FRO­NIUS TransPocket 2500 User manual

Operating
Instructions
TransPocket 2500/3500
TransPocket 2500/3500 RC
TransPocket 2500/3500 TIG
42,0426,0041,EN 011-28082023
EN Operating Instructions

Contents
Safety rules 5
Explanation of safety notices 5
General 5
Proper use 6
Environmental conditions 6
Obligations of the operator 6
Obligations of personnel 6
Mains connection 7
Residual current protective device 7
Protecting yourself and others 7
Noise emission values 8
Danger from toxic gases and vapours 8
Danger from flying sparks 9
Risks from mains current and welding current 9
Meandering welding currents 10
EMC Device Classifications 10
EMC measures 11
EMF measures 11
Specific hazards 11
Requirement for the shielding gas 12
Danger from shielding gas cylinders 13
Safety measures at the installation location and during transport 13
Safety measures in normal operation 14
Commissioning, maintenance and repair 14
Safety inspection 15
Disposal 15
Safety symbols 15
Data protection 16
Copyright 16
General 17
Principle 17
Device concept 17
Application areas 17
Control elements and connections 18
Safety 18
Connections 18
Operating elements 19
Before commissioning 21
Safety 21
Proper use 21
Setup regulations 21
Mains connection 21
Changing mains voltage (only MVm versions) 23
General remarks 23
Mains voltage tolerance range 23
Changing mains voltage 23
Single-phase operation 24
MMA welding 25
Safety 25
Preparations 25
Selecting the process 25
Adjusting welding current, igniting the arc 25
HotStart function (used with rutile and Cel processes) 26
SoftStart function (used with basic process) 26
Anti-stick function 26
TIG welding 27
Safety 27
General 27
Preparations 27
Setting the shielding gas flow rate 28
3
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Selecting the process 28
Adjusting welding current, igniting the arc 28
TIG Comfort Stop function 29
The Setup menu 31
Setting options 31
Functional principle 31
Setting parameters 31
Arc-force dynamic parameter 32
Cel characteristic parameter 32
TIG Comfort Stop parameter 32
Pulsing frequency parameter 33
Voltage Reduction Device (VRD versions only) 34
General 34
Safety principle 34
Troubleshooting 35
Safety 35
Fault diagnosis 35
Status indicators 37
Care, maintenance and disposal 39
General 39
At every start-up 39
Every 2 months 39
Every 6 months 39
Disposal 39
Average consumption values during welding 40
Average wire electrode consumption during MIG/MAG welding 40
Average shielding gas consumption during MIG/MAG welding 40
Average shielding gas consumption during TIG welding 40
Technical data 41
Safety 41
Generator-powered operation 41
TransPocket 2500, 2500 RC, 2500 TIG 41
TransPocket 2500 MVm, 2500 TIG MVm 42
TransPocket 3500, 3500 RC, 3500 TIG 43
TransPocket 3500 MVm, 3500 TIG MVm 44
Overview with critical raw materials, year of production of the device 45
4

