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- Words: 13,330
- Pages: 91
PlasmaModule 10 TransTig 800 / 2200 MagicWave 1700 / 2200
GB
Service Manual Spare Parts List TIG power source
42,0410,1121
012008
Contents Foreword and safety instructions .................................................................................................................. Safety ....................................................................................................................................................... Tech National (TSN) .................................................................................................................... General remarks ...................................................................................................................................... Tools and measuring devices ................................................................................................................... Function overview .................................................................................................................................... Error location aid ...................................................................................................................................... Detailed description .................................................................................................................................. Replacing components ............................................................................................................................. and abbreviations used ................................................................................................................. Spare parts list and entire circuit diagram ................................................................................................
4 4 4 4 5 5 5 5 5 5 5
Tools and measuring devices ........................................................................................................................ General remarks ...................................................................................................................................... Tools required .......................................................................................................................................... Measuring equipment, inspection equipment ........................................................................................... Ancillary materials ....................................................................................................................................
6 6 6 7 7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 ................................................... General remarks ...................................................................................................................................... Block diagram .......................................................................................................................................... Block diagram legend...............................................................................................................................
8 8 8 9
Error location aid ......................................................................................................................................... 10 General remarks .................................................................................................................................... 10 Error flowchart .............................................................................................................................................. 11 Overview ................................................................................................................................................. 11 Poor ignition and welding properties with TIG welding ........................................................................... 12 Poor ignition and welding properties with MMA welding ......................................................................... 13 No or incorrect welding current .............................................................................................................. 14 No lights on control ....................................................................................................................... 15 Inadequate welding torch cooling (FK 2200) .......................................................................................... 19 Open circuit voltage +50 V faulty ............................................................................................................ 21 UST service codes ...................................................................................................................................... Safety ..................................................................................................................................................... Table of service codes ........................................................................................................................... Special indications used with service codes ...........................................................................................
22 22 22 28
Detailed description ..................................................................................................................................... 29 General remarks .................................................................................................................................... 29 Overview ................................................................................................................................................ 29 BPS 17 - Power module PC board .............................................................................................................. General remarks .................................................................................................................................... Overview ................................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
30 30 30 30 31 32 33
BPS 22 - Power module PC board .............................................................................................................. General remarks .................................................................................................................................... Overview ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
34 34 34 34 34 36 36 37
1
HFF 22 - High frequency ignition unit, input filter ........................................................................................ General remarks .................................................................................................................................... Overview ................................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ......................................................................................................................................
38 38 38 39 40
NTFK 24 - Switched mode power supply for cooling unit ............................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
42 42 42 43 44 44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ......................................... General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
45 45 45 45 45 46
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ........................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... Important ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... LED checklist ......................................................................................................................................... Measuring points ....................................................................................................................................
47 47 47 47 47 48 48 48 48 48 48
TP 592S temperature sensor ...................................................................................................................... General remarks .................................................................................................................................... Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points ....................................................................................................................................
49 49 49 49 49 49
TTS 22 - IGBT driver and auxiliary power source ....................................................................................... General remarks .................................................................................................................................... Overview ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
50 50 50 50 50 51 51 51
UST - Control and regulation unit ................................................................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist ......................................................................................................................................... Change UST PC board ..........................................................................................................................
52 52 52 53 54 54 54
Changing modules ...................................................................................................................................... 55 General remarks .................................................................................................................................... 55 Overview ................................................................................................................................................ 55 Housing unit ................................................................................................................................................ General remarks .................................................................................................................................... Opening the housing .............................................................................................................................. Closing the housing ................................................................................................................................
2
56 56 56 57
Changing BPS 17 PC board ........................................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing BPS 22 PC board ........................................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing inverter module ........................................................................................................................... 59 Instructions ............................................................................................................................................. 59 Changing the TP 592S temperature sensor ................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing the TTS 22 PC board .................................................................................................................. ESD measures ....................................................................................................................................... Changing the TTS 22 PC board ............................................................................................................. Installing the TTS 22 PC board ..............................................................................................................
60 60 60 62
Changing the BSV 22 PC board .................................................................................................................. ESD measures ....................................................................................................................................... Removing the BSV 22 PC board ............................................................................................................ Installing the BSV 22 PC board .............................................................................................................. Installing UST PC board .........................................................................................................................
64 64 64 66 67
Changing the transformer ........................................................................................................................... 68 Removing the transformer ..................................................................................................................... 68 Installing the transformer ....................................................................................................................... 72 Safety Inspection ......................................................................................................................................... 78 Requirement .......................................................................................................................................... 78 Work instruction ..................................................................................................................................... 78 and abbreviations used .................................................................................................................... 79 General remarks .................................................................................................................................... 79 and abbreviations ........................................................................................................................ 79 Entire circuit diagram Spare parts lists Fronius Worldwide
3
Foreword and safety instructions
Safety
The following safety instructions apply to all activities described in these service instructions: 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 service technicians. Read the „Safety rules“ chapter in the power source operating instructions.
WARNING! An electric shock can be fatal. Before opening the device Turn the mains switch to the „O“ position Unplug the device from the mains Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have discharged 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 that do not provide a reliable PE conductor connection.
Tech National (TSN)
If you have any questions about error analysis, your Tech National (TSN) sales team is on hand. mailto: [email protected]
General remarks
The service instructions can be found in the Center TechGuide at „www.fronius.com\center“. Each chapter in the service manual deals with one complete topic. Use each chapter as a self-contained source of information. A short description of each chapter follows:
4
Tools and measuring devices
This provides an overview and description of all equipment required for servicing the power source professionally. This equipment includes: - Tools required - Measuring equipment, inspection equipment - Ancillary material
Function overview
Contains a brief descriptive overview of the entire system: - in text form - in block diagram form
Error location aid
Serves to systematically locate and rectify the source of errors, and contains the following elements: The actual error flowchart for dealing with general errors Service codes table for dealing with errors whose service codes appear on the display
Detailed description
Contains detailed descriptions of the relevant modules in the power source. For every module, the following topics are dealt with: General remarks (designation, item number of the module) Position of the module in the device Overview Technical data Function overview Pin assignment LED checklists Measuring points
Replacing components
The „Replacing components“ chapter describes how to replace components that have no instructions of their own for replacement and require detailed replacement instructions
and abbreviations used
Contains a description of essential specialist and abbreviations for a better understanding of the service manual
Spare parts list and entire circuit diagram
The „Spare parts list“ and „Entire circuit diagram“ chapters contain the complete spare parts list and complete circuit diagram for the power source.
