Fronius TransSynergic 4000, TransSynergic 5000, TransPuls Synergic 2700, TransPuls Synergic 3200 Service Manual
Page 1
TransSynergic 4000/5000
TransPuls Synergic 2700
TransPuls Synergic 3200/4000/5000
Service manual
Spare parts list
MIG/MAG Power source
/ Battery Charging Systems / Welding Technology / Solar Electronics
EN
42,0410,1237 011-28062017
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Page 3
1
EN
Table of contents
Foreword and safety instructions .................................................................................................................. 6
Safety ....................................................................................................................................................... 6
Fronius Technical Support Center (TSC) ................................................................................................. 6
General remarks ...................................................................................................................................... 6
Function overview .................................................................................................................................... 7
Fault location aid ...................................................................................................................................... 7
Detailed description ................................................................................................................................. 7
Changing components ............................................................................................................................. 7
Terms and abbreviations used ................................................................................................................. 7
Spare parts list and entire circuit diagram ............................................................................................... 7
Tools and measuring instruments ............................................................................................................ 7
Tools and measuring instruments ................................................................................................................. 8
General remarks ...................................................................................................................................... 8
Tools required .......................................................................................................................................... 8
Measuring and inspection equipment ...................................................................................................... 8
Ancillary materials .................................................................................................................................... 8
Function overview ......................................................................................................................................... 9
Principle of the digital family of machines ................................................................................................ 9
Useful information .................................................................................................................................... 9
Block diagram ........................................................................................................................................ 10
Block diagram legend ............................................................................................................................ 10
Fault location aid ......................................................................................................................................... 12
General remarks .................................................................................................................................... 12
Fault flowcharts ........................................................................................................................................... 13
Overview ................................................................................................................................................ 13
Poor ignition and welding properties with „MIG/MAG welding“ ............................................................. 14
Poor ignition and welding properties with „TIG welding“ ....................................................................... 15
Poor weld properties with „rod electrode (MMA) welding“ ..................................................................... 16
Nothing happens on control panel (TPS 2700) .....................................................................................17
Nothing happens on control panel (TPS 3200/4000/5000) ................................................................... 19
No or incorrect welding current.............................................................................................................. 21
No or incorrect wirefeed speed.............................................................................................................. 22
Insufficient torch cooling (FK 4000/FK 4000 R) ..................................................................................... 23
Service code Err 50 ............................................................................................................................... 25
UST service codes ...................................................................................................................................... 27
Safety ..................................................................................................................................................... 27
Table of service codes ........................................................................................................................... 27
Special displays used with service codes.............................................................................................. 33
Service codes SR 4xA ................................................................................................................................ 34
Safety ..................................................................................................................................................... 34
Table of service codes ........................................................................................................................... 34
Service codes for push-pull calibration ....................................................................................................... 35
Safety ..................................................................................................................................................... 35
Checking actual-value pick-up............................................................................................................... 35
Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 35
Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 36
Detailed description .................................................................................................................................... 38
General remarks .................................................................................................................................... 38
Position of electronic components ......................................................................................................... 38
Overview ................................................................................................................................................ 38
ASU 27 - additional PC board..................................................................................................................... 39
General remarks .................................................................................................................................... 39
Component position in the machine ...................................................................................................... 39
Overview ................................................................................................................................................ 39
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Technical Data ....................................................................................................................................... 39
Function overview .................................................................................................................................. 40
Plug layout ............................................................................................................................................. 40
LED checklist ......................................................................................................................................... 41
Measuring points ................................................................................................................................... 41
ASU 40 - additional PC board..................................................................................................................... 42
General remarks .................................................................................................................................... 42
Component position in the machine ...................................................................................................... 42
Overview ................................................................................................................................................ 42
Technical Data ....................................................................................................................................... 43
Function overview .................................................................................................................................. 43
Plug layout ............................................................................................................................................. 43
LED checklist ......................................................................................................................................... 44
Measuring points ................................................................................................................................... 45
BPS 25/BPT 27 - power module PC board ................................................................................................. 46
General remarks .................................................................................................................................... 46
Component position in the machine ...................................................................................................... 46
Overview ................................................................................................................................................ 46
Technical Data ....................................................................................................................................... 47
Function overview .................................................................................................................................. 47
Plug layout BPS 25/BPT 27 ................................................................................................................... 47
LED checklist ......................................................................................................................................... 49
Measuring points ................................................................................................................................... 49
BPS 32/40/42/43/50/53 - power module PC board .................................................................................... 51
General remarks .................................................................................................................................... 51
Component position in the machine ...................................................................................................... 51
Overview ................................................................................................................................................ 51
Technical Data ....................................................................................................................................... 52
Function overview .................................................................................................................................. 52
Plugs on the power module PC boards ................................................................................................. 53
Plug layout ............................................................................................................................................. 53
LED checklist of power module PC boards ........................................................................................... 55
Measuring points ................................................................................................................................... 55
NT 24 - switched mode power supply 24 V ................................................................................................ 58
General remarks .................................................................................................................................... 58
Component position in the machine ...................................................................................................... 58
Overview ................................................................................................................................................ 58
Technical Data ....................................................................................................................................... 59
Function overview .................................................................................................................................. 59
Plug layout ............................................................................................................................................. 59
LED checklist ......................................................................................................................................... 60
Measuring points ................................................................................................................................... 60
NT 60 - switched mode power supply 60 V ................................................................................................ 62
General remarks .................................................................................................................................... 62
Component position in the machine ...................................................................................................... 62
Overview ................................................................................................................................................ 62
Technical Data ....................................................................................................................................... 63
Function overview .................................................................................................................................. 63
Plug layout ............................................................................................................................................. 63
LED checklist ......................................................................................................................................... 64
Measuring points ................................................................................................................................... 64
UST - Control and regulation unit ............................................................................................................... 66
General remarks .................................................................................................................................... 66
Component position in the machine ...................................................................................................... 66
Overview ................................................................................................................................................ 66
Technical Data ....................................................................................................................................... 67
Plug layout ............................................................................................................................................. 67
Function overview .................................................................................................................................. 67
LED checklist ......................................................................................................................................... 69
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Measuring points ................................................................................................................................... 69
Changing UST PC board ....................................................................................................................... 69
NF 3160 - Line filter .................................................................................................................................... 70
General remarks .................................................................................................................................... 70
Component position in the machine ...................................................................................................... 70
Overview ................................................................................................................................................ 70
Technical Data ....................................................................................................................................... 70
Function overview .................................................................................................................................. 71
Plug layout ............................................................................................................................................. 71
LED checklist ......................................................................................................................................... 71
Measuring points ................................................................................................................................... 71
NF 3400 - Line filter/line filter 40 A/80 A ..................................................................................................... 72
General remarks .................................................................................................................................... 72
Component position in the machine ...................................................................................................... 72
Overview ................................................................................................................................................ 72
Technical Data ....................................................................................................................................... 73
Function overview .................................................................................................................................. 73
Plug layout NF 3400 .............................................................................................................................. 73
Plug layout line filter 40 A/80 A .............................................................................................................. 74
LED checklist ......................................................................................................................................... 74
Measuring points ................................................................................................................................... 74
Shunt........................................................................................................................................................... 75
General remarks .................................................................................................................................... 75
Component position in the machine ...................................................................................................... 75
Overview ................................................................................................................................................ 75
Technical Data ....................................................................................................................................... 76
Function overview .................................................................................................................................. 76
Plug layout ............................................................................................................................................. 76
