Battery Charging Systems / Welding Technology / Solar .../downloads/Perfect Welding/Service...

TransSynergic 4000/5000TransPuls Synergic 2700TransPuls Synergic 3200/4000/5000

Service manualSpare parts listMIG/MAG Power source

/ Battery Charging Systems / Welding Technology / Solar Electronics

EN

42,0410,1237 011-28062017

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Table of contentsForeword and safety instructions .................................................................................................................. 6

Safety ....................................................................................................................................................... 6Fronius Technical Support Center (TSC) ................................................................................................. 6General remarks ...................................................................................................................................... 6Function overview .................................................................................................................................... 7Fault location aid ...................................................................................................................................... 7Detailed description ................................................................................................................................. 7Changing components ............................................................................................................................. 7Terms and abbreviations used ................................................................................................................. 7Spare parts list and entire circuit diagram ............................................................................................... 7Tools and measuring instruments ............................................................................................................ 7

Tools and measuring instruments ................................................................................................................. 8General remarks ...................................................................................................................................... 8Tools required .......................................................................................................................................... 8Measuring and inspection equipment ...................................................................................................... 8Ancillary materials .................................................................................................................................... 8

Function overview ......................................................................................................................................... 9Principle of the digital family of machines ................................................................................................ 9Useful information .................................................................................................................................... 9Block diagram ........................................................................................................................................ 10Block diagram legend ............................................................................................................................ 10

Fault location aid ......................................................................................................................................... 12General remarks .................................................................................................................................... 12

Fault flowcharts ........................................................................................................................................... 13Overview ................................................................................................................................................ 13Poor ignition and welding properties with „MIG/MAG welding“ ............................................................. 14Poor ignition and welding properties with „TIG welding“ ....................................................................... 15Poor weld properties with „rod electrode (MMA) welding“ ..................................................................... 16Nothing happens on control panel (TPS 2700) ..................................................................................... 17Nothing happens on control panel (TPS 3200/4000/5000) ................................................................... 19No or incorrect welding current .............................................................................................................. 21No or incorrect wirefeed speed .............................................................................................................. 22Insufficient torch cooling (FK 4000/FK 4000 R) ..................................................................................... 23Service code Err 50 ............................................................................................................................... 25

UST service codes ...................................................................................................................................... 27Safety ..................................................................................................................................................... 27Table of service codes ........................................................................................................................... 27Special displays used with service codes .............................................................................................. 33

Service codes SR 4xA ................................................................................................................................ 34Safety ..................................................................................................................................................... 34Table of service codes ........................................................................................................................... 34

Service codes for push-pull calibration ....................................................................................................... 35Safety ..................................................................................................................................................... 35Checking actual-value pick-up ............................................................................................................... 35Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 35Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 36

Detailed description .................................................................................................................................... 38General remarks .................................................................................................................................... 38Position of electronic components ......................................................................................................... 38Overview ................................................................................................................................................ 38

ASU 27 - additional PC board ..................................................................................................................... 39General remarks .................................................................................................................................... 39Component position in the machine ...................................................................................................... 39Overview ................................................................................................................................................ 39

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Technical Data ....................................................................................................................................... 39Function overview .................................................................................................................................. 40Plug layout ............................................................................................................................................. 40LED checklist ......................................................................................................................................... 41Measuring points ................................................................................................................................... 41

ASU 40 - additional PC board ..................................................................................................................... 42General remarks .................................................................................................................................... 42Component position in the machine ...................................................................................................... 42Overview ................................................................................................................................................ 42Technical Data ....................................................................................................................................... 43Function overview .................................................................................................................................. 43Plug layout ............................................................................................................................................. 43LED checklist ......................................................................................................................................... 44Measuring points ................................................................................................................................... 45

BPS 25/BPT 27 - power module PC board ................................................................................................. 46General remarks .................................................................................................................................... 46Component position in the machine ...................................................................................................... 46Overview ................................................................................................................................................ 46Technical Data ....................................................................................................................................... 47Function overview .................................................................................................................................. 47Plug layout BPS 25/BPT 27 ................................................................................................................... 47LED checklist ......................................................................................................................................... 49Measuring points ................................................................................................................................... 49

BPS 32/40/42/43/50/53 - power module PC board .................................................................................... 51General remarks .................................................................................................................................... 51Component position in the machine ...................................................................................................... 51Overview ................................................................................................................................................ 51Technical Data ....................................................................................................................................... 52Function overview .................................................................................................................................. 52Plugs on the power module PC boards ................................................................................................. 53Plug layout ............................................................................................................................................. 53LED checklist of power module PC boards ........................................................................................... 55Measuring points ................................................................................................................................... 55

NT 24 - switched mode power supply 24 V ................................................................................................ 58General remarks .................................................................................................................................... 58Component position in the machine ...................................................................................................... 58Overview ................................................................................................................................................ 58Technical Data ....................................................................................................................................... 59Function overview .................................................................................................................................. 59Plug layout ............................................................................................................................................. 59LED checklist ......................................................................................................................................... 60Measuring points ................................................................................................................................... 60

NT 60 - switched mode power supply 60 V ................................................................................................ 62General remarks .................................................................................................................................... 62Component position in the machine ...................................................................................................... 62Overview ................................................................................................................................................ 62Technical Data ....................................................................................................................................... 63Function overview .................................................................................................................................. 63Plug layout ............................................................................................................................................. 63LED checklist ......................................................................................................................................... 64Measuring points ................................................................................................................................... 64

UST - Control and regulation unit ............................................................................................................... 66General remarks .................................................................................................................................... 66Component position in the machine ...................................................................................................... 66Overview ................................................................................................................................................ 66Technical Data ....................................................................................................................................... 67Plug layout ............................................................................................................................................. 67Function overview .................................................................................................................................. 67LED checklist ......................................................................................................................................... 69

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Measuring points ................................................................................................................................... 69Changing UST PC board ....................................................................................................................... 69

NF 3160 - Line filter .................................................................................................................................... 70General remarks .................................................................................................................................... 70Component position in the machine ...................................................................................................... 70Overview ................................................................................................................................................ 70Technical Data ....................................................................................................................................... 70Function overview .................................................................................................................................. 71Plug layout ............................................................................................................................................. 71LED checklist ......................................................................................................................................... 71Measuring points ................................................................................................................................... 71

NF 3400 - Line filter/line filter 40 A/80 A ..................................................................................................... 72General remarks .................................................................................................................................... 72Component position in the machine ...................................................................................................... 72Overview ................................................................................................................................................ 72Technical Data ....................................................................................................................................... 73Function overview .................................................................................................................................. 73Plug layout NF 3400 .............................................................................................................................. 73Plug layout line filter 40 A/80 A .............................................................................................................. 74LED checklist ......................................................................................................................................... 74Measuring points ................................................................................................................................... 74

Shunt ........................................................................................................................................................... 75General remarks .................................................................................................................................... 75Component position in the machine ...................................................................................................... 75Overview ................................................................................................................................................ 75Technical Data ....................................................................................................................................... 76Function overview .................................................................................................................................. 76Plug layout ............................................................................................................................................. 76LED checklist ......................................................................................................................................... 76Measuring points ................................................................................................................................... 76

SR 41 - Wire-feed unit regulation unit ......................................................................................................... 77General remarks .................................................................................................................................... 77Component position in the machine ...................................................................................................... 77Overview ................................................................................................................................................ 77Technical Data ....................................................................................................................................... 78Function overview .................................................................................................................................. 78Plug layout ............................................................................................................................................. 78LED checklist ......................................................................................................................................... 80Measuring points ................................................................................................................................... 81

Temperature sensor TP 592S ..................................................................................................................... 82General remarks .................................................................................................................................... 82Component position in the machine ...................................................................................................... 82Technical Data ....................................................................................................................................... 83Function overview .................................................................................................................................. 83Plug layout ............................................................................................................................................. 83Measuring points ................................................................................................................................... 83

Secondary power module TPS 2700 .......................................................................................................... 84General remarks .................................................................................................................................... 84Component position in the machine ...................................................................................................... 84Overview ................................................................................................................................................ 84Function overview .................................................................................................................................. 85Measuring points ................................................................................................................................... 85

Secondary power module TS 4000/5000, TPS 3200/4000/5000 ............................................................... 86General remarks .................................................................................................................................... 86Component position in the machine ...................................................................................................... 86Overview ................................................................................................................................................ 86Function overview .................................................................................................................................. 87Measuring points ................................................................................................................................... 87

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Primary rectifier ........................................................................................................................................... 88General remarks .................................................................................................................................... 88Component position in the machine ...................................................................................................... 88Overview ................................................................................................................................................ 88Function overview .................................................................................................................................. 88Plug layout ............................................................................................................................................. 89Measuring points ................................................................................................................................... 89

Changing components ................................................................................................................................ 90Safety ..................................................................................................................................................... 90General remarks .................................................................................................................................... 90Overview ................................................................................................................................................ 90

Changing throttle (TS 4000/5000, TPS 3200/4000/5000) .......................................................................... 91Removing throttle ................................................................................................................................... 91Fitting throttle ......................................................................................................................................... 92

Changing throttle (TPS 2700) ..................................................................................................................... 94Removing throttle ................................................................................................................................... 94Fitting throttle ......................................................................................................................................... 95

Changing earth current watchdog .............................................................................................................. 98Removing earth current watchdog ......................................................................................................... 98Fitting earth current watchdog ............................................................................................................... 99

Changing PC board ASU 27 (TPS 2700 MV) ........................................................................................... 101Removing ASU 27 ............................................................................................................................... 101Fitting ASU 27 ...................................................................................................................................... 101

Changing shunt (TPS 2700) ..................................................................................................................... 102Removing shunt ................................................................................................................................... 102Fitting shunt ......................................................................................................................................... 103

Changing temperature sensor TP 592S ................................................................................................... 105Notes .................................................................................................................................................... 105

Changing transformer (TS 4000/5000, TPS 3200/4000/5000) ................................................................. 106Removing transformer ......................................................................................................................... 106Fitting transformer ................................................................................................................................ 107

Changing transformer (TPS 2700) ............................................................................................................ 109Removing transformer ......................................................................................................................... 109Fitting transformer .................................................................................................................................110

Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000) ....................................112Removing intermediate circuit capacitors .............................................................................................112Fitting intermediate circuit capacitors ...................................................................................................113

Safety inspection........................................................................................................................................115General .................................................................................................................................................115Responsibility ........................................................................................................................................115

Visual inspections ......................................................................................................................................116General .................................................................................................................................................116General conditions ................................................................................................................................116Welding torch/electrode holder/welding current return terminal ...........................................................116Mains supply and connecting lines .......................................................................................................116Welding circuit .......................................................................................................................................116Housing and covers ..............................................................................................................................117Adjustment and display devices ...........................................................................................................117

Electrical tests ............................................................................................................................................118Ground conductor resistance ...............................................................................................................118Insulation resistance .............................................................................................................................119Open circuit voltage U0 ........................................................................................................................119

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Function tests ............................................................................................................................................ 120General ................................................................................................................................................ 120Mains power on/off equipment ............................................................................................................. 120Indicators and controls ......................................................................................................................... 120Gas solenoid valve .............................................................................................................................. 120Earth current watchdog........................................................................................................................ 120Test weld .............................................................................................................................................. 120

Documentation .......................................................................................................................................... 121Test record ........................................................................................................................................... 121Test label .............................................................................................................................................. 121

Terms and abbreviations used .................................................................................................................. 122General remarks .................................................................................................................................. 122Terms and abbreviations...................................................................................................................... 122

Entire circuit diagram ................................................................................................................................ 124Storage location ................................................................................................................................... 124

Spare parts list / Circuit diagram

Fronius Worldwide

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Foreword and safety instructions

General remarks The service instructions can be found in the TechGuide at www.fronius.com\techguide

Each chapter in the service instructions deals with one complete topic. Use eachchapter as a self-contained information source. A short description of each chapterfollows:

Safety The following safety instructions apply to all activities described in these service instruc-tions:

WARNING! Work performed incorrectly can cause serious injury and damage.All activities described in the service instructions must only be carried out byFronius-trained personnel. Take note of the „Safety rules“ chapter in the powersource operating instructions.

WARNING! An electric shock can be fatal. If the machine needs to be switchedon briefly for testing while the housing is open,- Do not touch the parts inside the housing- Only touch using suitable measuring or test probes

CAUTION! Inadequate PE conductor connections can cause serious injuryand damage. The housing screws provide a suitable PE conductor connectionfor earthing (grounding) the housing and must NOT be replaced by any otherscrews which do not provide a reliable PE conductor connection.

WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine 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 electrical-

ly charged components (e.g. capacitors) have been discharged

Fronius Techni-cal SupportCenter (TSC)

If you have any questions about fault isolation, there is a team of experts on hand.E-mail: [email protected]

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Contains a description of essential terms and abbreviations for a better understandingof the service instructions

The „Spare parts list“ and „Entire circuit diagram“ sections contain the complete spareparts list and complete circuit diagram for the power source.

In the „Changing components“ section there is a description of how to change compon-ents which- have no instructions of their own regarding changing and- require a complete description of how to change them

Serves to systematically locate and rectify the source of faults, and contains the follo-wing elements:- The actual fault flowchart for dealing with general faults- Service codes table for dealing with faults whose service codes appear on the

display

Contains detailed descriptions of the relevant components in the power source.

For every component, the following topics are dealt with:- General remarks (designation, item number of the component)- Component position in the machine- Overview- Technical Data- Function overview- Plug layout- LED checklists- Measuring points

Fault location aid

Detailed descrip-tion

Changing com-ponents

Terms and abbre-viations used

Spare parts listand entire circuitdiagram

Tools andmeasuringinstruments

This provides an overview and description of all equipment required for servicing thepower source professionally. This equipment includes:- Tools required- Measuring and inspection equipment- Ancillary materials

Function over-view

Contains a brief descriptive overview of the entire system:- in text form- in block diagram form

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„Tools and measuring instruments“ offers an overview and description of all equipmentneeded to service the machine professionally. This equipment includes:- Tools required- Measuring and inspection equipment- Ancillary materials

- Box spanner (8 mm)- Large needle nosed pliers (approx. 160 mm)- Small wire cutting pliers- Manual torque wrench (1-6 Nm, 42,0411,0013)- Slotted screwdriver (small)- Slotted screwdriver (medium)- Phillips screwdriver (PH1)- Phillips screwdriver (PH2)- Torx screwdriver (TX 20) or insert bit for manual torque wrench- Torx screwdriver (TX 25) or insert bit for manual torque wrench- Allen key (3 mm)- Allen key (4 mm)- Allen key (5 mm)- Flat spanner (13 mm)- Flat spanner (17 mm)- Flat spanner (19 mm)- Oeteker pliers- Molex extractor tool (42,0410,0290)

- Digital multimeter- PC with MS Windows operating system

(System requirements can be found in the operating instructions for the BSL tool)- „BSL tool“ (4,050,082)- „LocalNet RS 232 Converter“ (4,100,262)- CD ROM TechGuide (40,0006,2365)

- Contact spray (40,0009,0014) or alcoholic solvent- Heat-conductive paste (40,0009,0043)- Application instrument for heat-conductive paste (42,0435,0020)- Sandpaper (42,0410,0436), grit size 500 or finer

Tools and measuring instruments

General remarks

Tools required

Measuring andinspection equip-ment

Ancillary materi-als

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Fig. 1 Function outline

Function overview

Principle of thedigital family ofmachines

Useful informati-on

The machines are totally digitized, microprocessor-controlled inverter power sources. Auniversal control regulates the entire welding process. The actual data are measuredcontinuously, and the machine responds immediately to any changes. Special controlalgorithms ensure that the target status is maintained at all times. A decisive factor forthe power source welding properties is the software system, instead of a rigid, barelyalterable hardware system. This gives the weld process an unrivalled degree of precisi-on, with exact reproducibility of welding results and excellent operating properties.

BSL-Tool

OS

DB

UST

Local Net

CFM

In the universal control (UST), there is information on subsequently enabled options.Information on power source functions and parameters as well as data related to theprocess are called up from the operating system (OS) by the universal control. Thewelding program database (DB) contains welding-engineering know-how. Weldingcharacteristics for different materials and their parameter settings are called up fromthis database.