5
Tools and measuring devices General remarks
„Tools and measuring devices“ provides an overview and description of all the equipment required to service the device professionally. This equipment includes: - Tools required - Measuring equipment, inspection equipment - Ancillary materials
Tools required
-
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 (4) Torx screwdriver (TX 25) or insert bit for manual torque wrench (4) Allen key (3 mm) Allen key (4 mm) Allen key (5 mm) Flat spanner (10 mm) Flat spanner (13 mm) Flat spanner (17 mm) Flat spanner (19 mm) Flat spanner (32 mm) C extractor tool (42,0410,0677) Oeteker pliers Molex extractor tool (42,0410,0290)
6
Measuring equipment, inspection equipment
Ancillary materials
-
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) DVD TechGuide (40,0006,2910)
-
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), grade 500 or finer
7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 General remarks
The „Function overview“ section explains the underlying functional principle of the MagicWave 1700/2200 and TransTig 800/2200 power sources as well as PlasmaModule 10 with the help of a block diagram.
Welding torch control line
Workpiece
Welding torch
Remote control
Block diagram
prot. gas shield solenoid valve
HF transformer
(12)
LocalNet
protective gas shield
Fig. 1
Block diagram of the MagicWave 1700/2200, TransTig 1700/2200 and PlasmaModule 10 power sources
230 V
Line filter
Primary power module
**
Intermediate circuit capacitors
Primary rectifier
8
(11) (8)
(9)
Switching transistors
(7)
Welding transformer
(6)
Secondary rectifier
24 V
PFC (Power Factor Control)
Inverter
(5)
* Secondary power module
Control line
Uact
HF generator
(10)
Welding current sensor
Power supply
24 V power supply
(4) (3) (2)
* only for MagicWave 1700 and MagicWave 2200 power sources ** only for MagicWave 2200 and TransTig 2200 power sources
Control line
(1)
Control
Control and regulation unit
HF
Iact
Block diagram legend
(1) Control and regulation unit: Controls, regulates and monitors the welding process and all power source functions. (2) Line filter (EMC): Reduces unwanted high-frequency noise. (3) Primary rectifier: Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage. (4) PFC (Power Factor Control, MagicWave 2200 and TransTig 2200 only): Ensures sinusoidal current input, for - ing an optimum degree of efficiency - Preventing perturbations in the mains supply (5) Intermediate circuit capacitors: store and smooth the intermediate circuit voltage. (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 constructed to a very light, compact design - Thermal losses due to the low inductance required of the transformer windings 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) Inverter (only MagicWave 1700 and MagicWave 2200): Converts direct current to alternating current for “TIG AC welding” operating mode (10) HF generator: For non- HF ignition, the HF generator (high-frequency generator) generates the high-frequency primary voltage of the HF transformer (12). (11) Welding current sensor: Captures the actual current value for the welding process (12) HF transformer: For non- HF ignition, the HF transformer (high-frequency transformer) transmits high-voltage pulses to the welding circuit.
9
Error location aid General remarks
The chapter „Error location aid“ consists of the following parts - Error flowchart - Table of service codes The error flowchart is for the systematic locating and rectifying of errors. In the „Table of service codes“ chapter, there is also a table which deals with the service codes shown on the display, as well as the causes of errors and how to rectify them. Before using the error location aid, read the „Function overview“ chapter and study the entire circuit diagram in order to understand how the power source is constructed and how it operates. Important: The following applies to those who do not yet have much experience of troubleshooting and fault diagnosis on the MagicWave 1700 / 2200, TransTig 800 / 2200 and PlasmaModule 10 power sources. Before using the error location aid, read the following chapters: „Function overview“ „Entire circuit diagram“
10
Error flowchart Overview
The overview will help you to find the relevant sections of the flowchart from among those listed below. The positions and meanings of the measuring points and LEDs for the modules / PC boards can be found in the „Detailed description“ chapter, which contains an „LED checklist“ or a „Measuring points“ sub-section for each of the modules / PC boards (with LEDs). Poor ignition and welding properties with TIG welding
Poor ignition and welding properties with MMA welding
No or incorrect welding current
Move the mains switch to the „I“ position
No lights on control
Inadequate welding torch cooling (FK 2200)
Open circuit voltage + 50 V faulty
Table of service codes
11
Poor ignition and welding properties with TIG welding
Start
Correct protective gas shield connected, and l/min set correctly?
no
Connect correct protective gas shield and check l/min
yes
Gas test button: Protective gas shield flowing out?
no
Check protective gas shield solenoid valve, including control
yes
Welding torch and grounding (earthing) cable OK?
no
Check welding torch and grounding (earthing) cable
yes
Parameters set correctly? no yes
Open circuit voltage with selected „rod electrode (MMA) welding“ process = 50 V (+/- 1 V) ? yes
Check whether power source OK, and check application
End
12
no
- Check settings on control Check set-up parameters Possibly reset to factory settings (FAC) (see operating instructions)
See „Incorrect open circuit voltage“ section
Poor ignition and welding properties with MMA welding
Start
Electrodes / grounding (earthing) cable connected / functioning correctly?
Connect cable correctly no
yes
Welding process set correctly?
Select correct welding process no
yes
Parameters set correctly? no yes
Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ? yes
Check whether power source OK, and check application
End
13
no
- Check settings on control Check set-up parameters Possibly reset to factory settings (FAC) (see operating instructions)
See „Incorrect open circuit voltage“ section
No or incorrect welding current
Start
Welding torch and grounding (earthing) cable connected / functioning correctly?
no
Check welding torch and grounding (earthing) cable
yes
No lights on control ? yes
See section entitled „No lights on control “
no
Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ?
no
See „Incorrect open circuit voltage“ section
yes
-
Welding current Icomm no longer adjustable, or Welding current is always Imax ? no
Check whether power source OK, and check application
End
14
yes
Change current sensor A1 VAC
No lights on control
Start
Is the UZWK LED on the A2 BPS 17 / BPS 22 power module PC board on constantly?
no
Check mains cable, mains switch and supply voltage
yes
Are the LEDs for supply voltage on the A2 BPS 17 / BPS 22 power yes module PC board and the A5 UST control board on constantly?