LED checklist ......................................................................................................................................... 76
Measuring points ................................................................................................................................... 76
SR 41 - Wire-feed unit regulation unit......................................................................................................... 77
General remarks .................................................................................................................................... 77
Component position in the machine ...................................................................................................... 77
Overview ................................................................................................................................................ 77
Technical Data ....................................................................................................................................... 78
Function overview .................................................................................................................................. 78
Plug layout ............................................................................................................................................. 78
LED checklist ......................................................................................................................................... 80
Measuring points ................................................................................................................................... 81
Temperature sensor TP 592S ..................................................................................................................... 82
General remarks .................................................................................................................................... 82
Component position in the machine ...................................................................................................... 82
Technical Data ....................................................................................................................................... 83
Function overview .................................................................................................................................. 83
Plug layout ............................................................................................................................................. 83
Measuring points ................................................................................................................................... 83
Secondary power module TPS 2700 .......................................................................................................... 84
General remarks .................................................................................................................................... 84
Component position in the machine ...................................................................................................... 84
Overview ................................................................................................................................................ 84
Function overview .................................................................................................................................. 85
Measuring points ................................................................................................................................... 85
Secondary power module TS 4000/5000, TPS 3200/4000/5000 ............................................................... 86
General remarks .................................................................................................................................... 86
Component position in the machine ...................................................................................................... 86
Overview ................................................................................................................................................ 86
Function overview .................................................................................................................................. 87
Measuring points ................................................................................................................................... 87
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Primary rectifier ........................................................................................................................................... 88
General remarks .................................................................................................................................... 88
Component position in the machine ...................................................................................................... 88
Overview ................................................................................................................................................ 88
Function overview .................................................................................................................................. 88
Plug layout ............................................................................................................................................. 89
Measuring points ................................................................................................................................... 89
Changing components ................................................................................................................................ 90
Safety ..................................................................................................................................................... 90
General remarks .................................................................................................................................... 90
Overview ................................................................................................................................................ 90
Changing throttle (TS 4000/5000, TPS 3200/4000/5000) .......................................................................... 91
Removing throttle ................................................................................................................................... 91
Fitting throttle ......................................................................................................................................... 92
Changing throttle (TPS 2700) ..................................................................................................................... 94
Removing throttle ................................................................................................................................... 94
Fitting throttle ......................................................................................................................................... 95
Changing earth current watchdog .............................................................................................................. 98
Removing earth current watchdog ......................................................................................................... 98
Fitting earth current watchdog ............................................................................................................... 99
Changing PC board ASU 27 (TPS 2700 MV) ........................................................................................... 101
Removing ASU 27 ............................................................................................................................... 101
Fitting ASU 27 ...................................................................................................................................... 101
Changing shunt (TPS 2700) ..................................................................................................................... 102
Removing shunt ................................................................................................................................... 102
Fitting shunt ......................................................................................................................................... 103
Changing temperature sensor TP 592S ................................................................................................... 105
Notes.................................................................................................................................................... 105
Changing transformer (TS 4000/5000, TPS 3200/4000/5000) ................................................................. 106
Removing transformer ......................................................................................................................... 106
Fitting transformer ................................................................................................................................ 107
Changing transformer (TPS 2700)............................................................................................................ 109
Removing transformer ......................................................................................................................... 109
Fitting transformer ................................................................................................................................. 110
Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000) .................................... 112
Removing intermediate circuit capacitors .............................................................................................112
Fitting intermediate circuit capacitors ...................................................................................................113
Safety inspection........................................................................................................................................115
General .................................................................................................................................................115
Responsibility ........................................................................................................................................115
Visual inspections ......................................................................................................................................116
General .................................................................................................................................................116
General conditions ................................................................................................................................116
Welding torch/electrode holder/welding current return terminal ........................................................... 116
Mains supply and connecting lines .......................................................................................................116
Welding circuit....................................................................................................................................... 116
Housing and covers ..............................................................................................................................117
Adjustment and display devices ...........................................................................................................117
Electrical tests ............................................................................................................................................118
Ground conductor resistance ...............................................................................................................118
Insulation resistance .............................................................................................................................119
Open circuit voltage U0 ........................................................................................................................ 119
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Function tests............................................................................................................................................ 120
General ................................................................................................................................................ 120
Mains power on/off equipment............................................................................................................. 120
Indicators and controls......................................................................................................................... 120
Gas solenoid valve .............................................................................................................................. 120
Earth current watchdog........................................................................................................................ 120
Test weld .............................................................................................................................................. 120
Documentation .......................................................................................................................................... 121
Test record ........................................................................................................................................... 121
Test label .............................................................................................................................................. 121
Terms and abbreviations used .................................................................................................................. 122
General remarks .................................................................................................................................. 122
Terms and abbreviations ...................................................................................................................... 122
Entire circuit diagram ................................................................................................................................ 124
Storage location ................................................................................................................................... 124
Spare parts list / Circuit diagram
Fronius Worldwide
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EN
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 each
chapter as a self-contained information source. A short description of each chapter
follows:
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 by
Fronius-trained personnel. Take note of the „Safety rules“ chapter in the power
source operating instructions.
WARNING! An electric shock can be fatal. If the machine needs to be switched
on 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 injury
and damage. The housing screws provide a suitable PE conductor connection
for earthing (grounding) the housing and must NOT be replaced by any other
screws 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 electrically charged components (e.g. capacitors) have been discharged
Fronius Technical Support
Center (TSC)
If you have any questions about fault isolation, there is a team of experts on hand.
E-mail: techsupport@fronius.com
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Contains a description of essential terms and abbreviations for a better understanding
of the service instructions
The „Spare parts list“ and „Entire circuit diagram“ sections contain the complete spare
parts list and complete circuit diagram for the power source.
In the „Changing components“ section there is a description of how to change components 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 following 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 description
Changing components
Terms and abbreviations used
Spare parts list
and entire circuit
diagram
Tools and
measuring
instruments
This provides an overview and description of all equipment required for servicing the
power source professionally. This equipment includes:
- Tools required
- Measuring and inspection equipment
- Ancillary materials
Function overview
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 equipment
needed 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 and
inspection equipment
Ancillary materials
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Fig. 1 Function outline
Function overview
Principle of the
digital family of
machines
Useful information
The machines are totally digitized, microprocessor-controlled inverter power sources. A
universal control regulates the entire welding process. The actual data are measured
continuously, and the machine responds immediately to any changes. Special control
algorithms ensure that the target status is maintained at all times. A decisive factor for
the power source welding properties is the software system, instead of a rigid, barely
alterable hardware system. This gives the weld process an unrivalled degree of precision, 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 the
process are called up from the operating system (OS) by the universal control. The
welding program database (DB) contains welding-engineering know-how. Welding
characteristics for different materials and their parameter settings are called up from
this database.
Important! The operating system and the welding process database are constantly
being enhanced. Use „Update“ to bring the software up to date. The BSL tool is used for
this purpose. Enabled options need only be reactivated after the UST PC board has
been 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-feed
unit or remote control. Establishing a connection and disconnecting takes place according to the „plug and play“ principle.
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Block diagram
Control and
regulation unit
(1)
(2)
Mains
filter
(3)
Primary
rectifier
(4)
TPS 2700 only: PFC
(Power Factor Control)
(5)
Intermediate circuit
capacitors
(6)
Transistors
(7)
Welding transformer
(8)
Secondary
Rectifer
(9)
Output choke
(10)
Welding current
sensor
Workpiece
Welding torches
Control panel
Remote control
unit
Wire-feed unit
24 V 55 V
Power
supply
55 V
24 V
Primary power module
Local
Net
Local
Net
U
act
I
act
Control
lead
Fig. 2 Block diagram of Trans Synergic 4000/5000 and TransPuls Synergic 2700/3200/4000/5000 power
sources
3 x 400 V
Block diagram
legend
(1) Control and regulation unit:
Controls, regulates and monitors the welding process and all power source functions.
(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 diagram
legend
(continued)
(6) Transistors:
The transistors carry the intermediate circuit voltage in intervals at high frequency
to 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 service
codes 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 and
study the entire circuit diagram in order to understand the composition and functioning
of the power source.
Important! The following NOTE applies to those with even less experience of troubleshooting the power sources. Before working with the fault location aid, read the following
section:
- „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 found
in 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 with
the selected „TIG welding“ process
Nothing happens on control panel
(TPS 2700)
No welding current, or current does not
correspond to set value
Service codes displayed
Mains switch in the
“On” position
Poor weld properties with selected „rod
electrode (MMA) welding“ process
Insufficient welding torch cooling (FK
4000/FK 4000 R)
Poor ignition and weld properties with
the 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 and
welding properties with „MIG/
MAG welding“
End
Correct shielding gas connected,
and l/min set correctly?
Start
Gas-test button: Shielding gas
flowing out?
Welding torch and grounding
(earthing) cable OK?
Parameters set correctly?
Check shielding gas solenoid
valve, including control
Check welding torch and groun-
ding (earthing) cable
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory settings (FAC) (see operating instruc-
tions)
Check whether power source OK,
and check application
Connect correct shielding gas and
check l/min
Yes
No
No
No
Yes
Yes
Yes
No
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Poor ignition and
welding properties with „TIG
welding“
End
Correct shielding gas connected,
and l/min set correctly?
Start
Gas-test button: Shielding gas
flowing out?
Welding torch and grounding
(earthing) cable OK?
Parameters set correctly?
Check shielding gas solenoid
valve, including control
Check welding torch and groun-
ding (earthing) cable
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory settings (FAC) (see operating instruc-
tions)
Check whether power source OK,
and check application
Connect correct shielding gas and
check l/min
Yes
No
No
No
Yes
Yes
Yes
No
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EN
Poor weld properties with „rod
electrode (MMA)
welding“
Connect cable correctly
Electrodes/grounding (earthing)
cable connected/functioning
correctly?