Important! The operating system and the welding process database are constantlybeing enhanced. Use „Update“ to bring the software up to date. The BSL tool is used forthis purpose. Enabled options need only be reactivated after the UST PC board hasbeen changed.

Communication with system components takes place via a serial databus (LocalNet).The LocalNet connection socket is the interface for system components, e.g. wire-feedunit or remote control. Establishing a connection and disconnecting takes place accor-ding to the „plug and play“ principle.

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Block diagram

Control andregulation unit

(1)

(2)

Mai

nsfil

ter

(3)

Prim

ary

rect

ifier

(4)

TPS

270

0 on

ly: P

FC(P

ower

Fac

tor C

ontro

l)

(5)

Inte

rmed

iate

circ

uit

capa

cito

rs

(6)

Tran

sist

ors

(7)

Wel

ding

tran

sfor

mer

(8)SecondaryRectifer

(9)Output choke

(10)Welding currentsensor

Workpiece

Welding torches

Control panel

Remote controlunit

Wire-feed unit

24 V 55 V

Powersupply

55 V

24 V

Primary power module

LocalNet

LocalNet

Uact

Iact

Con

trol

lead

Fig. 2 Block diagram of Trans Synergic 4000/5000 and TransPuls Synergic 2700/3200/4000/5000 powersources

3 x 400 V

Block diagramlegend

(1) Control and regulation unit:Controls, regulates and monitors the welding process and all power source func-tions.

(2) Line filter (EMV):For attenuation of- high frequency parts of the mains supply- reactions on the mains supply

(3) Primary rectifier:Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage.

(4) PFC (Power Factor Control, TPS 2700 only):Ensures a sinusoidal current input.

(5) Intermediate circuit capacitors:Store and smooth the intermediate circuit voltage.

Regulation unit

Valve

Gas

Wire

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Block diagramlegend(continued)

(6) Transistors:The transistors carry the intermediate circuit voltage in intervals at high frequencyto the primary coil on the transformer. The high frequency means that- The transformer can be built very easily and compactly.- Thermal losses due to the low inductivity required of the transformer coils can

be kept to an absolute minimum.

(7) Welding transformer:- Transforms the high primary voltage into a low secondary voltage.- Ensures electrical isolation of primary and secondary power modules.

(8) Secondary rectifier:Converts the secondary voltage into a direct voltage.

(9) Output choke:smooths the output current.

(10) Welding current sensor:Registers the present actual current for the welding process.

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Fault location aid

General remarks The „Fault location aid“ section consists of the following parts- Fault flowcharts- Table of service codes

The fault flowcharts are for the systematic locating and rectifying of fault sources. In the„Table of service codes“ section, there is also a table which deals with the servicecodes shown on the display, as well as causes and measures for rectifying them.

Before starting with the fault location aid, read the „Function overview“ section andstudy the entire circuit diagram in order to understand the composition and functioningof the power source.

Important! The following NOTE applies to those with even less experience of troubles-hooting the power sources. Before working with the fault location aid, read the followingsection:- „Function overview“- „Entire circuit diagram“

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Overview The overview will help you to find the relevant (section of) flowchart.

The positions and meanings of the LEDs for the components/PC boards can be foundin the „Detailed description“ section. The „Detailed description“ section contains an„LED checklist“ sub-section for each of the components/PC boards (with LEDs).

Fault flowcharts

Poor ignition and weld properties withthe selected „TIG welding“ process

Nothing happens on control panel(TPS 2700)

No welding current, or current does notcorrespond to set value

Service codes displayed

Mains switch in the“On” position

Poor weld properties with selected „rodelectrode (MMA) welding“ process

Insufficient welding torch cooling (FK4000/FK 4000 R)

Poor ignition and weld properties withthe selected „MIG/MAG welding“

process

Nothing happens on control panel(TPS 3200/4000/5000)

No or incorrect wirefeed

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EN

Poor ignition andwelding proper-ties with „MIG/MAG welding“

End

Correct shielding gas connected,and l/min set correctly?

Start

Gas-test button: Shielding gasflowing out?

Welding torch and grounding(earthing) cable OK?

Parameters set correctly?

Check shielding gas solenoidvalve, including control

Check welding torch and groun-ding (earthing) cable

- Check settings on control panel- Check set-up parameters- Possibly reset to factory set-tings (FAC) (see operating instruc-

tions)

Check whether power source OK,and check application

Connect correct shielding gas andcheck l/min

Yes

No

No

No

Yes

Yes

Yes

No

16

Poor ignition andwelding proper-ties with „TIGwelding“

End

Correct shielding gas connected,and l/min set correctly?

Start

Gas-test button: Shielding gasflowing out?

Welding torch and grounding(earthing) cable OK?


Check shielding gas solenoidvalve, including control



tions)


Connect correct shielding gas andcheck l/min

Yes

No

No

No

Yes

Yes

Yes

No

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EN

Poor weld pro-perties with „rodelectrode (MMA)welding“

Connect cable correctlyElectrodes/grounding (earthing)cable connected/functioning

correctly?

Start



End

No

NoYes

Yes


tions)

18

Start

Voltage OK on prima-ry rectifier V1=320V/

560V DC?

Check mains cable,mains switch, linefilter, rectifier and

supply voltageNo

Voltage on intermedi-ate circuits 1 and 2 >

250V DC? Change BPS

Are LEDs +5V, +12Vflashing on the ASU 27,as well as LED for mains

400V at 400V Unom,and LED for mains 230V

at 230V Unom?

Change ASU 27

On MV power sources

Change BPS

+24V int/ext LEDsflashing on UST?

Switch power sourceoff, unplug plug X3from UST, switchpower source on

Change NT 24

Yes

Yes

Steady +24V int/extLEDs on NT 24?

Switch power sourceoff, plug X3 plug intoUST and unplug X7,switch power source

on

No

No

Check cooling unitSteady +24V int/ext

LEDs on UST?

Yes

No

Yes

No

Change BPS

No

Yes

Yes

A

Nothing happenson control panel(TPS 2700)

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EN

Nothing happenson control panel(TPS 2700)(continued)

Steady +5V, +15V, -15V on UST?

Check/change controlpanel/ribbon cable

Yes

Unplug X4 from UST

No

A

Steady +5V, +15V, -15V on UST? Change VAC shunt

Yes

Unplug X2 from UST

No



Yes

Unplug X6 from UST

No

Steady +5V, +15V, -15V on UST? Change BPS

Yes

Change UST

No

End

20

Nothing happenson control panel(TPS 3200/4000/5000)

Start

3x230V/3x400V onthe terminal strip X7/5

- X7/7 OK?

Check mains cable,line filter and supply

voltageNo

Voltage on intermedi-ate circuits 1 and 2 >

200V DC?Change primary

rectifier

Mains switch/cablingOK?

Check/change mainsswitch and cabling

Change BPS

Steady +24V int/extLEDs on UST?

Switch power sourceoff, unplug plug X3from UST, switchpower source on

Change NT 24

Yes

Yes

Steady +24V int/extLEDs on NT 24?

Switch power sourceoff, plug X3 plug intoUST and unplug X7,switch power source

on

No

Yes

No

Yes

No

Yes

A

Voltage present on 2phases of rectifier

V1?Yes

No

LED 230V flashing onASU 40 at Unom

230V?Change ASU 40

No

Yes

MV power sourceswith Unom 230V

No

No

B

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EN

Nothing happenson control panel(TPS 3200/4000/5000)(continued)



Yes

Unplug X4 from UST

No

A

Steady +5V, +15V, -15V on UST? Change VAC shunt

Yes

Unplug X2 from UST

No



Yes

Unplug X6 from UST

No

Steady +5V, +15V, -15V on UST? Change BPS

Yes

Change UST

No

End

Check cooling unitSteady +24V int/ext

LEDs on UST?

Change BPS

No

Yes

B

22

No or incorrectwelding current


Welding torch and grounding(earthing) cable connected/

functioning correctly?

Start

Nothing happening on controlpanel?

See subsection „Nothing happenson control panel“

- Welding current Icomm no longeradjustable, or

- Welding current is constantlyImax ?


End

Change current sensor A1 VAC

No

Yes

Yes

No

No

Yes

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EN

No or incorrectwirefeed speed Start

Service code display-ed?

see service codestableYes

Wire-feed unit enteredin the service module?

No

+24V LED flashingon SR 41?No

Steady +24Vext LEDon UST?No

Check cable harness/VSP

See „Nothing hap-pens on controlpanel“ flowchart

No

Yes

„BUS OK“ LEDflashing on the SR 41when service module

unplugged?

Connect servicemodule to the power

source

Power source enteredin the service module?

Check VSPChange SR 41

No

Yes

Change UST

No

Yes

YesYes

Check VSP, NT 60overloaded or faulty

+55V LED flashingon SR 41?

Does motor movewhen „Feeder in-ching“ button is No No

Change SR 41FWD LED flashing onSR 41? No

Change wire-feed unitmotor

Yes

Calibrate push-pullunit

Wrong motor speed?

Yes

Yes

Yes

No

A

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Insufficient torchcooling (FK 4000/FK 4000 R)

Start

Cooling unit set-upsettings switched to

OFF?

Switch set-up settingsto AUTO or ON

Yes

No

Sufficient coolant? Top up coolant; ventcooling unitNo

Yes

Coolant pump blo-cked?

Use a screwdriver toturn the pump shaft;

if coolant pump is stiff,change it;

Check securingdevice F1

YesNo

+24V available fromX1/4 - X1/3? Check cable harness;

Change USTNo

Yes

Fan turning? Change fanNo

Yes

Relay K1 can beaccessed? Change relay K1

NoYes

Check torch trigger/cabling

BRT LED flasheswhen torch trigger

pressed?No

Change SR 41

Yes

End

ANo or incorrectwirefeed speed(continued)

B

25

EN

400V AC availablefrom plug X10/6 -

X10/8?

Check cable harnessto power sourceNo

Yes

Securing device F1 inthe cooling unit OK?

Switch off unit;Disconnect pump;

Replace fuse;Switch on unit;

No

Yes

Check relay contact,cable harness in

cooling circuit, auto-transformer (if avai-

lable) and voltage onthe pump

Securing device F1OK?

End

Change pump

Yes

Change auto-transfor-merNo

Insufficient torchcooling (FK 4000/FK 4000 R)(continued)

B

26

Service code Err50 Start

Does service code Err50 appear directlyafter switching on,

although the primarypower module is not

operating?

Yes

Imbalance in interme-diate circuit > 35V?

+5V available on USTfrom X6/26 - X7/8?

No

Yes

Change BPS

Yes

Does Err 50 disappearafter a short while? Yes

No

Change intermediatecircuit electrolytic

capacitors

Switch off powersource; unplug X2

from NT 60; switch onpower source

Err 50? Change NT 60No

Yes

Switch off powersource; dischargeintermediate circuit

electrolytic capacitors;unplug X1 from NT 24;switch on power source

Imbalance in interme-diate circuit > 35V? No

Change NT 24

A

Select „Rod electro-de“ mode

On the BPS, thebrightness of the

control LEDs remainsunchanged when the

BPS is accessed

Change UST

No

Yes

NoChange UST

Yes

27

EN

Switch off powersource; dischargeintermediate circuit

electrolytic capacitors;unplug X7/1 - X7/4

switch on power source

Service code Err50(continued)

A

Yes

Imbalance in interme-diate circuit > 35V? No

Change BPS

Change intermediatecircuit electrolytic

capacitors

End

28

For every service code there is information on- Service code indicator (e.g. „Err | Arc“)- Code no. (e.g. when service code is displayed by a robot interface)- Reason for the service code being displayed- Corresponding troubleshooting measures

dsP | Axx (code no.20)

Cause: DSP displays general faults, xx stands for additional entries not requiredfor external service

Remedy: update software. Change UST2 PC board.

dsP | A21 (code no.20)

Cause: The power source is configured for either parallel operation (set-up para-meter P-C is set to “ON”) or for TimeTwin Digital (set-up parameter T-C isset to “ON”). However, the LHSB link has been disconnected, or hasbecome faulty, while the power source was switched on.

Remedy: Dismiss the service code: Switch the power source off and back on again.If necessary, restore or repair the LHSB link.

dsP | Cxx (code no.29)

Cause: DSP SoftCom fault, xx stands for additional entries not relevant for externalservice


dsP | E05 (code no.17)

Cause: DSP displays internal faultRemedy: update software. Change UST2 PC board.

dsP | Exx (code no.21)

Cause: DSP displays general fault, xx stands for1 timeout during charging2 EOF during charging3 fault on data channel (LT selection)4 fault on com channel (LT selection)5 timeout at EM stop command


dsP | Sy (code no.35)

Cause: internal fault (version conflict)Remedy: update software. Change UST2 PC board.

dsP | nSy (code no.36)

Cause: internal fault (version conflict)Remedy: update software. Change UST2 PC board.

Table of servicecodes

UST service codes

Safety WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine from the mains- Ensure that electrically charged components (e.g. capacitors) have been

discharged

29

EN

EcF | xxx (code no.32)

Cause: BPS configuration fault, x stands for:

1 TPS 2700 with incorrect power module2 TS/TPS/TP 4000 with incorrect power module3 TS/TPS/TP 5000 with incorrect power module4 TT 2200, MW 2200 with incorrect primary power module5 MW 1700 with incorrect primary power module253 This configuration functions only from UST2A V1.3 A onwards254 This configuration functions only from UST PC board, version

UST2A onwards255 Unknown primary power module

Remedy: Fit correct primary power module

EFD | xx.y (code no.30)

Cause: Fault in wirefeed system, xx and y emanate from the list of service codesfor the wirefeed system.

Remedy: check wirefeed system

EIF | xx.y (code no.63)

Cause: fault connected with a robot interface, xx and y emanate from the list ofservice codes of your robot interface.

Remedy: check robot interface, update software, change robot interface

Err | Arc (code no.61)

Cause: DPS 5000 only: DPS detected arc formationRemedy: check application

Err | bPS (code no.18)

Cause: DSP displays internal faultRemedy: update software. Change UST2 PC board. Change BPS PC board.

Err | Cfg (code no.72)

Cause: Power source configuration changed (e.g. connected in parallel with asecond power source)

Remedy: dismiss service code by pressing set-up button

Err | EPF (code no.22)

Cause: Fault during charging of flexRemedy: update software. Change UST2 PC board.

Err | IP (code no.19)

Cause: DSP displays primary overcurrentRemedy: check secondary power module. Change primary power module.

Err | Jo (code no.67)

Cause: JobMaster temperature sensor faultyRemedy: change JobMaster welding torch

Err | Lic (code no.40)

Cause: faulty/incorrect licence keyRemedy: check licence key. Check and update enable codes. Check/change earth

current watchdog

Table of servicecodes(continued)

30

Err | PE (code no.53)

Cause: Ground (earth) faultRemedy: remove earth fault. Configure machine in insulated state. Check earth

current watchdog and change if necessary.

Err | tF1 (code no.11), Err | tF2 (code no.12), Err | tF3 (code no.13), Err | tF4 (codeno.14), Err | tF5 (code no.15)

Cause: temperature sensor fault (short circuit or interruption)Remedy: check cable harness and change temperature sensor

Err | tF6 (code no.16)

Cause: fault on BPS PC board or on the connection to BPS PC boardRemedy: check ribbon cable. Change BPS PC board.


Cause: temperature sensor fault on USTRemedy: Changing UST PC board


Cause: in conjunction with thermostat option: cooling unit temperature sensor faultRemedy: check cable harness. Change temperature sensor.

Err | 027 (code no.27)

Cause: one of the supply voltages is outside the tolerance rangeRemedy: Change UST


Cause: Phase failureRemedy: Check the mains fuse, the mains supply lead and the mains plug


Cause: voltage intermediate circuit balance errorRemedy: see fault flowchart Err 50 if available.

If there is a voltage of +5 V on the UST from X6/26 - X7/8, change BPS.If there is a voltage of 0 V on the UST from X6/26 - X7/8 0V, change UST.