Change A6 FP 22 control
no
-
Turn the mains switch to the „O“ position Remove connectors A5 UST.X3, X6 from the control board - Turn the mains switch to the „I“ position
Are the LEDs for supply voltage on the A2 BPS 17 / BPS 22 on the no power module PC board on constantly? yes
-
Turn the mains switch to the „O“ position Connect plug to the A5 UST:X3 control board Turn the mains switch to the „I“ position
A
15
Change power module PC board A2 BPS 17 / BPS 22
No lights on control (continued)
A
LEDs for supply voltage on A5 UST control board constantly illuminated?
yes
Change power module PC board A2 BPS 17 / BPS 22
no
-
Turn the mains switch to the „O“ position - Connect plug X6 to the A5 UST control board Disconnect plugs X1, X2, X4, X7, X9 and X10 from the UST control board - Turn the mains switch to the „I“ position
LEDs for supply voltage on A5 UST control board constantly illuminated?
Change the A5 UST control board no
yes
Connect plug X1 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminated? yes
B
16
no
Change A4 TTS22 PC board (driver for inverter)
No lights on control (continued)
B
Connect plug X2 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminano ted?
Change A6 FP22 control
yes
Connect plug X4 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illumina- no ted?
Change current sensor A1 VAC
yes
Connect plug X7 to the A5 UST control board
LEDs for supply voltage on UST control board constantly illuminated? yes
C
17
Test FK 2200 cooling unit no
No lights on control (continued)
C
Connect plugs X9, X10 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminano ted? yes
Check whether power source OK, and check application
End
18
Change A7 HFF22 PC board (HF generator / filter)
Inadequate welding torch cooling (FK 2200)
Start
Cooling unit set-up parameters switched to „Off“?
yes
Switch set-up parameters to „Auto“ or „On“
no
Switch off power source
Sufficient coolant? no
Top up coolant, then vent cooling unit
yes
Fuse for coolant pump OK? no
Change fuse (check rating is same as original)
yes
Coolant pump blocked?
yes
no
Unplug X4 from power module A1 NTFK24, switch on power supply, change cooling unit’s set-up parameter to „On“
A
19
Use a screwdriver to turn the cooling unit pump shaft. If the pump is difficult to move, change the pump to avoid overloading the power module.
Inadequate welding torch cooling (FK 2200) (continued)
A
Power LED on the A1 NTFK24 power module illuminated constantly ?
no
yes
On LED on the A1 NTFK24 power module illuminated?
no
Check fuse F1 and 230 VAC power supply on the A1 NTFK24 X2 power module. Change A1 NTFK24 power module
Voltage at the A1 NTFK24 X3/2, X3/8 power module < 1 V DC
yes
no
yes
Check cable harness, change A5 UST controller in the power source
LEDs +15V, +24V, + 24V OK on the A1 NTFK24 power module illuminated constantly ? yes
Change coolant pump and/or fan
End
20
Change A1 NTFK24 power module no
Open circuit voltage +50 V faulty
Start
-
Open circuit voltage present for selected „MMA welding“ process ? yes
-
Change TTS 22 PC board (MW 1700 / 2200) Change BSV XX PC board (TT 2200)
no
-
Steady +5 V, +18V, +24V LEDs on TTS 22? - If the polarity is changed using the „Process“ button: „neg./pos. ignition“ LED lit ? yes
Check inverter (see detailed explanation - secondary power supply)
End
21
no
Change TTS 22 PC board
UST service codes Safety
Table of service codes
WARNING! An electric shock can be fatal. Before opening the device Turn the mains switch to the „O“ position Unplug the device from the mains Ensure that electrically charged components (e.g. capacitors) have been discharged
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 - The corresponding troubleshooting measure dsP | Axx (code no.20) Cause: Remedy:
DSP displays a general error, xx stands for additional entries not required for external service Update software. Change UST PC board.
dsP | A21 (code no.20) Cause:
Remedy:
The power source is configured for either parallel operation (set-up parameter 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. Acknowledge 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: Remedy:
DSP SoftCom error, xx stands for additional entries not relevant for external service Update software. Change UST PC board.
dsP | E05 (code no.17) Cause: Remedy:
DSP displays internal error Update software. Change UST PC board.
dsP | Exx (code no.21) Cause:
Remedy:
DSP displays general error, xx stands for 1 timeout during charging 2 EOF during charging 3 error on data channel (LT selection) 4 error on com channel (LT selection) 5 timeout at EM stop command Update software. Change UST PC board.
dsP | Sy (code no.35) Cause: Remedy:
Internal error (version conflict) Update software. Change UST PC board.
dsP | nSy (code no.36) Cause: Remedy:
Internal error (version conflict) Update software. Change UST PC board. 22
Table of service codes (continued)
EcF | xxx (code no.32) Cause:
BPS configuration error, x stands for: 1 2 3 4 5 253 254
Remedy:
TPS 2700 with incorrect power module TS/TPS/TP 4000 with incorrect power module TS/TPS/TP 5000 with incorrect power module TT 2200, MW 2200 with incorrect primary power module MW 1700 with incorrect primary power module This configuration functions only from UST2A V1.3 A onwards This configuration functions only from UST PC board, version UST2A 255 Unknown primary power module Fit correct primary power module
EFD | xx.y (code no.30) Cause: Remedy:
Error in wirefeed system, xx and y can be found in the list of service codes for the wirefeed system. Check wirefeed system
EIF | xx.y (code no.63) Cause: Remedy:
Error in conjunction with a robot interface, xx and y can be found in the list of service codes for your robot interface. Check robot interface, update software, change robot interface
Err | Arc (code no.61) Cause: Remedy:
DPS 5000 only: DPS detected arc formation Check application
Err | bPS (code no.18) Cause: Remedy:
DSP displays internal error Update software. Change UST PC board. Change BPS PC board.
Err | Cfg (code no.72) Cause: Remedy:
Power source configuration changed (e.g. connected in parallel with a second power source) Reset service code by pressing set-up button
Err | EPF (code no.22) Cause: Remedy:
Error during charging of flex Update software. Change UST PC board.
Err | IP (code no.19) Cause: Remedy:
DSP displays primary overcurrent Check secondary power module. Change primary power module.
Err | Jo (code no.67) Cause: Remedy:
JobMaster temperature sensor faulty Change JobMaster welding torch
Err | Lic (code no.40) Cause: Remedy:
Faulty/incorrect licence key Check licence key. Check and update enable codes.
