Fronius ActiveCharger 1000 Operating Instructions Manual Download Page 54

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Poor weld properties

(severe spattering)

Cause:

Incorrect electrode polarity

Remedy:

Reverse electrode polarity (refer to manufacturer's instructions)

Cause:

Poor grounding (earthing) connection

Remedy:

Fasten earthing clamps directly to workpiece

Cause:

Setup parameters not ideal for selected welding process

Remedy:

Select the optimal settings in the Setup menu for the selected welding pro

cess

Tungsten electrode melting

Tungsten inclusions in base metal during the ignition phase

Cause:

Incorrect tungsten electrode polarity

Remedy:

Connect the TIG welding torch to the (-) current socket

Cause:

Incorrect (or no) shielding gas

Remedy:

Use inert shielding gas (argon)

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

Cause:

VRD option not present

or internal device fault

Remedy:

Contact after-sales service

Summary of Contents for ActiveCharger 1000

Page 1: ...rine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy 42 0426 0176 EN 032 20012020 AccuPocket 150 400 ActiveCharger 1000 Operating Instructio...

Page 2: ...2...

Page 3: ...rom escaping shielding gas 16 Safety precautions in the place of use and for storage and transport 17 Safety measures in normal operation 17 Safety inspection 17 Commissioning maintenance and repair 1...

Page 4: ...e Setup menu 44 Accessing the Setup menu 44 Changing welding parameters 44 Exiting the Setup menu 44 Parameters for MMA welding 44 Parameters for TIG welding 45 VRD safety device optional 47 General 4...

Page 5: ...ng 64 Operating modes 65 Options 66 Fitting the wall bracket 66 Troubleshooting 67 Safety 67 Indicated errors 67 No function 67 Technical data 68 Operating environments 68 Technical data 230V 68 Stand...

Page 6: ...6...

Page 7: ...Safety rules...

Page 8: ......

Page 9: ...10 C to 40 C 14 F to 104 F during transport and storage 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 Relative humidity up to 50 at 40 C 104 F up...

Page 10: ...n 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 a...

Page 11: ...ed 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 devic...

Page 12: ...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 wel...

Page 13: ...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 rele...

Page 14: ...e 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 recha...

Page 15: ...elding 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...

Page 16: ...are Protect shielding gas cylinders containing compressed gas from excessive heat mechan ical impact slag naked flames sparks and arcs Mount the shielding gas cylinders vertically and secure according...

Page 17: ...that cooling air can flow in and out freely When transporting the device observe the relevant national and local guidelines and ac cident prevention regulations This applies especially to guidelines r...

Page 18: ...so applies to standard parts Do not carry out any modifications alterations etc to the device without the manufac turer s consent Components that are not in perfect condition must be replaced immediat...

Page 19: ...nformation 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 Environmental conditions Operati...

Page 20: ...ds must be secured undamaged insulated and adequately dimen sioned Loose connections scorched damaged or inadequately dimensioned cables and leads must be immediately repaired by authorised personnel...

Page 21: ...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 Do not carry out a...

Page 22: ...of an incorrect ex tension 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 th...

Page 23: ...Power source...

Page 24: ......

Page 25: ...ng mode can be selected to ensure perfect welding results TIG welding with touchdown ignition greatly extends the range of applications Warning notices on the device The warning notices and safety sym...

Page 26: ...26 Application areas MMA welding TIG welding with gas valve torch...

Page 27: ...t battery hand the power source over to a Fronius Service Part ner Storage and transport When storing or transporting the power source observe the environmental conditions in the Technical data sectio...

Page 28: ...ttery is completely discharged before recharging it Protect the power source from extreme influences Optimum environmental conditions for operation and storage Temperature 15 C to 25 C 59 F to 77 F Hu...

Page 29: ...e power source switches off automatically after three minutes CAUTION Storing the battery for longer periods in a discharged state may damage the battery If the deep discharge protector is triggered c...

Page 30: ...temperature indicator lights up and cold appears on the display both indicators go out after approx five seconds Repeat the procedure until the battery reaches the required operating temperature throu...

Page 31: ...structions performing all stipulated inspection and maintenance work Setup regulations WARNING Danger from machines falling or toppling over This can result in serious injury and damage to property Pl...

Page 32: ...nnected the battery capacity indicator on the power source flashes to indicate the current state of charge the battery is being charged If the battery is fully charged The COMPLETED indicator lights u...

Page 33: ...ally the safety rules As a result of software updates you may find that there are functions available on your de vice that are not described in these Operating Instructions or vice versa Certain illus...

Page 34: ...elding 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 grou...

Page 35: ...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 s...

Page 36: ...only 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...

Page 37: ...source the welding current indicator lights up the display shows the specified welding current MMA welding Use the welding process button to select one of the following processes MMA welding the MMA w...

Page 38: ...aning fewer cold shut defects Largely prevents slag inclusions Arc force dynam ic To obtain optimum welding results it will sometimes be necessary to adjust the arc force dynamic Setting range 0 100 c...

Page 39: ...namic 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 theoret...

Page 40: ...elding torch into the current socket and turn it clockwise to latch it in place Set up the welding torch in accordance with the welding torch operating instructions Plug the grounding cable into the c...

Page 41: ...e setting value button until the welding current indicator lights up Adjust the welding current using the adjusting dial Place the gas nozzle down on the ignition location ensuring there is a gap of a...

Page 42: ...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 de...

Page 43: ...43 EN 1 Gas pre flow 2 Gas post flow Downslope The downslope time tdown is 0 5 seconds and cannot be adjusted Gas post flow The gas post flow must be carried out manually...

Page 44: ...eter Turn the adjusting dial to change the value The new value becomes effective immediately Exception when restoring the factory settings press the adjusting dial after changing the value to activate...

Page 45: ...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 settings Reset the parameters for all...

Page 46: ...ed for the specified length of time it switches off automat ically Factory setting 900 seconds Factory setting FACtory no YES ALL The power source can be reset to its factory settings here Cancel rese...

Page 47: ...tive Open circuit voltage is limited to 14 V The VRD indicator lights up Example no risk ensues if both wel ding sockets are touched accidentally at the same time VRD is not active The welding circuit...

Page 48: ...all work has been completed WARNING Improper handling can cause injuries or damage Do not open the power source The power source may only be opened by a Fronius service engineer If you need a replace...

Page 49: ...49 EN Every 2 months Clean the air filter if fitted 2 Disposal Dispose of in accordance with the applicable national and local regulations 1...

Page 50: ...source remains disconnected from the mains until all work has been completed WARNING Improper handling can cause injuries or damage Do not open the power source The power source may only be opened by...

Page 51: ...usting dial Make a note of the error numbers shown in the display and of the serial number and con figuration of the power source and contact our after sales service team with a detailed de scription...

Page 52: ...ntrol panel defective Remedy Contact After Sales Service Battery is not charged Power source is connected to the charger charger is connected to the mains no charging indicator on the power source Cau...

Page 53: ...ource then turn it on again If the error occurs frequently contact After Sales Service Faulty operation Poor ignition properties during MMA welding Cause Incorrect welding process selected Remedy Sele...

Page 54: ...medy Select the optimal settings in the Setup menu for the selected welding pro cess Tungsten electrode melting Tungsten inclusions in base metal during the ignition phase Cause Incorrect tungsten ele...

Page 55: ...f the term duty cy cle Duty cycle D C 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 D C values specified on the ra...

Page 56: ...40 A TIG DC 3 150 A Welding current in hybrid mode manual metal arc welding 40 C 104 F 18 D C 1 140 A 40 C 104 F 25 D C 1 100 A 40 C 104 F 100 D C 1 40 A Welding current in hybrid mode TIG welding 40...

Page 57: ...Charger...

Page 58: ......

Page 59: ...urces 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...

Page 60: ...he capacitors is ap prox one minute Proper use The charger is designed to charge the power sources listed below Any use above and be yond this purpose is deemed improper The manufacturer shall not be...

Page 61: ...elivered 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...

Page 62: ...in a switch cabinet or a similar sealed area then forced air ven tilation must be provided to ensure adequate heat dissipation There should be an all round clearance of 10 cm 3 9 in around the charge...

Page 63: ...r vice versa Certain illustrations may also differ slightly from the actual controls on your device but these controls function in exactly the same way Connections and components 1 Mains cable for con...

Page 64: ...ted 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 operat...

Page 65: ...ully 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...

Page 66: ...g 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 corr...

Page 67: ...dy Contact After Sales Service Error flashing mains flashing Cause Mains fault overvoltage or undervoltage Remedy Check mains supply voltage see Technical data Error lit mains lit Cause Charger fault...

Page 68: ...gases or substances etc Can be used at altitudes up to 2000 m 6561 ft Technical data 230V Mains voltage 230 V AC 15 Mains frequency 50 60 Hz Mains current max 9 5 A eff Mains fuse max 16 A Efficiency...

Page 69: ...mpedance at the inter face PCC to the public grid none EMC device class A Mark of conformity cT Vus Output voltage range 30 58 V DC Output current max 18 A DC Output power max 1000 W Cooling Convectio...

Page 70: ...PCC to the public grid none EMC device class A Mark of conformity CE Output voltage range 30 58 V DC Output current max 18 A DC Output power max 840 W Cooling Convection and fan Dimensions l x w x h 2...

Page 71: ...71 EN...

Page 72: ...TERNATIONAL GMBH Froniusstra e 1 A 4643 Pettenbach Austria E Mail sales fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and...

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