Cause: mains undervoltage: The mains voltage has dropped below the tolerancerange

Remedy: check mains voltage


Cause: mains overvoltage: The mains voltage has exceeded the upper limit of thetolerance range

Remedy: check mains voltage


Cause: Wire stick control has trippedRemedy: remove short circuit on filler wire


Cause: In conjunction with wire-feed unit and „wire-end check“ option: no wireavailable

Remedy: insert new wire spool


31

EN


Cause: overvoltage in the secondary circuit: safety cut-out has trippedRemedy: check secondary circuit, including TP4CEL40


Cause: DPS5000 only: Due to an opened door contact, SITRE1A has triggeredsafety disconnection

Remedy: safety cut-out: close door contact


Cause: Remote control TP08 overtemperatureRemedy: allow TP08 to cool down. Change TP08.


Cause: secondary circuit safety cut-out has trippedRemedy: change TTS PC board


Cause: illegal change of mode or process during weldingRemedy: reignite arc


Cause: no communication between power source and remote control RCU 5000iRemedy: check LocalNet leads. Check software version (UST 3.21.4). Wait for

software update to finish.

Err | 23.x (code no.23)

Cause: config memory (CFM) fault on UST2B PC board, x stands for:1 config memory not found2 checksum error3 CFM undescribed5 unknown PC board type8 invalid identifier (identifier UST1 to UST2)

Remedy: update software. Change UST2B PC board.


Cause: config memory (CFM) fault on BPS PC board, x stands for:1 config memory not found2 checksum error3 CFM undescribed5 unknown PC board type8 invalid identifier (identifier UST1 to UST2)

Remedy: check ribbon cable. Change BPS PC board.


Cause: config memory (CFM) „alternator“ fault, x stands for:1 config memory not found2 checksum error3 never tested4 test was not OK5 unknown PC board type8 invalid identifier (identifier UST1 to UST2)

Remedy: change TTS


32



Cause: config memory (CFM) „machine“ fault, x stands for:1 config memory not found2 checksum error3 CFM undescribed5 unknown PC board type8 invalid identifier (identifier UST1 to UST2)

Remedy: check cable harness. change config memory on power source cableharness.


Cause: EEProm save errorRemedy: update software. Change UST2 PC board.


Cause: fault with the digital gas control option, x stands for:1 no sensor found2 no shielding gas3 calibration fault4 shielding gas solenoid valve interruption or short circuit5 no shielding gas solenoid valve found

Remedy: for cause x1 check cable harness, change shielding gas sensor2 check shielding gas supply (min. 2 bar)3 no or insufficient shielding gas, change shielding gas solenoid valve4 change shielding gas solenoid valve, change shielding gas sensor5 check cable harness, change shielding gas solenoid valve


Cause: Limit failure, x stands for:1 upper current limit exceed2 exceed of lower current limit3 voltage limit exceeded4 exceed of lower voltage limit

Remedy: check application. check parameters.

hot | H2O (code no.65)

Cause: in conjunction with thermostat option: Overtemperature in cooling systemRemedy: allow cooling unit to cool down. Open cooling unit and clean heat exchan-

ger. Check whether ventilator is functioning properly.

no | Arc (code no.58)

Cause: arc is broken, arc-break monitor has trippedRemedy: check welding parameters. Reignite arc Check grounding (earthing)

connection.

no | GAS (code no.57)

Cause: in conjunction with the digital gas control option: no shielding gas availableRemedy: check shielding gas supply

33

EN


no | H2O (code no.39)

Cause: flow watchdog reporting water deficiencyRemedy: check cooling system hosepipes. Check pump pressure and flow rate.

Check flow watchdog.

no | Ign (code no.55)

Cause: „Ignition time-out“ fault: no ignition within the value set in the set-up menu.The safety cut-out has tripped.

Remedy: clean workpiece surface. Check parameters in set-up menu. Checkgrounding (earthing) connection.

no | Prg (code no.1)

Cause: no saved program selectedRemedy: select saved program

off (code no.150)

Cause: no communication between the LocalNet participants (e.g. power source,wire-feed unit, remote control or welding torch)

Remedy: check LocalNet leads. Change remote control/welding torch. Wait forsoftware update to finish.

-Stop- (code no.38)

Cause: Robot not readyRemedy: when using a robot interface or field bus coupler, initialise the „Robot

ready“ and „Source error reset“ signals.

tJo | xxx (code no.66)

Cause: JobMaster overtemperatureRemedy: allow machine to cool down. Check cooling system.

tp1 | xxx (code no.5), tp2 | xxx (code no.6), tp3 | xxx (code no.7), tp4 | xxx (codeno.8), tp5 | xxx (code no.9)

Cause: overtemperature in power source primary circuit (XXX stands for tempera-ture indicator)

Remedy: allow the power source to cool down. Check that ventilator is running.

tp6 | xxx (code no.10)

Cause: overtemperature in power source primary circuit, temperature sensor onBPS PC board has tripped (XXX stands for temperature indicator)


ts1 | xxx (code no.2), tS2 | xxx (code no.3), tS3 | xxx (code no.4)

Cause: overtemperature in power source secondary circuit (XXX stands for tempe-rature indicator)


tSt | xxx (code no.33)

Cause: overtemperature in control circuit, xxx stands for the temperature indicatorRemedy: allow the power source to cool down. Check ventilator.

US | POL (code no.37)

Cause: measuring device for secondary voltage (USek) incorrectly connected, ordefective for some other reason

Remedy: check cable harness. Change UST2 PC board.

34

- And | Opc- Prt | Flt- Ill | Opa- Ill | Ina- Ill | Bus- Err | 105

If the service codes shown above appear, more detailed information can be requestedat the power source control panel. Using the parameter selection buttons (left/rightarrows), you can switch between the following display levels:- Level 1 (e.g. „And | Opc“): service codes display

(appears automatically)- Level 2 (e.g. „CS 01“): segment display

(press parameter selection button once)- Level 3 (e.g. „IP 3456“): instruction pointer

(press parameter selection button again)

Important! Please make a note of the displays in levels 1, 2, and 3, and pass them onto Fronius. Using this data, Fronius can locate the precise cause of the fault.

- STK | OVL- STK | UVL- Err | Dog- ASS | Ert- Edg | 1

Special displaysused with servicecodes

The following service codes are special displays for software problems:

35

EN

EFD 1.x

Cause: flex communication errorRemedy: change SR 4x

EFD2.1

Cause: oscillator watchdog faultRemedy: change SR 4x

EFD 3.1

Cause: watchdog timer faultRemedy: change SR 4x

EFD 5.x

Cause: SR 4x config memory (CFM) not legibleRemedy: change SR 4x

EFD 7.x

Cause: wire-feed unit config memory (CFM) not legibleRemedy: check cable harness. Change config memory (CFM) in cable harness.

EFD 8.x

Cause: motor overcurrent, x stands for:1 motor overcurrent SR 4x (main motor)2 motor overcurrent PM 4x (PM motor)

Remedy: check wirefeed system. For permitted nominal currents, see operatinginstructions for the relevant wire-feed unit.

EFD 9.x

Cause: supply to motor, x stands for:1 exceed of lower motor supply voltage limit2 motor supply upper voltage limit exceed

Remedy: check VSP. check/change mains adapter NTxx

EFD 10.x

Cause: PMxxA config memory (CFM) not legibleRemedy: check PM xx connection to SR 4x. Change PM xx

EFD 12.x

Cause: VD actual speed value check outside of range, x stands for:1 actual-value pick-up fault 12 actual-value pick-up fault 2

Remedy: check cable harness and actual value pick-up.

Service codes SR 4xA

Safety WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine from the mains- Ensure that electrically charged components (e.g. capacitors) have been

discharged

Table of servicecodes

36

Service codes for push-pull calibration

Safety

Err | Eto

Cause: Incorrect measurement during push-pull calibrationRemedy: Repeat push-pull calibration

St1 | E 1

Cause: At minimum wire feed speed, the wire-feed unit motor does not deliver anyactual rotational speed value.

Remedy: Repeat the push-pull calibration. If the error message re-appears: checkthe actual-value pick-up and the cable connections to and from it

St1 | E 2

Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver anyactual rotational speed value.


St1 | E 3



St1 | E 4

Cause: At minimum wirefeed speed, the motor of the push-pull unit does notdeliver any actual rotational speed value.


WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine from the mains- Ensure that electrically charged components (e.g. capacitors) have been

discharged

Error codesshown when thedrive units areengaged („enga-ged“ calibration)

Checking actual-value pick-up

The actual-value pick-up is checked by measuring the direct voltage on the actual-valuepick-up leads.

Motor not activated:- the voltage on the actual-value pick-up cable connections is approx. 13 V.

Motor activated:- The motor speed is conveyed in the form of impulses on the actual-value pick-up

cable connections.- The voltage sinks to approx. 11 V.

37

EN

St1 | E 5



St1 | E 6

Cause: At maximum wirefeed speed, the motor of the push-pull unit does notdeliver any actual rotational speed value.


St1 | E 16

Cause: push-pull calibration has been interrupted: Quick-stop was activated bypressing the torch trigger.

Remedy: Repeat push-pull calibration

St2 | E 7

Cause: „Push-pull calibration - open-circuit“ has not been carried outRemedy: Carry out „push-pull calibration - open-circuit“

St2 | E 8



St2 | E 9

Cause: At minimum wirefeed speed, the motor of the push-pull unit does notdeliver any actual rotational speed value.


St2 | E 10

Cause: At minimum wirefeed speed, the motor current of the wire-feed unit motoris outside the permitted range. Possible causes of this include the wire-feed unit motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wire-feed unit motors, arrange the hose-pack in as straight a line as possible; check the inner liner for kinks orsoiling; check the contact pressure on the 2-roller or 4-roller drive of thepush-pull unit;Repeat the push-pull calibration

St2 | E 11

Cause: At minimum wirefeed speed, the motor current of the push-pull unit isoutside the permitted range. Possible causes of this include the wire-feedunit motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wire-feed unit motors, arrange the hose-pack in as straight a line as possible; check the inner liner for kinks orsoiling; check the contact pressure on the 2-roller or 4-roller drive of thepush-pull unit;Repeat the push-pull alignment. If the error message re-appears: checkPPU settings

Error codesshown when thedrive units areengaged („enga-ged“ calibration)

38

Error codesshown when thedrive units areengaged („enga-ged“ calibration)(continued)

St2 | E 12



St2 | E 13

Cause: At maximum wirefeed speed, the motor of the push-pull unit does notdeliver any actual rotational speed value.

Remedy: Repeat the push-pull calibration. If the error message re-appears: checkthe actual-value pick-up and the cable connections to and from it, andchange if necessary.

St2 | E 14

Cause: At maximum wirefeed speed, the motor current of the wire-feed unit motoris outside the permitted range. Possible causes of this include the wire-feed unit motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wire-feed unit motors, arrange the hose-pack in as straight a line as possible; check the inner liner for kinks orsoiling; check the contact pressure on the 2-roller or 4-roller drive of thepush-pull unit.Repeat the push-pull calibration. If the error message re-appears: checkPPU settings

St2 | E 15

Cause: At maximum wirefeed speed, the motor current of the push-pull unit isoutside the permitted range. Possible causes of this include the wire-feedunit motors not being engaged, and other wirefeed problems.

Remedy: Engage the drive units of both wire-feed unit motors, arrange the hose-pack in as straight a line as possible; check the inner liner for kinks orsoiling; check the contact pressure on the 2-roller or 4-roller drive of thepush-pull unit.Repeat the push-pull calibration. If the error message re-appears: checkPPU settings

St2 | E 16

Cause: push-pull calibration has been interrupted: quick-stop was activated bypressing the torch trigger.

Remedy: Repeat push-pull calibration

39

EN

Detailed description

General remarks This section contains a detailed description of the electronic components with regard tothe following points:- General (designation, item number)- Component position in the machine- Overview- Technical Data- Function overview- Plug layout- LED checklist- Measuring points

Position ofelectronic com-ponents

Overview „Detailed description“ is composed of the following sections:- ASU 27 - additional PC board- ASU 40 - additional PC board- BPS 25/BPT 27 - power module PC board- BPS 32/40/42/50 - power module PC board- NT 24 - 24 V switched mode power supply for control and regulation unit- NT 60 - 60 V switched mode power supply for wire-feed unit- UST - Control and regulation unit- NF 3160 - Line filter- NF 3400 - Line filter/“black box“- Shunt- SR 41 - Wire-feed regulation unit- Temperature sensor TP 592S- Secondary power module TPS 2700- Secondary power module TS 4000/5000, TPS 3200/4000/5000- Primary rectifier

Fig. 3 TPS 2700: Position of electronic components Fig. 4 TS 4000/5000, TPS 3200/4000/5000:Position of electronic components

40

The ASU 27 PC board (item number 4,070,691,Z) is an additional PC board for the TPS2700 MV power sources and is for switching between 230 V and 400 V.

Componentposition in themachine

Fig.5 TPS 2700 MV: Position of ASU 27 PC board

Overview

Fig.6 ASU 27 PC board

Technical Data Input voltage 230/400 V ACInput voltage tolerance +/- 15 %

X2

X1

LED +5 VLED +12 VLED 230 V ACLED 400 V AC

ASU 27 - additional PC board

General remarks

41

EN

Function over-view

Plug layout

Pin FunctionX1 Connection to cooling unit

Fig.7 Plug and connections on ASU 27 PC board

(X6)

(X5)

(X4)

(X1)

(X3)

(X2)

Pin 1 NCPin 2 230/400 V from

primary rectifierPin 3 NCPin 4 Cooler 400 VPin 5 NCPin 6 Cooler 230 VPin 7 NCPin 8 NC

Pin 9 NCPin 10 NC

Pin 11 NCPin 12 NCPin 13 NCPin 14 NCPin 15 NCPin 16 NC

- For switching between 230 V AC and 400 V AC- For generating control voltage +12 V and +5 V from the input voltage- When switching on, the switching mechanism on the PC board detects the input

voltage:a) With an input voltage of 400 V AC, the ASU 27 PC board switches both power

modules on BPS 25/BPT 27 in seriesb) With an input voltage of 230 V AC, the ASU 27 PC board switches both power

modules on BPS 25/BPT 27 in parallel.

X2 not connectedX3 Connection to BPS 25/BPT 27 PC board (intermediate circuit 1+)X4 Connection to BPS 25/BPT 27 PC board (intermediate circuit 1-)X5 Connection to BPS 25/BPT 27 PC board (intermediate circuit 2+)X6 Connection to BPS 25/BPT 27 PC board (intermediate circuit 2-)

42

Measuring points

LED checklist

Fig. 8 LED indicators on ASU 27 PC board

There are no measuring points available on the ASU 27 PC board.

LED +5 VLED +12 VLED 230 V ACLED 400 V AC

43

EN

The ASU 40 PC board (item number 4,070,685) is an additional PC board for TPS 3200MV,TS/TPS 4000/5000 MV, and is for switching the input voltage between 230 V AC and400 V AC.


Fig. 9 TPS 3200 MV, TS/TPS 4000/5000:Position of ASU 40 PC board

Overview

Fig. 10 ASU 40 PC board

(X1)

(X8)

LED charge unit

(X12)

LED + 5 V

LED + 12 VLED 230 V

ASU 40 - additional PC board

General remarks

44

Technical Data Input voltage 230/400 V ACInput voltage tolerance +/- 15 %

Function over-view

Plug layout

Fig. 11 Plug and connections on ASU 40 PC board

(X9)

(X10)

(X11)

(X12)

(X3)

(X1)

(X8)

(X5)

(X2)

(X6)

(X7)

(X4)

- For switching between 230 V AC and 400 V AC- For generating control voltage +12 V and +5 V from the input voltage- When switching on, the switching mechanism on the PC board detects the input

voltage:a) With an input voltage of 400 V AC, the ASU 40 PC board switches both power

modules on BPS 32/40/42/43/50/53 in seriesb) With an input voltage of 230 V AC, the ASU 40 PC board switches both power

modules on BPS 32/40/42/43/50/53 in parallel.- High charging connection by means of resistance; the relays for bridging the resis-

tances are controlled by the BPS PC board. The high charging connection is onlyactive at an input voltage of 230 V AC.

