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/ Perfect Charging / Perfect Welding / Solar Energy
TransPocket 180 RC HW
Operating Instructions
Robot option
EN-US
42,0426,0267,EA 002-06022019
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Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarize yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features your Fronius product has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN-US
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Contents
Safety Instructions ..................................................................................................................................... 7
Explanation of Safety Instructions......................................................................................................... 7
General ................................................................................................................................................. 7
Intended Use......................................................................................................................................... 8
Environmental Conditions ..................................................................................................................... 8
Obligations of the Operating Company................................................................................................. 8
Obligations of Personnel....................................................................................................................... 9
Grid Connection .................................................................................................................................... 9
Residual current circuit breaker ............................................................................................................ 9
Personal Protection and Protection of Others....................................................................................... 9
Data regarding Noise Emission Values ................................................................................................ 10
Danger from Toxic Gases and Vapors.................................................................................................. 10
Danger from Flying Sparks ................................................................................................................... 11
Risks from Grid Current and Welding Current ...................................................................................... 11
Stray Welding Currents......................................................................................................................... 12
EMC Device Classifications .................................................................................................................. 12
EMC Measures ..................................................................................................................................... 12
EMF measures...................................................................................................................................... 13
Particular Hazard Areas........................................................................................................................ 13
Undesired Welding Results................................................................................................................... 14
Danger from Shielding Gas Cylinders................................................................................................... 14
Safety Measures at the Setup Location and During Transport ............................................................. 15
Safety Measures in Normal Operation.................................................................................................. 15
Maintenance and repair ........................................................................................................................ 16
Safety Inspection .................................................................................................................................. 16
Disposal ................................................................................................................................................ 17
Safety Symbols ..................................................................................................................................... 17
Backup .................................................................................................................................................. 17
Copyright............................................................................................................................................... 17
General ...................................................................................................................................................... 18
Device concept ..................................................................................................................................... 18
Warning Notices on the Device............................................................................................................. 19
Application Example ............................................................................................................................. 20
Before installation ...................................................................................................................................... 21
Safety.................................................................................................................................................... 21
Intended Use......................................................................................................................................... 21
Setup Regulations................................................................................................................................. 21
Generator-powered Operation .............................................................................................................. 21
Operating controls, connections and mechanical components.................................................................. 23
Safety.................................................................................................................................................... 23
Operating Controls, Connections, and Mechanical Components ......................................................... 24
Control Panel ........................................................................................................................................ 25
Connecting and Starting the Power Source............................................................................................... 26
Configuring the TIG Multi Connector Plug ............................................................................................ 26
Installing the Power Source .................................................................................................................. 26
Starting Pre-heating .............................................................................................................................. 27
Setup Menu................................................................................................................................................ 28
Accessing the Setup Menu ................................................................................................................... 28
Adjusting Parameters............................................................................................................................ 28
Exiting the Setup Menu......................................................................................................................... 28
Setup Menu Parameters ....................................................................................................................... 28
Setup Menu 2nd Level ............................................................................................................................... 29
Setup Menu 2nd Level Parameters ...................................................................................................... 29
Service, maintenance and disposal ........................................................................................................... 31
Safety.................................................................................................................................................... 31
General ................................................................................................................................................. 31
During Each Start-up ............................................................................................................................ 31
Every Two Months ................................................................................................................................ 32
Disposal ................................................................................................................................................ 32
Fault Correction ......................................................................................................................................... 33
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Safety.................................................................................................................................................... 33
Displayed Faults ................................................................................................................................... 33
Service messages................................................................................................................................. 34
No Function........................................................................................................................................... 35
Technical Data ........................................................................................................................................... 37
Explanation of the Term Duty Cycle ..................................................................................................... 37
Technical Data ...................................................................................................................................... 38
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Safety Instructions
EN-US
Explanation of
Safety Instructions
DANGER!
Indicates an immediate danger.
► Death or serious injury may result if appropriate precautions are not taken.
WARNING!
Indicates a possibly dangerous situation.
► Death or serious injury may result if appropriate precautions are not taken.
CAUTION!
Indicates a situation where damage or injury could occur.
► Minor injury or damage to property may result if appropriate precautions are not taken.
NOTE!
Indicates the possibility of flawed results and damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety Rules," special care is required.
General The device has been manufactured using state-of-the-art technology and according to rec-
ognized 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 equipment
All persons involved in the commissioning, operation, maintenance, and servicing of the
device must
- Be suitably qualified
- Have knowledge of welding
- Have completely read and followed these Operating Instructions
The Operating Instructions must always be at hand wherever the device is being used. In
addition to the Operating Instructions, all applicable local rules and regulations regarding
accident prevention and environmental protection must also be followed.
All safety and danger notices on the device must
- Be kept in a legible state
- Not be damaged/marked
- Not be removed
- Not be covered, pasted, or painted over
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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, remove any faults that could compromise safety.
Your personal safety is at stake!
Intended Use The device is to be used exclusively for its intended purpose.
The device is intended exclusively for the welding process specified on the rating plate.
