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

The welding circuit resistance is less than the minimum human body resistance (less than 200 Ohm):

The VRD indicator lights up Example: no risk ensues if both welding sockets are touched accidentally at the same time.

VRD is inactive Output voltage not limited in order to ensure sufficient welding power The VRD indicator does not light up

Example: Start of welding

Within 0.

3 seconds of the end of welding:

VRD is active again

▶

The output voltage is limited to 14 V again

▶

Care and maintenance

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

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

▶

Service Partner.

General Under normal operating conditions, the device requires only a minimum of care

and maintenance. However, it is vital to observe some important points to ensure the device remains in a usable condition for many years.

At every startup

Check the charging lead, welding torch/electrode holder, welding power-lead

and grounding (earthing) connection for damage. Replace any damaged components Check that there is an all-round clearance of 0.5 m (1 ft. 8 in.) around the

power source to ensure that cooling air can ﬂow in and out freely

NOTE!

Air inlets and outlets must never be covered, not even partially.

Every 2 months Clean the air filter (if fitted):

Disposal

General Dispose of in accordance with the applicable national and local regulations.

Always dispose of the device separately from the installed battery.

The following section explains how to remove the battery.

Safety

WARNING!

Danger due to incorrect operation and incorrectly performed work.

This can result in serious injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by trained and qualified personnel. Read and understand this document.

▶

Read and understand all the Operating Instructions for the system compon-

▶

ents, especially the safety rules.

WARNING!

Danger from electric current.

An electric shock can be fatal.

Switch off the power source.

▶

Disconnect the power source from the battery charger.

▶

Ensure that the power source remains disconnected from the battery char-

▶

ger until all work has been completed. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

Removing the re-

chargeable battery pack

NOTE!

The following steps on removing the rechargeable battery pack must only be used when disposing of the device!

If the rechargeable battery pack needs to be repaired or replaced, contact

▶

After-Sales Service.

NOTE!

Before removing the rechargeable battery pack, the power source must be disconnected from the battery charger!

Ensure that the power source is completely discharged.

▶

Remove the control panel

Disconnect the (+) power cable from the rechargeable battery pack, remove 2 TX25 screws

Remove 2 TX25 screws, remove device feet at the front

Remove 2 TX25 screws, remove the cover

Remove 2 TX25 screws, remove device feet, fold rear to one side

Press front and rear outwards, remove device casing

Press front and rear outwards, remove carrying handle

CAUTION!

Fire hazard due to short circuit of the battery!

If the battery is short-circuited, sparks may be generated and the battery may catch fire.

After terminating the (-) power cable, insulate it well (e.g. wrap it with insulat-

▶

ing tape)!

Remove TX25 screw and terminate (-) power cable of the rechargeable battery back; IMPORTANT! Insulate the terminated cable lug well!

Dispose of the device and rechargeable battery pack separately according to

Disconnect 16-pin connector X1 from the battery pack, remove 6 TX 20 screws, remove the rechargeable battery pack

the local guidelines

Troubleshooting

Safety

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

WARNING!

Danger from electrical current.

This can result in serious personal injury and damage to property.

Before starting work, switch off all devices and components involved and dis-

▶

connect them from the grid. Secure all devices and components involved so they cannot be switched back

▶

on. After opening the device, use a suitable measuring instrument to check that

▶

electrically charged components (such as capacitors) have been discharged.

WARNING!

Indicated errors

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

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

▶

Service Partner.

Overtemperature

"hot" appears on the display, the temperature indicator lights up

Cause: Remedy:

Undertemperature

"cold" appears as scrolling text on the display, the temperature indicator lights up

Device is too hot Check/reduce ambient temperature, allow power source to cool

down

Cause: Remedy:

Device temperature too low Check/increase ambient temperature, operate the power source in a

warmer environment

For more information see the Environmental conditions section on page 66

Deep discharge protector

"Lo" appears in the display, the "Battery capacity" indicator ﬂashes

Service messages

Cause: Remedy:

Danger due to prolonged storage of the battery in a discharged state.

This can damage the battery.

If the deep discharge protector is triggered, charge the power source

▶

promptly!

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.

Battery discharged, deep discharge protection has been activated Charge the battery now

Battery operation is possible again above 25% capacity

CAUTION!