Start
Parameters set correctly?
Check whether power source OK,
and check application
End
No
No
Yes
Yes
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory settings (FAC) (see operating instruc-
tions)
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Start
Voltage OK on prima-
ry rectifier V1=320V/
560V DC?
Check mains cable,
mains switch, line
filter, rectifier and
supply voltage
No
Voltage on intermedi-
ate circuits 1 and 2 >
250V DC?
Change BPS
Are LEDs +5V, +12V
flashing on the ASU 27,
as well as LED for mains
400V at 400V U
nom
,
and LED for mains 230V
at 230V U
nom?
Change ASU 27
On MV power sources
Change BPS
+24V int/ext LEDs
flashing on UST?
Switch power source
off, unplug plug X3
from UST, switch
power source on
Change NT 24
Yes
Yes
Steady +24V int/ext
LEDs on NT 24?
Switch power source
off, plug X3 plug into
UST and unplug X7,
switch power source
on
No
No
Check cooling unit
Steady +24V int/ext
LEDs on UST?
Yes
No
Yes
No
Change BPS
No
Yes
Yes
A
Nothing happens
on control panel
(TPS 2700)
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EN
Nothing happens
on control panel
(TPS 2700)
(continued)
Steady +5V, +15V, -
15V on UST?
Check/change control
panel/ribbon cable
Yes
Unplug X4 from UST
No
A
Steady +5V, +15V, -
15V on UST?
Change VAC shunt
Yes
Unplug X2 from UST
No
Steady +5V, +15V, -
15V on UST?
Check/change control
panel/ribbon cable
Yes
Unplug X6 from UST
No
Steady +5V, +15V, -
15V on UST?
Change BPS
Yes
Change UST
No
End
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Nothing happens
on control panel
(TPS 3200/4000/
5000)
Start
3x230V/3x400V on
the terminal strip X7/5
- X7/7 OK?
Check mains cable,
line filter and supply
voltage
No
Voltage on intermedi-
ate circuits 1 and 2 >
200V DC?
Change primary
rectifier
Mains switch/cabling
OK?
Check/change mains
switch and cabling
Change BPS
Steady +24V int/ext
LEDs on UST?
Switch power source
off, unplug plug X3
from UST, switch
power source on
Change NT 24
Yes
Yes
Steady +24V int/ext
LEDs on NT 24?
Switch power source
off, plug X3 plug into
UST and unplug X7,
switch power source
on
No
Yes
No
Yes
No
Yes
A
Voltage present on 2
phases of rectifier
V1?
Yes
No
LED 230V flashing on
ASU 40 at U
nom
230V?
Change ASU 40
No
Yes
MV power sources
with U
nom
230V
No
No
B
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EN
Nothing happens
on control panel
(TPS 3200/4000/
5000)
(continued)
Steady +5V, +15V, -
15V on UST?
Check/change control
panel/ribbon cable
Yes
Unplug X4 from UST
No
A
Steady +5V, +15V, -
15V on UST?
Change VAC shunt
Yes
Unplug X2 from UST
No
Steady +5V, +15V, -
15V on UST?
Check/change control
panel/ribbon cable
Yes
Unplug X6 from UST
No
Steady +5V, +15V, -
15V on UST?
Change BPS
Yes
Change UST
No
End
Check cooling unit
Steady +24V int/ext
LEDs on UST?
Change BPS
No
Yes
B
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22
No or incorrect
welding current
Check welding torch and groun-
ding (earthing) cable
Welding torch and grounding
(earthing) cable connected/
functioning correctly?
Start
Nothing happening on control
panel?
See subsection „Nothing happens
on control panel“
- Welding current I
comm
no longer
adjustable, or
- Welding current is constantly
I
max
?
Check whether power source OK,
and check application
End
Change current sensor A1 VAC
No
Yes
Yes
No
No
Yes
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EN
No or incorrect
wirefeed speed
Start
Service code display-
ed?
see service codes
table
Yes
Wire-feed unit entered
in the service module?
No
+24V LED flashing
on SR 41?
No
Steady +24V
ext
LED
on UST?
No
Check cable harness/
VSP
See „Nothing hap-
pens on control
panel“ flowchart
No
Yes
„BUS OK“ LED
flashing on the SR 41
when service module
unplugged?
Connect service
module to the power
source
Power source entered
in the service module?
Check VSP
Change SR 41
No
Yes
Change UST
No
Yes
Yes
Yes
Check VSP, NT 60
overloaded or faulty
+55V LED flashing
on SR 41?
Does motor move
when „Feeder in-
ching“ button is
No
No
Change SR 41
FWD LED flashing on
SR 41?
No
Change wire-feed unit
motor
Yes
Calibrate push-pull
unit
Wrong motor speed?
Yes
Yes
Yes
No
A
Page 26
24
Insufficient torch
cooling (FK 4000/
FK 4000 R)
Start
Cooling unit set-up
settings switched to
OFF?
Switch set-up settings
to AUTO or ON
Yes
No
Sufficient coolant?
Top up coolant; vent
cooling unit
No
Yes
Coolant pump blo-
cked?
Use a screwdriver to
turn the pump shaft;
if coolant pump is stiff,
change it;
Check securing
device F1
Yes
No
+24V available from
X1/4 - X1/3?
Check cable harness;
Change UST
No
Yes
Fan turning?
Change fan
No
Yes
Relay K1 can be
accessed?
Change relay K1
No
Yes
Check torch trigger/
cabling
BRT LED flashes
when torch trigger
pressed?
No
Change SR 41
Yes
End
A
No or incorrect
wirefeed speed
(continued)
B
Page 27
25
EN
400V AC available
from plug X10/6 -
X10/8?
Check cable harness
to power source
No
Yes
Securing device F1 in
the 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 on
the pump
Securing device F1
OK?
End
Change pump
Yes
Change auto-transfor-
mer
No
Insufficient torch
cooling (FK 4000/
FK 4000 R)
(continued)
B
Page 28
26
Service code Err
50
Start
Does service code Err
50 appear directly
after switching on,
although the primary
power module is not
operating?
Yes
Imbalance in interme-
diate circuit > 35V?
+5V available on UST
from X6/26 - X7/8?
No
Yes
Change BPS
Yes
Does Err 50 disappear
after a short while?
Yes
No
Change intermediate
circuit electrolytic
capacitors
Switch off power
source; unplug X2
from NT 60; switch on
power source
Err 50?
Change NT 60
No
Yes
Switch off power
source; discharge
intermediate 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, the
brightness of the
control LEDs remains
unchanged when the
BPS is accessed
Change UST
No
Yes
No
Change UST
Yes
Page 29
27
EN
Switch off power
source; discharge
intermediate circuit
electrolytic capacitors;
unplug X7/1 - X7/4
switch on power source
Service code Err
50
(continued)
A
Yes
Imbalance in interme-
diate circuit > 35V?
No
Change BPS
Change intermediate
circuit electrolytic
capacitors
End
Page 30
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 required
for 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 is
set to “ON”). However, the LHSB link has been disconnected, or has
become 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 external
service
Remedy: update software. Change UST2 PC board.
dsP | E05 (code no.17)
Cause: DSP displays internal fault
Remedy: update software. Change UST2 PC board.
dsP | Exx (code no.21)
Cause: DSP displays general fault, xx stands for
1 timeout during charging
2 EOF during charging
3 fault on data channel (LT selection)
4 fault on com channel (LT selection)
5 timeout at EM stop command
Remedy: update software. Change UST2 PC board.
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 service
codes
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
Page 31
29
EN
EcF | xxx (code no.32)
Cause: BPS configuration fault, x stands for:
1 TPS 2700 with incorrect power module
2 TS/TPS/TP 4000 with incorrect power module
3 TS/TPS/TP 5000 with incorrect power module
4 TT 2200, MW 2200 with incorrect primary power module
5 MW 1700 with incorrect primary power module
253 This configuration functions only from UST2A V1.3 A onwards
254 This configuration functions only from UST PC board, version
UST2A onwards
255 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 codes
for 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 of
service 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 formation
Remedy: check application
Err | bPS (code no.18)
Cause: DSP displays internal fault
Remedy: 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 a
second power source)
Remedy: dismiss service code by pressing set-up button
Err | EPF (code no.22)
Cause: Fault during charging of flex
Remedy: update software. Change UST2 PC board.
Err | IP (code no.19)
Cause: DSP displays primary overcurrent
Remedy: check secondary power module. Change primary power module.