Pin 1 NCPin 2 NCPin 3 NCPin 4 NCPin 5 NCPin 6 NCPin 7 NCPin 8 +15 V primary

Pin 9 Intermediate circuit voltage 1+Pin 10 NCPin 11 Intermediate circuit voltage 2-Pin 12 NCPin 13 NCPin 14 NCPin 15 GND primaryPin 16 High charging connection signal

Pin FunctionX1 Connection to BPS 40/42/50 PC board

45

EN

Plug layout(continued)

LED checklist

Fig. 12 LED indicators on ASU 40 PC board

LED 230 V

LED charge unit

LED + 5 V

LED + 12 V

Pin 1 Rectifer L1Pin 2 NCPin 3 Rectifer L2Pin 4 NCPin 5 Rectifer L3Pin 6 NCPin 7 NCPin 8 NC

Pin 9 NCPin 10 NCPin 11 Rectifer L2Pin 12 NCPin 13 NCPin 14 NCPin 15 NCPin 16 NC

Pin FunctionX2 Connection to 2nd line filter L1 outX3 Connection to 2nd line filter L2 outX4 Connection to 3rd line filter L3 outX5 Connection to 2nd rectifer L1X6 Connection to 2nd rectifer L2X7 Connection to 2nd rectifer L3X8 not connectedX9 Connection to cooling unit 230 VX10 Connection to cooling unit L2X11 Connection to cooling unit L1X12 Connection to 1st primary rectifer

46

Measuring points There are no measuring points available on the ASU 40 PC board.

LED checklist(continued)

LED charge unit ............. flashes once the intermediate circuit has been chargedLED 230 V ...................... flashes at an input voltage of 230 V

47

EN

BPS 25/BPT 27 - power module PC board

General remarks BPS 25 (item number 4,070,631,Z) and BPT 27 (item number 4,070,739,Z) are powermodule PC boards for the TPS 2700 power source.The BPT 27 has serial numbers of 14481582 and upwards and replaces the BPS 25.

Important! On PC boards BPS 25/BPT 27, primary voltage is on!

BPS 25/BPT 27 consist of 2 PC boards:- Power module PC board BPS 25/BPT 27- PC board BPZ 25 for primary/secondary isolation

PC board BPZ 25 and BPS 25/BPT 27 form one unit. BPZ 25 and BPS 25/BPT 27cannot be ordered separately.


Fig. 13 TPS 2700, position of PC board BPS 25/BPT 27

Fig. 14 PC board BPS 25/BPT 27

Overview

PC board BPZ 25with X1

X2

Tran

sist

or m

odul

e co

ntro

l LE

Ds

LED 15 V primary

Control LEDBoost converter

48

Function over-view

- Basic composition: two individual power modules (advantage: power modules canbe switched in series as well as parallel)

- Suitable for a 3 x 400 V AC and 3 x 230 V AC mains supply- Inputs and outputs are electrically isolated by means of isolating transformers and

optical couplers- 3 temperature sensors, each one in the transistor module housing- Temperature analysed by a PWM signal electrically isolated by an optical coupler:

the temperature of the warmest transistor module is transmitted to the UST PCboard

- Monitoring of both intermediate circuits for imbalance: a signal is transmitted to theUST PC board if there is any deviation from a permitted range

- Switching with boost converter for increasing the intermediate circuit voltage fromapprox. 282 V DC to 320 Volt DC per circuit (at 400 V AC input voltage).

- Controlling the transistor module via driver stages from the UST PC board- High charging connection via PTC resistors, time for bridging the PTC by means of

relay is given by UST PC board- Activation of boost converter only once the high charging time is completed- Quick switch-off of power module in the case of a module fault due to permanent

primary current measurement

Technical Data Input voltage 3 x 230/400 V ACInput voltage tolerance (+/-15%)Supply voltage (from NT 24A) 15 V DC primaryBoost converter work frequency 47 kHzTransistor module switching frequency 100 kHz

Plug layout BPS25/BPT 27 (X13) (X14) (X10) (X4)

(X3)

(X9)

(X6)

(X11)

(X5)(X12)(X2)(X15)(X16)

(X1)

Fig. 15 Plugs and connections on PC board BPS 25/BPT 27

(X7)

(X8)

49

EN

Pin FunctionX1 Ribbon cable connection to UST PC board (on BPZ 25 PC board)

Plug layout BPS25/BPT 27(continued)

X3 Intermediate circuit 1+ (for MV only)X4 Intermediate circuit ZWK 1-, bridge for operation in seriesX5 Intermediate circuit ZWK 2+, bridge for operation in seriesX6 Intermediate circuit 2- (for MV only)X7 Cable with blade terminal, rectifer +X8 Cable with blade terminal, rectifer -X9 PFC throttle connection L2X10 PFC throttle connection L2X11 PFC throttle connection L3X12 PFC throttle connection L3X13 Primary transformer connection (e.g. blue)X14 Primary transformer connection (e.g. blue)X15 Primary transformer connection (e.g. orange)X16 Primary transformer connection (e.g. orange)

Pin 1 Intermediate circuit 1 +Pin 2 NCPin 3 Intermediate circuit 1 -Pin 4 NCPin 5 Intermediate circuit 2 +Pin 6 NCPin 7 Intermediate circuit 2 - GNDPPin 8 + 15 V primary


X2 Intermediate circuits 1 and 2 primary connection

Pin 1 Primary current measurement+T1


Pin 5 Transistor controlPin 7 Transistor controlPin 9 Transistor controlPin 11 Transistor controlPin 13 GNDDPin 15 + 5 VPin 17 + 24 V

Pin 19 Temperature value PWM signal

Pin 21 CFM data linePin 23 NCPin 25 NC

Pin 2 Primary current measurementGND T1


Pin 6 Transistor controlPin 8 Transistor controlPin 10 Transistor controlPin 12 Transistor controlPin 14 GNDDPin 16 + 15 VPin 18 Main switch detection

(0 V = off/5 V = on)Pin 20 Signal for high charging

connection(0 V = relay on/15 V = relay off)

Pin 22 CFM data linePin 24 NCPin 26 Intermediate circuit imbalance

detection(0 = fault/5 V = OK)

50

8 transistor module control LEDs

LED checklist

Fig. 16 LED indicators on PC board BPS 25/BPT 27

1 x 15 V primary supply LED2 control LEDsBoost converter

Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor fieldeffect transistors) with diode. This diode provides information about the state of thetransistor:using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltagecannot be measured, the module is faulty.

Fig. 17 Measuring points on the BPS 25/BPT 27 PC board

4 x diode(module M1)

4 x diode (module M3)

4 x diodemodule M2

Charging resistor (PTC)120 R at 25°C

51

EN

Measuring points Plug/pin Measuring result commandvalue

Intermediate circuit voltage 1 M1/TP1-TP3 320 V DCIntermediate circuit voltage 2 M2/TP5-TP7 320 V DCDiode check module M1 M1/TP1-TP2 (+) 0.46 V

M1/TP1-TP4 (+) 0.46 VM1/TP3 (+) - TP2 0.46 VM1/TP3 (+) - TP4 0.46 V

Diode check module M2 M2/TP5-TP6 (+) 0.46 VM2/TP5-TP8 (+) 0.46 VM2/TP7 (+) - TP6 0.46 VM2/TP7 (+) - TP8 0.46 V

Diode check module M3 M3/TP9 (+) - TP11 0.46 VM3/TP11 (+) - TP10 0.38 VM3/TP13 (+) - TP14 0.46 VM3/TP14 (+) - TP12 0.38 V

NOTE!The resulting measurement command values change according to the temperature.

Measuring points(continued)

52

BPS 32/40/42/43/50/53 - power module PC board

General remarks BPS 32/40/42/43/50/53 are power module PC boards:TPS 3200 ..................BPS 32 (item number 4,070,681,Z)

BPS 42 >/= V1.4A (item number 4,070,738,Z)BPS 43 (item number 4,070,771,Z)

TS/TPS 4000.............BPS 40 (item number 4,070,617,Z)BPS 42 (item number 4,070,738,Z)BPS 43 (item number 4,070,771,Z)

TS/TPS 5000.............BPS 50 (item number 4,070,658,Z)BPS 53 (item number 4,070,772,Z)

Important! On the power module PC boards, primary voltage is on!


Fig. 18 TS 4000/5000, TPS 3200/4000/5000:Position of PC board BPS xx

Overview

Fig. 19 PC board BPS 50 < V1.4A (BPS 42 < V1.4A / BPS 32)

*) ... not on PC board BPS 42 < V1.4A **) ... not on PC board BPS 32

X1 X2

X3

8 tra

nsis

tor m

odul

e co

ntro

l LE

Ds

*)

*)

**)

53

EN

Overview(continued)

X1 X2

X3

8 tra

nsis

tor m

odul

e co

ntro

l LE

Ds

Fig. 20 PC board BPS 53 / 50 >/= V1.4A / 43 / 42 >/= V1.4A

*) ... not on PC board BPS 42 >/= V1.4A and BPS 43

Main switch LED

Intermediate circuitimbalance LED

LED +15 V primary

High charging relay LED

*)

Function over-view

- Basic composition: two individual power modules (advantage: power modules canbe switched in series as well as parallel)

- Suitable for a 3 x 400 V AC and 3 x 230 V AC mains supply- Inputs are electrically isolated by means of isolating transformers and optical

couplers- Outputs are electrically isolated by means of optical couplers- 4 parallel transistor modules for BPS 32, BPS 42 >/= V1.4A and BPS 43

6 parallel transistor modules for BPS 42 < V1.4A, BPS 50 and BPS 53- Each transistor module has a temperature sensor- Temperature analysed by a PWM signal electrically isolated: the temperature of the

warmest transistor module is transmitted to the UST PC board- Monitoring of both intermediate circuits for imbalance: a signal is transmitted if

there is any deviation from a permitted range- Controlling the transistor module via driver stages from the UST PC board- High charging connection via resistors, time for bridging the resistors by means of

relay is given by UST PC board- Quick switch-off of power module in the case of a module fault due to permanent

primary current measurement

Technical Data Input voltage 3 x 230/400 V ACInput voltage tolerance (+/-15%)Supply voltage (from NT 24A) 15 V DC primaryTransistor module switching frequency 70 kHzIntermediate circuit voltage at 400 V AC 2 x 280 V DC

54

Pin FunctionX1 Ribbon cable connection to PC board UST (secondary voltage)

Plug layout

(X13)

(X10)(X4)

(X9) (X3)

(X11)(X12) (X2)

(X15)

(X1)

Fig. 21 Plugs and connections on power module PC board, e.g. BPS 50 < V1.4A

The position of the plug and connections is identical for all power module PC boards.

(X8)

(X21)(X20)(X7)(X18)(X19)

Plugs on thepower modulePC boards

(X5)(X16)(X17)(X14)(X6)



Pin 6 Transistor controlPin 8 Transistor controlPin 10 Transistor controlPin 12 Transistor controlPin 14 GNDDPin 16 + 15 VPin 18 Main switch detection

(0 V = off/5 V = on)Pin 20 Signal for high charging

connection(0 V = relay on/15 V = relay off)

Pin 22 CFM data linePin 24 15 V supplyPin 26 Intermediate circuit balance

detection (0/5 V)



Pin 5 Transistor controlPin 7 Transistor controlPin 9 Transistor controlPin 11 Transistor controlPin 13 GNDDPin 15 + 5 VPin 17 + 24 V

Pin 19 Temperature value PWM signal

Pin 21 CFM data linePin 23 NCPin 25 NC

55

EN

X4 N1- transformer connectionX5 N2- transformer connectionX6 N2+ transformer connectionX7 N1+ transformer connectionX8 Primary rectifier L1X9 Line filter L1X10 Line filter L3X11 Primary rectifier L3X12 Line filter L2X13 Primary rectifier L2X14 Intermediate circuit 2-, blue cableX15 Intermediate circuit 2-, blue cableX16 Intermediate circuit 2+, red cableX17 Intermediate circuit 2+, red cableX18 Intermediate circuit 1-, blue cableX19 Intermediate circuit 1-, blue cableX20 Intermediate circuit 1+, red cableX21 Intermediate circuit 1+, red cable




Pin FunctionX2 Intermediate circuits 1 and 2 primary connection

X3 Main switch connection (primary voltage)

Pin 1 L1Pin 2 NCPin 3 L2Pin 4 NCPin 5 NCPin 6 Main switch detectionPin 7 NCPin 8 +15 V primary

Pin 9 NCPin 10 High charging resistor L1Pin 11 NCPin 12 High charging resistor L2Pin 13 NCPin 14 NCPin 15 NCPin 16 High charging connection

56

LED checklist ofpower modulePC boards

Fig. 22 LED indicators on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32

8 tra

nsis

tor m

odul

e co

ntro

l LE

Ds

8 tra

nsis

tor m

odul

e co

ntro

l LE

Ds

Fig. 22a LED indicators on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A

Main switch LED

Intermediate circuitimbalance LED

LED +15 V primary

High charging relay LED

Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor fieldeffect transistors) with diode. This diode provides information about the state of thetransistor:using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltagecannot be measured, the module is faulty.

57

EN

Fig. 23 Measuring points on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32

4 x diode

4 x diode


Fig. 23a Measuring points on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A

58


Measuring points Plug/pin Measuring result command valueIntermediate circuit voltage 1 TP1-TP3 320 V DCIntermediate circuit voltage 2 TP5-TP7 320 V DCDiode check module M1 TP1-TP2 (+) 0.46 V

TP1-TP4 (+) 0.46 VTP3 (+) - TP2 0.46 VTP3 (+) - TP4 0.46 VTP5 - TP6 (+) 0.46 VTP5 - TP8 (+) 0.46 VTP7 (+) - TP6 0.46 VTP7 (+) - TP8 0.46 V

Important! No continuity during diode check of module M1 with reverse polarity.

NOTE!The resulting measurement command values change according to the temperature.

59

EN

NT 24 - switched mode power supply 24 V

General remarks NT 24 switched mode power supply (item number 4,070,626,Z) for internal and externalcomponents.

Important! On NT 24 switched mode power supply, the primary voltage is on!


Fig. 24 TPS 2700, position of NT 24

Fig. 26 NT 24

Overview

Fig. 25 TPS 3200, TS/TPS 4000/5000:Position of NT 24

Primary voltageSecondary voltage

X2X1

LED 24 V internal LED 15 V primary

LED 24 V external

60

8

5

6

7

8

1

2

3

4

7

6

5

4

3

2

16

1

15

14

13

12

11

10

9

Input voltages 2 x 230 - 380 V DC from intermediate circuitOutput voltages 15 V DC primary

24 V DC internal24 V DC external

Fuse protection from PTC 15 V primary 2 A24 V internal 5 A24 V external 2 A

Technical Data

Function over-view

- Internal and external components supplied with +24 V DC- Power module supplied with +15 V DC primary

NOTE! +15 V DC is for primary. Do not use for supplying other components.

- Supply voltages are electrically isolated and protected by PTC- Electrically isolated measurement of intermediate circuit voltage, evaluation on UST

PC board

Plug layout

(X1)(X2)

Fig. 27 Plug on NT 24 A

Pin FunctionX1 Primary connection intermediate circuit 1 and 2

Pin 1 Intermediate circuit 1 +Pin 2 NCPin 3 Intermediate circuit 1 -Pin 4 NCPin 5 Intermediate circuit 2 +Pin 6 NCPin 7 Intermediate circuit 2 - GNDPPin 8 +15 V primary

Pin 9 Intermediate circuit 1 +Pin 10 NCPin 11 Intermediate circuit 1 -Pin 12 NCPin 13 Intermediate circuit 2 +Pin 14 NCPin 15 Intermediate circuit 2 - GNDPPin 16 +15 V primary

61

EN

Fig. 28 LED indicators on mains adapter NT 24 A

LED checklist

Measuring points

8

5

6

7

8

1

2

3

4

7

6

5

4

3

2

16

1

15

14

13

12

11

10

9


LED 24 V internal LED 15 V primary

LED 24 V external

X2

Fig. 29 Plug X1 and X2 on mains adapter NT 24 A

X1

Pin functionX2 Secondary connection +24 V

Pin 1 +24 V externalPin 2 NCPin 3 Intermediate circuit voltage UZWPin 4 +24 V internal

Pin 5 GND EXTPin 6 NCPin 7 GND UZWPin 8 GND INT

62

Measuring points Plug/pin Measuring result command valueIntermediate circuit voltage 1 X1/1 - X1/3 approx. 280 V DC at a nominal voltage of

400 V ACapprox. 320 V DC at a nominal voltage of230 V AC

Intermediate circuit voltage 2 X1/5 - X1/7 approx. 280 V DC at a nominal voltage of400 V ACapprox. 320 V DC at a nominal voltage of230 V AC

+15 V primary X1/8 - X1/7 approx. 15 V DC+24 V internal X2/4 - X2/8 approx. 24 V DC+24 V external X2/1 - X2/5 approx. 24 V DC


63

EN

The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feedunit motor.