Utilization for any other purpose, or in any other manner, shall be deemed to be "not in accordance with the intended purpose." The manufacturer is not responsible for any damage
resulting from improper use.
Proper use also means
- Completely reading and obeying all instructions in the Operating Instructions
- Completely reading and obeying all safety instructions and danger notices
- Carrying out all the specified inspection and servicing work
Never use the device for the following applications:
- Thawing pipes
- Charging batteries
- Starting motors
The device is designed for operation in industry and business. The manufacture shall not
be liable for any damage resulting from use in a living area.
Environmental
Conditions
Obligations of the
Operating Company
The manufacture shall also not be liable for faulty or incorrect work results.
Operation or storage of the device outside the stipulated area will be deemed as not in accordance with the intended purpose. The manufacturer accepts no liability for any damage
resulting from improper use.
Temperature range of the ambient air:
- During operation: -10°C to +40°C (14°F to 104°F)
- During transport and storage: -20°C to +55°C (-4°F to 131°F)
Relative humidity:
- Up to 50% at 40°C (104°F)
- Up to 90% at 20°C (68°F)
Ambient air: free of dust, acids, corrosive gases or substances, etc.
Altitude above sea level: up to 2000 m (6561 ft. 8.16 in.)
The operating company must only allow persons to work with the device if they
- Are familiar with the basic occupational safety and accident prevention regulations
and are trained in handling the device
- Have read and understood these Operating Instructions, especially the section "Safety Rules," and have confirmed this with their signature
- Are trained according to the requirements for the work results
The safety-conscious work of the personnel must be checked regularly.
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Obligations of
Personnel
All persons who are assigned to work with the device must do the following before beginning the work:
- Follow the basic regulations for occupational safety and accident prevention
- Read these Operating Instructions, especially the section "Safety Rules," and confirm
that they have understood and will follow them by signing
Before leaving the workplace, ensure that no personal injury or property damage can occur
in one's absence.
Grid Connection Devices with a high output can influence the energy quality of the grid due to their current
consumption.
This may affect a number of device types in terms of:
- connection restrictions
- criteria regarding maximum permissible grid impedance
- criteria regarding the minimum required short-circuit power
*)
both at the interface with the public grid
*)
*)
See technical data
In this case, the operator or the person using the device should check whether or not the
device is allowed to be connected, where appropriate through discussion with the power
supply company.
EN-US
Residual current
circuit breaker
Personal Protection and Protection of Others
IMPORTANT! Ensure secure grounding of the grid connection!
Local regulations and national guidelines may mean that a residual current circuit breaker
is required when connecting a device to the public grid.
The residual current circuit breaker recommended for the device by the manufacturer can
be found in the technical data.
You are exposed to numerous hazards while handling the device, for example:
- Flying sparks and pieces of hot metal
- Arc radiation that poses a risk of injury to the eyes and skin
- Hazardous electromagnetic fields that pose a risk of death for individuals with pacemakers
- Electrical risks from grid current and welding current
- Increased noise exposure
- Harmful welding fumes and gases
Wear suitable protective clothing when dealing with the device. The protective clothing
must have the following properties:
- Flame resistant
- Insulating and dry
- Covering the entire body and in good condition with no damage
- Safety helmet
- Cuffless pants
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Protective clothing involves the following:
- Protecting the face and eyes from UV radiation, heat and flying sparks with a face
guard featuring a regulation-compliant filter
- Wearing regulation-compliant protective goggles with side protection behind the face
guard
- Wearing rigid, wet-insulating footwear
- Protecting hands with appropriate gloves (featuring electrical insulation and thermal
protection)
- Wearing ear protection to reduce noise exposure and protect against injury
Keep persons, especially children, away during the operation of the devices and during the
welding process. If persons are in the vicinity, however:
- Instruct them about all hazards (blinding hazard due to arcs, risk of injury from flying
sparks, welding fumes hazardous to health, noise exposure, possible hazard due to
grid current or welding current, etc.)
- Provide suitable protective equipment or
- Construct suitable protective walls and curtains.
Data regarding
Noise Emission
Values
Danger from Toxic Gases and Vapors
The device produces a maximum noise level of <80 dB(A) (ref. 1pW) when idling and in
the cooling phase following operation in relation to the maximum permitted operating point
at standard loading in accordance with EN 60974-1.
A workplace-specific emission value for welding (and cutting) cannot be specified because
this value depends on the welding process and the environmental conditions. It is influenced by a wide range of parameters, such as the welding process itself (MIG/MAG, TIG
welding), the selected current type (direct current, alternating current), the power range,
the type of weld metal, the resonance properties of the workpiece, the workplace environment, and many other factors.
The fumes produced during welding contain toxic gases and vapors.
Welding fumes contain substances that may cause birth defects and cancer in some circumstances.
Keep your head out of the welding fumes and gases.
Take the following precautionary measures for fumes and harmful gases:
- Do not breathe them in
- Extract them from the work area using appropriate equipment
Ensure there is a sufficient supply of fresh air with a ventilation flow rate of at least 20 m³
per hour.
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Use breathing apparatus with air supply if there is insufficient ventilation.