Err | Jo (code no.67)
Cause: JobMaster temperature sensor faulty
Remedy: change JobMaster welding torch
Err | Lic (code no.40)
Cause: faulty/incorrect licence key
Remedy: check licence key. Check and update enable codes. Check/change earth
current watchdog
Table of service
codes
(continued)
Page 32
30
Err | PE (code no.53)
Cause: Ground (earth) fault
Remedy: 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 (code
no.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 board
Remedy: check ribbon cable. Change BPS PC board.
Err | tF7 (code no.34)
Cause: temperature sensor fault on UST
Remedy: Changing UST PC board
Err | tF8 (code no.64)
Cause: in conjunction with thermostat option: cooling unit temperature sensor fault
Remedy: check cable harness. Change temperature sensor.
Err | 027 (code no.27)
Cause: one of the supply voltages is outside the tolerance range
Remedy: Change UST
Err | 049 (code no.49)
Cause: Phase failure
Remedy: Check the mains fuse, the mains supply lead and the mains plug
Err | 050 (code no.50)
Cause: voltage intermediate circuit balance error
Remedy: 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.
Err | 051 (code no.51)
Cause: mains undervoltage: The mains voltage has dropped below the tolerance
range
Remedy: check mains voltage
Err | 052 (code no.52)
Cause: mains overvoltage: The mains voltage has exceeded the upper limit of the
tolerance range
Remedy: check mains voltage
Err | 054 (code no.54)
Cause: Wire stick control has tripped
Remedy: remove short circuit on filler wire
Err | 056 (code no.56)
Cause: In conjunction with wire-feed unit and „wire-end check“ option: no wire
available
Remedy: insert new wire spool
Table of service
codes
(continued)
Page 33
31
EN
Err | 059 (code no.59)
Cause: overvoltage in the secondary circuit: safety cut-out has tripped
Remedy: check secondary circuit, including TP4CEL40
Err | 060 (code no.60)
Cause: DPS5000 only: Due to an opened door contact, SITRE1A has triggered
safety disconnection
Remedy: safety cut-out: close door contact
Err | 062 (code no.62)
Cause: Remote control TP08 overtemperature
Remedy: allow TP08 to cool down. Change TP08.
Err | 068 (code no.68)
Cause: secondary circuit safety cut-out has tripped
Remedy: change TTS PC board
Err | 069 (code no.69)
Cause: illegal change of mode or process during welding
Remedy: reignite arc
Err | 073 (code no.73)
Cause: no communication between power source and remote control RCU 5000i
Remedy: 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 found
2 checksum error
3 CFM undescribed
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: update software. Change UST2B PC board.
Err | 24.x (code no.24)
Cause: config memory (CFM) fault on BPS PC board, x stands for:
1 config memory not found
2 checksum error
3 CFM undescribed
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: check ribbon cable. Change BPS PC board.
Err | 25.x (code no.25)
Cause: config memory (CFM) „alternator“ fault, x stands for:
1 config memory not found
2 checksum error
3 never tested
4 test was not OK
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: change TTS
Table of service
codes
(continued)
Page 34
32
Table of service
codes
(continued)
Err | 26.x (code no.26)
Cause: config memory (CFM) „machine“ fault, x stands for:
1 config memory not found
2 checksum error
3 CFM undescribed
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: check cable harness. change config memory on power source cable
harness.
Err | 31.x (code no.31)
Cause: EEProm save error
Remedy: update software. Change UST2 PC board.
Err | 70.x (code no.70)
Cause: fault with the digital gas control option, x stands for:
1 no sensor found
2 no shielding gas
3 calibration fault
4 shielding gas solenoid valve interruption or short circuit
5 no shielding gas solenoid valve found
Remedy: for cause x
1 check cable harness, change shielding gas sensor
2 check shielding gas supply (min. 2 bar)
3 no or insufficient shielding gas, change shielding gas solenoid valve
4 change shielding gas solenoid valve, change shielding gas sensor
5 check cable harness, change shielding gas solenoid valve
Err | 71.x (code no.71)
Cause: Limit failure, x stands for:
1 upper current limit exceed
2 exceed of lower current limit
3 voltage limit exceeded
4 exceed of lower voltage limit
Remedy: check application. check parameters.
hot | H2O (code no.65)
Cause: in conjunction with thermostat option: Overtemperature in cooling system
Remedy: 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 tripped
Remedy: 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 available
Remedy: check shielding gas supply
Page 35
33
EN
Table of service
codes
(continued)
no | H2O (code no.39)
Cause: flow watchdog reporting water deficiency
Remedy: 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. Check
grounding (earthing) connection.
no | Prg (code no.1)
Cause: no saved program selected
Remedy: 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 for
software update to finish.
-Stop- (code no.38)
Cause: Robot not ready
Remedy: 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 overtemperature
Remedy: 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 (code
no.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 on
BPS PC board has tripped (XXX stands for temperature indicator)
Remedy: allow the power source to cool down. Check that ventilator is running.
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)
Remedy: allow the power source to cool down. Check that ventilator is running.
tSt | xxx (code no.33)
Cause: overtemperature in control circuit, xxx stands for the temperature indicator
Remedy: allow the power source to cool down. Check ventilator.
US | POL (code no.37)
Cause: measuring device for secondary voltage (U
Sek
) incorrectly connected, or
defective for some other reason
Remedy: check cable harness. Change UST2 PC board.
Page 36
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 requested
at the power source control panel. Using the parameter selection buttons (left/right
arrows), 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 on
to Fronius. Using this data, Fronius can locate the precise cause of the fault.
- STK | OVL
- STK | UVL
- Err | Dog
- ASS | Ert
- Edg | 1
Special displays
used with service
codes
The following service codes are special displays for software problems:
Page 37
35
EN
EFD 1.x
Cause: flex communication error
Remedy: change SR 4x
EFD2.1
Cause: oscillator watchdog fault
Remedy: change SR 4x
EFD 3.1
Cause: watchdog timer fault
Remedy: change SR 4x
EFD 5.x
Cause: SR 4x config memory (CFM) not legible
Remedy: change SR 4x
EFD 7.x
Cause: wire-feed unit config memory (CFM) not legible
Remedy: 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 operating
instructions for the relevant wire-feed unit.
EFD 9.x
Cause: supply to motor, x stands for:
1 exceed of lower motor supply voltage limit
2 motor supply upper voltage limit exceed
Remedy: check VSP. check/change mains adapter NTxx
EFD 10.x
Cause: PMxxA config memory (CFM) not legible
Remedy: 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 1
2 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 service
codes
Page 38
36
Service codes for push-pull calibration
Safety
Err | Eto
Cause: Incorrect measurement during push-pull calibration
Remedy: Repeat push-pull calibration
St1 | E 1
Cause: At minimum wire feed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the 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 any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St1 | E 3
Cause: At minimum wire feed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St1 | E 4
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
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 codes
shown when the
drive units are
engaged („engaged“ calibration)
Checking actualvalue pick-up
The actual-value pick-up is checked by measuring the direct voltage on the actual-value
pick-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.
Page 39
37
EN
St1 | E 5
Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St1 | E 6
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St1 | E 16
Cause: push-pull calibration has been interrupted: Quick-stop was activated by
pressing the torch trigger.
Remedy: Repeat push-pull calibration
St2 | E 7
Cause: „Push-pull calibration - open-circuit“ has not been carried out
Remedy: Carry out „push-pull calibration - open-circuit“
St2 | E 8
Cause: At minimum wire feed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St2 | E 9
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St2 | E 10
Cause: At minimum wirefeed speed, the motor current of the wire-feed unit motor
is outside the permitted range. Possible causes of this include the wirefeed 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 or
soiling; check the contact pressure on the 2-roller or 4-roller drive of the
push-pull unit;
Repeat the push-pull calibration
St2 | E 11
Cause: At minimum wirefeed speed, the motor current of the push-pull unit is
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 or
soiling; check the contact pressure on the 2-roller or 4-roller drive of the
push-pull unit;
Repeat the push-pull alignment. If the error message re-appears: check
PPU settings
Error codes
shown when the
drive units are
engaged („engaged“ calibration)
Page 40
38
Error codes
shown when the
drive units are
engaged („engaged“ calibration)
(continued)
St2 | E 12
Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St2 | E 13
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it, and
change if necessary.
St2 | E 14
Cause: At maximum wirefeed speed, the motor current of the wire-feed unit motor
is outside the permitted range. Possible causes of this include the wirefeed 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 or
soiling; check the contact pressure on the 2-roller or 4-roller drive of the
push-pull unit.