Make a note of the error numbers shown in the display, and of the serial number and configuration of the power source, and contact our after-sales service team with a detailed description of the error.

E02 / E03 / E05 / E06

Cause:

Remedy:

E07 / E72

Cause: Remedy:

E09 / E10

Cause: Remedy:

E11

Cause: Remedy:

E12 / E13 /E14

Cause: Remedy:

Internal temperature sensor fault on ACCUPLT / ACCUPLT-TIG PC board

Contact after-sales service

Internal supply voltage 15 V outside the valid range Contact After-Sales Service

Load too high on power source current sockets Use power source correctly (welding)

No communication with the control panel Contact after-sales service

Internal error on ACCUPLT / ACCUPLT-TIG PC board Contact after-sales service

E16

Cause:

Remedy:

E18

Cause: Remedy:

E19 / E22 / E30 / E53 / E83

Cause: Remedy:

E23

Cause: Remedy:

Communication error between battery and ACCUPLT / ACCUPLTTIG PC board

Contact after-sales service

Wrong firmware (software) has been loaded Contact after-sales service

Battery fault Contact After-Sales Service

A voltage of > 113 V DC has been measured on the current sockets Contact After-Sales Service

No function

The power source cannot be switched on

Cause:

Remedy:

Cause: Remedy:

Battery is not charged

Power source is connected to the charger, charger is connected to the mains, no charging indicator on the power source

Cause: Remedy:

The battery has entered a state of deep discharge as it has been stored for too long without being charged

Charge the battery now

Battery operation is possible again above 25% capacity.

If charging is no longer possible, contact After-Sales Service.

Control panel defective Contact After-Sales Service

Device is too hot Check/reduce ambient temperature, allow battery to cool down

Device temperature too low Check/increase ambient temperature, disconnect and reconnect bat-

tery charger

Charging cable defective Renew charging cable

No welding current

Power source is switched on, indicator for the selected welding process is lit

Cause: Remedy:

Cause:

Remedy:

No welding current

Power source is switched on, indicator for the selected welding process is lit, overtemperature indicator lit

Cause: Remedy:

Welding power-lead connections have been disconnected Establish proper welding power-lead connections

Poor or no earth Establish a connection to the workpiece

There is a break in the power cable in the welding torch or electrode holder

Replace welding torch or electrode holder

Duty cycle exceeded - power source overloaded - fan running Keep within duty cycle

Thermostatic automatic circuit breaker has been tripped Wait until the power source comes back on automatically at the end

of the cooling phase

The fan in the power source is faulty Contact After-Sales Service

Faulty operation

Cause: Remedy:

No welding current

Power source is switched on, indicator for the selected welding process is lit, overtemperature indicator lit

Cause: Remedy:

Poor ignition properties during MMA welding

Cause: Remedy:

Insufficient cooling air intake Ensure adequate air supply

Air filter is dirty Clean air filter

Power module error Turn off the power source, then turn it on again.

If the error occurs frequently, contact After-Sales Service

Incorrect welding process selected Select "MMA welding" or "MMA welding with Cel electrode" process

Starting current too low; electrode sticking during ignition Increase starting current using HotStart function

Cause:

Remedy:

Starting current too high; electrode consumed too quickly during ignition or is generating a lot of spatter

Reduce starting current using SoftStart function

In some cases, arc breaks during welding

Cause: Remedy:

Electrode (e.g. grooved electrode) voltage too high If possible, use alternative electrode or a power source with more

welding power

Cause: Remedy:

Rod electrode tends to stick

Cause: Remedy:

Poor weld properties

(severe spattering)

Cause: Remedy:

Comfort Stop Sensitivity (CSS) setting is too sensitive Increase or deactivate the CSS value in the Setup menu

Break voltage (Uco) set too low Increase break voltage (Uco) in Setup menu

Value of arc-force dynamic parameter (MMA welding) set too low Increase value of arc-force dynamic parameter

Incorrect electrode polarity Reverse electrode polarity (refer to manufacturer's instructions)

Poor grounding (earthing) connection Fasten earthing clamps directly to workpiece

Setup parameters not ideal for selected welding process Select the optimal settings in the Setup menu for the selected weld-

ing process

Tungsten electrode melting

Tungsten inclusions in base metal during the ignition phase

Cause: Remedy:

VRD does not light up even though no welding process is taking place

Cause:

Remedy:

Incorrect tungsten electrode polarity Connect the TIG welding torch to the (-) current socket

Incorrect (or no) shielding gas Use inert shielding gas (argon)

VRD option not present or internal device fault

Contact after-sales service

Technical data

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.)