Safety rules
Explanation of
safety notices DANGER!
Indicates immediate danger.
▶If not avoided, death or serious injury will result.
WARNING!
Indicates a potentially hazardous situation.
▶If not avoided, death or serious injury may result.
CAUTION!
Indicates a situation where damage or injury could occur.
▶If not avoided, minor injury and/or damage to property may result.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
General The device is manufactured using state-of-the-art technology and according to
recognised safety standards. If used incorrectly or misused, however, it can
cause:
-injury or death to the operator or a third party,
-damage to the device and other material assets belonging to the operating
company,
-inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing the
device must:
-be suitably qualified,
-have sufficient knowledge of welding and
-read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being
used. In addition to the operating instructions, attention must also be paid to any
generally applicable and local regulations regarding accident prevention and en-
vironmental protection.
All safety and danger notices on the device
-must be in a legible state,
-must not be damaged,
-must not be removed,
-must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the sec-
tion headed "General" in the operating instructions for the device.
Before switching on the device, rectify any faults that could compromise safety.
This is for your personal safety!
5
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Proper use The device is to be used exclusively for its intended purpose.
The device is intended solely for the welding processes specified on the rating
plate.
Any use above and beyond this purpose is deemed improper. The manufacturer
shall not be held liable for any damage arising from such usage.
Proper use includes:
-carefully reading and following all the instructions given in the operating in-
structions
-studying and obeying all safety and danger notices carefully
-performing all stipulated inspection and maintenance work.
Never use the device for the following purposes:
-Thawing out pipes
-Charging batteries
-Starting engines
The device is designed for use in industry and the workshop. The manufacturer
accepts no responsibility for any damage caused through use in a domestic set-
ting.
The manufacturer likewise accepts no liability for inadequate or incorrect results.
Environmental
conditions
Operation or storage of the device outside the stipulated area will be deemed as
not in accordance with the intended purpose. The manufacturer shall not be held
liable for any damage arising from such usage.
Ambient temperature range:
-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)
The surrounding air must be free from dust, acids, corrosive gases or substances,
etc.
Can be used at altitudes of up to 2000 m (6561 ft. 8.16 in.)
Obligations of
the operator
The operator must only allow persons to work with the device who:
-are familiar with the fundamental instructions regarding safety at work and
accident prevention and have been instructed in how to use the device
-have read and understood these operating instructions, especially the sec-
tion "safety rules", and have confirmed as much with their signatures
-are trained to produce the required results.
Checks must be carried out at regular intervals to ensure that operators are
working in a safety-conscious manner.
Obligations of
personnel
Before using the device, all persons instructed to do so undertake:
-to observe the basic instructions regarding safety at work and accident pre-
vention
-to read these operating instructions, especially the "Safety rules" section and
sign to confirm that they have understood them and will follow them.
6

Before leaving the workplace, ensure that people or property cannot come to any
harm in your absence.
Mains connec-
tion
Devices with a higher rating may affect the energy quality of the mains due to
their current consumption.
This may affect a number device types in terms of:
-Connection restrictions
-Criteria with regard to the maximum permissible mains impedance *)
-Criteria with regard to the minimum short-circuit power requirement *)
*) at the interface with the public grid
see "Technical data"
In this case, the plant operator or the person using the device should check
whether the device may be connected, where appropriate by discussing the mat-
ter with the power supply company.
IMPORTANT! Ensure that the mains connection is earthed properly
Residual current
protective
device
Local regulations and national guidelines may require a residual current protect-
ive device when connecting equipment to the public grid.
The type of residual current protective device recommended by the manufac-
turer for the equipment is indicated in the technical data.
Protecting your-
self and others
Anyone working with the device exposes themselves to numerous risks, e.g.
-flying sparks and hot pieces of metal
-Arc radiation, which can damage eyes and skin
-Hazardous electromagnetic fields, which can endanger the lives of those us-
ing cardiac pacemakers
-Risk of electrocution from mains current and welding current
-Greater noise pollution
-Harmful welding fumes and gases
Suitable protective clothing must be worn when working with the device. The
protective clothing must have the following properties:
-Flame-resistant
-Insulating and dry
-Covers the whole body, is undamaged and in good condition
-Safety helmet
-Trousers with no turn-ups
Protective clothing refers to a variety of different items. Operators should:
-Protect eyes and face from UV rays, heat and sparks using a protective visor
and regulation filter
-Wear regulation protective goggles with side protection behind the protect-
ive visor
-Wear stout footwear that provides insulation even in wet conditions
-Protect the hands with suitable gloves (electrically insulated and providing
protection against heat)
-Wear ear protection to reduce the harmful effects of noise and to prevent in-
jury
7
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Keep all persons, especially children, out of the working area while any devices
are in operation or welding is in progress. If, however, there are people in the vi-
cinity:
-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 cur-
rent and welding current, etc.)
-Provide suitable protective equipment
-Alternatively, erect suitable safety screens/curtains.
Noise emission
values
The device generates a maximum sound power level of <80 dB(A) (ref. 1pW)
when idling and in the cooling phase following operation at the maximum per-
missible operating point under maximum rated load conditions according to EN
60974-1.
It is not possible to provide a workplace-related emission value during welding
(or cutting) as this is influenced by both the process and the environment. All
manner of different welding parameters come into play, including the welding
process (MIG/MAG, TIG welding), the type of power selected (DC or AC), the
power range, the type of weld metal, the resonance characteristics of the work-
piece, the workplace environment, etc.
Danger from tox-
ic gases and va-
pours
The fumes produced during welding contain harmful gases and vapours.
Welding fumes contain substances that cause cancer, as stated in Monograph
118 of the International Agency for Research on Cancer.
Use at-source extraction and a room extraction system.
If necessary, use a welding torch with an integrated extraction device.
Keep your face away from welding fumes and gases.
Fumes and hazardous gases
-must not be breathed in
-must be extracted from the working area using appropriate methods.
Ensure an adequate supply of fresh air. Ensure that there is a ventilation rate of
at least 20 m³ per hour at all times.
Otherwise, a welding helmet with an air supply must be worn.
If there is any doubt about whether the extraction capacity is sufficient, the
measured toxic emission values should be compared with the permissible limit
values.
The following components are responsible, amongst other things, for the degree
of toxicity of welding fumes:
-Metals used for the workpiece
-Electrodes
-Coatings
-Cleaners, degreasers, etc.
-Welding process used
The relevant material safety data sheets and manufacturer's specifications for
the listed components should therefore be studied carefully.
Recommendations for trade fair scenarios, risk management measures and for
identifying working conditions can be found on the European Welding Associ-
ation website under Health & Safety (https://european-welding.org).
8