Important! On NT 60 switched mode power supply, the primary voltage is on!

Fig.30 TPS 2700, position of NT 60

Fig.32 NT 60

Fig.31 TPS 3200, TS/TPS 4000/5000:Position of NT 60

Primary voltage Secondary voltage

X1X2

Intermediate circuit 1 supply LED „Error“ LED (PTC active) Supply LED55 V

Intermediatecircuit 2 supplyLED

NT 60 - switched mode power supply 60 V

General remarks


Overview

64

Supply voltage from intermediate circuit 2 x 230 - 380 V DCOutput voltage Idle 59 (+/- 2) V

at a load of 4 A 55 (+/- 2) V

Technical Data

Function over-view

- Output voltage is electrically isolated and protected by 2 parallel switched PTCresistors.

- The 1 V/A falling output characteristic of the NT 60 circuit enables several NT 60adapters to be connected in parallel.

- If there is a short circuit, the NT 60 restricts to max. 15 A, using the internal currentlimit, until the PTC resistors have reached the switch-off temperature. In the case ofa short circuit, the 55 V supply LED does not flash. As soon as the PTC resistorstrip, the „Error“ LED flashes.

Plug layout

(X1)(X2)

Fig. 33 Plug on NT 60 mains adapter

Pin 9 Intermediate circuit 1+Pin 10 NCPin 11 Intermediate circuit 1 -Pin 12 NCPin 13 Intermediate circuit 2+Pin 14 NC

Pin FunctionX1 Connection to wire-feed unit (secondary voltage)

Pin 1 + 55 VPin 2 + 55 V

Pin 3 GNDPin 4 GND

X2 Primary connection intermediate circuit 1 and 2

Pin 1 Intermediate circuit 1+Pin 2 NCPin 3 Intermediate circuit 1 -Pin 4 NCPin 5 Intermediate circuit 2+Pin 6 NC

65

EN

Fig. 34 LED indicators on mains adapter NT 60

LED checklist

Intermediate circuit 1 supply LED

Intermediate circuit 2 supply LED

„Error“ LED (PTC highly resistive)

55 V supply LED

Measuring points


Pin 7 Intermediate circuit 2- GND PPin 8 + 15 V primary

Fig. 35 Plug X1 and X2 on mains adapter NT 60

X1X2

Pin 15 Intermediate circuit 2- GND PPin 16 + 15 V primary

66

Measuring points Plug/pin Measuring result command valueIntermediate circuit voltage 1 X2/1 - X2/3 approx. 280 V DC at a nominal voltage of

400 V ACapprox. 320 V DC at a nominal voltage of230 V AC

Intermediate circuit voltage 2 X2/5 - X2/7 approx. 280 V DC at a nominal voltage of400 V ACapprox. 320 V DC at a nominal voltage of230 V AC

+55 V X1/1 - X1/3 approx. 57-61 V DC in idleX1/2 - X1/4

X2/9 - X2/11

X2/13 - X2/15


67

EN

UST - Control and regulation unit

General remarks The UST PC board is a universal control, regulation and monitoring unit for fully digiti-sed Fronius power sources.Following versions are available:- UST 2C (4,070,960,Z)- UST-Pipe (4,070,963,Z)


Fig.36 TPS 2700: position of UST PC board Fig.37 TPS 3200, TS/TPS 4000/5000:position of UST PC board

Overview

Fig.38 UST PC board

X4

X1

X6 X2 X8X7 X5

X10

X9

X3

LED +24 V internalLED +15 V

LED +5 VLED -15 V

LED STAT LED +24 V externalLED +5 V (RS 485)

68

- Power module control (driver switches on UST PC board)- Operating panel control in the form of a databus connection (LocalNet)- Evaluation of the mains switch signal coming from the BPS PC board:

a) Mains switch ON: Once the intermediate circuit voltage reaches a certain value,the relays on the BPS PC board are controlled by the UST PC board

b) Mains switch OFF: UST stores present settings and activates the ventilators fordischarging the intermediate circuit capacitors

- Evaluation of signals from the temperature sensors; if there is a rise in temperatureand the ventilators do not cool sufficiently, (e.g. because the duty cycle was excee-ded), the power source switches off and displays an appropriate service code.

- Ventilator control subject to temperature and firmware- Data transmission to peripheral devices via LocalNet interface- Regulation of welding current and welding voltage via the integral digital signal

processor (DSP) in the UST PC board- Converter module control

Technical Data Supply voltage (from NT 24A) 24 V DC

Function over-view

Plug layout

Fig.39 Plug on UST PC board

(X4)

(X1)

(X6) (X2) (X8) (X7) (X5)

(X10)

(X9)

(X3)

Pin FunctionX1 not assignedX2 Connection to control panelX3 Supply

Pin 1 +24 V externalPin 2 NCPin 3 Intermediate circuit voltagePin 4 +24 V internal

Pin 5 GND externalPin 6 NCPin 7 GND Intermediate circuit voltagePin 8 GND internal

69

EN


Pin FunctionX4 Temperature transmission; voltage command value, current command value

Pin 1 Voltage actual valuePin 2 NCPin 3 Shunt C 4000,Pin 4 Shunt A 3000,Pin 5 Shunt B 2000,Pin 6 -15 V ShuntPin 7 TH error 1Pin 8 GND A (UP 400)Pin 9 CFM-Pin 10 ESC 1Pin 11 Temperature 2-Pin 12 Temperature 1-

Pin 13 Voltage actual value +Pin 14 NCPin 15 Shunt D 5000,Pin 16 NCPin 17 GND ShuntPin 18 +15 V ShuntPin 19 TH error 2Pin 20 UP 400Pin 21 CFM+Pin 22 ESC 2Pin 23 Temperature 2+Pin 24 Temperature 1+

X5 Ventilator control

Pin 1 +24 VPin 2 FAN

Pin 3 +24 VPin 4 FAN

X6 Power module PC board control

Pin 1 Primary current T1+Pin 3 Primary current T2+Pin 5 OUT A1Pin 7 OUT A2Pin 9 OUT B1Pin 11 OUT B2Pin 13 GND DPin 15 +5 VPin 17 +24 VPin 19 PWM temperaturePin 21 SCL (CLOCK)Pin 23 FAST OUT 1Pin 25 SYNC

Pin 2 Primary current GND T1Pin 4 Primary current GND T2Pin 6 OUT A3Pin 8 OUT A4Pin 10 OUT B3Pin 12 OUT B4Pin 14 GND DPin 16 +15 VPin 18 Main switchPin 20 High charging connectionPin 22 SDA (DATA)Pin 24 +15 VPin 26 OV/UV

X7 Cooling unit control

Pin 1 Temperature +Pin 2 Cooling unit ONPin 3 Water controlPin 4 CFM +Pin 5 NC

Pin 6 Temperature -Pin 7 + 24 VPin 8 GND (Water control)Pin 9 CFM-Pin 10 GND (SUPPLY)

X8 Programming interface, for updating firmware via BSL toolX9 Connection to wire-feed unit

Pin 1 +24 V externalPin 2 RXDL-485Pin 3 RXDH-485

Pin 4 GND external (+24 V)Pin 5 TXDL-485Pin 6 TXDH-485

70


LED checklist

Fig.40 LED indicators on UST PC board

LED +24 V externalLED +24 V internalLED +5 V (RS 485)

LED -15 V

LED +15 V

LED +5 VLED STAT

- LED STAT flashes when there is no firmware available

Changing USTPC board

NOTE! Options enabled via „service module“ software are stored on the UST,and must be re-enabled after changing the UST. Before changing the UST, theenabled options must be clarified with the customer - the enable codes mustbe supplied by the customer.

Measuring points See plug layout.

Measuring points Plug/pin Measuring result command valueIntermediate circuit imbalance X6/26 - X7/8 5 V = OK, 0 V = fault

Pin functionX10 Control for gas solenoid valve and TIG welding torch (optional)

Pin 1 High frequency on/off HFPin 2 Gas 1Pin 3 Gas 2Pin 4 Crater fill BRTPin 5 BRT UPPin 6 GND (gun trigger)

Pin 7 GND (HF)Pin 8 +24 V (Gas 1)Pin 9 +24 V (Gas 2)Pin 10 Main current BRTPin 11 BRT DOWNPin 12 Detection

71

EN

NF 3160 - Line filter

General remarks The NF 3160 PC board (item number 4,070,662) is used with the TPS 2700 powersource and is for filtering out parasitic frequencies:- generated by the power source and which can affect other consumer loads- that come from the mains supply and which can affect the power source

Important! On the NF 3160 PC board, the mains voltage is on!


Fig.41 TPS 2700, position of NF 3160 PC board

Fig.42 NF 3160 PC board

Overview

Technical Data Attenuation of parasitic frequencies > 60 Hz

X1

X2

X3

X4

X5

X6

72

Function over-view

- Varistors provide protection against momentary overvoltage of the mains- Capacitors and coils form an LC low-pass filter that moderates the parasitic fre-

quencies over 60 Hz- Capacitors divert disturbances to earth and also between the phases- Resistors discharge the line filter capacitors

Plug layout

LED checklist

Measuring points

Fig. 43 Connections on NF 3160 PC board

X1

X2

X3

X4 X5

X6

Pin FunctionX1 L1 in, cableX2 L1 out, cableX3 L2 in, cableX4 L2 out, cableX5 L3 in, cableX6 L3 out, cable

There are no LED indicators on NF 3160 PC board.

There are no measuring points on NF 3160 PC board.

73

EN

NF 3400 - Line filter/line filter 40 A/80 A

General remarks The NF 3400 PC board (item number 4,070,664) is used with the TPS 3200, TS/TPS4000/5000 power sources and is for filtering out parasitic frequencies:- generated by the power source and which can affect other consumer loads- that come from the mains supply and which can affect the power source

PC board NF 3400 (serial number 14280747 upwards) has been replaced by line filter40 A (item number 43,0001,1199).The line filter 40 A is used with TS 4000/5000, TPS 3200/3200 MV/4000/5000.The line filter 80 A (serial number 15191632 upwards) is used with TS 4000/5000 MV,TPS 4000/5000 MV.

Important! On the NF 3400 PC board, the mains voltage is on!


Fig.44 TPS 3200, TS/TPS 4000/5000 position ofNF 3400 PC board

Fig.46 NF 3400 PC board

Overview

Fig.45 TPS 3200, TS/TPS 4000/5000 position ofline filter 40 A/80 A

X1

X2

X3

X4

X5

X6

74

Function over-view

- Varistors provide protection against momentary overvoltage of the mains- Capacitors and coils form an LC low-pass filter that moderates the parasitic fre-

quencies over 60 Hz- Capacitors divert disturbances to earth and also between the phases- Resistors discharge the line filter capacitors- The earth current watchdog is integrated on line filter 40 A/80 A

Plug layout NF3400

Technical Data Attenuation of parasitic frequencies > 60 Hz

Fig.48 Connections on NF 3400 PC board

X1

X2

X3

X4

X5X6

Pin FunctionX1 L1 in, cableX2 L1 out, cableX3 L2 in, cableX4 L2 out, cableX5 L3 in, cableX6 L3 out, cable

Overview(continued) Line filter 40 A

Fig. 47 Line filter 40 A and 80 A

Line filter 80 A

X1

X3X2

X1

X3

X2

X4

75

EN

LED checklist

Measuring points

There are no LED indicators on PC board NF 3400 or line filters 40 A/80 A.

There are no measuring points on PC board NF 3400 or line filters 40 A/80 A.

Plug layout linefilter 40 A/80 A Line filter 40 A

Fig. 49 Connections on line filter 40 A and 80 A

Line filter 80 A

Pin FunctionX1 Mains supply

U1 L1 inV1 L2 inW1 L3 inPE PE conductor

X2 Connection to BPS 42/50/53

U2 L1 outV2 L2 outW2 L3 out

X3 Earth current watchdogX4 Connection to ASU 40 (on line filter 80 A only)

U2 L1 outV2 L2 outW2 L3 out

X1

X3

X2 X1

X3

X2 X4

76

The shunt (item number 43,0001,1138) is a current sensor which permits the isolatedcapture of the welding current.

Shunt

General remarks


Fig. 50 TPS 2700, position of shunt

Fig. 52 Shunt

Overview

Fig. 51 TPS 3200, TS/TPS 4000/5000:position of shunt

Shunt

Shunt(behind the motor plate)

77

EN

Plug layout

LED checklist

Measuring points

Technical Data

The shunt operates according to the compensation principle, where a magnetically soft,probe functions as a magnetic field detector. The shunt is characterised by the followingfeatures:- Compact design- Low offset current- Low hysteresis- High temperature stability- Integrated electronics

The shunt is supplied by a bipolar operating voltage of +/- 15 V and provides an outputsignal which is proportional to the measured welding current. The output signal to welding current transfer ratio is 1:2000.

Other functions:- Electric isolation between high-voltage circuit and electronic circuit- Null balance and amplification procedures do not apply- Based on the principle of compensation of magnetic fields, the current transducers

provide a measured current proportional to the primary current

Function over-view

There are no LED indicators on the shunt.

The welding current can be captured indirectly using a tension gauge. At a weldingcurrent of 100 A for instance, a voltage of 0.33 V must be measured on the UST PCboard, plug X4, pins 5 and 17.

Measuring points Plug/pin Measuring result command valueWelding current X4/5 - X4/17 0.33 V at a welding current of 100 A

NOTE! To prevent malfunction, and to exclude the possibility of damage toother parts in the power source, use only the adapter cable supplied.

Supply voltage +15 V /- 15 VNominal current 500 AOutput current at nominal current 250 mATransformation ratio 1 : 2000

Pin functionX1 Molex plug from adapter cable

Pin 1 +15 VPin 2 -15 V

Pin 3 I Real -Pin 4 GND

78

SR 41 - Wire-feed unit regulation unit

General remarks On the TPS 2700 power source, the SR 41 PC board (item number 4,070,677,Z) is theregulation unit for powering and controlling the wire-feed unit.


Fig. 53 TPS 2700, position of SR 41 PC board

Fig. 54 SR 41 PC board

Overview

X9

X2

X1

X3 X4 X5 X6 X7

X8

X10

X11

LED BUS OKLED FLEX OK

LED +15 VLED +5 V

LED +55 V

LED -24 VLED µP OK

LED -15 VLED backwardsLED gasLED forwards

LED BRT

79

ENFunction over-

view- Digital adjuster with power module (flow converter) for the wire-feed unit motor- two-stage adjustment for permanent stabilisation of the motor:

a) Stabilisation of fast, dynamic changes, using a voltage/current regulatorb) Stabilisation of slow, dynamic changes, using a speed controller via the actual-

value pick-up- Controls the wire-feed unit via PWM signal- Full bridge for controlling the motor, changing the motor’s direction of rotation and

for controlled accelerating and decelerating- The switched mode supply on the SR 41 is supplied with 24 V from outside the

power source, and ensures an independent supply for the PC board, and supply forany connected peripheral devices with voltages of +15 V, -15 V and + 5 V .