Explanation of the term "duty cycle"

Duty cycle (ED) is the proportion of time in a 10-minute cycle at which the device may be operated at its rated output without overheating.

NOTE!

The ED values specified on the rating plate are based on an ambient temperature of 40 °C.

If the ambient temperature is higher, either the ED or output must be reduced accordingly.

Example: Welding at 150 A at 60% ED

Welding phase = 60% of 10 minutes = 6 minutes

Cooling phase = remaining time = 4 minutes

After the cooling phase, the cycle begins again.

10 Min.6 Min.

150 A

0 Min.

0 A

4 Min.6 Min.

60 %

If the device is to be continuously operated without stopping:

Look in the technical data for a ED value of 100% for the current ambient

temperature.

Reduce the output or amperage in line with this value so that the device can

remain in use without observing a cooling phase.

Technical data

Rated battery voltage 50.4 V

Charging current 10 A

Rapid charging current 18 A

Battery capacity 15 Ah

Battery type Li-ion

Standard charging 90 min.

Rapid charging 50 min.

Weld time Ø 2.5 mm Electrode 21 - 27 pcs

Ø 3.25 mm

Electrode 9 - 12 pcs

Welding current range Electrode DC 10 - 150 A

TIG DC 3 - 150 A

Welding current in hybrid mode (manual metal arc welding)

40 °C (104 °F)

18 % D.C.

25 % D.C.

100 % D.C.

150 A

100 A

40 A

Welding current in hybrid mode (TIG welding)

40 °C (104 °F)

25 % D.C.

50 % D.C.

100 % D.C.

150 A

100 A

65 A

Open circuit voltage 91 V

Reduced open circuit voltage (only with VRD option)

14 V

Protection class IP 23

Type of cooling AF

Dimensions L x W x H 435 x 160 x 310 mm

17.1 x 6.3 x 12.2 in.

Weight 11.4 kg (25.1 lb)

Max. shielding gas pressure 5 bar (72 psi)

D.C. = Duty cycle

Charger

General

xxxxxxxx

4,010,341,xxx

In:

ActiveCharger 1000/230V

~230V 50/60Hz; 1100W

DC 58V/18A

A-4600 Wels

www.fronius.com

Protective class I

Out

MAX

IP 43S

Chr. No.

Part No.

EMC Emission

Class A

Warning notices on the device

A number of safety symbols can be seen on the charger's rating plate. The safety symbols 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

source, especially the safety rules

Possible sources of ignition, such as fire, sparks and naked ﬂames, must be kept away from the battery.

Ensure an adequate supply of fresh air during charging. Maintain a distance of at least 0.5 m (19.69 in.) between battery and charger during the charging procedure.

Do not dispose of used devices with domestic waste. Dispose of them according to the safety rules.

Warning notices

Entladezeit > 5 sek. Discharge time > 5 sec. Temps de décharge > 5 s

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 service 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. capacitors) are fully discharged. Ensure that the device remains disconnected from the mains until all work has been completed.

This warning sign is located inside the device. It must NOT be removed or painted over.

The discharge time of the capacitors is approx. one minute.

Intended use The charger is designed to charge the power sources listed below. Any use above

and beyond this purpose is deemed improper. The manufacturer shall not be liable for any damage resulting from such use. Proper use also includes:

Carefully reading these Operating Instructions

Following all the instructions and safety rules in these Operating Instruc-

tions

WARNING!

Charging any other devices can cause serious injury or damage, and is therefore prohibited.

The following power sources may be charged:

Fronius AccuPocket 150/400

Fronius AccuPocket 150/400 TIG

Fronius Ignis 150 B /750

The charger is intended solely for commercial use.

Before commissioning

Mains connection

Generatorpowered operation

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 required fuse protection for the mains lead, see theTechnical data section on page 80. If there is no mains cable or mains plug on your version of the appliance, fit one that conforms to national standards.

CAUTION!

Danger due to insufficiently dimensioned electrical installations.