Flammable vapours (e.g. solvent fumes) should be kept away from the arc's radi-
ation area.
Close the shielding gas cylinder valve or main gas supply if no welding is taking
place.
Danger from fly-
ing sparks
Flying sparks may cause fires or explosions.
Never weld close to flammable materials.
Flammable materials must be at least 11 metres (36 ft. 1.07 in.) away from the
arc, or alternatively covered with an approved cover.
A suitable, tested fire extinguisher must be available and ready for use.
Sparks and pieces of hot metal may also get into adjacent areas through small
gaps or openings. Take appropriate precautions to prevent any danger of injury or
fire.
Welding must not be performed in areas that are subject to fire or explosion or
near sealed tanks, vessels or pipes unless these have been prepared in accord-
ance with the relevant national and international standards.
Do not carry out welding on containers that are being or have been used to store
gases, propellants, mineral oils or similar products. Residues pose an explosive
hazard.
Risks from mains
current and
welding current
An electric shock is potentially life threatening and can be fatal.
Do not touch live parts either inside or outside the device.
During MIG/MAG welding and TIG welding, the welding wire, the wirespool, the
feed rollers and all pieces of metal that are in contact with the welding wire are
live.
Always set the wirefeeder up on a sufficiently insulated surface or use a suitable,
insulated wirefeeder holder.
Make sure that you and others are protected with an adequately insulated, dry
base or cover for the earth or ground potential. This base or cover must extend
over the entire area between the body and the earth or ground potential.
All cables and leads must be secured, undamaged, insulated and adequately di-
mensioned. Replace loose connections and scorched, damaged, or inadequately
dimensioned cables and leads immediately.
Use the handle to ensure the power connections are tight before every use.
In the case of power cables with a bayonet connector, rotate the power cable
around the longitudinal axis by at least 180° and pretension.
Do not wrap cables or leads around the body or parts of the body.
The electrode (rod electrode, tungsten electrode, welding wire, etc.) must
-never be immersed in liquid for cooling
-Never touch the electrode when the power source is switched on.
Double the open circuit voltage of a power source can occur between the welding
electrodes of two power sources. Touching the potentials of both electrodes at
the same time may be fatal under certain circumstances.
Arrange for the mains cable to be checked regularly by a qualified electrician to
ensure the ground conductor is functioning properly.
9
EN