23
Table of service codes (continued)
Err | PE (code no.53) Cause: Remedy:
Earth-fault error Remove earth fault. Configure device 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:
Remedy:
Temperature sensor error (short circuit or break) - examples: tF1 - temperature sensor error on secondary rectifier, tF2 - temperature sensor error on primary power module Check cable harness and change the relevant temperature sensor
Err | tF6 (code no.16) Cause: Remedy:
Error on BPS PC board or on the connection to the BPS PC board Check ribbon cable. Change BPS PC board.
Err | tF7 (code no.34) Cause: Remedy:
Temperature sensor error on UST Change UST PC board
Err | tF8 (code no.64) Cause: Remedy:
In conjunction with thermostat option: cooling unit temperature sensor error Check cable harness. Change temperature sensor.
Err | 027 (code no.27) Cause: Remedy:
One of the supply voltages is outside the tolerance range Change UST
Err | 049 (code no.49) Cause: Remedy:
Phase failure Check the mains fuse, the mains supply lead and the mains plug
Err | 050 (code no.50) Cause: Remedy:
Voltage intermediate circuit symmetry error See error flowchart Err 50 if available. If there is a voltage of +5V on the UST from X6/26 - X7/8, change UST. If there is a voltage of 0 V on the UST from X6/26 - X7/8 0V, change BPS.
Err | 051 (code no.51) Cause: Remedy:
Mains undervoltage: The mains voltage has fallen below the tolerance range Check mains voltage
Err | 052 (code no.52) Cause: Remedy:
Mains overvoltage: The mains voltage has risen above the tolerance range Check mains voltage
Err | 054 (code no.54) Cause: Remedy:
Wire stick control has tripped Remove short circuit on welding wire
24
Table of service codes (continued)
Err | 056 (code no.56) Cause: Remedy:
In conjunction with wire-feed unit and „wire-end check“ option: no wire available Insert new wirespool
Err | 059 (code no.59) Cause: Remedy:
Overvoltage in the secondary circuit: safety cut-out has tripped Check secondary circuit, including TPCEL40
Err | 060 (code no.60) Cause: Remedy:
DPS5000 only: Due to an opened door , SITRE1A has triggered safety disconnection Safety cut-out: close door
Err | 062 (code no.62) Cause: Remedy:
Remote control TP08 overtemperature Allow TP08 to cool down. Change TP08.
Err | 068 (code no.68) Cause: Remedy:
Secondary circuit safety cut-out has tripped Change TTS PC board
Err | 069 (code no.69) Cause: Remedy:
Illegal change of mode or process during welding Reignite arc
Err | 23.x (code no.23) Cause:
Remedy:
Config memory (CFM) error on UST PC board, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Update software. Change UST PC board.
Err | 24.x (code no.24) Cause:
Remedy:
Config memory (CFM) error on BPS PC board, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Check ribbon cable. Change BPS PC board.
Err | 25.x (code no.25) Cause:
Remedy:
Config memory (CFM) „alternator“ error, 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) Change TTS
25
Table of service codes (continued)
Err | 26.x (code no.26) Cause:
Remedy:
Config memory (CFM) „machine“ error, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Check cable harness. Change config memory on power source cable harness.
Err | 31.x (code no.31) Cause: Remedy:
EEProm save error Update software. Change UST2 PC board.
Err | 70.x (code no.70) Cause:
Remedy:
Error with the digital gas control option, x stands for: 1 no sensor found 2 no protective gas shield 3 alignment error 4 protective gas shield solenoid valve break or short circuit 5 no protective gas shield solenoid valve found For cause x 1 check cable harness, change protective gas shield sensor 2 check protective gas shield supply (min. 2 bar) 3 no or insufficient protective gas shield, change protective gas shield solenoid valve 4 change protective gas shield solenoid valve, change protective gas shield sensor 5 check cable harness, change protective gas shield solenoid valve
Err | 71.x (code no.71) Cause:
Remedy:
Limit error, x stands for: 1 exceed of upper current limit 2 exceed of lower current limit 3 exceed of upper voltage limit 4 exceed of lower voltage limit Check application. Check parameters.
hot | H2O (code no.65) Cause: Remedy:
In conjunction with thermostat option: Overtemperature in cooling system Allow cooling unit to cool down. Open cooling unit and clean heat exchanger. Check whether fan is functioning properly.
no | Arc (code no.58) Cause: Remedy:
Arc is broken, arc-break monitor has tripped Check welding parameters. Reignite arc Check grounding (earthing) connection.
no | GAS (code no.57) Cause: Remedy:
In conjunction with the digital gas control option: no protective gas shield available Check protective gas shield supply
26
Table of service codes (continued)
no | H2O (code no.39) Cause: Remedy:
Flow watchdog reporting water deficiency Check cooling system hose lines. Check pump pressure and flow rate. Check flow watchdog.
no | Ign (code no.55) Cause: Remedy:
„Ignition time-out“ error: No ignition within the value set in the set-up menu. The safety cut-out has tripped. Clean workpiece surface. Check parameters in set-up menu. Check grounding (earthing) connection.
no | Prg (code no.1) Cause: Remedy:
No saved program selected Select saved program
off (code no.150) Cause: Remedy:
No communication between the LocalNet participants (e.g. power source, wire feed unit, remote control or welding torch) Check LocalNet cables. Change remote control/welding torch. Wait for software update to finish.
-Stop- (code no.38) Cause: Remedy:
Robot not ready When using a robot interface or field bus coupler, initialise the „Robot ready“ and „Source error reset“ signals.
tJo | xxx (code no.66) Cause: Remedy:
JobMaster overtemperature Allow device 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: Remedy:
Overtemperature in power source primary circuit (XXX stands for temperature indicator) - Example: tp1 - overtemperature at primary power module Allow the power source to cool down. Check that fan is running.
tp6 | xxx (code no.10) Cause: Remedy:
Overtemperature in power source primary circuit, temperature sensor on BPS PC board has tripped (XXX stands for temperature indicator) Allow the power source to cool down. Check that fan is running.
tp7 | Hot Cause: Remedy:
Duty cycle exceeded Allow the power source to cool down. Check that fan is running.
ts1 | xxx (code no.2), tS2 | xxx (code no.3), tS3 | xxx (code no.4) Cause:
Remedy:
Overtemperature in power source secondary circuit (XXX stands for temperature indicator) - Examples: ts1 - overtemperature at secondary rectifier, ts2 - overtemperature at the auxiliary voltage source, tst - overtemperature at UST PC board Allow the power source to cool down. Check that fan is running.