Repeat the push-pull calibration. If the error message re-appears: check
PPU settings
St2 | E 15
Cause: At maximum wirefeed speed, the motor current of the push-pull unit is
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 or
soiling; check the contact pressure on the 2-roller or 4-roller drive of the
push-pull unit.
Repeat the push-pull calibration. If the error message re-appears: check
PPU settings
St2 | E 16
Cause: push-pull calibration has been interrupted: quick-stop was activated by
pressing the torch trigger.
Remedy: Repeat push-pull calibration
Page 41
39
EN
Detailed description
General remarks This section contains a detailed description of the electronic components with regard to
the following points:
- General (designation, item number)
- Component position in the machine
- Overview
- Technical Data
- Function overview
- Plug layout
- LED checklist
- Measuring points
Position of
electronic components
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
Page 42
40
The ASU 27 PC board (item number 4,070,691,Z) is an additional PC board for the TPS
2700 MV power sources and is for switching between 230 V and 400 V.
Component
position in the
machine
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 AC
Input voltage tolerance +/- 15 %
X2
X1
LED +5 V
LED +12 V
LED 230 V AC
LED 400 V AC
ASU 27 - additional PC board
General remarks
Page 43
41
EN
Function overview
Plug layout
Pin Function
X1 Connection to cooling unit
Fig.7 Plug and connections on ASU 27 PC board
(X6)
(X5)
(X4)
(X1)
(X3)
(X2)
Pin 1 NC
Pin 2 230/400 V from
primary rectifier
Pin 3 NC
Pin 4 Cooler 400 V
Pin 5 NC
Pin 6 Cooler 230 V
Pin 7 NC
Pin 8 NC
Pin 9 NC
Pin 10 NC
Pin 11 NC
Pin 12 NC
Pin 13 NC
Pin 14 NC
Pin 15 NC
Pin 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 series
b) 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 connected
X3 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-)
Page 44
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 V
LED +12 V
LED 230 V AC
LED 400 V AC
Page 45
43
EN
The ASU 40 PC board (item number 4,070,685) is an additional PC board for TPS 3200
MV,
TS/TPS 4000/5000 MV, and is for switching the input voltage between 230 V AC and
400 V AC.
Component
position in the
machine
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 V
LED 230 V
ASU 40 - additional PC board
General remarks
Page 46
44
Technical Data
Input voltage 230/400 V AC
Input voltage tolerance +/- 15 %
Function overview
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 series
b) 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 only
active at an input voltage of 230 V AC.
Pin 1 NC
Pin 2 NC
Pin 3 NC
Pin 4 NC
Pin 5 NC
Pin 6 NC
Pin 7 NC
Pin 8 +15 V primary
Pin 9 Intermediate circuit voltage 1+
Pin 10 NC
Pin 11 Intermediate circuit voltage 2Pin 12 NC
Pin 13 NC
Pin 14 NC
Pin 15 GND primary
Pin 16 High charging connection signal
Pin Function
X1 Connection to BPS 40/42/50 PC board
Page 47
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 L1
Pin 2 NC
Pin 3 Rectifer L2
Pin 4 NC
Pin 5 Rectifer L3
Pin 6 NC
Pin 7 NC
Pin 8 NC
Pin 9 NC
Pin 10 NC
Pin 11 Rectifer L2
Pin 12 NC
Pin 13 NC
Pin 14 NC
Pin 15 NC
Pin 16 NC
Pin Function
X2 Connection to 2nd line filter L1 out
X3 Connection to 2nd line filter L2 out
X4 Connection to 3rd line filter L3 out
X5 Connection to 2nd rectifer L1
X6 Connection to 2nd rectifer L2
X7 Connection to 2nd rectifer L3
X8 not connected
X9 Connection to cooling unit 230 V
X10 Connection to cooling unit L2
X11 Connection to cooling unit L1
X12 Connection to 1st primary rectifer
Page 48
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 charged
LED 230 V ...................... flashes at an input voltage of 230 V
Page 49
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 power
module 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 27
cannot be ordered separately.
Component
position in the
machine
Fig. 13 TPS 2700, position of PC board BPS 25/
BPT 27
Fig. 14 PC board BPS 25/BPT 27
Overview
PC board BPZ 25
with X1
X2
Transistor module control LEDs
LED 15 V primary
Control LED
Boost converter
Page 50
48
Function overview
- Basic composition: two individual power modules (advantage: power modules can
be 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 PC
board
- Monitoring of both intermediate circuits for imbalance: a signal is transmitted to the
UST PC board if there is any deviation from a permitted range
- Switching with boost converter for increasing the intermediate circuit voltage from
approx. 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 AC
Input voltage tolerance (+/-15%)
Supply voltage (from NT 24A) 15 V DC primary
Boost converter work frequency 47 kHz
Transistor module switching frequency 100 kHz
Plug layout BPS
25/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)
Page 51
49
EN
Pin Function
X1 Ribbon cable connection to UST PC board (on BPZ 25 PC board)
Plug layout BPS
25/BPT 27
(continued)
X3 Intermediate circuit 1+ (for MV only)
X4 Intermediate circuit ZWK 1-, bridge for operation in series
X5 Intermediate circuit ZWK 2+, bridge for operation in series
X6 Intermediate circuit 2- (for MV only)
X7 Cable with blade terminal, rectifer +
X8 Cable with blade terminal, rectifer X9 PFC throttle connection L2
X10 PFC throttle connection L2
X11 PFC throttle connection L3
X12 PFC throttle connection L3
X13 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 NC
Pin 3 Intermediate circuit 1 Pin 4 NC
Pin 5 Intermediate circuit 2 +
Pin 6 NC
Pin 7 Intermediate circuit 2 - GNDP
Pin 8 + 15 V primary
Pin 9 Intermediate circuit 1 +
Pin 10 NC
Pin 11 Intermediate circuit 1 Pin 12 NC
Pin 13 Intermediate circuit 2 +
Pin 14 NC
Pin 15 Intermediate circuit 2 - GNDP
Pin 16 + 15 V primary
X2 Intermediate circuits 1 and 2 primary connection
Pin 1 Primary current measurement
+T1
Pin 3 Primary current measurement
+T2
Pin 5 Transistor control
Pin 7 Transistor control
Pin 9 Transistor control
Pin 11 Transistor control
Pin 13 GNDD
Pin 15 + 5 V
Pin 17 + 24 V
Pin 19 Temperature value PWM signal
Pin 21 CFM data line
Pin 23 NC
Pin 25 NC
Pin 2 Primary current measurement
GND T1
Pin 4 Primary current measurement
GND T2
Pin 6 Transistor control
Pin 8 Transistor control
Pin 10 Transistor control
Pin 12 Transistor control
Pin 14 GNDD
Pin 16 + 15 V
Pin 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 line
Pin 24 NC
Pin 26 Intermediate circuit imbalance
detection
(0 = fault/5 V = OK)
Page 52
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 LED
2 control LEDs
Boost converter
Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor field
effect transistors) with diode. This diode provides information about the state of the
transistor:
using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltage
cannot 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 diode
module M2
Charging resistor (PTC)
120 R at 25°C
Page 53
51
EN
Measuring points Plug/pin Measuring result command
value
Intermediate circuit voltage 1 M1/TP1-TP3 320 V DC
Intermediate circuit voltage 2 M2/TP5-TP7 320 V DC
Diode check module M1 M1/TP1-TP2 (+) 0.46 V
M1/TP1-TP4 (+) 0.46 V
M1/TP3 (+) - TP2 0.46 V
M1/TP3 (+) - TP4 0.46 V
Diode check module M2 M2/TP5-TP6 (+) 0.46 V
M2/TP5-TP8 (+) 0.46 V
M2/TP7 (+) - TP6 0.46 V
M2/TP7 (+) - TP8 0.46 V
Diode check module M3 M3/TP9 (+) - TP11 0.46 V
M3/TP11 (+) - TP10 0.38 V
M3/TP13 (+) - TP14 0.46 V
M3/TP14 (+) - TP12 0.38 V
NOTE!
The resulting measurement command values change according to the temperature.
Measuring points
(continued)
Page 54
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!