When no welding is taking place, close the valve of the shielding gas cylinder or the main
gas supply.
If there is uncertainty as to whether the extraction capacity is sufficient, compare the measured toxic emission values against the permissible limit values.
The following components are factors that determine how toxic the welding fumes are:
- The metals used for the workpiece
- Electrodes
- Coatings
- Cleaning agents, degreasers, and the like
Consult the corresponding material safety data sheets and manufacturer's instructions for
the components listed above.
Keep flammable vapors (such as solvent vapors) out of the arc radiation range.
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Danger from Flying Sparks
Flying sparks can cause fires and explosions.
Never undertake welding near flammable materials.
Flammable materials must be kept at least 11 meters (36 ft. 1.07 in.) from the arc or protected with a certified cover.
Keep suitable, tested fire extinguishers on hand.
Sparks and pieces of hot metal may also get into surrounding areas through small cracks
and openings. Take appropriate measures to ensure that there is no risk of injury or fire.
Do not undertake welding in areas at risk of fire and explosion, or on sealed tanks, drums,
or pipes if these have not been prepared in accordance with corresponding national and
international standards.
Do not undertake welding on containers in which gases, fuels, mineral oils, and the like are/
were stored. Residues pose a risk of explosion.
EN-US
Risks from Grid
Current and
Welding Current
An electric shock is life-threatening and may be deadly.
Do not touch voltage-carrying parts inside or outside of the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the feed rollers, as well as all pieces of metal that are in contact with the welding wire, are live.
Always place the wirefeeder on a sufficiently insulated base or use a suitable insulating
wirefeeder holder.
Ensure suitable personal protection with dry temporary backing or cover with sufficient insulation against the ground potential. The temporary backing or cover must completely
cover the entire area between the body and the ground potential.
All cables and leads must be secured, undamaged, insulated, and adequately dimensioned. Replace loose connections and scorched, damaged, or inadequately dimensioned
cables and leads immediately.
Before every use, check power connections for secure fit by hand.
In the case of power cables with bayonet connectors, turn the power cable by at least 180°
around the longitudinal axis and pretension.
Do not wrap cables or leads around your body or parts of the body.
Concerning the electrode (rod electrode, tungsten electrode, welding wire, etc.)
- never immerse it in liquids to cool it
- never touch it when the power source is switched on.
The open circuit voltage of a welding system may double, for example, between the electrodes of two welding systems. Touching the potentials of both electrodes at the same time
may be life-threatening in some cases.
Have the grid and device supply lead regularly inspected by an electrician to ensure that
the ground conductor is functioning properly.
Only operate the device on a grid with a ground conductor and a socket with a ground conductor contact.
Operating the device on a grid without a ground conductor and on a socket without a
ground conductor contact is considered gross negligence. The manufacturer accepts no
liability for any damage resulting from improper use.
Use suitable equipment to ensure that the workpiece is sufficiently grounded if necessary.
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Switch off unused devices.
When working at elevated heights, wear a safety harness to prevent falls.
Before working on the device, switch off the device and remove the grid plug.
Secure the device to prevent the grid plug from being connected and switched on again by
applying a clearly legible and understandable warning sign.
After opening the device:
- Discharge all electrically charged components
- Ensure that all components are disconnected from the power supply
If work is needed on voltage-carrying parts, bring in a second person who will switch off the
main switch at the correct time.
Stray Welding
Currents
EMC Device Classifications
If the following instructions are not observed, stray welding currents may occur, which pose
a risk of the following:
- Fire
- Overheating of components connected to the workpiece
- Destruction of ground conductors
- Damage to the device and other electrical equipment
Ensure that the workpiece terminal is securely connected to the workpiece.
Secure the workpiece terminal as close to the spot to be welded as possible.
If the floor is electrically conductive, ensure that there is sufficient insulation between the
device and the floor.
Observe the following when using electrical distributors, double-headed retainers, etc.:
Even the electrode of the welding torch/electrode holder not in use carries electric potential. Ensure that there is sufficient insulation when the unused welding torch/electrode holder is stored.
In automated MIG/MAG applications, only guide the wire electrode from the welding wire
drum, large spool or wirespool to the wirefeeder with insulation.
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 low-voltage grid.
EMC device classification as per the rating plate or technical data.
EMC Measures In certain cases, even though a device complies with the standard limit values for emis-
sions, 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.
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Test and assess the immunity of equipment in the vicinity of the device in accordance with
national and international provisions. Examples of interference-prone equipment that could
be affected by the device:
- Safety devices
- Grid power lines, signal lines and data transfer lines
- EMC and telecommunications equipment
- Devices for measuring and calibrating
Supporting measures to avoid EMC problems:
1. Grid power supply
- If electromagnetic interference occurs despite a grid connection that complies
with regulations, take additional measures (e.g., use a suitable grid filter).