Remedy:
Check cable harness. Change UST2 PC board.
27
Table of service codes (continued)
tSt | xxx (code no.33) Cause: Remedy:
Overtemperature in control circuit, xxx stands for the temperature indicator Allow the power source to cool down. Check fan.
US | POL (code no.37) Cause:
Special indications used with service codes
Measuring device for secondary voltage (Usec) incorrectly connected, or defective for some other reason
The following service codes are special indications for software problems: -
-
And | Opc Prt | Flt Ill | Opa Ill | Ina Ill | Bus Err | 105
STK | OVL STK | UVL Err | Dog ASS | Ert Edg | 1
If the service codes shown above appear, more detailed information can be requested at the power source control . Using the parameter selection buttons (left/right arrows), you can switch between the following display levels: Level 1 (e.g. „And | Opc“): service code 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 indications in levels 1, 2, and 3, and them on to Fronius. Using this data, Fronius can locate the precise cause of the error.
28
Detailed description General remarks
This section contains a detailed description of the electronic modules with regard to the following points: General (designation, item number) Position of the module in the device Overview Technical data Function overview Pin assignment LED checklist Measuring points
Overview
„Detailed description“ is composed of the following sections: BPS 17 - Power module PC board BPS 22 - Power module PC board HFF 22 - High frequency ignition unit, input filter NTFK 24 - 24 V switched mode power supply for supplying KK 2200 cooling unit Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 TP 592S temperature sensor TTS 22 - IGBT driver and auxiliary power source UST - Control and regulation unit
29
BPS 17 - Power module PC board General remarks
BPS 17 (item no. 4,070,798,Z) is the power module PC board for power sources TT 800, MW 1700 and PlasmaModule 10.
Overview
Still required
Function overview
Input voltage
230 VAC (+15 % / -20 %)
Supply voltage from the power module
24 Vint (+/-20 %), 2.5 A 24 Vext (+/-20 %), 1.5 A 15 Vp (+10 %), 0.2 A
Components on the BPS 17 PC board (5)
(1)
(3)
(4)
(6)
(2)
Fig. 6 Components on the BPS 17 power module PC board
30
Function overview (continued)
The BPS 17 PC board includes the following components: (1) Line filter (2) Rectifier (3) High-charging circuit (4) Intermediate circuit capacitors (5) Switched mode power supply (+24 V internal, +24 V external) (6) Power full bridge The BPS 17 PC board also contains a safety-related primary/secondary ing point. (1) Line filter The line filter is located in the AC branch, and has a two-stage structure. The line filter serves to reduce the interference produced in the device for the for the mains lead. (2) Rectifier The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the intermediate circuit. (3) Switched-mode power supply The switched mode power supply is a flyback converter that is supplied by the intermediate circuit capacitors. The switched-mode power supply is synchronised at 65 kHz and provides the output voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); where the 15 Vp coil is for primary and only supplies the power for the PWM ICs of the power supply. The output voltages are electrically isolated from one another and fused with a PTC each. (4) High-charging circuit PTC resistors limit the starting current. The controller (UST PC board) dictates the high charging time. The expiry of a preset length of time plus a preset value for the intermediate circuit voltage are prerequisites for bridging the high charging resistors with relays. Bridging the high charging resistors using relays is done after: - the high charging time has expired - the preset value for the intermediate voltage has been reached (5) Intermediate circuit capacitors The intermediate circuit capacitors are used to smooth out and stabilise the rectified input voltage. (6) Power full bridge The power full bridge breaks the rectified intermediate circuit voltage into a 100kHz signal. The bridge circuit (with 4 power MOSFETs) is controlled with driver stages.
Pin assignment
X1 ...... (secondary), ribbon cable from UST (X6) Details on the pin assignment can be found in the chapter entitled „Detailed description“ - „UST“ in the section „Pin assignment X6“. X3 ...... TRANSF2 (primary voltage), connecting lead to welding transformer X4 ...... TRANSF1 (primary voltage), connecting lead to welding transformer X9 ...... (L1 - phase - primary voltage), connecting lead to mains switch X10 .... (N - neutral conductor - primary voltage), connecting lead to mains switch
31
Pin assignment (continued)
Measuring points
X28 .... (secondary voltage), voltage supply internal/external Pin
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
Measurement on each of the diode regions depicted below must produce a result of 0.4 V. The picture also shows the HS LED and the HLS LED (see following section „Control LEDs“).
HS LED
HLS LED
Fig. 7 Diode regions on the BPS 17 power module PC board
Further measuring points can be found in the chapter entitled „Detailed description“ „UST“ in the section „Pin assignment“.
32
LED checklist
Control LEDs on BPS 17 PC board
Uzwk
+15 Vp
HLS LED
+24 Vext
+24 Vint
HS LED
Fig. 8 Control LEDs on BPS 17 power module PC board
Uzwk ................. lights up when there is supply from the intermediate circuit LEDs for supply voltage: +15 Vp ............. lights up when switched mode power supply is working correctly +24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint ............ lights up when switched mode power supply is working correctly HS LED .......... lights up when the mains switch is in the „I“ position HLS LED ........ lights up when the high charging relay is activated
33
BPS 22 - Power module PC board General remarks
BPS 22 (item no. 4,070,799,Z) is the power module PC board for TT 2200 and MW 2200 power sources.