Component
position in the
machine
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 transistor module control LEDs
*)
*)
**)
Page 55
53
EN
Overview
(continued)
X1
X2
X3
8 transistor module control LEDs
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 circuit
imbalance LED
LED +15 V primary
High charging relay LED
*)
Function overview
- Basic composition: two individual power modules (advantage: power modules can
be 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 AC
Input voltage tolerance (+/-15%)
Supply voltage (from NT 24A) 15 V DC primary
Transistor module switching frequency 70 kHz
Intermediate circuit voltage at 400 V AC 2 x 280 V DC
Page 56
54
Pin Function
X1 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 the
power module
PC boards
(X5)(X16)(X17)(X14)
(X6)
Pin 2 Primary current measurement
GND T1
Pin 4 Primary current measurement
GND T2
Pin 6 Transistor control
Pin 8 Transistor control
Pin 10 Transistor control
Pin 12 Transistor control
Pin 14 GNDD
Pin 16 + 15 V
Pin 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 line
Pin 24 15 V supply
Pin 26 Intermediate circuit balance
detection (0/5 V)
Pin 1 Primary current measurement
+T1
Pin 3 Primary current measurement
+T2
Pin 5 Transistor control
Pin 7 Transistor control
Pin 9 Transistor control
Pin 11 Transistor control
Pin 13 GNDD
Pin 15 + 5 V
Pin 17 + 24 V
Pin 19 Temperature value PWM signal
Pin 21 CFM data line
Pin 23 NC
Pin 25 NC
Page 57
55
EN
X4 N1- transformer connection
X5 N2- transformer connection
X6 N2+ transformer connection
X7 N1+ transformer connection
X8 Primary rectifier L1
X9 Line filter L1
X10 Line filter L3
X11 Primary rectifier L3
X12 Line filter L2
X13 Primary rectifier L2
X14 Intermediate circuit 2-, blue cable
X15 Intermediate circuit 2-, blue cable
X16 Intermediate circuit 2+, red cable
X17 Intermediate circuit 2+, red cable
X18 Intermediate circuit 1-, blue cable
X19 Intermediate circuit 1-, blue cable
X20 Intermediate circuit 1+, red cable
X21 Intermediate circuit 1+, red cable
Plug layout
(continued)
Pin 1 Intermediate circuit 1 +
Pin 2 NC
Pin 3 Intermediate circuit 1 Pin 4 NC
Pin 5 Intermediate circuit 2 +
Pin 6 NC
Pin 7 Intermediate circuit 2 - GNDP
Pin 8 + 15 V primary
Pin 9 Intermediate circuit 1 +
Pin 10 NC
Pin 11 Intermediate circuit 1 Pin 12 NC
Pin 13 Intermediate circuit 2 +
Pin 14 NC
Pin 15 Intermediate circuit 2 - GNDP
Pin 16 + 15 V primary
Pin Function
X2 Intermediate circuits 1 and 2 primary connection
X3 Main switch connection (primary voltage)
Pin 1 L1
Pin 2 NC
Pin 3 L2
Pin 4 NC
Pin 5 NC
Pin 6 Main switch detection
Pin 7 NC
Pin 8 +15 V primary
Pin 9 NC
Pin 10 High charging resistor L1
Pin 11 NC
Pin 12 High charging resistor L2
Pin 13 NC
Pin 14 NC
Pin 15 NC
Pin 16 High charging connection
Page 58
56
LED checklist of
power module
PC boards
Fig. 22 LED indicators on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32
8 transistor module control LEDs
8 transistor module control LEDs
Fig. 22a LED indicators on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A
Main switch LED
Intermediate circuit
imbalance LED
LED +15 V primary
High charging relay LED
Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor field
effect transistors) with diode. This diode provides information about the state of the
transistor:
using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltage
cannot be measured, the module is faulty.
Page 59
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
Measuring points
(continued)
Fig. 23a Measuring points on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A
Page 60
58
Measuring points
(continued)
Measuring points Plug/pin Measuring result command value
Intermediate circuit voltage 1 TP1-TP3 320 V DC
Intermediate circuit voltage 2 TP5-TP7 320 V DC
Diode check module M1 TP1-TP2 (+) 0.46 V
TP1-TP4 (+) 0.46 V
TP3 (+) - TP2 0.46 V
TP3 (+) - TP4 0.46 V
TP5 - TP6 (+) 0.46 V
TP5 - TP8 (+) 0.46 V
TP7 (+) - TP6 0.46 V
TP7 (+) - 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.
Page 61
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 external
components.
Important! On NT 24 switched mode power supply, the primary voltage is on!
Component
position in the
machine
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 voltage
Secondary voltage
X2
X1
LED 24 V internal LED 15 V primary
LED 24 V external
Page 62
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 circuit
Output voltages 15 V DC primary
24 V DC internal
24 V DC external
Fuse protection from PTC 15 V primary 2 A
24 V internal 5 A
24 V external 2 A
Technical Data
Function overview
- 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 Function
X1 Primary connection intermediate circuit 1 and 2
Pin 1 Intermediate circuit 1 +
Pin 2 NC
Pin 3 Intermediate circuit 1 Pin 4 NC
Pin 5 Intermediate circuit 2 +
Pin 6 NC
Pin 7 Intermediate circuit 2 - GNDP
Pin 8 +15 V primary
Pin 9 Intermediate circuit 1 +
Pin 10 NC
Pin 11 Intermediate circuit 1 Pin 12 NC
Pin 13 Intermediate circuit 2 +
Pin 14 NC
Pin 15 Intermediate circuit 2 - GNDP
Pin 16 +15 V primary
Page 63
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
Plug layout
(continued)
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 function
X2 Secondary connection +24 V
Pin 1 +24 V external
Pin 2 NC
Pin 3 Intermediate circuit voltage UZW
Pin 4 +24 V internal
Pin 5 GND EXT
Pin 6 NC
Pin 7 GND UZW
Pin 8 GND INT
Page 64
62
Measuring points Plug/pin Measuring result command value
Intermediate circuit voltage 1 X1/1 - X1/3 approx. 280 V DC at a nominal voltage of
400 V AC
approx. 320 V DC at a nominal voltage of
230 V AC
Intermediate circuit voltage 2 X1/5 - X1/7 approx. 280 V DC at a nominal voltage of
400 V AC
approx. 320 V DC at a nominal voltage of
230 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
Measuring points
(continued)
Page 65
63
EN
The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feed
unit 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
X1
X2
Intermediate circuit 1 supply LED
„Error“ LED (PTC active) Supply LED
55 V
Intermediate
circuit 2 supply
LED
NT 60 - switched mode power supply 60 V
General remarks
Component
position in the
machine
Overview
Page 66
64
Supply voltage from intermediate circuit 2 x 230 - 380 V DC
Output voltage Idle 59 (+/- 2) V
at a load of 4 A 55 (+/- 2) V
Technical Data
Function overview
- Output voltage is electrically isolated and protected by 2 parallel switched PTC
resistors.
- The 1 V/A falling output characteristic of the NT 60 circuit enables several NT 60
adapters to be connected in parallel.
- If there is a short circuit, the NT 60 restricts to max. 15 A, using the internal current
limit, until the PTC resistors have reached the switch-off temperature. In the case of
a short circuit, the 55 V supply LED does not flash. As soon as the PTC resistors
trip, the „Error“ LED flashes.