2. Welding power-leads
- Keep them as short as possible
- Route them close together (also to avoid EMF problems)
- Route them far from other lines
3. Equipotential bonding
4. Workpiece grounding
- If necessary, establish grounding using suitable capacitors
5. Shield, if necessary
- Shield other devices in the vicinity
- Shield the entire welding installation
EN-US
EMF measures Electromagnetic fields may cause health problems that are not yet known:
- Effects on the health of persons close by, e.g., those with pacemakers and hearing
aids
- Persons with pacemakers must seek advice from their doctor before staying in the immediate vicinity of the device and the welding process
- Keep distances between welding cables and the head/torso of the welder as large as
possible for safety reasons
- Do not carry welding cables and hosepacks over one's shoulder or wrap them around
one's body or body parts
Particular Hazard
Areas
Keep hands, hair, loose clothing, and tools away from moving parts, such as:
- fans
- gears
- rollers
- shafts
- wirespools and welding wires.
Do not reach into rotating gears of the wire drive or into rotating drive parts.
Covers and side parts must only be opened/removed during maintenance and repair work.
During operation:
- Ensure that all covers are closed, and all side parts have been mounted properly.
- Keep all covers and side parts closed.
The protrusion of welding wire from the welding torch represents a high risk of injury (cuts
to the hand, facial and eye injuries, etc.)
Therefore always hold the welding torch away from the body (devices with wirefeeder) and
use suitable protective goggles.
Do not touch the workpiece during or after welding—burning hazard.
Slag may fly off cooling workpieces. Therefore, also wear regulation-compliant protective
equipment when reworking workpieces and ensure that other persons are sufficiently protected.
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Leave the welding torch and other parts with a high operating temperature to cool before
working on them.
Special regulations apply in areas at risk of fire or explosion
– follow the appropriate national and international regulations.
Power sources for work in areas with increased electrical hazard (e.g. boilers) must be labeled with the symbol (Safety). However, the power source may not be located in such areas.
Risk of scalding due to leaking coolant. Switch off the cooling unit before disconnecting
connections for the coolant supply or return.
When handling coolant, observe the information on the coolant safety data sheet. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
Only use suitable load-carrying equipment from the manufacturer when transporting devices by crane.
- Attach chains or ropes to all designated attachments of the suitable load-carrying
equipment.
- Chains or ropes must be the smallest angle possible from vertical.
- Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
In the event of crane attachment of the wirefeeder during welding, always use a suitable,
insulating wirefeeder hoisting attachment (MIG/MAG and TIG devices).
Undesired Welding Results
If the device is equipped with a carrier belt or handle, then this is used exclusively for transport by hand. The carrier belt is not suitable for transport by crane, counterbalanced lift
truck or other mechanical lifting tools.
All lifting equipment (belts, buckles, chains, etc.), which is used in association with the device or its components, must be checked regularly (e.g. for mechanical damage, corrosion,
or changes due to other environmental influences).
The test interval and scope must at least comply with the respective valid national standards and guidelines.
There is a risk of colorless, odorless shielding gas escaping without notice if an adapter is
used for the shielding gas connection. Use suitable Teflon tape to seal the thread of the
shielding gas connection adapter on the device side before installation.
The following specifications concerning shielding gas quality must be met in order to ensure the safe and proper function of the welding system:
- Solid particle size < 40 μm
- Pressure condensation point < -20 °C
- Max. oil content < 25 mg/m³
Use filters if necessary.
IMPORTANT! Ring lines in particular pose a risk of contamination.
Danger from
Shielding Gas
Cylinders
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Shielding gas cylinders contain compressed gas and may explode if damaged. Shielding
gas cylinders are an integral part of the welding equipment, so they must be handled very
carefully.
Protect shielding gas cylinders with compressed gas from excessive heat, mechanical impact, slag, open flames, sparks, and arcs.
Mount the shielding gas cylinders vertically and secure them in accordance with instructions so they cannot fall over.
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Keep shielding gas cylinders away from welding or other electrical circuits.
Never hang a welding torch on a shielding gas cylinder.
Safety Measures
at the Setup Location and During
Transport
Never touch a shielding gas cylinder with an electrode.
Risk of explosion: Never weld on a compressed shielding gas cylinder.
Always use suitable shielding gas cylinders for the application in question and the correct
matching accessories (controller, hoses, and fittings, etc.) Only use shielding gas cylinders
and accessories that are in good condition.
If a valve on a shielding gas cylinder is open, turn your face away from the outlet.
When no welding is taking place, close the valve of the shielding gas cylinder.
Leave the cap on the valve of the shielding gas cylinder when the cylinder is not connected.
Follow the manufacturer's instructions and applicable national and international provisions
for shielding gas cylinders and accessories.
A toppling device can be deadly! Set up the device securely on an even, solid surface
- The maximum permitted tilt angle is 10°.
Special regulations apply in areas at risk of fire or explosion
- Follow the appropriate national and international regulations.
Use instructions and checks within the company to ensure that the vicinity of the workplace
is always clean and organized.
EN-US
Safety Measures
in Normal Operation
Only set up and operate the device in accordance with the protection class shown on the
rating plate.
When setting up the device, ensure that there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to allow cooling air to circulate unhindered.
Take care to ensure that the applicable national and regional guidelines and accident prevention regulations are observed when transporting the device, especially guidelines concerning hazards during transport and shipment.