Overview
Still required
Technical data
Function overview
Input voltage
230 VAC (+15 % / -30 %)
Supply voltage from the power module
24 Vint (+/-20 %), 2.5 A 24 Vext (+/-20 %), 1.5 A 15 Vp (+10 %), 0.2 A
Components on the BPS 22 PC board
(1)
(2) (8)
(3)
(4)
(7)
(5)
(6)
Fig. 9 Components on the BPS 22 power module PC board
34
Function overview (continued)
The BPS 22 PC board includes the following components: (1) Line filter (2) High-charging circuit (3) Intermediate circuit capacitors (4) Rectifier (5) PFC (Power Factor Control) (6) Shunt (7) Power full bridge (8) Switched mode power supply (+24 V internal, +24 V external) (1) Line filter The line filter is located in the AC branch, and has a two-stage structure. The line filter serves to reduce the interference produced in the device for the for the mains lead. (2) High-charging circuit PTC resistors limit the starting current. The controller (UST PC board) dictates the high charging time. The expiry of a preset length of time plus a preset value for the intermediate circuit voltage are prerequisites for bridging the high charging resistors with relays. (3) Intermediate circuit capacitors The intermediate circuit capacitors are used to smooth out and stabilise the rectified input voltage. (4) Rectifier The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the intermediate circuit. (5) PFC (Power Factor Control) The Power Factor Control s a sinusoidal mains current input. Therefore, so that almost no reactive current occurs, the largest current input possible is possible from the single phase mains. (6) Shunt Measures the mains current for the PFC. (7) Power full bridge The power full bridge generates a 100kHz signal from the rectified intermediate circuit voltage. The bridge circuit (with 4 power MOSFETs) is controlled with driver stages. (8) Switched mode power supply The switched mode power supply is a flyback converter that is supplied by the intermediate circuit capacitors. The switched-mode power supply is synchronised at 65 kHz and provides the output voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); where the 15 Vp coil is for primary and only supplies the power for the PWM ICs of the power supply. The output voltages are electrically isolated from one another and fused with a PTC each.
35
Pin assignment
X1 ...... (secondary), ribbon cable from UST (X6) Details on the pin assignment can be found in the chapter entitled „Detailed description“ - „UST“ in the section „Pin assignment X6“. X3 ...... TRANSF2 (primary voltage), connecting lead to welding transformer X4 ...... TRANSF1 (primary voltage), connecting lead to welding transformer X9 ...... (L1 - phase - primary voltage), connecting lead to mains switch X10 .... (N - neutral conductor - primary voltage), connecting lead to mains switch X28 .... (secondary voltage), voltage supply internal/external Pin
Measuring points
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
Measurement on each of the diode regions depicted below must produce a result of 0.4 V.
Fig. 10 Diode regions on the BPS 22 power module PC board
Further measuring points can be found in the chapter entitled „Detailed description“ „UST“ in the section „Pin assignment“.
36
LED checklist
Control LEDs on BPS 22 PC board
PFC LED
Uzwk +15 Vp
HLS LED HS LED
+24 Vext
+24 Vint
Fig. 11 Control LEDs on BPS 22 power module PC board
Uzwk ................. lights up when there is supply from the intermediate circuit LEDs for supply voltage: +15 Vp ............. lights up when switched mode power supply is working correctly +24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint ............ lights up when switched mode power supply is working correctly HS LED .......... lights up when the mains switch is in the „I“ position HLS LED ........ lights up when the high charging relay is activated PFC LED ........ lights up or flashes with varying degrees of brightness depending on power drawn. High brightness equals high power.
37
HFF 22 - High frequency ignition unit, input filter General remarks
HFF 22 (item number 4,070,812,Z) is used for high frequency ignition in the MW 1700 and MW 2200 power sources and is also a filter assignment for remote controls and torch triggers.
Overview
HF module
Filter module
Fig. 25 HFF 22
38
Function overview
Supply voltage
+ 24 VDC (+/- 20 %)
Output voltage
1000 VDC
The HFF 22 PC board includes the following components:
(1) HF module From the +24 V supply (24 V LED green), the HF module generates a +15 V supply (+15 V LED green) for the internal control module. A flyback converter charging circuit charges the impulse capacitor from +24 V to 1000 V. Immediately after charging the ignition thyristor is activated and the impulse capacitor discharges the HF launch coil via the primary coil The HF launch coil transforms the charge voltage of the impulse capacitor from 1000 V to approx. 10 kV. Each charging process of the impulse capacitor is indicated by the SIG LED (red) lighting up.
(2) Filter module The filter module comprises two 6-pin, current-compensated filter chokes (one choke each for remote control and torch trigger). The filter chokes eliminate high-frequency impulses on the data lines caused by parasitic capacities. A circuit layout of capacitors and Transil arrays (protective diodes) is used for discharging overvoltage of the data lines.
39
Pin assignment (X3)
(X1)
(X2)
(X5)
(X4)
(X6)
(X7)
Fig. 26 Pin assignment on HFF 22 PC board
40
Pin assignment (continued)
X1 ...... HF pulse positive pole (blade terminal connection to primary voltage of the HF launch coil X2 ...... HF pulse negative pole (blade terminal connection to primary voltage of the HF launch coil)
X3 ...... High frequency control cables (connection to UST) Pin
Designation
Pin
Designation
1
NC
3
SIGNAL
2
+ 24 V
4
GND
X4 ...... Torch trigger cables (connection to UST) Pin
Designation
Pin
Designation
1
NC
6
NC
2
DOWN
7
NC
3
CRATERFILL
8
IDENTIF
4
UP
9
GND
5
MAIN CURR
10
NC
X5 ...... Torch trigger cables (connection to welding torch) Pin
Designation
Pin
Designation
1
NC
6
NC
2
DOWN
7
NC
3
CRATERFILL
8
IDENTIF
4
UP
9
GND
5
MAIN CURR
10
NC
X6 ...... Remote control cables (connection to remote control) Pin
Designation
Pin
Designation
1
+24 V EXT
4
GND 485
2
RXDL 485
5
TXDL 485
3
RXDH 485
6
TXDH 485
X7 ...... Remote control cables (connection to UST) Pin
Designation
Pin
Designation
1
+24 V EXT
4
GND 485
2
TXDL 485
5
RXDL 485
3
TXDH 485
6
RXDH 485
41
NTFK 24 - Switched mode power supply for cooling unit General remarks
Function overview
NTFK 24 (item number 4,070,819,Z) is the switched mode power supply for the FK 2200 cooling unit.
Range of input voltage
140 VAC... 280 VAC 200 VDC... 400 VDC
Output voltage
24 V (+/- 1 V), 5.5 A (max. 30 V in idle)
Max. current
5.5 A (fused with PTCs)
The NTFK 22 PC board includes the following components:
(1) Charging circuit When switched on, NTC resistors limit the charging current. The resistors R58 and R59 are NTCs and have a high ohm rating during operation. An external glass-tube fuse of 4 A (slow-blow fuse) is required, as NTCs do not limit fault current when it occurs.
(2) Control If the pin X3:2 (=/cooler on) is set to signal ground, the cooling unit starts.
(3) Control of the fan and coolant pump The +24 V supply is fused with PTCs. The PTCs become highly resistant when there is a overcurrent. This process depends on the level of overload and the ambient temperature (5.5 A at 60 °C).