This can result in serious damage to property.

The mains lead and its fuse must be dimensioned to suit the local power sup-

▶

ply. Read the technical data on the rating plate.

▶

The charger is completely generator-compatible, provided the maximum apparent power delivered by the generator is at least 2 kVA. This also applies if the generator in question is an inverter.

NOTE!

The voltage delivered by the generator must never exceed the upper or lower limits of the mains voltage tolerance range.

Setup regulations

Details on the mains voltage tolerance can be found in the Technical data section on page 80.

WARNING!

Danger from machines toppling over or falling.

This can result in serious personal injury and damage to property.

Set up the device securely on an even, solid surface.

▶

Check all screw connections are tightly fastened after installation.

▶

The device is tested to IP40 protection, meaning:

Protection against penetration by solid foreign bodies with diameters > 1.0

mm (0.04 in.) Protection against spraywater at any angle up to 60° to the vertical when fan

is not running.

Dust

Ensure that metallic dust is not sucked into the system by the fan, when carrying out grinding for example.

Outdoor operation

The device can be set up and operated outdoors in accordance with IP40 degree of protection. Avoid direct wetting (e.g. from rain).

Space require-

100 mm

3.9 inch

168 mm

6.6 inch

275 mm

10.8 inch

ments

If the charger is installed in a switch cabinet (or a similar sealed area), then forced-air ventilation must be provided to ensure adequate heat dissipation. There should be an all-round clearance of 10 cm (3.9 in.) around the charger.

Control elements and connections

(1) (2) (3)

CHARGING

ActiveCharger 1000

QUICK CHA RGING

QUICK

CHARGE

QUICK

CHARGE

COMPLETED

(5)(4)

(1)

(2)

(3)

(6)

Safety

Connections and components

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

(1) Mains cable

for connection to the mains

(2) Connection P1 - charging lead

socket

to plug in the charging cable for connection to the power source

Control panel

(3) Control panel

(1) CHARGING indicator (green)

Charging in progress

(2) QUICK CHARGING indicator

(green)

Quick charging in progress

(3) COMPLETED indicator (green)

Power source fully charged

(4) Error indicator (red)

See section Troubleshooting on page 79

(5) Mains indicator (green)

Mains supply voltage available

(6) QUICK CHARGE button

Starts and stops quick charging

Start-up

Safety

Commissioning

WARNING!

Danger from incorrect operation and work that is not carried out properly.

This can result in serious personal injury and damage to property.

All the work and functions described in this document must only be carried

▶

out by technically trained and qualified personnel. Read and understand this document in full.

▶

Read and understand all safety rules and user documentation for this device

▶

and all system components.

If the battery is fully charged:

NOTE!

The system includes the following features for maximum user-friendliness:

▶ ▶

Once connected, the battery capacity indicator on the power source

ﬂashes to indicate the current state of charge; the battery is being charged

Select Quick Charge mode if required - details on the available operating modes can be found in the following section

The COMPLETED indicator lights up on the charger

On the power source, all segments of the battery capacity indicator are

lit

It does not matter in what order the devices are connected to the mains The power source can even be connected to the charger while it is in use

Operating modes Charging

Starts automatically when the battery charger is connected to the power source and the mains

The CHARGING indicator is lit

Mains indicator lit The power source is charged at optimum charging power The charging characteristic of this mode maximises the service life of the power source

When the COMPLETED indicator lights up, the power source is fully charged and the battery charger switches to conservation charging mode

Quick charging

Activation:

Press the QUICK CHARGING button

The QUICK CHARGING indicator is lit

Mains indicator lit The power source is charged at the maximum possible charging power

When the COMPLETED indicator lights up, the power source is fully charged and the battery charger switches to conservation charging mode

Deactivation:

Press the QUICK CHARGING button again

Charging mode resumes

Conservation charging

Starts automatically once the battery charger has fully charged the power source

Mains indicator lit

The COMPLETED indicator is lit The power source is charged at conservation charging power In this mode, the power source can remain connected to the charger without being damaged.

Hybrid mode

= the battery charger is charging the power source while the power source is in operation

Acivation:

Start welding during charging

or connect the power source to the charger while it is in operation

The QUICK CHARGING indicator is lit (charging at the maximum possible charging power in hybrid mode)

Mains indicator lit The power source is discharged according to its operating load and simultaneously re-charged by the charger

Options

~ 120 mm

~ 4.72 inch

130 mm

5.12 inch

Fitting the wall bracket

NOTE!