Do not lift or transport any active devices. Switch off devices before transport or lifting.
Before transporting the device, completely drain the coolant and dismantle the following
components:
- wirefeeder
- wirespool
- shielding gas cylinder
It is essential to conduct a visual inspection of the device to check for damage after it has
been transported but before commissioning. Have any damage repaired by trained service
technicians before commissioning the device.
Only operate the device when all safety devices are fully functional. If the safety devices
are not fully functional, there is a danger of:
- 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
Safety devices that are not fully functional must be repaired before the device is switched
on.
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Never bypass or disable safety devices.
Before switching on the device, ensure that no one can be put in danger.
The device must be examined at least once a week for externally detectable damage and
functionality of the safety devices.
Always secure the shielding gas cylinder well and remove before transporting by crane.
Only the original coolant from the manufacturer is suitable for use in our devices due to its
properties (electrical conductivity, anti-freeze, material compatibility, flammability, etc.)
Only use appropriate original coolant from the manufacturer.
Do not mix original coolant from the manufacturer with other coolants.
Only connect system components from the manufacturer to the cooling unit circuit.
If there is damage due to use of other system components or other coolants, the manufacturer accepts no liability for this and all warranty claims are forfeited.
Cooling Liquid FCL 10/20 is not flammable. The ethanol-based coolant is flammable in certain conditions. Only transport the coolant in closed original containers and keep away from
sources of ignition.
Properly dispose of used coolant according to national and international regulations. The
coolant safety data sheet can be obtained from your service center or via the manufacturer’s website.
When the system is cool, always check the coolant level before starting welding.
Maintenance and
repair
Safety Inspection The manufacturer recommends that a safety inspection of the device be performed at least
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.
every 12 months.
The manufacturer recommends calibrating power sources within the same 12-month interval.
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A safety inspection by a certified electrician is recommended:
- After changes
- After alterations
- After repair, care, and maintenance
- At least every 12 months
For the safety inspection, follow the appropriate national and international standards and
guidelines.
You can obtain more information about the safety inspection and calibration from your service center. The service center will provide the necessary documents upon request.
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Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive on Waste Electrical and Electronic Equipment and its implementation as national
law, electrical equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer require must
be returned to your dealer, or you must locate the approved collection and recycling facilities in your area. Ignoring this European Directive may have potentially adverse affects on
the environment and your health!
Safety Symbols Devices with the CE label satisfy the essential requirements of the low-voltage and elec-
tromagnetic compatibility directive (e.g. relevant product standards of the EN 60974 series).
Fronius International GmbH declares that the device complies with Directive 2014/53/EU.
The full text of the EU Declaration of Conformity is available on the following website: http:/
/www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant standards
for Canada and the USA.
Backup The user is responsible for backing up any changes made to the factory settings. The man-
ufacturer accepts no liability for any deleted personal settings.
EN-US
Copyright Copyright of these operating instructions remains with the manufacturer.
Text and illustrations are technically correct at the time of going to print. The right to make
modifications is reserved. 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 operating instructions, we will be most grateful for your comments.
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General
Device concept The power source is specifically designed
to pre-heat welding wires during TIG hotwire welding and has the following characteristics:
- Compact dimensions
- Robust plastic housing
- High reliability even under tough usage
conditions
- Carrier belt for easy transport even on
construction sites
- Securely attached operating elements
- Current sockets with bayonet latch
Additionally, the power source offers Power Factor Correction, meaning the current consumption of the power source is adapted to the sinusoidal grid voltage. This has many advantages for the user, such as:
- Low primary current
- Low conductivity losses
- Late tripping of the power circuit breaker
- Improved stability during voltage fluctuations
- Compatibility with long grid leads
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Warning Notices
on the Device
EN-US
The warning notices and safety symbols located on the power source must not be removed or painted over. They warn against incorrect operation, which may result in serious injury and damage.
Meaning of the safety symbols on the device:
Welding is dangerous. To ensure that this device can be used correctly and
safely, the following basic requirements must be met:
- Adequate welding qualifications
- Appropriate protective equipment
- Keep unauthorized people away from the welding process
Do not use the functions described here until you have fully read and understood
the following documents:
- These Operating Instructions
- All operating instructions for the system components of the power source,
especially the safety rules
Dispose of old devices in accordance with safety rules and not in normal domestic waste.
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Application Example
(5)
(9)
(1) Robot
(2) Workpiece
(3) Welding torch
(4) Wirefeeder
(5) Power cable (positive pole)
(6) Power source
(7) Robot control/power source connection cable
(8) Robot control
(9) Grounding cable (negative pole)
(10) Robot control/robot connection cable
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Before installation
EN-US
Safety
Incorrect operation and incorrectly performed work can cause serious injury and
damage to property.
All work listed in these Operating Instructions may only be performed by trained specialist
personnel. All functions described in these Operating Instructions may only be used by
trained specialist personnel. All work and functions described must only be performed and
used once the following documents have been read and understood in full:
► These Operating Instructions
► All operating instructions for system components, especially the safety rules
Intended Use The power source is intended exclusively for pre-heating welding wires during TIG hot-wire
welding in combination with the manufacturer's system components.