- Controls the gas magnet valve, „blow-off“ signal- Controls a push-pull system via the X12 plug- Analyses the torch trigger signal- Analyses the actual rotational speed value of the wire-feed unit motor,- Analyses the robot sensor signals (e.g. wire end)- 3 LocalNet interfaces for communicating between SR 41, power source, remote

control and options:a) X2 for internal components (e.g.: control panel)b) X6 for external components (e.g.: remote control)c) X7 for the power sourceOvervoltage protection (varistors) and overcurrent protection (PTC) on all LocalNetinterfaces, except X2

- Firmware update using BSL tool via programming connection X9

Technical Data Supply voltage (from NT 24) + 24 V DCSupply voltage (from NT 60) + 55 V DC

Plug layout

(X10)

(X4)(X3)

(X9)

(X6)

(X11)

(X1)

(X7)

(X8)

(X5)

(X2)

Fig. 55 Plug on SR 41 PC board

(X12)

80


Pin functionX1 Connection to control panel

Pin 1 GND for power potentiometerPin 2 +5 V for power potentiometerPin 3 Power+ (actual value of power

potentiometer)Pin 4 Power - (clip on pin 1 with

potentiometer)

Pin 5 GND (arc correction)Pin 6 +5 V (arc correctionPin 7 ARC-CORR + (arc correction

actual value)Pin 8 ARC-CORR - (clip on pin 5 with

potentiometer)

Pins 3/4 and 7/8 with differential amplifier

X2 LocalNet connection to control panel (ribbon cable)

Pin 1 -15 VPin 3 GND DPin 5 +5 VPin 7 RXDLPin 9 TXDL

Pin 2 +15 VPin 4 +5 VPin 6 GND DPin 8 RXDHPin 10 TXDH

X3 Welding torch control

Pin 1 Gun Trigger EuroPin 2 +5 V PullMig potentiometerPin 3 PM LSP (PullMig potentiometer

actual value)Pin 4 UP / DOWN (+ 5 V = up,

0 V = down, 2.5 V = no buttonspressed)

Pin 5 Gun Trigger - torch trigger

Pin 6 GND D EuroPin 7 GND Pullmig potentiometerPin 8 Torch detection

Pin 9 GND torch

Pin 10 +15 V

X4 Robot sensors/feeder inching and gas test

Pin 1 Torch blow outPin 2 I on - current flow signalPin 3 Wire retractPin 4 Wire inPin 5 Wire endPin 6 Gas pressure watchdogPin 7 KAT - cut-out box

Pin 8 +24 V torch blow outPin 9 +24 V (res)Pin 10 Gas testPin 11 GND to pin 3/4/6/10/12Pin 12 Real value - actual rotational

speed valuePin 13 GND wire endPin 14 GND cut-out box

X5 Actual rotational speed value, gas solenoid valve and configuration memory

Pin 1 GND actual rotational speedvalue

Pin 2 VD-ANA - (wire buffer sensor)

Pin 3 CFM-Pin 4 +24 V gas solenoid valve

Pin 5 Actual rotational speed value inPin 6 VD-ANA + (wire buffer sensor,

0-5 V)Pin 7 CFM +Pin 8 Gas solenoid valve

X6 LocalNet connection for remote control

Pin 1 +24 VPin 2 RXDL-RCPin 3 RXDH-RC

Pin 4 GNDPin 5 TXDL-RCPin 6 TXDH-RC

81

EN

Fig.56 LED indicators on SR 41 PC board

LED Bus OKLED Flex OK

LED +15 VLED +5 V

LED +55 V

LED -24 VLED uP OK

LED -15 VLED backwardsLED gasLED forwards


LED checklist

X12 not connected (connection for PMR 4000 push-pull option and RobactaDrive)

LED BRT

Pin functionX7 LocalNet power source connection

Pin 1 +24 VPin 2 RXDL-485Pin 3 RXDH-485

Pin 4 GNDPin 5 TXDL-485Pin 6 TXDH-485

X8 Wire-feed unit motor connection

Pin 1 Motor + (red) Pin 2 Motor - (blue)

X9 BSL tool (20 pin) connectionX10 + 55 V (NT 60) supply

Pin 1 +55 VPin 2 +55 V

Pin 3 GNDPin 4 GND

X11 + 55 V remote control supply

Pin 1 +55 VPin 2 +55 V

Pin 3 GNDPin 4 GND

82

LED checklist(continued)

LED BUS OK .................. flashes when connection with Bus master (power source) is OKLED FLEX OK ................ flashes when there is no faultLED µP OK..................... flashes when the processor is workingLED BRT ........................ flashes when the torch trigger is pressedLED + 55 V..................... flashes when the supply voltage is OKLED + 24 V..................... flashes when the supply voltage is OKLED + 15 V..................... flashes when the supply voltage is OKLED + 5 V ....................... flashes when the supply voltage is OKLED forwards .................. flashes when the wire is moved forwards by the drive unit motorLED backwards ............... flashes when the wire is moved backwards by the drive unit

motorLED Gas ........................ flashes when the gas solenoid valve is activated

Measuring points There are no measuring points for checking the SR 41 PC board. Checking can only bedone by referring to the LED indicators.

83

EN

Temperature sensor TP 592S

General remarks The TP 592S temperature sensor (itemnumber 43,0001,0600) is an electronictemperature sensor. It has an integratedtemperature/current converter chip.The chip is integrated into the plastichousing and provided with a pluggableMolex connection.

Fig.57 Temperature sensor TP 592S


Fig.58 TPS 2700: position of temperature sensorTP 592S

Fig.59 TPS 3200, TS/TPS 4000/5000: position oftemperature sensor TP 592S (1)

Temperature sensor

Fig.60 TPS 3200, TS/TPS 4000/5000: position oftemperature sensor TP 592S (2)

Temperature sensor Temperature sensor

84

Measuring points

Function over-view

- The temperature sensor is fitted to the cooling element and measures theelement’s temperature.

- The temperature sensor emits a current of exactly 1 μA per K (Kelvin), providedthat there is a voltage of 4 - 30 V DC.0 K corresponds to a temperature of -273.15°C0°C corresponds to 273.15 K273.15 K corresponds to 273.15 µA

Pin functionX1 2-pin Molex plug

Plug layout

Measure the current flowing through the temperature sensor as follows:- Remove lead at pin 1 from Molex plug using Molex extractor tool.- Switch multimeter between removed lead and now free Molex plug pin in series

The temperature can now be calculated using the measured current, as described in„function overview“.

Technical Data Check supply 4 - 30 V DCOutput current 1 µA/K

Pin 1 Temp. 1+ Pin 2 Temp. 1-

85

EN

Secondary power module TPS 2700

General remarks On the TPS 2700, the secondary power module consists of two diode modules (itemnumber 41,0003,0215 ), each of which has two integral diodes.


Fig.61 TPS 2700, position of secondary powermodule

Fig.62 Secondary power module

Overview

Secondary power module

Welding transformer

PC board BPS 25/BPT 27

Cooling element

Diode module

Diode module

86

Function over-view

The diode modules go together to make up the secondary rectifier. The secondaryrectifier transforms the welding transformer’s alternating current into a direct current,which is fed to the welding sockets

Measuring points There are two diodes in every diodemodule. Measurement on the dioderegions must produce a result of approx.0.2 V.

Fig.63 Diode module

Torques:- Copper clips and PC board on power semiconductors:

Pre-tighten with 0.5 Nm, tighten with 1.5 Nm- Power semiconductors on heat sink:

Pre-tighten with 0.5 Nm, tighten 2.1 Nm

87

EN

Secondary power module TS 4000/5000, TPS 3200/4000/5000

General remarks On the TS 4000/5000 and TPS 3200/4000/5000, the secondary power module consistsof four diode modules (item number 41,0003,0203), each of which has two integraldiodes.


Fig.64 TPS 2700, position of secondary powermodule

Secondary power module(on cooling element)

Important! In the course of replacement,the diodes must not be interchanged.

(1) Diode modul 41,0003,0203

(2)(1)

88

Function over-view

The diode modules go together to make up the secondary rectifier. The secondaryrectifier transforms the welding transformer’s alternating current into a direct current,which is fed to the welding sockets

Measuring points There are two diodes in every diodemodule. Measurement on the dioderegions must produce a result of approx.0.2 V.

Fig.66 Diode module

Fig.65 Secondary power module

Overview

Welding transformer

Temperature sensor

Cooling element

Diode module

Diode module

Diode module

Diode module

Copper busbar

Copper busbar

Copper busbar

89

EN

Primary rectifier

General remarks The following primary rectifiers are used:- TPS 2700: rectifier with item number 41,0002,0059- TS 4000/5000, TPS 3200/4000/5000: rectifier with item number 42,0001,0060


Primary rectifierPrimary rectifier

Fig.68 TS 4000/5000, TPS 3200/4000/5000:position of primary rectifier

Fig.67 TPS 2700: position of primary rectifier

Overview

Fig.69 Primary rectifier TPS 2700 Fig.70 Primary rectifier TS 4000/5000, TPS 3200/4000/5000

Function over-view

The primary rectifier converts the input voltage (mains voltage) into a rectified voltagefor the intermediate circuit.

L1

L2

L3(-)

(+)

L1

L2

L3

(-)

(+)

90

Plug layout

Fig.71 Connections on the primary rectifierTPS 2700

Fig.72 Connections on the primary rectifierTS 4000/5000, TPS 3200/4000/5000

L1

L2

(-)

(+)

L1

L2

L3

(-)

(+)

Pin functionL1 Mains voltage input L1L2 Mains voltage input L2L3 Mains voltage input L3(+) Intermediate circuit voltage output +(-) Intermediate circuit voltage output -

L3

Measuring points

Fig.73 Measuring points on primary rectifier TPS2700

Fig.74 Measuring points on primary rectifier TS4000/5000, TPS 3200/4000/5000

Measurement on each of the diode regions must produce a result of 0.4 V.

91

EN

„Changing components“ contains the following subsections:- Changing throttle (TS 4000/5000, TPS 3200/4000/5000)- Changing throttle (TPS 2700)- Changing earth current watchdog- Changing PC board ASU 27 (TPS 2700 MV)- Changing shunt (TPS 2700)- Changing temperature sensor TP 592S- Changing transformer (TS 4000/5000, TPS 3200/4000/5000)- Changing transformer (TPS 2700)- Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000)

Changing components

General remarks

Overview

In the „Changing components“ section there is a description of how to change compon-ents which- have no instructions of their own regarding changing and- require a complete description of how to change them

WARNING! An electric shock can be fatal. Before opening up the machine- Move the mains switch to the “O” position- Unplug machine 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 electrical-

ly charged components (e.g. capacitors) have been discharged

Safety

92

Fig. 1 Preparing throttle lead for removal

(2)(3)

(4)

(5)

Fig. 2 Removing throttle lead

Fig. 3 Removing front of the housing

1. Remove side panels2. On the minus socket, loosen hexagon

bolt (1) using a size 19 spanner- Feed out the throttle lead (2) from the

shunt (3)

1. On the transformer, loosen hexagonnut (4) using a size 13 spanner

2. Remove protective element (5) andthrottle lead (2)

1. Remove screw (6) from the front ofthe housing:

NOTE! When removing thecontrol panel (7), take care not tobend, stretch or strain the ribboncable connected to it.

2. Carefully swivel out the control panel(7) and unplug the ribbon cable

Changing throttle (TS 4000/5000, TPS 3200/4000/5000)

Removing throttle

(1)

(6)

(6)

(6)

(7)

(2)

93

EN

Removing throttle(continued)

1. Loosen 2 screws (8)2. Remove front of housing

1. Unscrew 4 screws (10) and removesheet nuts (11) from throttle

2. Remove throttle (9)

Fig.4 Removing front of housing

Fig.5 Removing throttle

(10)

(11)

(11)

Fitting throttle 1. Put throttle (9) in place and fix inplace with 4 screws (10) and sheetnuts (11)

Fig.6 Fitting throttle

1. On the transformer, fit the following components in the order they are listed:- Throttle lead cable lug (2)- Protective element cable lug (5)- Spacer (12)- Spring washer (13)

2. Tighten hexagon nut (4) using a size 13 spanner

Fig.7 Fitting throttle lead

(8) (8)

(9)

(10)

(11)

(11)

(9)

(4)

(5) (2)

Fig. 8 Fitting throttle lead(4) (13) (5)

(12)

(2)

94

1. Feed the throttle lead (2) into the shunt (3)2. Push the following components onto the hexagon bolt (size 13) in the order they

are given below:- Spring washer (14)- Spacer (15)- Throttle lead cable lug (16)- Star with protective element (17)

3. Tighten hexagon bolt (1) onto minus socket using a size 13 spanner4. Fitting the side panels

Fitting throttle(continued)

Fig. 10 Fitting front of the housing

NOTE! When fitting the controlpanel (7), take care not to bend,stretch or strain the ribbon cable.

1. Plug ribbon cable into control panel (7)2. Carefully put control panel (7) in

place3. Tighten screw (6) on front of the

housing

1. Place front of housing onto baseplate and press upwards and inwards

2. Tighten 2 screws (8)

Fig.9 Putting front of housing in place

Fig. 11 Fitting throttle lead Fig. 12 Components on the minus socket(1)

(14)

(15) (16)

(17)

(2)

(6)

(6)

(6)

(7)

(2)(3)

(1)

(8) (8)

95

EN

Fig.1 Screws on the front aperture

Fig.2 Loosening the drive unit

Fig.3 Removing the drive unit

1. Open wire-feed unit cover2. Remove side panel3. Loosen two screws (1) on front

aperture

1. Loosen two screws (3) on the driveunit (2)

NOTE! When lifting the drive unit(2), do not pinch, bend or strainthe cables.

2. Carefully raise the entire drive unit (2)

1. Loosen 2-pin Molex plug connection (4)2. Carefully place the entire drive unit (2) to one side

(1)

(2)

(3)

(2)

(4)

Changing throttle (TPS 2700)

Removing throttle

96

1. Remove both upper copper clips (10)and (11) from the transformer

2. Loosen screw (12) on the middle tapconnection

1. Loosen hexagon bolt (5) on minussocket using size 19 spanner

2. Feed out the throttle lead (9) from theshunt (8)

Removing throttle(continued)

Fig.4 Loosening hexagon bolt

1. Loosen three screws (13) on throttle(14)

2. Carefully remove throttle (14) andthrottle lead (15) together

Fig.5 Exposing throttle

Fig.6 Removing throttle

(11)

(10) (12)

(13)

(13)

(15)

(14)

Fitting throttle 1. Feed throttle lead (9) through bushing(16)

Fig. 7 Feeding throttle lead

(16)

(5)

(6)

(8)(9)

(9)

97

EN

1. Fit throttle (14) using three screws(13)


1. Fasten throttle lead (9) - Fig.8 - ontomiddle tap connection using screw(12) - Fig.9.

2. Fit copper clips (11) and (10) asshown in Fig.9

Fig.8 Fitting throttle

(13)

(13)

(14)

Fig.9 Connecting throttle

(11)

(10) (12)

1. Feed throttle lead (9) through shunt (8)2. Push following components onto hexagon bolt (5):

- Lock washer (18)- Spacer (19)- Throttle lead cable lug (20)- Star (21)

3. Tighten hexagon bolt (5)

(5)

(18)

(19)(20)

(21)

Fig. 11 Components on the minus socketFig.10 Fitting throttle lead

(5)

(6)

(8)(9)

(9)

(9)

98

Fig.12 Connecting drive unit

1. Reconnect two-pin Molex plug (4)

(4)


Fig.13 Fitting drive unit

NOTE! When putting the driveunit (2) in place, do not pinch,bend or strain the cables.