Depending on the underlying surface, different wall plugs and screws are 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 correct wall plugs and screws.

1 2

Troubleshooting

QUICK

CHARGE

QUICK

CHARGE

Safety

Indicated errors

WARNING!

Danger from electric current.

An electric shock can be fatal.

Do not open the device.

▶

Error ﬂashing, mains lit

Cause: Remedy:

Error ﬂashing, mains ﬂashing

Cause: Remedy:

Error lit, mains lit

Cause: Remedy:

Battery fault Contact After-Sales Service

Mains fault (overvoltage or undervoltage) Check mains supply voltage (see Technical data)

Charger fault Contact After-Sales Service

An error is signalled by the following indicators ﬂashing or lighting up:

Error indicator Mains indicator

No function

Mains fuse or automatic circuit breaker trips

Cause: Remedy:

Mains fuse underrated/incorrect circuit breaker Fuse mains correctly (see Technical data)

Mains fuse trips in open circuit Contact After-Sales Service

Technical data

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.)

Technical data 230V

Mains voltage ~ 230 V AC, ±15%

Grid frequency 50/60 Hz

Mains current max. 9.5 A eff.

Mains fuse protection max. 16 A

Efficiency max. 95 %

Effective power max. 1100 W

Apparent power max. 2370 VA

Power input (stand-by) max. 2.1 W

Safety class I (with ground conductor)

Maximum permitted mains impedance at the interface (PCC) to the public grid

EMC emission class A

Mark of conformity CE

Output voltage range 30 - 58 V DC

Output current max. 18 A DC

Output power max. 1040 W

Cooling Convection and fan

Dimensions L x W x H 270 x 168 x 100 mm

Weight (without cable) Approx. 2 kg

Protection class IP43S

Overvoltage category Device may only be operated on neutralearthed networks.

None

Standards 230V

EN 62477-1

EN 60974-10 (Class A)

Technical data 120V

Mains voltage ~ 120 V AC, ±15%

Grid frequency 50/60 Hz

Mains current max. 15 A eff.

Mains fuse protection max. 20 A

Efficiency max. 94 %

Effective power max. 1100 W

Apparent power max. 1900 VA

Power input (stand-by) max. 1.6 W

Safety class I (with ground conductor)

Maximum permitted mains impedance at the interface (PCC) to the public grid

EMC emission class A

Output voltage range 30 - 58 V DC

Output current max. 18 A DC

Output power max. 1000 W

Cooling Convection and fan

Dimensions L x W x H 270 x 168 x 100 mm

Weight Approx. 2 kg

Protection class IP43S

Overvoltage category Device may only be operated on neutralearthed networks.

None

Standards 120V

UL 1012

C22.2 No.107.1-01

FCC CFR 47 Part 15 (Class A)

Technical data 100V

Mains voltage ~ 100 - 110 V AC, +10% /

-15%

Grid frequency 50/60 Hz

Mains current max. 15.7 A eff.

Mains fuse protection max. 16 A

Efficiency max. 92 %

Effective power max. 940 W

Apparent power max. 1600 VA

Power input (stand-by) max. 1.6 W

Safety class I (with ground conductor)

Maximum permitted mains impedance at the interface (PCC) to the public grid

EMC emission class A

Output voltage range 30 - 58 V DC

Output current max. 15 A DC

Output power max. 840 W

Cooling Convection and fan

Dimensions L x W x H 270 x 168 x 100 mm

Weight Approx. 2 kg

Protection class IP43S

Overvoltage category Device may only be operated on neutralearthed networks.

None

Standards 100V

EN 62477-1

EN 60974-10 (Class A)

Fronius International GmbH

Froniusstraße 1

4643 Pettenbach

Austria

contact@fronius.com

www.fronius.com

Under www.fronius.com/contact you will find the adresses

of all Fronius Sales & Service Partners and locations.

spareparts.fronius.com

SPAREPARTS

ONLINE

Fronius AccuPocket 150/400 TIG, ActiveCharger 1000 Operating Instruction [EN]

Specifications and Main Features

Frequently Asked Questions

User Manual