Any other use does not constitute proper use.
The manufacturer is not responsible for any damage resulting from improper use.
Proper use also means:
- Reading these Operating Instructions in their entirety
- Following all instructions and safety rules in these Operating Instructions
- Carrying out all the specified inspection and servicing work
WARNING!
Setup Regulations
Generator-powered Operation
WARNING!
Toppling or falling devices can be deadly.
Securely set up the devices on a level and stable surface.
The device has been tested according to degree of protection IP23. This means:
- Protection against solid foreign bodies larger than Ø 12.5 mm (0.49 in.)
- Protection against spraywater up to an inclined angle of 60°
Cooling air
The device must be set up so that cooling air can flow through the air vents on the front
and back unhindered.
Dust
Ensure that any metallic dust is not sucked into the device fan during grinding work, for example.
Operation outdoors
The device can be installed and operated outdoors in accordance with degree of protection
IP23. Avoid the effects of direct moisture (from rain, for example).
The power source is generator-compatible.
The maximum apparent power S
necessary generator output.
of the power source is required for dimensioning the
1max
21
Page 22
The maximum apparent power S
S
= I
1max
I
and U1 according to the device rating plate and technical data
1max
1max
x U1
of the power source is calculated as follows:
1max
The necessary generator apparent power S
is calculated according to the following
GEN
empirical formula:
S
GEN
= S
1max
x 1.35
A smaller generator can be used when not welding at full power.
IMPORTANT! The generator apparent power S
apparent power S
of the power source!
1max
must not be less than the maximum
GEN
When single phase devices are being operated with a 3-phase generator, note that the
stated apparent power of the generator is often just the total that can be present across all
three phases of the generator. If necessary, obtain further information about the singlephase power of the generator from the generator manufacturer.
NOTE!
The specified voltage of the generator must never fall outside of the grid voltage tolerance range.
The grid voltage tolerance is specified in the "Technical Data" section.
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Operating controls, connections and mechanical
components
EN-US
Safety
WARNING!
Operating the device incorrectly can cause serious injury and damage.
Do not use the functions described until you have thoroughly read and understood the following documents:
► these operating instructions
► all operating instructions for system components, especially the safety rules
NOTE!
Because of software updates, certain functions may be available for your device but
not described in these Operating Instructions or vice versa.
In addition, individual figures may also differ slightly from the operating elements of your
device. However, the function of these operating elements is identical.
23
Page 24
Operating Controls, Connections, and
Mechanical Components
(5)
(6)
(7)
(8)
(1) Control panel
(2) (-) current socket
Connect the grounding cable here
(3) TIG Multi Connector
For connecting an external control system
(4) (+) current socket
For connecting the power cable to the wirefeeder
(5) Carry strap
(6) Cable strap
To hold the mains cable and the welding power-leads
Do not use to transport the device!
(7) Power switch
(8) Air filter
24
Page 25
Control Panel
EN-US
(1)
(2)
(6)
(5)
(1) Set value display
displays the currently selected amperage
- The symbol is always lit; the other indicators have no function
(2) Setup button 1
For accessing the Setup menu
(3) Display
(4) Setup button 2
For accessing the Setup menu
(5) Selection dial
To change the amperage | To navigate through the Setup menu
6) Status indicators
Used to indicate the different operating statuses of the power source:
- VRD - No function
- Setup - Lights up when in Setup mode
- Temperature - Lights up when the device is outside of the permitted temperature range
- Error - Lights up when there is an error, also see Fault Correction section on page 33
- TAC - No function
(3)
(4)
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Connecting and Starting the Power Source
Configuring the
TIG Multi Connector Plug
Installing the
Power Source
Connect the TIG Multi Connector plug
1
to the robot control unit and connect
pins B (pink cable) and E (green cable)
with a floating switch
- the pins B and E are needed to
start the pre-heating process
A
G
B
F
H
C
E
D
1
1
26
2
2
Page 27
3
3
* Correctly connect the cable to the wirefeeder
4
4
EN-US
Starting Pre-heating
Set the desired amperage using the selection dial on the control panel of the power
1
source
Activate pre-heating through a signal on the robot control unit (close the switch be-
2
tween pin A and pin E on the TIG Multi Connector plug - also see Configuring the
TIG Multi Connector Plug, on page 26)
NOTE!
The power source will pre-heat the welding wire for as long as the signal from the
robot control unit is active.
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Setup Menu
Accessing the
Setup Menu
Adjusting Parameters
Exiting the Setup
Menu
1
1
2
3
4
1
+ Press both buttons at the same time
- The code of the first parameter from the Setup menu is displayed on the control
panel
Turn the selection dial to select the desired parameter
Press the selection dial to display the set value of the parameter
Press the selection dial to change the value
– The set value is immediately active
– Exception: When resetting to the factory settings, the selection dial needs to be
pressed after changing the value in order to activate the change.