42
Function overview (continued)
(4) Flow controller and undervoltage control If no flow monitor is present, pin X1/2 (/water ctrl.sig.) is switched to signal ground (GND) via a short circuit jumper. The undervoltage detector of the coolant pump is also coupled to the flow controller. If the supply voltage of the coolant pump is lower than 20 V, (e.g the pump is blocked), a message to the UST controller board is sent (service code). The flow monitor is powered from the power source. The signal voltages at pins X3 and X1, as well as the supply voltage of the coolant pump are electrically isolated from one another.
Pin assignment
X1 ...... Flow monitor connection Pin
Pin
Designation
Designation
1
+24V flow monitor supply
3
GND
2
Flow monitor signal (low active)
4
GND
X2 ...... Mains voltage (fused with external glass-tube F1, 4 A - slow blow) Pin 1
Designation
Pin
Phase
2
Designation Neutral conductor
X3 ...... Connection to power source Pin
Designation
Pin
Designation
1
NC
6
NC
2
/Cooler on 0 V = cooling unit on
7
+ 24 V - Control supply voltage from the power source
3
/Watercontrol 0 V = coolant flow and supply voltage of the cooling unit OK
8
GND water control - GND of the supply voltage from the power source
4
NC
9
NC
5
NC
10
43
GND (+ 24 V) - GND of the supply voltage from the power source
Pin assignment (continued)
Measuring points
X4 ...... Connection for fan and coolant pump of the cooling unit Pin
Designation
Pin
Designation
1
+ 24 V coolant pump
4
GND coolant pump
2
+24 V Fan
5
GND fan
3
LED+, external control LED
6
GND LED
See pin assignment
LED checklist +15 VP
Power
+24 VOK +24 V
ON Fig. 31 Control LEDs on NTFK 24 PC board
Power ............. + 15 VP ........... +24 VOK ......... +24 V .............. ON ..................
Mains voltage present Supply for PWM IC present The supply voltage to the coolant pump is greater than 20 V Pump and fan voltage present External signal for switching on the coolant pump is present
44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 General remarks
The secondary power module for the TransTig 800 / 2200, MagicWave 1700 / 2200 and PlasmaModule 10 power sources contains the following number(s) of diode modules (item number 41,0003,0203): Secondary rectifier 1 diode module (PlasmaModule 10) 2 diode modules (TT 800 / 2200) 4 diode modules (MW 1700 / 2200) Inverter previous version consisting of MW 2200 inverter checked (item number 41,0003,0282,Z) new version from serial number 17352516 comprising 4 IGBT transistor modules (item number 41,0003,0279) and PC board FMW22IS (item number 4,070,949,Z)
Function overview
The rectifier generates DC from the AC from the welding transformer. Important: The following description only applies to MagicWave 1700 / 2200 power sources. The transistor modules on the inverter module convert the DC to AC, which is then sent to the welding sockets. The transistor modules are controlled by the TTS 22 PC board. On the FMW 22 IS PC board the integrated suppressor diodes protect the inverter transistors from excessive voltages from the welding circuit.
Pin assignment
Important: The following description only applies to MagicWave 1700 / 2200 power sources. X8 ...... Connection from inverter module to TTS 22.
Measuring points
Measurements taken on the diode regions depicted below must produce approximately the following results: approx. 0.4 V at the suppressor diodes on the inverter module (A) (measuring points can be found in the following picture). approx. 0.15 V at the rectifier diodes (B) (measuring points can be found in „Pin assignment“ section). Torques: - Copper clips and PC board on power semiconductors: 1.5 Nm - Power semiconductors on heat sink: 2.1 Nm
45
Measuring points (continued)
(B)
(B)
(A)
Welding current LED Welding current LED 0.15 V
(B)
0.15 V
0.4 V
(B)
0.15 V
0.15 V
Fig. 39 Diode regions on secondary power module, previous version
Important: TransTig 800 / 2200 power sources only offer two diode modules and the PlasmaModule 10 only offers one. On the TransTig 800 and PM 10 power sources the single diode is fitted on the top left. On the TransTig 2200 the two diodes are fitted on the left. On the MagicWave 1700 / 2200 power sources all 4 diodes are fitted. The temperature sensor can be found between the diode modules, where the connecting leads of the temperature sensor run off to the left. Welding current LED Welding current LED
(B)
(B)
(B) 0.15 V (B) (B)
0.15 V (B)
0.15 V33 (B)
0.15 V 0.15 V
0.15 V
0.15 V (B)
Fig.40 Diode regions on secondary power module, new version
LED checklist
See „Measuring points“ section
46
0.15 V
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 General remarks
The shunt (item number 43,0001,1191) is a current sensor and is used on the TransTig and MagicWave 1700 / 2200 power sources for electrically isolated capture of the welding current.
Fig.43 Shunt for capturing welding current
Function overview
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 welding current transmission ratio is 1:2000.
Pin assignment
X1 ...... Molex plug from adapter cable Pin
Measuring points
Pin
Designation
Designation
1
NC
5
NC
2
NC
6
NC
3
Iact 100 A gives 0.33 V
7
GND
4
- 15 V
8
+ 15 V
The welding current can be captured indirectly using by measuring the voltage. With a welding current of 100 A for example, there should be a voltage of 0.33 V measured: - Either on the Molex plug of the adapter cable, pin 3 and pin 7 - On UST PC board, Molex plug X4, pin 5 and pin 17
47
Important
Various versions of the shunt are in use. NOTE! To prevent malfunctions, and to exclude the possibility of damage to other parts in the power source, use only the adapter cable supplied.
Technical data
Supply voltage
+15 V /- 15 V
Nominal current
Function overview
500 A
Output current at nominal current
250 mA
Transformation ratio
1 : 2000
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 welding current transmission ratio is 1:2000. Other functions: Electric isolation between power 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
Pin assignment
Plug
Function
X1
Molex plug from adapter cable
Pin 1 Pin 2
+15 V -15 V
Pin 3 Pin 4
I Real GND
LED checklist
There are no LED indicators on the shunt.
Measuring points
The welding current can be captured indirectly using by measuring the voltage. 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 set value
Welding current
X4/5 - X4/17
0.33 V at a welding current of 100 A
NOTE! To prevent malfunctions, and to exclude the possibility of damage to other parts in the power source, use only the adapter cable supplied.
48
TP 592S temperature sensor 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 has a plug-in Molex connection.