Plug layout
(X1)(X2)
Fig. 33 Plug on NT 60 mains adapter
Pin 9 Intermediate circuit 1+
Pin 10 NC
Pin 11 Intermediate circuit 1 -
Pin 12 NC
Pin 13 Intermediate circuit 2+
Pin 14 NC
Pin Function
X1 Connection to wire-feed unit (secondary voltage)
Pin 1 + 55 V
Pin 2 + 55 V
Pin 3 GND
Pin 4 GND
X2 Primary connection intermediate circuit 1 and 2
Pin 1 Intermediate circuit 1+
Pin 2 NC
Pin 3 Intermediate circuit 1 Pin 4 NC
Pin 5 Intermediate circuit 2+
Pin 6 NC
Page 67
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
Plug layout
(continued)
Pin 7 Intermediate circuit 2- GND P
Pin 8 + 15 V primary
Fig. 35 Plug X1 and X2 on mains adapter NT 60
X1
X2
Pin 15 Intermediate circuit 2- GND P
Pin 16 + 15 V primary
Page 68
66
Measuring points Plug/pin Measuring result command value
Intermediate circuit voltage 1 X2/1 - X2/3 approx. 280 V DC at a nominal voltage of
400 V AC
approx. 320 V DC at a nominal voltage of
230 V AC
Intermediate circuit voltage 2 X2/5 - X2/7 approx. 280 V DC at a nominal voltage of
400 V AC
approx. 320 V DC at a nominal voltage of
230 V AC
+55 V X1/1 - X1/3 approx. 57-61 V DC in idle
X1/2 - X1/4
X2/9 - X2/11
X2/13 - X2/15
Measuring points
(continued)
Page 69
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)
Component
position in the
machine
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 X8
X7 X5
X10
X9
X3
LED +24 V internal
LED +15 V
LED +5 V
LED -15 V
LED STAT
LED +24 V external
LED +5 V (RS 485)
Page 70
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 for
discharging the intermediate circuit capacitors
- Evaluation of signals from the temperature sensors; if there is a rise in temperature
and the ventilators do not cool sufficiently, (e.g. because the duty cycle was exceeded), 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 overview
Plug layout
Fig.39 Plug on UST PC board
(X4)
(X1)
(X6) (X2) (X8) (X7) (X5)
(X10)
(X9)
(X3)
Pin Function
X1 not assigned
X2 Connection to control panel
X3 Supply
Pin 1 +24 V external
Pin 2 NC
Pin 3 Intermediate circuit voltage
Pin 4 +24 V internal
Pin 5 GND external
Pin 6 NC
Pin 7 GND Intermediate circuit voltage
Pin 8 GND internal
Page 71
69
EN
Plug layout
(continued)
Pin Function
X4 Temperature transmission; voltage command value, current command value
Pin 1 Voltage actual value
Pin 2 NC
Pin 3 Shunt C 4000,
Pin 4 Shunt A 3000,
Pin 5 Shunt B 2000,
Pin 6 -15 V Shunt
Pin 7 TH error 1
Pin 8 GND A (UP 400)
Pin 9 CFMPin 10 ESC 1
Pin 11 Temperature 2Pin 12 Temperature 1-
Pin 13 Voltage actual value +
Pin 14 NC
Pin 15 Shunt D 5000,
Pin 16 NC
Pin 17 GND Shunt
Pin 18 +15 V Shunt
Pin 19 TH error 2
Pin 20 UP 400
Pin 21 CFM+
Pin 22 ESC 2
Pin 23 Temperature 2+
Pin 24 Temperature 1+
X5 Ventilator control
Pin 1 +24 V
Pin 2 FAN
Pin 3 +24 V
Pin 4 FAN
X6 Power module PC board control
Pin 1 Primary current T1+
Pin 3 Primary current T2+
Pin 5 OUT A1
Pin 7 OUT A2
Pin 9 OUT B1
Pin 11 OUT B2
Pin 13 GND D
Pin 15 +5 V
Pin 17 +24 V
Pin 19 PWM temperature
Pin 21 SCL (CLOCK)
Pin 23 FAST OUT 1
Pin 25 SYNC
Pin 2 Primary current GND T1
Pin 4 Primary current GND T2
Pin 6 OUT A3
Pin 8 OUT A4
Pin 10 OUT B3
Pin 12 OUT B4
Pin 14 GND D
Pin 16 +15 V
Pin 18 Main switch
Pin 20 High charging connection
Pin 22 SDA (DATA)
Pin 24 +15 V
Pin 26 OV/UV
X7 Cooling unit control
Pin 1 Temperature +
Pin 2 Cooling unit ON
Pin 3 Water control
Pin 4 CFM +
Pin 5 NC
Pin 6 Temperature -
Pin 7 + 24 V
Pin 8 GND (Water control)
Pin 9 CFM-
Pin 10 GND (SUPPLY)
X8 Programming interface, for updating firmware via BSL tool
X9 Connection to wire-feed unit
Pin 1 +24 V external
Pin 2 RXDL-485
Pin 3 RXDH-485
Pin 4 GND external (+24 V)
Pin 5 TXDL-485
Pin 6 TXDH-485
Page 72
70
Plug layout
(continued)
LED checklist
Fig.40 LED indicators on UST PC board
LED +24 V external
LED +24 V internal
LED +5 V (RS 485)
LED -15 V
LED +15 V
LED +5 VLED STAT
- LED STAT flashes when there is no firmware available
Changing UST
PC 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, the
enabled options must be clarified with the customer - the enable codes must
be supplied by the customer.
Measuring points See plug layout.
Measuring points Plug/pin Measuring result command value
Intermediate circuit imbalance X6/26 - X7/8 5 V = OK, 0 V = fault
Pin function
X10 Control for gas solenoid valve and TIG welding torch (optional)
Pin 1 High frequency on/off HF
Pin 2 Gas 1
Pin 3 Gas 2
Pin 4 Crater fill BRT
Pin 5 BRT UP
Pin 6 GND (gun trigger)
Pin 7 GND (HF)
Pin 8 +24 V (Gas 1)
Pin 9 +24 V (Gas 2)
Pin 10 Main current BRT
Pin 11 BRT DOWN
Pin 12 Detection
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NF 3160 - Line filter
General remarks
The NF 3160 PC board (item number 4,070,662) is used with the TPS 2700 power
source 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!
Component
position in the
machine
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
X2X3X4X5X6
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72
Function overview
- Varistors provide protection against momentary overvoltage of the mains
- Capacitors and coils form an LC low-pass filter that moderates the parasitic frequencies 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 Function
X1 L1 in, cable
X2 L1 out, cable
X3 L2 in, cable
X4 L2 out, cable
X5 L3 in, cable
X6 L3 out, cable
There are no LED indicators on NF 3160 PC board.
There are no measuring points on NF 3160 PC board.
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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/TPS
4000/5000 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 filter
40 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!
Component
position in the
machine
Fig.44 TPS 3200, TS/TPS 4000/5000 position of
NF 3400 PC board
Fig.46 NF 3400 PC board
Overview
Fig.45 TPS 3200, TS/TPS 4000/5000 position of
line filter 40 A/80 A
X1
X2X3X4X5X6
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Function overview
- Varistors provide protection against momentary overvoltage of the mains
- Capacitors and coils form an LC low-pass filter that moderates the parasitic frequencies 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 NF
3400
Technical Data
Attenuation of parasitic frequencies > 60 Hz
Fig.48 Connections on NF 3400 PC board
X1
X2
X3
X4
X5
X6
Pin Function
X1 L1 in, cable
X2 L1 out, cable
X3 L2 in, cable
X4 L2 out, cable
X5 L3 in, cable
X6 L3 out, cable
Overview
(continued)
Line filter 40 A
Fig. 47 Line filter 40 A and 80 A
Line filter 80 A
X1
X3
X2
X1
X3
X2
X4
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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 line
filter 40 A/80 A
Line filter 40 A
Fig. 49 Connections on line filter 40 A and 80 A
Line filter 80 A
Pin Function
X1 Mains supply
U1 L1 in
V1 L2 in
W1 L3 in
PE PE conductor
X2 Connection to BPS 42/50/53
U2 L1 out
V2 L2 out
W2 L3 out
X3 Earth current watchdog
X4 Connection to ASU 40 (on line filter 80 A only)
U2 L1 out
V2 L2 out
W2 L3 out
X1
X3
X2 X1
X3
X2 X4
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The shunt (item number 43,0001,1138) is a current sensor which permits the isolated
capture of the welding current.
Shunt
General remarks
Component
position in the
machine
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)
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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 following
features:
- 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 output
signal which is proportional to the measured welding current. The output signal to wel
ding 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 overview
There are no LED indicators on the shunt.
The welding current can be captured indirectly using a tension gauge. At a welding
current of 100 A for instance, a voltage of 0.33 V must be measured on the UST PC
board, plug X4, pins 5 and 17.
Measuring points Plug/pin Measuring result command value
Welding 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 to
other parts in the power source, use only the adapter cable supplied.
Supply voltage +15 V /- 15 V
Nominal current 500 A
Output current at nominal current 250 mA
Transformation ratio 1 : 2000
Pin function
X1 Molex plug from adapter cable
Pin 1 +15 V
Pin 2 -15 V
Pin 3 I Real Pin 4 GND
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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 the
regulation unit for powering and controlling the wire-feed unit.