Press the selection dial to go back in the list of parameters
Press Setup 1 or
Setup 2 button to exit the Setup menu
Setup Menu Parameters
Parameter Description Range Unit
Factory setting (FACtory)
Here the device can be reset to its factory settings
- Cancel reset no
- Reset the parameters for the set welding process to the factory settings
- Reset the parameters for all welding processes to the factory settings
Confirm resetting of the selected value to the factory setting by pressing the selection dial!
Setup menu 2nd level
For setting general parameters
For details see "Setup Menu 2nd Level" section
YES
ALL
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Setup Menu 2nd Level
EN-US
Setup Menu 2nd
Level Parameters
Parameter Description Range Unit
Software version
The complete version number of the current software is divided across several displays and can
be viewed by turning the selection dial
Automatic shutdown (time Shut down)
If the device is not used or operated within a set
period of time, it automatically switches into
Standby mode
Pressing a button on the control panel switches off
Standby mode - the device is now ready for welding
Factory setting: OFF
Fuse
To display/set the fuse being used
Factory setting:
- For grid voltage 230 V = 16 A
- For grid voltage 120 V = 20 A
If a fuse is set on the power source, the power
source will limit the current drawn from the grid,
which prevents an immediate tripping of the power
circuit breaker
5 - 60
OFF
At
230 V
10 / 13 /
16 / OFF
At
120 V:
15 / 16 /
20 / OFF
Minutes
Ampere
Relationship between set fuse and pre-heating current:
Grid voltage Set
fuse
10 A 180 A 35%
13 A 180 A 35%
230 V
16 A 180 A 35%
OFF 180 A 35%
15 A 140 A 35%
16 A 140 A 35%
120 V
20 A 170 A 35%
OFF 170 A 35%
Pre-heating current Duty cycle
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Parameter Description Range Unit
Operating duration (System on time)
For displaying the operating duration (count begins as soon as the device is switched on)
The complete operating duration is divided across
several displays and can be accessed by turning
the selection dial
Pre-heating duration (System Active time)
For displaying the pre-heating duration (shows
only the time during which the power source has
been pre-heating the wire electrode)
The complete pre-heating duration is divided
across several displays and can be viewed by
turning the selection dial
Hours,
minutes,
seconds
Hours,
minutes,
seconds
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Service, maintenance and disposal
EN-US
Safety
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
All work described below may only be performed by trained specialist personnel. Do not
perform the work described below until you have thoroughly read and understood the following documents:
► This document
► All operating instructions for system components, especially the safety rules
WARNING!
An electric shock can be fatal.
Before starting the described work:
► Set the power switch of the power source to - O ► Disconnect the power source from the grid
► Ensure that the power source remains disconnected from the grid until all work is com-
plete
After opening the device, use a suitable measuring tool to ensure that electrically charged
components (e.g. capacitors) are discharged.
WARNING!
An inadequate ground conductor connection can cause serious injury and damage
to property.
The housing screws provide an adequate ground conductor connection for grounding the
housing and should not be replaced under any circumstances by other screws that do not
provide a reliable ground conductor connection.
General The device only requires a minimum of service and maintenance under normal operating
conditions. However, several points must be observed in order for the device to remain operational for years to come.
During Each
Start-up
- Ensure that the mains plug and mains cable, as well as the positive cable and grounding cable, are undamaged. Replace damaged components
- Ensure a proper grounding connection to the component
- Ensure that the all-round clearance of the device is 0.5 m (1 ft. 8 in.) so that cooling
air can circulate unimpeded
NOTE!
Air intake and exhaust openings must not be blocked or even partially covered.
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Page 32
Every Two
Months
Clean air filter:
5
1
Disposal Materials should be disposed of according to valid local and national regulations.
32
Page 33
Fault Correction
EN-US
Safety
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
All work described below may only be performed by trained specialist personnel. Do not
perform the work described below until you have thoroughly read and understood the following documents:
► This document
► All operating instructions for system components, especially the safety rules
WARNING!
An electric shock can be fatal.
Before starting the described work:
► Set the power switch of the power source to - O ► Disconnect the power source from the grid
► Ensure that the power source remains disconnected from the grid until all work is com-
plete
After opening the device, use a suitable measuring tool to ensure that electrically charged
components (e.g. capacitors) are discharged.
WARNING!
An inadequate ground conductor connection can cause serious injury and damage
to property.
The housing screws provide an adequate ground conductor connection for grounding the
housing and should not be replaced under any circumstances by other screws that do not
provide a reliable ground conductor connection.
Displayed Faults High temperature
Temperature indication lights up, and "hot" is shown on the display
+
Cause: Operating temperature is too high
Remedy: Leave the device to cool (Do not switch off the device - the fan will cool the
device)
High temperature
Error indication lights up, and "FUS" is shown on the display
+
Cause: The power limiter on the power source has triggered
Remedy: Leave the device to cool (Do not switch off the device - the fan will cool the
device)
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Page 34
Service messages
If "E" and a two-digit error code (e.g., "E02") appears on the display and the fault indication
lights up, this is an internal service code for the power source.
Example:
There can be multiple error codes. These appear by turning the adjustment wheel.