General remarks
Fig. 45 TP 592S temperature sensor
Technical data
Function overview
Supply voltage
4 - 30 V DC
Output current
1 µA/K
-
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 assignment
Measuring points
Plug
Function
X1
2-pin Molex plug
Pin 1
Temp. 1+
Pin 2
Temp. 1-
Measure the current flowing through the temperature sensor as follows: Remove lead at pin 1 from Molex plug using Molex extractor tool. Connect 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 „Functional description“.
49
TTS 22 - IGBT driver and auxiliary power source General remarks
The TTS 22 PC board (item number 4,070,804) fulfills the function of an IGBT driver and an auxiliary power source.
Overview Negative ignition
Positive ignition
Error + 24 V + 18 V +6V
Fig. 46 TTS 22
Technical data
Supply voltage
Function overview
The TTS 22 controls the polarity of the welding current and the auxiliary power source. The auxiliary power source allows the arc to be reignited. The TTS 22 and FMW PC boards work in tandem.
24 V DC
The TTS 22 generates two independent voltages (+5V and +18V) for PC board control from the +24V supply voltage. The control unit conditions the control signals (polarity of welding current and reignition) and is used to electrically isolate and forward the signals to the relevant transistor module (IGBT). The process is displayed: - On the „neg ignition“ and „pos. ignition“ LEDs for the auxiliary power source - On the FMW PC board „LED +“ and „LED -“ for the polarity of the welding current The welding voltage is also measured. If the welding voltage should fall outside the permitted range, the following occurs: - Inverter control signal goes to „Stop“ - 18V PC board supply stopped: „+18 V“ LED goes out - Error LED (red) lights up - Error signal „X7:4“ to UST PC board active (low signal)
50
Pin assignment
X1 ...... Common X2 ...... AC, alternating voltage for positive half wave X3 ...... AC, alternating voltage for positive half wave X4 ...... AC, alternating voltage for negative half wave X5 ...... AC, alternating voltage for negative half wave X6 ...... Connection to FMW22 PC board X7 ...... Connection to UST PC board X8 ...... Measurement of welding voltage Pin 1
Designation
Pin
Uact-
2
Designation Uact+
X9 ...... Connection to control (UST PC board) Pin 1
Designation
Pin
Uact-
Measuring points
See pin assignment
LED checklist
See overview
2
51
Designation Uact+
UST - Control and regulation unit General remarks
The UST PC board (item number 4,070,860,Z) is a universal control, regulation and monitoring unit for fully digitised Fronius power sources.
Function overview
The UST PC board performs the following functions: (1) Power module control The control of the power module is performed by the UST via plug X6; the driver circuits are on the UST. (2) Control of control The UST controls the control via a 10-pin ribbon cable (X2). The control is handled via a databus connection (LocalNet) (3) Mains switch evaluation The UST evaluates the incoming mains switch signal from the BPS PC board. If the intermediate circuit voltage reaches a certain level, the relays close after a specified time. The UST uses the mains switch signal to detect when the power source is switched off. The UST stores the current settings and activates the fans to discharge the intermediate circuit. (4) Temperature evaluation The UST evaluates the signals from the temperature sensors and controls the fans. If the temperature continues to rises and the fans cannot cool sufficiently (e.g. because the duty cycle is exceeded), the power source switches off and outputs an appropriate service code. (5) Control of fan The UST controls the fan (X5) depending on temperature and firmware. (6) LocalNet interface The LocalNet interface is used to transmit data from the plug connection (X9) to the peripheral devices via the filter PC board (e.g. HFF22). (7) Regulation of welding current and voltage The welding current and voltage is regulated by the DSP (digital signal processor) and the firmware integrated in the UST. (8) Control of inverter The UST PC board controls the inverter module via the plug (X1).
52
Pin assignment
X1 ...... Inverter control (connection to TTS 22) X2 ...... Connection to control (10-pin ribbon cable) X3 ...... Supply Pin
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
X4 ...... Temperature; Uact, Iact Pin
Designation
Pin
Designation
1
Uact -
13
U ACT +
2
NC
14
NC
3
LEM C 4000, Shunt
15
LEM D 5000
4
LEM A 3000, Shunt
16
NC
5
LEM B 2000, Shunt
17
GNDD LEM
6
- 15 V LEM
18
+ 15 V LEM
7
TH - ERROR 1
19
TH - ERROR 2
8
GND A (UP 400)
20
UP 400
9
CFM-
21
CFM+
10
ESC 1
22
ESC 2
11
TEMP 2 -
23
TEMP 2 +
12
TEMP 1 -
24
TEMP 1 +
X5 ...... Fan Pin
Designation
Pin
Designation
1
+ 24 V
3
+ 24 V
2
FAN, fan power module
4
FAN, fan control unit
X6 ...... Powersource - connection to power module (BPS), 26-pin ribbon cable X7 ...... Cooling unit Pin
Designation
Pin
Designation
1
Temp 6 +
6
TEMP 6 -
2
COOLER ON
7
+ 24 V
3
WAT. CONTR.
8
GND (WAT. CONTR.)
4
CFM+
9
CFM-
5
NC
10
53
GND (SUPPLY)
Pin assignment (continued)
X8 ...... Programming interface for updating firmware via BSL tool NOTE! Risk of damage to electronic components. Switch off the power supply before connecting or removing BSL tools. X9 ...... RS485 connection to remote control via a filter PC board
Measuring points
See pin assignment
LED checklist
+24 Vext +24 Vint + 5V +15 V - 15 V
STAT
+ 5V
Fig.47 Control LEDs on UST PC board
+24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint + 5V ................ RS 485 +15 V - 15 V + 5V STAT .............. Status LED lights up if no firmware is present if it does not light up: process OK
Change 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.
54
Changing modules General remarks
The „Changing modules“ chapter describes how to replace components that have no instructions of their own for replacement and require detailed replacement instructions NOTE! Danger of damage to threads, especially when fastening screws with power tools (e.g. power screwdrivers). In order to avoid damage to threads, proceed as follows: - Turn screws slightly to the left to guarantee optimum centring. - Screw in at least two full turns by hand. This prevents the screw from forming a new thread: - Carefully tighten the screw
Overview
The „Replacing components“ section contains the following subsections: Housing unit Changing BPS 17 PC board (Refer to the installation instructions for the BPS 17 PC board) Changing BPS 22 PC board (Refer to the installation instructions for the BPS 22 PC board) