FRO­NIUS TransPocket 2500 User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0041,EN 001-13072018
TransPocket 2500/3500
TransPocket 2500/3500 RC
TransPocket 2500/3500 TIG
Operating Instructions
Rod electrode power source
EN

2

3
EN
Contents
General ...................................................................................................................................................... 5
Principle ................................................................................................................................................ 5
Device concept ..................................................................................................................................... 5
Application areas .................................................................................................................................. 5
Control elements and connections............................................................................................................. 6
Safety.................................................................................................................................................... 6
Connections .......................................................................................................................................... 6
Operating elements............................................................................................................................... 7
Before commissioning................................................................................................................................ 8
Safety.................................................................................................................................................... 8
Proper use ............................................................................................................................................ 8
Setup regulations .................................................................................................................................. 8
Mains connection .................................................................................................................................. 8
Changing mains voltage (only MVm versions)........................................................................................... 9
General remarks ................................................................................................................................... 9
Mains voltage tolerance range.............................................................................................................. 9
Changing mains voltage ....................................................................................................................... 9
Single-phase operation ......................................................................................................................... 10
MMA welding ............................................................................................................................................. 11
Safety.................................................................................................................................................... 11
Preparations.......................................................................................................................................... 11
Selecting the process............................................................................................................................ 11
Adjusting welding current, igniting the arc ............................................................................................ 11
HotStart function (used with rutile and Cel processes) .........................................................................12
SoftStart function (used with basic process)......................................................................................... 12
Anti-stick function.................................................................................................................................. 12
TIG welding................................................................................................................................................ 13
Safety.................................................................................................................................................... 13
General ................................................................................................................................................. 13
Preparations.......................................................................................................................................... 13
Setting the shielding gas flow rate ........................................................................................................ 13
Selecting the process............................................................................................................................ 14
Adjusting welding current, igniting the arc ............................................................................................ 14
TIG Comfort Stop function .................................................................................................................... 15
The Setup menu ........................................................................................................................................ 17
Setting options ...................................................................................................................................... 17
Functional principle ............................................................................................................................... 17
Setting parameters................................................................................................................................ 17
Arc-force dynamic parameter................................................................................................................ 18
Cel characteristic parameter ................................................................................................................. 18
TIG Comfort Stop parameter ................................................................................................................ 18
Pulsing frequency parameter ................................................................................................................ 19
Voltage Reduction Device (VRD versions only)......................................................................................... 20
General ................................................................................................................................................. 20
Safety principle ..................................................................................................................................... 20
Troubleshooting ......................................................................................................................................... 21
Safety.................................................................................................................................................... 21
Fault diagnosis...................................................................................................................................... 21
Status indicators ................................................................................................................................... 23
Care, maintenance and disposal ............................................................................................................... 25
General ................................................................................................................................................. 25
At every start-up.................................................................................................................................... 25
Every 2 months ..................................................................................................................................... 25
Every 6 months ..................................................................................................................................... 25
Disposal ................................................................................................................................................ 25
Technical data............................................................................................................................................ 26
Safety.................................................................................................................................................... 26

4
Generator-powered operation............................................................................................................... 26
TransPocket 2500, 2500 RC, 2500 TIG................................................................................................ 26
TransPocket 2500 MVm, 2500 TIG MVm .............................................................................................27
TransPocket 3500, 3500 RC, 3500 TIG................................................................................................ 27
TransPocket 3500 MVm, 3500 TIG MVm ............................................................................................28

5
EN
General
Principle
TP 2500 welding system
The TP 2500 and TP 3500 power sources
are a further highlight of the new generation
of inverter power sources. Using powerful
electronics, a unique high-performance,
lightweight welding system has been crea-
ted.
The power source works on resonance in-
verter principles and therefore offers a
number of advantages:
- Intelligent control for stable arc and
ideal characteristic
- Excellent ignition and weld properties,
extremely lightweight and with a very
small footprint
- High switching frequencies and opti-
mum efficiency
An electronic adjuster adapts the power source characteristic to suit the welding electrode.
Selectable modes provide perfect welding results when using rutile electrodes, basic elec-
trodes or cellulose electrodes (CEL).
Device concept All versions of the TP 2500/3500 power source are small and compact, yet at the same
time so robust that they will function reliably even under harsh conditions. A powder-coated
sheet steel housing with stainless steel runners, controls and connection sockets (with
bayonet fixing) protected by a plastic frame satisfy the highest demands. The handle facil-
itates easy transportation, both in-house or on-site.
In addition to the many features of the standard TP 2500/3500 power source, the TP 2500/
3500 RC, TP 2500/3500 TIG, TP 2500/3500 VRD and TP 2500/3500 MVm versions offer
a further raft of options.
Application areas In addition to manual metal arc welding, the systems in the TP 2500/3500 series also offer
convenient functions for TIG welding, e.g. touchdown ignition and the practical TIG Com-
fort Stop (TCS). The TP 2500/3500 TIG also has the TIG pulsed arc welding mode.
Thanks to their small dimensions, the machines in the TP 2500/3500 series are especially
well suited to portable use on building sites and for assembly work. But even when used
as stationary units in workshops or industrial facilities, the machines are powerful and eco-
nomical alternatives.

6
Control elements and connections
Safety
Connections
Controls and connections on the front and back of the
machine
(1) Mains switch
(2) Shielding gas connection socket (TP 2500/3500 TIG only)
For connecting the gas hose
(3) Dust filter
Where the fan draws in air
- Prevents contamination of the housing interior if large amounts of dust have ac-
cumulated
(4) (+) current socket with bayonet latch
For connecting the:
- Rod electrode or grounding cable for manual metal arc (MMA) welding, depend-
ing on the type of electrode being used
- Grounding cable for TIG welding
WARNING! Operating the equipment 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 the operating instructions for the system components, especially the safe-
ty rules
NOTE! Due to software updates, you may find that your device has certain func-
tions that are not described in these operating instructions or vice versa. Individ-
ual illustrations may also differ slightly from the actual controls on your device, but
these controls function in exactly the same way.
(4)
(6)
(5)
(2)
(3)
(1)
NOTE! The manufacturer strongly recommends that a dust filter be used with
the power source.

7
EN
(5) (-) current socket with bayonet latch
For connecting the:
- Rod electrode or grounding cable for manual metal arc (MMA) welding, depend-
ing on the type of electrode being used
- Welding torch in TIG welding (current connection)
(6) Remote control connection socket
For connecting a remote control
Operating ele-
ments
Controls and indicators on the control panel
(1) "Process" button
For selecting the welding process
- Manual metal arc welding with HotStart function (recommended for rutile elec-
trode)
- Manual metal arc welding with SoftStart function (recommended for basic elec-
trode)
- MMA welding with Cel electrode
- TIG welding
- TIG pulsed arc welding (TP 2500/3500 TIG only)
(2) Remote control indicator
Lights up when a remote control is connected
(3) Error indicator
Lights up if the device is too hot
(4) Welding current adjuster
For continuously adjusting the welding current
(5) VRD indicator
- Lights up green when the Voltage Reduction Device (VRD) is active and the open
circuit voltage is less than 35 V
- Lights up red when the Voltage Reduction Device (VRD) is active and the open
circuit voltage is greater than 35 V
- Does not light up if an open circuit voltage outside the VRD range is set
(3)
(4)
(5)
(1)
(2)
IMPORTANT! The selected welding process remains in memory even after the mains
plug is disconnected.

8
Before commissioning
Safety
Proper use The power source is intended exclusively for MMA welding and TIG welding in conjunction
with system components from Fronius.
Utilisation for any other purpose, or in any other manner, shall be deemed to be not in ac-
cordance with the intended purpose.
The manufacturer shall not be held liable for any damages arising from such usage.
Proper use also includes:
- 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
The device is tested to IP 23 protection, meaning:
- protection against penetration by solid foreign bodies with diameters > 12.5 mm (0.49
in.)
- protection against direct sprays of water at any angle up to 60° from 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 grind-
ing for example.
Outdoor operation
The device can be set up and operated outdoors in accordance with IP23 degree of pro-
tection. Avoid direct wetting (e.g. from rain).
Mains connection The devices are designed for the mains voltage specified on the rating plate. The fuse pro-
tection required for the mains lead can be found in the "Technical data" section. If there is
no mains cable or mains plug on your device, fit one that conforms to national standards.
WARNING! Incorrect operation or shoddy workmanship can cause serious injury
or damage. All activities described in these operating instructions may only be
carried out by trained and qualified personnel. All functions described in these op-
erating instructions may only be used by trained and qualified personnel. Do not
carry out any of the work or use any of the functions described until you have fully
read and understood the following documents:
- these operating instructions
- all the operating instructions for the system components, especially the safe-
ty rules
WARNING! Toppling or falling devices can cause life-threatening injuries. Place
devices on a solid, level surface so that they remain stable.
NOTE! An inadequately dimensioned electrical installation can cause serious
damage. The mains lead and its fuse must be dimensioned to suit the local power
supply. The technical data shown on the rating plate applies.

9
EN
Changing mains voltage (only MVm versions)
General remarks MVm machines (MultiVoltage manual) are suitable for operation with a mains voltage of
380 - 460V and a mains voltage of 200 - 240V.
Detailed information can be found in the "Technical data" chapter.
Mains voltage tol-
erance range
200 V - 240 V
380 V - 460 V
Changing mains
voltage
1 2
NOTE! Machines are supplied with the 380 - 460V setting as standard. If the
mains voltage range needs to be reset, this must be done manually.
180 V ~ 200 V ~ 230 V ~ 253 V ~240 V ~
- 10% + 10%
342 V ~ 380 V ~ 400 V ~ 506 V ~460 V ~
- 10% + 10%
WARNING! An electric shock can be fatal. Before opening the device
- Move the mains switch to the "O" position
- Unplug the device from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrically
charged components (e.g. capacitors) have been discharged
380V - 460V
2
3
1
1
1
1
2

10
1 2
Single-phase op-
eration
MVm machines can be used in single phase operation (e.g. 1x230V) if required. However,
this reduces the welding current range. Please see the "Technical Data" section for the rel-
evant performance data. Fit the mains cable and mains plug in accordance with the appli-
cable national standards.
1
2
3
200V - 240V
2
2
1
3
4

11
EN
MMA welding
Safety
Preparations 1. Plug the welding power-lead into the current socket, depending upon which type of
electrode is to be used, and latch it by turning it clockwise
2. Plug the grounding cable into the current socket, depending on which type of electrode
is to be used, and latch it by turning it clockwise
3. Plug in the mains plug
Selecting the pro-
cess
1. Move the mains switch to the "I" position
2. Select one of the following processes using the Process button:
When welding with rutile electrodes, manual metal arc welding with HotStart
is recommended.
When welding with basic electrodes, manual metal arc welding with SoftStart
is recommended.
When welding with cellulose electrodes, the manual metal arc welding pro-
cess with a Cel electrode must always be selected.
Adjusting weld-
ing current, ignit-
ing the arc
1. Select amperage using welding current adjuster
2. Carry out welding
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. 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, especially the
safety rules
WARNING! An electric shock can be fatal. If the device is plugged into the mains
during installation, there is a high risk of very serious injury and damage. Only car-
ry out work on the device when:
- The mains switch is in the "O" position
- The device is unplugged from the mains
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the rod electrode in the electrode holder is LIVE. Make
sure that the rod electrode does not touch any persons or electrically conductive
or earthed parts (e.g. housing, etc.)

12
HotStart function
(used with rutile
and Cel process-
es)
Example of HotStart function
Benefits:
- Improved ignition properties, even
when using electrodes with poor igniti-
on properties
- Better fusion of the base material du-
ring the start-up phase, meaning fewer
cold-shut defects
- Largely prevents slag inclusions
Mode of operation:
The welding current is raised to a specific value for 1.5 seconds. This value is around 30%
higher than the set welding current
Example: 90 A was set on the adjuster.
The HotStart current is 90 A + 30% = 117 A
SoftStart function
(used with basic
process)
The SoftStart function is intended for basic electrodes. Ignition takes place at a low welding
current. Once the arc is stable, the welding current continues to rise until it reaches the
welding current command value.
Example of SoftStart function
Benefits:
- Improved ignition properties for elec-
trodes that ignite at low welding cur-
rents
- Largely prevents slag inclusions
- Reduces welding spatter
Anti-stick func-
tion
As the arc becomes shorter, the welding voltage may drop so far that the rod electrode will
tend to stick.
The anti-stick function prevents the electrode from burning out. If the rod electrode begins
to stick, the power source switches the welding current off after 1 second. After the rod
electrode has been lifted off the workpiece, the welding operation can be continued without
difficulty.
117A
I (A)
90A
1,5 s t
IMPORTANT! If the welding current is set to 192 A or higher, the HotStart current is limited
to 250 A.
I (A)
90A
30A
t

13
EN
TIG welding
Safety
General
The following applies to the TP 2500/3500 TIG power source: The complete functional
range for TIG welding can only be guaranteed if using the TTG 2200 TCS welding torch.
Preparations 1. Plug the current plug of the TIG welding torch into the "minus" current socket and twist
it clockwise to latch it into place
2. Plug the grounding cable into the (+) current socket and turn it clockwise to latch it in
place
3. Tool up the welding torch (see the Operating Instructions for the torch)
4. Connect the following to the remote control connection socket (TP 2500/3500 TIG):
- Remote control
5. Establish a grounding (earthing) connection to the workpiece
6. Attach pressure regulator to the gas cylinder
If using a gas-valve torch:
- Connect the gas hose to the pressure regulator
If using welding torch TTG 2200 TCS (TP 2500/3500 TIG only):
- Connect pressure regulator to the shielding gas connection socket using gas
hose
- Tighten the union nut
7. Open the gas cylinder valve
8. Plug in the mains plug
Setting the
shielding gas
flow rate
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. 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, especially the
safety rules
WARNING! An electric shock can be fatal. If the device is plugged into the mains
during installation, there is a high risk of very serious injury and damage. Only car-
ry out work on the device when:
- The mains switch is in the "O" position
- The device is unplugged from the mains
NOTE! Do not use pure tungsten electrodes (colour-coded green) if the TIG weld-
ing or TIG pulsed arc welding process is selected.
CAUTION! Risk of injury and damage from electric shock. As soon as the mains
switch is in the "I" position, the tungsten electrode of the welding torch is LIVE.
Make sure that the tungsten electrode does not touch any persons or electrically
conductive or earthed parts (e.g. housing, etc.)

14
If using a gas-valve torch:
1. Move the mains switch to the "I" position
2. Open the gas cut-off valve on the torch or press the torch trigger and set the desired
gas flow rate at the pressure regulator
If using welding torch TTG 2200 TCS (TP 2500/3500 TIG only) to set the gas flow rate:
1. Move the mains switch to the "O" position
2. Press the process button and simultaneously move the mains switch to the "I" position
- All indicators on the control panel flash
- The fan switches on
- The gas solenoid valve picks up
3. Set the desired shielding gas flow rate using the pressure regulator
4. Press the "Process" button
- The indicators on the control panel stop flashing
- The fan switches off (if the temperature allows)
- The gas solenoid valve drops out
Selecting the pro-
cess
1. Select one of the following processes using the Process button:
The following indicator lights up if the TIG welding process is selected:
The following indicator lights up if the TIG pulsed arc process is selected:
Adjusting weld-
ing current, ignit-
ing the arc
1. Select amperage using welding current adjuster
2. Place the gas nozzle in the ignition location so that there is a gap of 2 - 3 mm (0.08 -
0.12 in.) between the tungsten tip and the workpiece Gap exists
3. Gradually tilt up the welding torch until the tungsten electrode touches the workpiece
4. Raise the torch and tilt it into the normal position - the arc now ignites
5. Carry out welding
IMPORTANT! The test gas flow lasts for a maximum of 15 seconds if it is not interrupted
by pressing the Process button.
IMPORTANT! As long as the torch is touching the workpiece, the gas pre-flow takes place
automatically. If the torch and workpiece remain in contact for more than 3 seconds, the
welding current switches off automatically. Place the gas nozzle on the ignition location
again.

15
EN
Torch settings when welding begins
TIG Comfort Stop
function
The "TIG Comfort Stop" function (TCS) is only available with the TP 2500/3500 TIG power
source. The TIG-Comfort-Stop function is deactivated as standard. Activating and setting
the TIG Comfort Stop function is described in the "The Setup menu" section.
If the TIG Comfort Stop function is deactivated, end crater filling through current decrease
or gas shielding of the end crater does not occur. To finish welding lift the torch away from
the workpiece until the arc goes out.
To finish welding with activated TCS function, proceed as follows:
1. Welding
2. During welding, raise the welding torch
- The arc length is increased significantly
3. Lower the welding torch
- The arc length is decreased significantly
- This triggers the TIG Comfort Stop function
4. Keep the welding torch at the same height
- The welding current continuously decreases until it reaches the minimum welding
current (10 A) (downslope)
- The minimum welding current is held constant for 0.2 seconds
- Arc goes out
5. Wait for the gas post-flow time to finish, and lift the torch off the workpiece
TIG Comfort Stop
Downslope:
Placing the gas nozzle down Arc ignites when electrode is
touched down on workpiece
Raising the gas nozzle, arc ig-
nites
Welding Raise torch Lower torch Maintain height

16
The downslope depends on the welding current selected and cannot be adjusted. The du-
ration of the downslope between the following values must be extrapolated.
- Downslope with low welding current (10 A):0.4 seconds
- Downslope with maximum welding current (250 A):10 seconds
Gas post-flow time:
The gas post-flow time depends on the welding current selected and cannot be adjusted.
- Gas post-flow time with minimum welding current (10 A):3 seconds
- Gas post-flow time with maximum welding current (250 A):15 seconds
The following diagram shows the welding current sequence and the gas flow when the TIG
Comfort Stop function is activated:
TIG Comfort Stop: Welding current and gas flow
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17
EN
The Setup menu
Setting options
Functional princi-
ple
The parameters can be set at 4 levels (TP 2500/3500) or 5 levels (TP 2500/3500 TIG). The
number of indicators lit corresponds to the level reached.
Setting parame-
ters
To alter a parameter setting, proceed as follows:
1. Using the "Process" button, select the desired parameter and hold the Process button
down.
- the set level is indicated for 1 second
- while the Process button is held down, the set value is raised one level every sec-
ond
2. Release the process button once the desired level is set.
3. The setting is now saved
4. The set process is displayed
Welding process Settable parameters Factory setting
Arc-force dynamic Level 2
Arc-force dynamic Level 2
Cel characteristic and arc-force dynamic Level 2
TIG Comfort Stop Level 0
Pulse frequency (TP 2500/3500 TIG only) Level 1
Level 0 Level 1 Level 2 Level 3 Level 4 Level 5
IMPORTANT! The welding parameters are retained even if the mains plug is disconnect-
ed.

18
Arc-force dynam-
ic parameter
Arc-force dynamic parameter setting
The purpose of the arc-force dynamic para-
meter is to influence the short-circuit ampe-
rage at the moment of droplet transfer.
If the rod electrode has a tendency to stick,
adjust the arc-force dynamic parameter to a
higher level.
Level 0 produces a particularly soft, low-
spatter arc. Level 4 or 5 produces a particu-
larly hard and stable arc.
Factory setting: Level 2
Cel characteristic
parameter
Cel characteristic parameter setting
The Cel characteristic parameter sets the
slope for the falling welding current charac-
teristic. When welding cellulose electrodes,
the characteristic slope is the most import-
ant criterion for the weld properties.
If the cellulose electrode has a tendency to
stick, adjust the characteristic parameter to
a higher level (flat characteristic).
Factory setting: Level 2
TIG Comfort Stop
parameter
The "TIG Comfort Stop" parameter is only available with the TP 2500/3500 TIG power
source. On the TP 2500/3500 power source, the response at the end of welding is the
same as the response with the TIG Comfort Stop function deactivated.
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IMPORTANT! The instructions for setting the TIG Comfort Stop parameter also apply to
the "TIG pulsed arc welding" process (TP 2500/3500 TIG only).
The TIG Comfort Stop parameter determines how high the torch must be temporarily
raised to trigger the TIG Comfort Stop function. If the welding process is frequently stopped
unintentionally, increase the value of the TIG-Comfort-Stop parameter.
Level Increase in arc size before function is triggered
5 Very large increase required
4 Large increase required
3 Normal increase required
2 Small increase required
1 Very small increase required
0 TIG Comfort Stop deactivated (factory setting)

19
EN
Pulsing frequen-
cy parameter
The frequency parameter is only available on the TP 2500/3500 TIG power source and is
used to set the frequency of the pulsed arc.
The pulsed arc frequency is one of the most important criterion for the TIG pulsed arc weld-
ing properties.
Level Pulse frequency
5 60 Hz
4 10 Hz
3 4 Hz
2 2 Hz
1 1 Hz (factory setting)
0 0.5 Hz

20
Voltage Reduction Device (VRD versions only)
General A Voltage Reduction Device (VRD) is an optional safety device for reducing the voltage.
As far as possible, VRD prevents output voltages at the current sockets that may pose a
danger to persons.
Safety principle
VRD is active
Welding circuit resistance is greater than
the minimum human body resistance (gre-
ater than or equal to 200 Ohm):
- VRD is active
- Open circuit voltage is limited to 12 V
(otherwise 90 V)
- There is no risk in unintentionally
touching both welding sockets at the
same time
VRD is not active
Welding circuit resistance is less than the
minimum human body resistance (less than
200 Ohm):
- VRD is inactive
- Output voltage not restricted in order to
ensure sufficient welding power
- Example: Start of welding
IMPORTANT! Within 0.3 seconds of the end of welding:
- VRD is active again
- The output voltage is limited to 12 V again