1. Fit the drive unit (2) using two screws(3)

(2)

(3)


1. Fit two screws (1) on front aperture2. Fit side panel3. Close wire-feed unit cover

(1)

99

EN

Changing earth current watchdog

1. Remove side panels2. Loosen two screws (2) on earth

current watchdog (1)

Removing earthcurrent watch-dog

1. Loosen screw (3) on luster terminal2. Remove lead (4)

Fig. 1 Removing earth current watchdog

Fig. 2 Loosening luster terminal on earth currentwatchdog

Fig. 3 Removing fan and exposing watchdog cable

1. Remove fan sheet (5) (including fan)2. Cut through the cable ties on watchdog cable (6)

(5) (6)

(3)(4)

(1)

(2)

100

1. Insert leads (8) and (9) of the watch-dog cable (6) into the following pinson the 24-pin Molex plug (7):- X4:10- X4:22

2. Plug 24-pin Molex plug (7) intoUST:X4 PC board

Fitting earthcurrent watch-dog

1. Unplug 24-pin Molex plug (7) fromUST:X4 PC board

2. Remove leads (8) and (9) of thewatchdog cable (6) from the followingpins on the 24-pin Molex plug (7):- X4:10- X4:22- Use Molex extractor tool

Fig. 4 Detaching watchdog cable

Removing earthcurrent watch-dog(continued)

Fig.5 Connecting watchdog cable

Fig.6 Fixing watchdog cable in place and fitting fan

(5) (6)

1. Fix watchdog cable (6) using cable ties2. Fit fan sheet (5) (including fan)

(9) (8)

(7)

(6)

(9) (8)

(7)

(6)

101

EN

1. Insert lead (4) into earth currentwatchdog luster terminal

2. Tighten screw (3) on luster terminal

1. Fix earth current watchdog (1) inplace using two screws (2)

2. Fitting the side panels

(3)

Fig. 7 Connecting earth current watchdog lusterterminal

Fitting earthcurrent watchdog(continued) (4)

(1)

(2)

Fig. 8 Fitting earth current watchdog

102

- Remove side panel- Unplug leads (for cable harness (1),

Fig.2) from the following slots on theBPT/BPS PC board:X3X4X5X6

- Cut open cable tie on cable harness (1)- Feed cable harness (1) out through

bushing (2)- Unplug 16-pin Molex plug ASU 27:X4

(3)- Loosen four spacers (4) and remove

ASU 27 PC board

Fig. 1 Detaching leads from BPT/BPS

Fig. 2 Removing ASU 27 PC board

X3X4

X6X5

(1)

(2)

(4)

(4)

(4)

(4)

(3)

- Put ASU 27:X4 PC board in place and fit using four spacers (4) (Fig.2)- Plug in 16-pin Molex plug ASU 27:X4 (3) (Fig.2)- Feed cable harness (1) through bushing (2) (Fig.2)

- Plug leads (for cable harness (1),Fig.2) into the following slots on theBPT/BPS PC board:X3X4X5X6

- Bind cables together with cable tie- Fit side panel

Fig. 3 Plugging leads into BPT/BPS

X3X4

X6X5

Changing PC board ASU 27 (TPS 2700 MV)

Removing ASU27

Fitting ASU 27

103

EN

Changing shunt (TPS 2700)

Removing shunt


Fig.2 Loosening the drive unit

Fig.3 Removing the drive unit

1. Open wire-feed unit cover2. Remove side panel3. Loosen two screws (1) on front

aperture

1. Loosen two screws (3) on the driveunit (2)

NOTE! When lifting the drive unit(2), do not pinch, bend or strainthe cables.

2. Carefully raise the entire drive unit (2)

1. Loosen 2-pin Molex plug connection (4)2. Carefully place the entire drive unit (2) to one side

(1)

(2)

(3)

(2)

(4)

104

1. Loosen hexagon bolt (5) on minussocket using size 19 spanner

2. Unplug 8-pin Molex plug (6)3. Loosen two screws (7) on shunt (8)4. Remove shunt (8) and feed out

throttle lead (9)

Removing shunt(continued)

Fig.4 Removing shunt

(5)

(6)

(7)

(7)(8)(9)

Fitting shunt

Fig.5 Fitting shunt

(5)

(6)

(7)

(7)(8)(9)

1. Feed throttle lead (9) through shunt2. Fit shunt (8) using two screws (7)3. Plug in 8-pin Molex plug (6)4. Push following components onto hexagon bolt (5):

Lock washer (10)spacer (11)throttle lead cable lug (12)star (13) with protective element

5. Tighten hexagon bolt (5)

Fig.6 Components on the minus socket

(5)

(10)

(11) (12)

(13)

(2)

Fig. 7 Connecting drive unit

1. Reconnect two-pin Molex plug (4) for drive unit

(4)

105

EN

Fitting shunt(continued)

NOTE! When putting the driveunit (2) in place, do not pinch,bend or strain the cables.

1. Put entire drive unit (2) in place2. Fit the drive unit (2) using two screws

(3)

Fig.8 Fitting drive unit

(2)

(3)

1. Tighten two screws (1) on frontaperture

2. Fit side panel3. Close wire-feed unit cover


(1)

106

The temperature sensor is fixed and can be lifted out by carefully using a simple scre-wdriver or removed with flat pliers.

Before putting the new temperature sensor in place, fill the hole for the sensor with heatconductive paste to ensure perfect heat transfer.

If the temperature sensor is covered by other parts, please refer to instructions forremoving the part concerned, and see the special NOTEs in the „Changing compon-ents“ section, if available.

Changing temperature sensor TP 592S

Notes

107

EN

Changing transformer (TS 4000/5000, TPS 3200/4000/5000)

1. Remove side panels2. On BPS 42/50 PC board, loosen 4

screws (1) for primary transformerleads

3. Remove protective elements (2)

1. Cut open cable tie on toroidal tapecores (3) and (4)

Important! If necessary, cut open anyother cable ties near the toroidal tapecores as well.

Removing trans-former (1)

(1)

(2)

(2)

Fig. 1 Removing transformer leads

Fig. 2 Loosening toroidal tape cores

(3)

1. Feed primary transformer leads „1+“and „2+“ out through toroidal tapecores (3) and (4)

2. Feed all primary transformer leadsthrough bushing (6)

Fig. 3 Feeding transformer leads

(4)

(4)

(3)

(6)

108

Fitting transfor-mer

1. Feed transformer leads throughbushing (13)

1. Put transformer (14) in place

1. Loosen 4 screws (7) for secondarytransformer leads on copper sheet

2. Loosen hexagon nut (8) using a size13 spanner

3. Remove protective element (9) andthrottle lead (10)

4. Loosen 4 screws (11) on the transfor-mer holder (12)

5. Remove transformer holder (12)6. Remove transformer with leads

Removing trans-former(continued)

(7)

(7)

(8)

(9)(10)

(11)

(11)Fig. 4 Removing transformer

(12)

(14)

Fig.5 Putting transformer in place

(13)

(7)

(7)

(8)

(9)(10)

(11)

(11)Fig.6 Fitting transformer

(12)

1. Fit transformer holder (12) using 4screws (11)

2. Using 4 screws (7), fix secondarytransformer leads to copper sheet

3. Using a size 13 spanner, fit protectiveelement (9) and throttle lead (10) bymeans of hexagon bolt (8)

1. Feed primary transformer leadsthrough bushing (6)

2. Feed primary transformer lead „1+“through upper ferrite ring (3) from theinside out

3. Feed primary transformer lead „2+“through second ferrite ring (4) fromthe inside out

(6)

Fig. 7 Feeding through transformer leads

„1+“

(4)

„2+“

(3)

109

EN

Fitting transfor-mer(continued)

NOTE! When fitting the primarytransformer leads, ensure thatthey are assigned to the correctterminals:- e.g. screw transformer lead

„1+“ to terminal „N1+“

1. Fit the following to the BPS 42/50 PCboard using 4 screws (1):- Primary transformer leads, as

described on labelling- Protective elements (2)

(1)

(1)

(2)

(2)

Fig. 8 Fitting transformer leads

110

Changing transformer (TPS 2700)

1. Remove side panel2. Loosen terminal screws (2) and

remove primary transformer leads (3)3. Cut open cable tie (4)4. Remove copper clips (5) and (6)

Removing trans-former

Fig. 1 Exposing transformer 1

1. Remove copper clips (7) and (8)2. Loosen screw (9) on middle tap

connection and remove throttle lead(10)

(3)

(4)

(2)

(2)

(2)

(5)

(6)

Fig. 2 Exposing transformer 2

1. Loosen four screws (11) on thetransformer holder (12)

2. Remove transformer holder (12) andtransformer (13) together

(7)

(8)

(9)

(10)

1. Cut open cable tie (14) on ferrite coreand feed out cable

2. Remove insulators (15) from se-condary connections

(11)

(13) (12)

Fig. 3 Removing transformer

Fig. 4 Removing insulators and ferrite core

(14)(15)

(15)

111

EN

Fitting transfor-mer

1. Push insulators (15) onto secondaryconnections

2. Wind both of the middle primary leadstwice around the ferrite core andfasten with cable tie (14)

Fig.5 Fastening insulators and ferrite core

(14)(15)

(15)

Before fitting the transformer, arrange theprimary leads as follows:1. Feed the „blue lead“ through the

upper sensor (16)2. Feed the „orange lead“ through the

lower sensor (17)

1. Fit transformer holder (12), includingtransformer (13), using four screws (11)

Fig.6 Feeding primary leads through sensors

(16)

(17)

(11)

(13) (12)

Fig. 7 Fitting transformer

1. Fit throttle lead (10) to middle tapconnection using screw (9)

2. Fit copper clips (7) and (8)

(7)

(8)

(9)

(10)

Fig. 8 Connecting transformer 1

112

1. Fit copper clips (5) and (6)2. Feed „outer blue primary lead“ through cut-outs (18) on PC board and clamp in

place with terminal screw (19)3. Feed „outer orange primary lead“ through cut-outs (20) on PC board and clamp in

place with terminal screw (21)4. Clamp „inner blue primary lead“ using terminal screw (22)5. Clamp „inner orange primary lead“ using terminal screw (23)6. Fit side panel

Fig. 9 Connecting transformer 2

Fitting transfor-mer(continued) (5)

(6) (21)

(19)

(18)

(20)

(22)

(23)

113

EN

Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000)

1. Remove side panels2. Loosen three screws (1) on rear of

housing (2)3. Remove rear of housing (2)

Removing inter-mediate circuitcapacitors

1. Loosen two screws (3) on coversheet (4)

2. Remove cover sheet (4)

Fig. 1 Removing rear of housing

(1)

(1)

(2)

Fig. 2 Removing cover sheet

1. Loosen four capacitor screws (5)

NOTE! When loosening capacitor nuts (6) - Fig.4 - hold the capacitors (7) -Fig.3 - in place.

2. Loosen two capacitor nuts (6)3. Remove capacitors (7)

(3) (3)

(4)

Fig. 3 Loosening capacitor screws

(5)

(5)Fig. 4 Loosening capacitor nuts

(7)(6)

114

1. Fit capacitors (7), including grommets (8), in place (Fig.5)2. Hold capacitors in place and fit using capacitor nuts (6) (Fig.7)

Fitting intermedi-ate circuit capa-citors

Important! After removing a capacitor (7), its grommets (8) - Fig.5 - can either- adhere to the front of the capacitor (7)- remain on the partition (9) inside the power source- be disposed of

NOTE! When fitting the capaci-tors, ensure that the grommets(8) are arranged correctly, asshown in Fig.5.

Fig.6 Putting capacitors in place Fig. 7 Fitting capacitors

(7)(6)

Fit the following elements using capacitor screws (5):1. Capacitor leads „ELKO1+“ to „ELKO2-“2. Connecting lead (10)

Fig. 8 Connecting leads

(5)

(5)

(7)

Fig.5 Fitting capacitors

Fig 9 Installing capacitor

+ -

+ - (5)

„ELKO1-“

„ELKO2+“

„ELKO1+“

„ELKO2-“

(10)

(7) (8) (6)

(5) (5)

(5)

(9)

115

EN

1. Fit cover sheet (4) using two screws(3)

(3) (3)

(4)

Fitting intermedi-ate circuit capa-citors(continued)

Fig. 10 Fitting cover sheet

1. Fasten rear of housing (2) with threescrews (1)

2. Fit side panels

Fig. 11 Fitting rear of housing

(1)

(1)

(2)

116

Safety inspection

This section outlines the safety inspection of the welding systems described in thisservice manual. This section is fully compliant with IEC 60974-4. Extracts of the requisi-te measuring methods are documented in Fronius work instruction PMÜ-01.

Please also be aware of the requirements and standards relevant to your country, asthe measured values or steps taken during the tests may vary.

Should there be no relevant requirements and standards in your country, this testshould still be carried out.

General

The repair engineer is responsible for carrying out and documenting the safety inspec-tion properly and for making the correct decision regarding the outcome of the inspec-tion.

Should any defects be identified during the test, then the entire safety inspection mustbe repeated once such defects have been rectified.

The following tests must be performed in the prescribed sequence. Each test must bepassed before the next test is started.If it is not possible to perform a particular test, the examiner must decide whether thesafety of the device can nevertheless still be verified. Justifications for the resultingdecision must be documented in the test record under „Comments“.

Responsibility

117

EN

Visual inspections

The following must be visually inspected without any further dismantling of the system.Obvious defects in any safety-related device components are unacceptable.

Any defects that could cause other hazards must be repaired immediately or restrictionsplaced on the further use of the system until repairs have been effected.

General

- Markings and stickers (rating plate, warning stickers) must be present and legible- There must be no damage or indications of improper use- Cooling circuit must not demonstrate any leaks and must contain a sufficient

coolant level- Gas pipes/connections must not be faulty

General conditi-ons

- All insulation must be present and undamaged- Connections must not be faulty- Switches must not be damaged- There must be no other indications of damage

Welding torch/electrode holder/welding currentreturn terminal

- Line must not be damaged or faulty (do not use insulation or adhesive tapes torepair damage)

- Connectors and plug/socket devices must not be damaged or deformed- Plug pins must not be broken or damaged by heat- Strain-relief devices, bending-protection devices, line routings or mountings must

all be effective- Lines/plugs must be suitable for the application and the power level

Mains supply andconnecting lines

- Line must not be damaged or faulty (do not use insulation or adhesive tapes torepair damage)

- Connectors and plug/socket housings must not be damaged or deformed- Strain-relief devices must be effective- Lines/plugs must be suitable for the application and the power level

Welding circuit

Nominal cross Load capacity [A] Load capacity [A] Max IN fuse Recommendedsection of copper at 30°C at 40°C for KS mains plugconductor [mm2] protection

0.75 14 12.5 32 161 17 15.1 40 161.5 21 18.7 63 252.5 30 26.7 80 324 41 36.5 125 636 53 47.2 200 6310 74 65.9 315 63

118

- Housing components/insulation components must be present and undamaged (donot use insulation or adhesive tapes to repair damage)

- No unauthorised modifications must have been made (e.g. installations, conversi-ons that have not been approved by the manufacturer)

- Cooling openings must not be dirty or blocked and an air filter must be present- There must be no signs of overloading or improper use- Protection devices (e.g. gas cylinder holder) must be present- Rollers, transportation devices, brackets, etc., must not be damaged- There must not be any conductive objects in the housing

Housing andcovers

- Controls and indicators must not be faulty- Gas pressure regulator and flow meter must not be faulty- Fuses accessible from outside the housing must not be defective

Adjustment anddisplay devices

119

EN

Electrical tests

- All housing components must befitted

- The ground conductor resistancemay not exceed < 0.3 Ω (for mainscables up to 5 m; extra 0.1Ω for eachadditional 7.5 m; max. 1Ω)

- The measuring current must be nolower than 200 mA (recommendation:10 A)

- Mains cable: the measurement mustbe taken from the ground conductorcontact of the mains plug to a reliableearthing point (e.g. the mountingscrew of a side panel). While thismeasurement is being carried out,mains cables should be bent, flexedand twisted along their entire length,particularly where they enter thehousing, so that any breaks in theground conductor can be detected.

Ground conduc-tor resistance

1 Measuring device2 Welding system9 Instrument leads

- Furthermore, measurements must be taken from the ground conductor contact ofthe mains cable or from a reliable earthing point to all earthed housing componentsthat can be touched from the outside (gas connection, lid, side panels, front andrear panels of power source and cooling circuit).The mounting screw of the particular component can be used as the measuringpoint.

- The highest measured value must be entered in the test record

IMPORTANT! Screws visible from the outside have a die ring, which is needed toensure reliable earthing of the respective components. The use of any other type ofscrew is therefore prohibited.

IMPORTANT! The side panel on the wire-feed unit side of the TPS 2700 power sourceis not part of the earthing concept and does not have to be tested.

120

- Test voltage for all insulation measu-rements - 500 V DC

- The mains switch must be switchedon during the measurement

- The insulation resistance must not bebelow the limit values shown in thetable below

- The welding torch must not be con-nected during the measurement

- Power sources with cooling circuitsmust be checked with no coolant inthe system

- The lowest measured value must beentered in the test record

IMPORTANT! If no conductive connectionexists between the mains plug contactsduring the measurement, then the measu-rement must be performed on every line.