Take note of all displayed error codes as well as the serial number and configuration of the
power source, and then contact the service center with a detailed error description.
E01 - E03 / E11 / E15 / E21 / E33 - E35 / E37 - E40 / E42 - E44 / E46 - E52
Cause: Power module error
Remedy: Inform service team
E04
Cause: Open circuit voltage has not been reached:
Electrode is in contact with the component/hardware defect
Remedy: Remove the electrode support from the component. If the service code con-
tinues to be displayed, contact service team
E05 / E06 / E12
Cause: System start failure
Remedy: Turn device off and on again. If this happens multiple times, inform service
team
E10
Cause: Overvoltage at the current socket (> 113 VDC)
Remedy: Inform service team
E16 / E17
Cause: Memory error
Remedy: Inform service team / press selection dial to acknowledge service message
E19
Cause: Overtemperature or undertemperature
Remedy: Operate device at permitted ambient temperature. For more information
about environmental conditions see "Environmental Conditions" in the "Safety
Rules" section
E20
Cause: Improper use of the device
Remedy: Only use the device in accordance with the intended purpose
E22
Cause: Amperage is set too high
Remedy: Ensure that the power source is being operated at the correct grid voltage; en-
sure the correct fuse is set; set a lower amperage
34
Page 35
E37
Cause: Grid voltage exceeds admissible limits
Remedy: Immediately pull out the mains plug and ensure that the power source is being
operated at the correct grid voltage
E36 E41 E45
Cause: Grid voltage is outside of the tolerance or grid output is insufficient for the con-
nected device(s)
Remedy: Ensure that the power source is being operated at the correct grid voltage; en-
sure the correct fuse is set;
E65 - E75
Cause: Communication error with welding torch/remote control
Remedy: Check TIG Multi Connector plug connection / turn device off and on again /
inform service team if this happens multiple times
No Function Device cannot be switched on
Cause: Defective power switch
Remedy: Inform service team
EN-US
No current for pre-heating the wire electrode
The power source is switched on
Cause: Power cable connection has been interrupted
Remedy: Properly connect power cable
Cause: Poor or no ground earth connection
Remedy: Establish a connection with the workpiece
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Page 36
No current for pre-heating the wire electrode
The device is switched on, overtemperature indication lights up
Cause: Duty cycle exceeded - device overloaded - fan running
Remedy: Observe duty cycle
Cause: Thermal automatic circuit breaker has shut down the device
Remedy: Wait for device to cool down (do not switch off the device - the fan will cool the
device); the power source will switch on again automatically after a short time
Cause: Fan in the power source is faulty
Remedy: Inform service team
Cause: Cooling air supply is insufficient
Remedy: Ensure there is a sufficient air supply
Cause: Air filter is dirty
Remedy: Clean air filter
Cause: Power module error
Remedy: Switch the device off and then on again
If this error persists, inform service team
36
Page 37
Technical Data
EN-US
Explanation of
the Term Duty Cycle
The duty cycle (D.C.) is the period of a ten minute cycle in which the device may be operated at the stated power without overheating.
NOTE!
The D.
C. values cited on the rating plate relate to an ambient temperature of 40 °C. If the ambient
temperature is higher, the D.C. or power must be lowered accordingly.
Example: Welding with 150 A at 60% D.C.
- Welding phase = 60% of 10 mins = 6 mins
- Cool-down phase = rest time = 4 mins
- Following the cool-down phase, the cycle begins again.
60 %
4 Min.6 Min.
150 A
0 A
0 Min.
To use the device without interruptions:
Search for a 100% D.C. value in the technical data, which corresponds to the existing
1
ambient temperature.
Reduce the power or amperage value correspondingly so that the device can operate
2
without a cool-down phase.
10 Min.6 Min.
37
Page 38
Technical Data
Grid voltage (U1) 1 x 240 V
Max. effective primary current (I
Max. primary current (I
) 7 A
1max
) 5 A
1eff
Mains fuse 16 A time-delay fuse
Grid voltage (U1) 1 x 120 V
Max. effective primary current (I
Max. primary current (I
) 13 A
1max
) 9 A
1eff
Mains fuse 15 A time-delay fuse
Grid voltage tolerance -20%/+ 15%
Grid frequency 50/60 Hz
Cos phi 0.99
Recommended residual current circuit breaker Type B
Pre-heating current range (I2) 10 – 180 A
Pre-heating current 10 min/40 °C (104 °F) 35% 60% 100%
U1 (240 V) 180 A 155 A 125 A
U1 (120 V) 170 A 155 A 125 A
Output voltage 6 V
Open circuit voltage (U0 peak) 35 V
Degree of protection IP 23
Type of cooling AF
Overvoltage category III
Degree of pollution according to standard IEC
60664
EMC device class A
Safety symbols S, CE
Dimensions L × W × H 435 x 160 x 310 mm
17.1 x 6.3 x 12.2 in.
Weight 8.9 kg
19.6 lb.
3
38
Page 39
EN-US
39
Page 40
FRONIUS INTERNATIONAL GMBH
Froniusplatz 1, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
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