Component
position in the
machine
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 OK
LED FLEX OK
LED +15 V
LED +5 V
LED +55 V
LED -24 V
LED µP OK
LED -15 V
LED backwards
LED gas
LED forwards
LED BRT
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EN
Function overview
- 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 regulator
b) 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 for
any 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 source
Overvoltage protection (varistors) and overcurrent protection (PTC) on all LocalNet
interfaces, except X2
- Firmware update using BSL tool via programming connection X9
Technical Data
Supply voltage (from NT 24) + 24 V DC
Supply 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)
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80
Plug layout
(continued)
Pin function
X1 Connection to control panel
Pin 1 GND for power potentiometer
Pin 2 +5 V for power potentiometer
Pin 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 correction
Pin 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 V
Pin 3 GND D
Pin 5 +5 V
Pin 7 RXDL
Pin 9 TXDL
Pin 2 +15 V
Pin 4 +5 V
Pin 6 GND D
Pin 8 RXDH
Pin 10 TXDH
X3 Welding torch control
Pin 1 Gun Trigger Euro
Pin 2 +5 V PullMig potentiometer
Pin 3 PM LSP (PullMig potentiometer
actual value)
Pin 4 UP / DOWN (+ 5 V = up,
0 V = down, 2.5 V = no buttons
pressed)
Pin 5 Gun Trigger - torch trigger
Pin 6 GND D Euro
Pin 7 GND Pullmig potentiometer
Pin 8 Torch detection
Pin 9 GND torch
Pin 10 +15 V
X4 Robot sensors/feeder inching and gas test
Pin 1 Torch blow out
Pin 2 I on - current flow signal
Pin 3 Wire retract
Pin 4 Wire in
Pin 5 Wire end
Pin 6 Gas pressure watchdog
Pin 7 KAT - cut-out box
Pin 8 +24 V torch blow out
Pin 9 +24 V (res)
Pin 10 Gas test
Pin 11 GND to pin 3/4/6/10/12
Pin 12 Real value - actual rotational
speed value
Pin 13 GND wire end
Pin 14 GND cut-out box
X5 Actual rotational speed value, gas solenoid valve and configuration memory
Pin 1 GND actual rotational speed
value
Pin 2 VD-ANA - (wire buffer sensor)
Pin 3 CFMPin 4 +24 V gas solenoid valve
Pin 5 Actual rotational speed value in
Pin 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 V
Pin 2 RXDL-RC
Pin 3 RXDH-RC
Pin 4 GND
Pin 5 TXDL-RC
Pin 6 TXDH-RC
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Fig.56 LED indicators on SR 41 PC board
LED Bus OK
LED Flex OK
LED +15 V
LED +5 V
LED +55 V
LED -24 V
LED uP OK
LED -15 V
LED backwards
LED gas
LED forwards
Plug layout
(continued)
LED checklist
X12 not connected (connection for PMR 4000 push-pull option and RobactaDrive)
LED BRT
Pin function
X7 LocalNet power source connection
Pin 1 +24 V
Pin 2 RXDL-485
Pin 3 RXDH-485
Pin 4 GND
Pin 5 TXDL-485
Pin 6 TXDH-485
X8 Wire-feed unit motor connection
Pin 1 Motor + (red) Pin 2 Motor - (blue)
X9 BSL tool (20 pin) connection
X10 + 55 V (NT 60) supply
Pin 1 +55 V
Pin 2 +55 V
Pin 3 GND
Pin 4 GND
X11 + 55 V remote control supply
Pin 1 +55 V
Pin 2 +55 V
Pin 3 GND
Pin 4 GND
Page 84
82
LED checklist
(continued)
LED BUS OK ..................flashes when connection with Bus master (power source) is OK
LED FLEX OK ................flashes when there is no fault
LED µP OK..................... flashes when the processor is working
LED BRT ........................flashes when the torch trigger is pressed
LED + 55 V..................... flashes when the supply voltage is OK
LED + 24 V..................... flashes when the supply voltage is OK
LED + 15 V..................... flashes when the supply voltage is OK
LED + 5 V....................... flashes when the supply voltage is OK
LED forwards .................. flashes when the wire is moved forwards by the drive unit motor
LED backwards ............... flashes when the wire is moved backwards by the drive unit
motor
LED 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 be
done by referring to the LED indicators.
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Temperature sensor TP 592S
General remarks
The TP 592S temperature sensor (item
number 43,0001,0600) is an electronic
temperature sensor. It has an integrated
temperature/current converter chip.
The chip is integrated into the plastic
housing and provided with a pluggable
Molex connection.
Fig.57 Temperature sensor TP 592S
Component
position in the
machine
Fig.58 TPS 2700: position of temperature sensor
TP 592S
Fig.59 TPS 3200, TS/TPS 4000/5000: position of
temperature sensor TP 592S (1)
Temperature sensor
Fig.60 TPS 3200, TS/TPS 4000/5000: position of
temperature sensor TP 592S (2)
Temperature sensor Temperature sensor
Page 86
84
Measuring points
Function overview
- The temperature sensor is fitted to the cooling element and measures the
element’s temperature.
- The temperature sensor emits a current of exactly 1 μA per K (Kelvin), provided
that there is a voltage of 4 - 30 V DC.
0 K corresponds to a temperature of -273.15°C
0°C corresponds to 273.15 K
273.15 K corresponds to 273.15 µA
Pin function
X1 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 DC
Output current 1 µA/K
Pin 1 Temp. 1+ Pin 2 Temp. 1-
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EN
Secondary power module TPS 2700
General remarks On the TPS 2700, the secondary power module consists of two diode modules (item
number 41,0003,0215 ), each of which has two integral diodes.
Component
position in the
machine
Fig.61 TPS 2700, position of secondary power
module
Fig.62 Secondary power module
Overview
Secondary power module
Welding transformer
PC board BPS 25/BPT 27
Cooling element
Diode module
Diode module
Page 88
86
Function overview
The diode modules go together to make up the secondary rectifier. The secondary
rectifier 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 diode
module. Measurement on the diode
regions 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
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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 consists
of four diode modules (item number 41,0003,0203), each of which has two integral
diodes.
Component
position in the
machine
Fig.64 TPS 2700, position of secondary power
module
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)
Page 90
88
Function overview
The diode modules go together to make up the secondary rectifier. The secondary
rectifier 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 diode
module. Measurement on the diode
regions 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
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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
Component
position in the
machine
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 overview
The primary rectifier converts the input voltage (mains voltage) into a rectified voltage
for the intermediate circuit.
L1
L2
L3
(-)
(+)
L1
L2
L3
(-)
(+)
Page 92
90
Plug layout
Fig.71 Connections on the primary rectifier
TPS 2700
Fig.72 Connections on the primary rectifier
TS 4000/5000, TPS 3200/4000/5000
L1
L2
(-)
(+)
L1
L2
L3
(-)
(+)
Pin function
L1 Mains voltage input L1
L2 Mains voltage input L2
L3 Mains voltage input L3
(+) Intermediate circuit voltage output +
(-) Intermediate circuit voltage output -
L3
Measuring points
Fig.73 Measuring points on primary rectifier TPS
2700
Fig.74 Measuring points on primary rectifier TS
4000/5000, TPS 3200/4000/5000
Measurement on each of the diode regions must produce a result of 0.4 V.
Page 93
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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 components 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 electrically charged components (e.g. capacitors) have been discharged
Safety
Page 94
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 panels
2. 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 hexagon
nut (4) using a size 13 spanner
2. Remove protective element (5) and
throttle lead (2)
1. Remove screw (6) from the front of
the housing:
NOTE! When removing the
control panel (7), take care not to
bend, stretch or strain the ribbon
cable 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)
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EN
Removing throttle
(continued)
1. Loosen 2 screws (8)
2. Remove front of housing
1. Unscrew 4 screws (10) and remove
sheet 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 in
place with 4 screws (10) and sheet
nuts (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)
Page 96
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 spanner
4. Fitting the side panels
Fitting throttle
(continued)
Fig. 10 Fitting front of the housing
NOTE! When fitting the control
panel (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
place
3. Tighten screw (6) on front of the
housing
1. Place front of housing onto base
plate 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)
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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 cover
2. Remove side panel
3. Loosen two screws (1) on front
aperture
1. Loosen two screws (3) on the drive
unit (2)
NOTE! When lifting the drive unit
(2), do not pinch, bend or strain
the 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
Page 98
96
1. Remove both upper copper clips (10)
and (11) from the transformer
2. Loosen screw (12) on the middle tap
connection
1. Loosen hexagon bolt (5) on minus
socket using size 19 spanner
2. Feed out the throttle lead (9) from the
shunt (8)
Removing throttle
(continued)
Fig.4 Loosening hexagon bolt
1. Loosen three screws (13) on throttle
(14)
2. Carefully remove throttle (14) and
throttle 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)
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1. Fit throttle (14) using three screws
(13)
Fitting throttle
(continued)
1. Fasten throttle lead (9) - Fig.8 - onto
middle tap connection using screw
(12) - Fig.9.
2. Fit copper clips (11) and (10) as
shown 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)
Page 100
98
Fig.12 Connecting drive unit
1. Reconnect two-pin Molex plug (4)
(4)
Fitting throttle
(continued)
Fig.13 Fitting drive unit
NOTE! When putting the drive
unit (2) in place, do not pinch,
bend or strain the cables.
1. Fit the drive unit (2) using two screws
(3)
(2)
(3)
Fig.14 Screws on the front aperture
1. Fit two screws (1) on front aperture
2. Fit side panel
3. Close wire-feed unit cover
(1)
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