Insulation resis-tance

1 Measuring device2 Welding system9 Instrument leads

WARNING! Danger of electric shock! The test voltage is 500 V DC. Do nottouch the test piece during the test. Following the test, discharge the capaci-tors between secondary / earth and primary / earth using a suitable resistance(e.g.: 10 kΩ / 5 W).

Measurement Limit valuePrimary - Secondary Mains plug L1, L2, L3, N -> Current sockets ≥ 5 MΩPrimary - Earth (PE) Mains plug L1, L2, L3, N -> Earth ≥ 2.5 MΩSecondary - Earth (PE) Current sockets -> Earth ≥ 2.5 MΩ

IMPORTANT! If no conductive connection exists between the welding current socketsduring the measurement, then the measurement must be performed on every currentsocket.

- Peak value measurement of open circuit voltage at the power source currentsockets

- The measurement must be performed using the „Measuring circuit for U0 measure-ment“

- The measurement must be performed in „Electrode“ mode- The open circuit voltage may not exceed the value specified on the rating plate for

a power source supply at rated welding voltage

Performing the measurement:- Connect the measuring circuit and the multimeter to the power source- Set the multimeter to DC voltage measurement and the measuring circuit to Upeak- Briefly press the Reset button to discharge the capacitors- Adjust the potentiometer until the largest voltage value is shown

Open circuitvoltage U0

121

EN

Function tests

Under normal circumstances, function tests are only mandatory following repair work.However, we recommend that the following function tests are carried out on a regularbasis to ensure that the welding system is safe and working properly at all times.

General

- Mains switch - check the switch is fully operational by turning the mains switch onand off

- Fan - the fan must start up when the power source is switched off

Mains power on/off equipment

Check that indicators and controls work in line with the operating instructionsIndicators andcontrols

- The correct operation of the gas solenoid valve must be tested by activating thetorch trigger several times

- To check the gas solenoid valve and the gas pipes for leaks, the gas pipe to thegas solenoid valve must be subjected to pressure -> Turn off the gas feed at thegas cylinder and observe any fall in pressure with a pressure gauge over a periodof 2 minutes - there must be no noticeable fall in pressure on the gauge.

Gas solenoidvalve

A test weld should be carried out after performing the safety inspection.Test weld

- Set up the welding system in aninsulated condition

- Connect a power source (10-25 A)between the housing earth conductorof the housing lid and the PE conduc-tor on the mains terminal

- Switch on the welding system- Switch on the power source- The error „Err | PE“ must appear on

the power source

IMPORTANT! The apparatus tester mayperform the power source role by usingthe „Ground conductor resistance 10 A“function.

Earth currentwatchdog

1 Power source2 Test piece9 Instrument lead

1 2

122

Documentation

- The „Safety Inspection / Maintenance Test Record“ must be used to document thesafety inspection. The latest version is available to download from EnergyNet /DownloadCenter.

- The test record must be completed in full and archived according to nationalregulations.

Test record

- After a positive inspection, the test label (article number 42,200,101) is to be affixedto the housing in a visible position.

Test label

123

EN

Terms and abbreviations used

General remarks „Terms and abbreviations“ is a glossary of specific technical terms essential for anunderstanding of the service instructions.

Terms and abbre-viations

BSL tool:The BSL tool is a special tool for updating the power source with new firmware. A PC ornotebook is required for the update.

Config memory (CFM):The CFM component supplements the UST2B PC board firmware (central control andregulation unit) with individual, machine- specific data.

DSP:Digital signal processor. Part of the UST2B PC board (central control and regulationunit). The DSP captures digitised actual values on the part of the welding process, andensures constant regulation and optimisation of the welding current and voltage, on thebasis of- the parameters set- the saved firmware- the actual values measured

EMI:Electromagnetical interference. Electromagnetical interference is high-frequencyoverlaps in the mains voltage. The line filter absorbs such overlaps and thereby ensu-res optimum welding results and trouble-free operation of the power source.

FAC:Factory resets settings in the setup menu. By pressing and holding the „Store“ buttonfor two seconds, the original factory settings can be restored. When the display reads„PrG“, the welding machine has been reset. Jobs and parameter settings in the secondlevel of the set-up menu are not deleted.

Hall shunt:Ensures electrically isolated measuring of the welding current. The UST2B (centralcontrol and regulation unit) analyses the signal.

IGBT:Insulated gate bipolar transistor. Is a special bipolar transistor for switching to highpower settings. IGBTs are used in the power source as modules. On the TT/MW 1700/2200 power sources, IGBT modules are used in a secondary role to prepare the wel-ding current for AC welding.

Instruction pointer:When a software fault appears: Third display level displays more detailed informationon the cause of the fault (see „fault location aid“ section)

LocalNet RS232 converter:For connecting the power source to the serial interface on a PC, for:- uploading software options- communicating data from the power source using PC-based software (Fronius

Backup, Fronius Service Module, Job-Explorer, etc.)

124

Terms and abbre-viations(continued)

NTC resistors:NTC = negative temperature coefficient. These resistors have high resistance at lowtemperatures. As long as the operating temperature has not been reached, the highresistance ensures the limitation of the starting current. Shortly after switching on, thecurrent limit is raised as a result of the rapid heating of the NTC resistors.

PTC resistors:PTC = positive temperature coefficient These resistors acquire a higher resistance asthe temperature rises. Since the resistor temperature rises as the current increases, thecurrent is automatically limited.

PFC:Power factor control Ensures sinusoidal power consumption, for- supporting an optimum degree of efficiency- preventing reactions on the mains supply

Voltage doubling:Ensures that the open circuit voltage and welding voltage are increased at greater arclengths. The voltage doubling contributes considerably to optimum ignition propertiesand a stable arc.

Segment display:When a software fault appears: Second display level displays more detailed informationon localising the fault (see „fault location aid“ section)

Software service module:The software service module helps determine the hardware and software configurationfor the power source and peripheral devices. The display of the following components isespecially useful:- Design and version of the power sources and peripheral devices.- The accompanying software modules and PC boards.- Indication of serial numbers for some machines

In addition, the software service module allows you to call up the relevant order infor-mation for the selected options.

Temperature/current converter chip:is used in the temperature sensor. +A specially endowed semi-conductor ensuresconversion of the measured temperature into a corresponding voltage signal. Thevoltage signal arrives at the UST2B PC board (central control and regulation unit), andthe computer uses it to calculate the actual temperature.

125

EN

The circuit diagram is located inside the power source.- attached to the inside of the right side panel

Entire circuit diagram

Storage location

126

ud_fr_st_tb_00149 012014

DE

EN

FRIT

ESP

T-B

RN

LN

OC

SR

USK

SVTR

PL

Liste de pièces de rechangeSchéma de connexions

ErsatzteillisteSchaltplan

Spare Parts ListCircuit Diagram

Lista parti di ricambioSchema

Lista de repuestosEsquema de cableado

Lista de peças sobresselen-tesEsquema de conexões

OnderdelenlijstBedradingsschema

ReservdelslisteKoblingsplan

Seznam náhradních dílùSchéma zapojení

Ñïèñîê çàïàñíûõ ÷àñòåéÝëåêòðè÷åñêàÿ ñõåìà

Zoznam náhradných dielovSchéma zapojenia

ReservdelslistanKopplingsschema

Parça ListesiBaðlantý þemasý

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei RicambiConnector F++

1/1

40,0001,0310 xx)

42,0405,0559

44,0350,1818 44,0350,1819

44,0350,1929 44,0350,5009 44,0350,5008

44,0350,3458

42,0402,0081

42,0402,0156

42,0402,0157

42,0100,1366

42,0400,0308

43,0004,0106

43,0004,0105

43,0004,2025

43,0004,0272

43,0004,0116

42,0407,0284

40,0001,0062

40,0001,0310

43,0004,1086 43,0004,1087

42,0407,0272

E

- 2,5m ( 8,2ft)

- 1,5m ( 4,1ft)

xx) gewünschte Länge angeben

xx) Specify the length required

xx) Indiquer la longueur désirée

xx) Indicar la longitud deseada

xx) Indicare la lunghezza desiderat

xx) indicar o comprimento desejado

ø9,0mm (.354inch)

xx)

xx) T.I.M.E

- 3,0m (9.75ft)

- 3,5m (11.5ft)

- 4,5m (14,8ft)

T.I.M.E - 3,5m (11.5ft)T.I.M.E - 4,5m (14.8ft)

ø16,0x2,0mm(.63x.079inch)

ø8,0x2,0mm(.315x.79inch)

ø7,0x1,5mm(.276x.059inch)

- 3,5m (11.5ft)- 4,5m (14.8ft)

- 3,0m (9.75ft)- 2,5m (11.5ft)- 1,5m (14.8ft)

ø8,0mm (.315inch)

42,0,0001,0541

42,0405,0553

42,0405,0560

34,0350,1190

42,0401,0886

42,0407,0284

42,0405,0559

42,0001,1506

42,0405,0548

40,0001,0310

42,0407,0284

42,0407,0284

F++

Tab. Inner liner Steel

Tab. Inner liner Combi/Teflon

ø9mm (.354inch)

ø9mm (.354inch)

xx)

ø9mm (.354inch)

(3x)

42,0100,1058

Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei RicambiTS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

1/3

el_fr_st_mi_00153 012017

TransPuls Synergic 3200 4,075,124

TransSynergic 4000 C 4,075,097

TransSynergic 5000 C 4,075,098

TransSynergic 4000 4,075,099

TransSynergic 5000 4,075,101



MV

TransPuls Synergic 3200 MV 4,075,124,630

TransSynergic 4000 C MV 4,075,097,630


TransSynergic 4000 MV 4,075,099,630

TransSynergic 5000 MV 4,075,101,630



RC

TransPuls Synergic 3200 R 4,075,124,R

TransSynergic 4000 R 4,075,097,R

TransSynergic 5000 R 4,075,098,R



MV/RC

TransPuls Synergic 3200 MV R 4,075,124,630,R

TransSynergic 4000 MV R 4,075,097,630,R


TransPulsSynergic 4000 MV R 4,075,100,630,R


AUS

TransPuls Synergic 3200 4,075,124,638



CMT

TransPuls Synergic 3200 CMT 4,075,137



TransPuls Synergic 3200 CMT MV 4,075,137,630



TransPuls Synerg.3200 CMT MV US 4,075,137,800



TransPuls Synerg.3200 CMT 460 V 4,075,137,801



CMT/RC

TransPuls Synergic 3200 CMT R 4,075,137,R



TransPuls Synergic 3200 CMT MV R 4,075,137,630,R



TransPulsSynerg.3200 CMT MV US R 4,075,137,800,R



US






TransPuls Syn. 4000 MV Pipe 4,075,100,810

US/RC

TransPuls Synergic 3200 MV R 4,075,124,800,R





460V

TransPuls Synergic 3200 460V 4,075,124,801

TransPuls Syn. 3200 Pipe Single 4,075,124,808

TransPuls Syn. 3200 Pipe Tandem 4,075,124,809

TransPuls Syn. 3200 Pipe HE 4,075,124,810

TransPuls Syn. 3200 Pipe BA 4,075,124,811

TransSynergic 4000 C 460V 4,075,097,801


TransSynergic 4000 460V 4,075,099,930



TransSynergic 5000 460V 4,075,101,930





460V/RC

TransSynergic 4000 460V R 4,075,097,930,R

TransSynergic 5000 460V R 4,075,098,930,R

TransPulsSynergic4000 460V R 4,075,100,930,R

TransPulsSynergic5000 460V R 4,075,102,930,R

CrNi

TransPuls Synergic 3200 CrNi 4,075,124,631

TransPuls Synergic 3200 MV CrNi 4,075,124,632


TransPuls Synergic 4000 MV CrNi 4,075,100,632


TransPuls Synergic 5000 CrNi 460V 4,075,102,632

TIME 5000 Digital 4,075,140,93

YARD

TransPulsSynergic 4000 Yard 4,075,100,634

TransPulsSynergic 4000 MV Yard 4,075,100,635

TransPulsSynergic 4000 460V Yard 4,075,100,802


TransPulsSynergic 5000 Yard 4,075,102,634


TransPulsSynergic 5000 460V Yard 4,075,100,802



2/3

el_fr_st_mi_00153 012017

43,0001,1186

33,0005,4120

42,0200,8860

AM2,0200,8819

32,0405,0164

40,0009,0043

41,0002,0060

43,0001,0600

43,0001,0600

43,0001,1104

40,0009,0043

33,0005,4112

43,0001,1139

43,0001,1103

43,0001,1187

43,0001,1092

41,0009,0187

12,0405,0208

12,0405,0208

33,0005,4120

4,100,413

43,0006,0152

33,0010,0335

33,0010,0345

45,0200,091845,0200,118645,0200,120145,0200,1307

45,0200,091845,0200,118645,0200,120145,0200,1307

32,0405,0164

41,0003,0203

41,0003,0203

4,070,738,Z4,070,771,Z4,070,658,Z4,070,772,Z

BPS

- CrNi- CMT- YARD

- CrNi- CMT- YARD

- MV- 460V/US

- TPS3200

- TIME 5000

- BPS42 TS/TPS 3200/4000- BPS43 TS/TPS 3200/4000- BPS50 TS/TPS 5000/TIME- BPS53 TS/TPS 5000/TIME


3/3

el_fr_st_mi_00153 012017

43,0409,3223

42,0406,0093

42,0406,0315

42,0407,0284

32,0409,2656

43,0003,0031

42,0406,0299

43,0002,035843,0002,0423

43,0001,1213

43,0001,1199

4,100,423

43,0001,3234

43,0001,323543,0001,3253

43,0001,326043,0001,326843,0001,327043,0001,3327

43,0001,327643,0001,327743,0001,3306

42,0409,5083

42,0409,305542,0409,2650

42,0409,265142,0409,2652

42,0409,265342,0409,3013

42,0409,301442,0409,3027

42,0409,309742,0409,3082

42,0409,320242,0409,3203

42,0409,325642,0409,3257

43,0004,2955

BE2,0201,1355

43,0004,058643,0004,0664

42,0407,0437

BE2,0201,1593

43,0004,2324

42,0407,053442,0407,0533

43,0013,0015

BE2,0201,1934

42,0400,0132

32,0409,2740

43,0003,0485

32,0405,0229

32,0405,0183

42,0300,1511

43,0003,0031

4,070,963,Z

4,070,626,Z

4,070,627,Z

43,0006,0168

32,0409,2657

32,0409,2658

42,0300,1523

41,0005,0288

43,0004,0987

4,070,677,Z

43,0004,2727

42,0300,1815

40,0001,0352

4,070,685,Z

43,0003,0986

4,070,905,Z

4,070,928,Z

NT24

NT60

specify length

UST

SR41

SR43

- PIPE

- 5pol.,PIPE

ASU40

- MV/US 80A

- 40A

- ASU40

- US AWG 10

- 460V- MV

- US AWG 6- TIME 5000

- MV

- US AWG 10- US AWG 6

- US

- MV

- US

TIME 5000 -

- black- red

- MV/US

- NT60

- SR41

- SR43

- UST-PIPE

- NT24

- NT24T PIPE

- COMF

- CMT COMF- TIME 5000- CMT Rem.

- YARD- CrNi- AUS- US

- RC- TS

- TPS 3200 Pipe Single

- TIME 5000- TPS 3200 Pipe

- TPS 4000 Pipe- TPS 5000 AUS

- TPS 4000 AUS- TPS 5000

- TS 5000- TPS 4000

- TS 4000- TPS 3200 AUS

- TPS 3200

- TPS 3200 Pipe HE- TPS 3200 Pipe BA

- TPS 3200 Pipe Tandem

TPS 2700

TPS 2700 MV

TS 4000 / 5000, TPS 3200 / 4000 / 5000

TPS 3200 MV (Teil 1)

TPS 3200 MV (Teil 2)

TS 4000 MV / 5000 MV, TPS 4000 MV / 5000 MV

ud_fr_st_so_00082 012011

FRONIUS INTERNATIONAL GMBHFroniusplatz 1, A-4600 Wels, Austria

Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940E-Mail: [email protected]

www.fronius.com

www.fronius.com/addressesUnder http://www.fronius.com/addresses you will find all addresses

of our Sales & service partners and Locations.

Date post:	28-Jan-2020
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