Protection class I devices require a mains supply with ground conductor and a
connector system with ground conductor contact for proper operation.
Operation of the device on a mains supply without ground conductor and on a
socket without ground conductor contact is only permitted if all national regula-
tions for protective separation are observed.
Otherwise, this is considered gross negligence. The manufacturer shall not be
held liable for any damage arising from such usage.
If necessary, provide adequate earthing for the workpiece.
Switch off unused devices.
Wear a safety harness if working at height.
Before working on the device, switch it off and pull out the mains plug.
Attach a clearly legible and easy-to-understand warning sign to the device to
prevent anyone from plugging the mains plug back in and switching it on again.
After opening the device:
-Discharge all live components
-Ensure that all components in the device are de-energised.
If work on live parts is required, appoint a second person to switch off the main
switch at the right moment.
Meandering
welding currents
If the following instructions are ignored, meandering welding currents can devel-
op with the following consequences:
-Fire hazard
-Overheating of parts connected to the workpiece
-Damage to ground conductors
-Damage to device and other electrical equipment
Ensure that the workpiece is held securely by the workpiece clamp.
Attach the workpiece clamp as close as possible to the area that is to be welded.
Position the device with sufficient insulation against electrically conductive envir-
onments, such as insulation against conductive floor or insulation to conductive
racks.
If power distribution boards, twin-head mounts, etc., are being used, note the fol-
lowing: The electrode of the welding torch / electrode holder that is not used is
also live. Make sure that the welding torch / electrode holder that is not used is
kept sufficiently insulated.
In the case of automated MIG/MAG applications, ensure that only an insulated
wire electrode is routed from the welding wire drum, large wirefeeder spool or
wirespool to the wirefeeder.
EMC Device
Classifications
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 mains.
10

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
emissions, it may affect the application area for which it was designed (e.g. when
there is sensitive equipment at the same location, or if the site where the device
is installed is close to either radio or television receivers).
If this is the case, then the operator is obliged to take appropriate action to recti-
fy the situation.
Check and evaluate the immunity to interference of nearby devices according to
national and international regulations. Examples of equipment that may be sus-
ceptible to interference from the device include:
-Safety devices
-Network, signal and data transfer lines
-IT and telecommunications devices
-Measuring and calibrating devices
Supporting measures for avoidance of EMC problems:
1.Mains supply
-If electromagnetic interference arises despite the correct mains connec-
tion, additional measures are necessary (e.g. use of a suitable line filter)
2.Welding power-leads
-must be kept as short as possible
-must be laid close together (to avoid EMF problems)
-must be kept well apart from other leads
3.Equipotential bonding
4.Earthing of the workpiece
-If necessary, establish an earth connection using suitable capacitors.
5.Shield, if necessary
-Shield other devices nearby
-Shield the entire welding installation
EMF measures Electromagnetic fields may pose as yet unknown risks to health:
-Effects on the health of persons in the vicinity, e.g. those with pacemakers
and hearing aids
-Individuals with pacemakers must seek advice from their doctor before ap-
proaching the device or any welding that is in progress
-For safety reasons, maintain as large a distance as possible between the
welding power-leads and the head/torso of the welder
-Do not carry welding power-leads and hosepacks over the shoulders or wind
them around any part of the body
Specific hazards Keep hands, hair, clothing and tools away from moving parts. For example:
-Fans
-Cogs
-Rollers
-Shafts
-Wirespools and welding wires
Do not reach into the rotating cogs of the wire drive or into rotating drive com-
ponents.
Covers and side panels may only be opened/removed while maintenance or repair
work is being carried out.
11
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During operation
-Ensure that all covers are closed and all side panels are fitted properly.
-Keep all covers and side panels closed.
The welding wire emerging from the welding torch poses a high risk of injury
(piercing of the hand, injuries to the face and eyes, etc.).
Therefore, always keep the welding torch away from the body (devices with
wirefeeder) and wear suitable protective goggles.
Never touch the workpiece during or after welding - risk of burns.
Slag can jump off cooling workpieces. The specified protective equipment must
therefore also be worn when reworking workpieces, and steps must be taken to
ensure that other people are also adequately protected.
Welding torches and other parts with a high operating temperature must be al-
lowed to cool down before handling.
Special provisions apply in areas at risk of fire or explosion
- observe relevant national and international regulations.
Power sources for work in areas with increased electric risk (e.g. near boilers)
must carry the "Safety" sign. However, the power source must not be located in
such areas.
Risk of scalding from escaping coolant. Switch off cooling unit before discon-
necting coolant flow or return lines.
Observe the information on the coolant safety data sheet when handling coolant.
The coolant safety data sheet may be obtained from your service centre or down-
loaded from the manufacturer's website.
Use only suitable load-carrying equipment supplied by the manufacturer when
transporting devices by crane.
-Hook chains or ropes onto all suspension points provided on the load-carry-
ing equipment.
-Chains and ropes must be at the smallest angle possible to the vertical.
-Remove gas cylinder and wirefeeder (MIG/MAG and TIG devices).
If the wirefeeder is attached to a crane holder during welding, always use a suit-
able, insulated wirefeeder hoisting attachment (MIG/MAG and TIG devices).
If the device has a carrying strap or handle, this is intended solely for carrying by
hand. The carrying strap is not to be used if transporting with a crane, counter-
balanced lift truck or other mechanical hoist.
All lifting tackle (straps, handles, chains, etc.) used in connection with the device
or its components must be tested regularly (e.g. for mechanical damage, corro-
sion or changes caused by other environmental factors).
The testing interval and scope of testing must comply with applicable national
standards and directives as a minimum.
Odourless and colourless shielding gas may escape unnoticed if an adapter is
used for the shielding gas connection. Prior to assembly, seal the device-side
thread of the adapter for the shielding gas connection using suitable Teflon tape.
Requirement for
the shielding gas
Especially with ring lines, contaminated shielding gas can cause damage to
equipment and reduce welding quality.
Meet the following requirements regarding shielding gas quality:
-Solid particle size < 40 µm
-Pressure condensation point < -20 °C
-Max. oil content < 25 mg/m³
12

Use filters if necessary.
Danger from
shielding gas cyl-
inders
Shielding gas cylinders contain gas under pressure and can explode if damaged.
As the shielding gas cylinders are part of the welding equipment, they must be
handled with the greatest of care.
Protect shielding gas cylinders containing compressed gas from excessive heat,
mechanical impact, slag, naked flames, sparks and arcs.
Mount the shielding gas cylinders vertically and secure according to instructions
to prevent them falling over.
Keep the shielding gas cylinders well away from any welding or other electrical
circuits.
Never hang a welding torch on a shielding gas cylinder.
Never touch a shielding gas cylinder with an electrode.
Risk of explosion - never attempt to weld a pressurised shielding gas cylinder.
Only use shielding gas cylinders suitable for the application in hand, along with
the correct and appropriate accessories (regulator, hoses and fittings). Only use
shielding gas cylinders and accessories that are in good condition.
Turn your face to one side when opening the valve of a shielding gas cylinder.
Close the shielding gas cylinder valve if no welding is taking place.
If the shielding gas cylinder is not connected, leave the valve cap in place on the
cylinder.
The manufacturer's instructions must be observed as well as applicable national
and international regulations for shielding gas cylinders and accessories.
Safety measures
at the installa-
tion location and
during transport
A device toppling over could easily kill someone. Place the device on a solid, level
surface such that it remains stable
-The maximum permissible tilt angle is 10°.
Special regulations apply in rooms at risk of fire or explosion
-Observe relevant national and international regulations.
Use internal directives and checks to ensure that the workplace environment is
always clean and clearly laid out.
Only set up and operate the device in accordance with the degree of protection
shown on the rating plate.
When setting up the device, ensure there is an all-round clearance of 0.5 m (1 ft.
7.69 in.) to ensure that cooling air can flow in and out freely.
When transporting the device, observe the relevant national and local guidelines
and accident prevention regulations. This applies especially to guidelines regard-
ing the risks arising during transport.
Do not lift or transport operational devices. Switch off devices before transport
or lifting.
13
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Before transporting the device, allow coolant to drain completely and detach the
following components:
-Wirefeeder
-Wirespool
-Shielding gas cylinder
After transporting the device, the device must be visually inspected for damage
before commissioning. Any damage must be repaired by trained service techni-
cians before commissioning the device.
Safety measures
in normal opera-
tion
Only operate the device when all safety devices are fully functional. If the safety
devices are not fully functional, there is a risk of
-injury or death to the operator or a third party
-damage to the device and other material assets belonging to the operator
-inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable safety devices.
Before switching on the device, ensure that no one is likely to be endangered.
Check the device at least once a week for obvious damage and proper function-
ing of safety devices.
Always fasten the shielding gas cylinder securely and remove it beforehand if the
device is to be transported by crane.
Only the manufacturer's original coolant is suitable for use with our devices due
to its properties (electrical conductibility, anti-freeze agent, material compatibil-
ity, flammability, etc.).
Only use suitable original coolant from the manufacturer.
Do not mix the manufacturer's original coolant with other coolants.
Only connect the manufacturer's system components to the cooling circuit.
The manufacturer accepts no liability for damage resulting from use of other sys-
tem components or a different coolant. In addition, all warranty claims will be
forfeited.
Cooling Liquid FCL 10/20 does not ignite. The ethanol-based coolant can ignite
under certain conditions. Transport the coolant only in its original, sealed con-
tainers and keep well away from any sources of ignition.
Used coolant must be disposed of properly in accordance with the relevant na-
tional and international regulations. The coolant safety data sheet may be ob-
tained from your service centre or downloaded from the manufacturer's website.
Check the coolant level before starting to weld, while the system is still cool.
Commissioning,
maintenance and
repair
It is impossible to guarantee that bought-in parts are designed and manufac-
tured to meet the demands made of them, or that they satisfy safety require-
ments.
14

-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 spe-
cified torque.
Safety inspec-
tion
The manufacturer recommends that a safety inspection of the device is per-
formed at least once every 12 months.
The manufacturer recommends that the power source be calibrated during the
same 12-month period.
A safety inspection should be carried out by a qualified electrician
-after any changes are made
-after any additional parts are installed, or after any conversions
-after repair, care and maintenance has been carried out
-at least every twelve months.
For safety inspections, follow the appropriate national and international stand-
ards and directives.
Further details on safety inspection and calibration can be obtained from your
service centre. They will provide you on request with any documents you may re-
quire.
Disposal Waste electrical and electronic equipment must be collected separately and re-
cycled in an environmentally responsible manner in accordance with the EU Dir-
ective and national law. Used equipment must be returned to the distributor or
through a local, authorised collection and disposal system. Proper disposal of the
old device promotes sustainable recycling of material resources. Ignoring this
may lead to potential health/environmental impacts.
Packaging materials
Collected separately. Check your municipality’s regulations. Reduce the volume
of the box.
Safety symbols Devices with the CE mark satisfy the essential requirements of the low-voltage
and electromagnetic compatibility directives (e.g. relevant product standards of
the EN 60 974 series).
Fronius International GmbH hereby declares that the device is compliant with
Directive 2014/53/EU. The full text on the EU Declaration of Conformity can be
found at the following address: http://www.fronius.com
Devices marked with the CSA test mark satisfy the requirements of the relevant
standards for Canada and the USA.
15
EN

Data protection The user is responsible for the safekeeping of any changes made to the factory
settings. The manufacturer accepts no liability for any deleted personal settings.
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the pur-
chaser. If you have any suggestions for improvement, or can point out any mis-
takes that you have found in the instructions, we will be most grateful for your
comments.
16

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 created.
The power source works on resonance
inverter principles and therefore offers
a number of advantages:
-Intelligent control for stable arc
and ideal characteristic
-Excellent ignition and weld proper-
ties, extremely lightweight and
with a very small footprint
-High switching frequencies and op-
timum 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 electrodes 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 condi-
tions. 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 facilitates 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 Comfort 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 economical alternatives.
17
EN

Control elements and connections
Safety WARNING!
Danger from incorrect operation and work that is not carried out properly.
This can result in serious personal injury and damage to property.
▶All the work and functions described in this document must only be carried
out by technically trained and qualified personnel.
▶Read and understand this document in full.
▶Read and understand all safety rules and user documentation for this device
and all system components.
As a result of software updates, you may find that there are functions available
on your device that are not described in these Operating Instructions, or vice
versa.
Certain illustrations may also differ slightly from the actual controls on your
device, but these controls function in exactly the same way.
Connections
(4)
(6)
(5)
Controls and connections on the front and back
of the machine
(2)
(3)
(1)
(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 accumulated
NOTE!
The manufacturer strongly recommends that a dust filter be used with the
power source.
(4) (+) current socket with bayonet latch
For connecting the:
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-Rod electrode or grounding cable for manual metal arc (MMA) weld-
ing, depending on the type of electrode being used
-Grounding cable for TIG welding
(5) (-) current socket with bayonet latch
For connecting the:
-Rod electrode or grounding cable for manual metal arc (MMA) weld-
ing, depending 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
(3)
(4)
(5)
(1)
(2)
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 electrode)
-Manual metal arc welding with SoftStart function (recommended for
basic electrode)
-MMA welding with Cel electrode
-TIG welding
-TIG pulsed arc welding (TP 2500/3500 TIG only)
IMPORTANT! The selected welding process remains in memory even
after the mains plug is disconnected.
(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
19
EN

-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
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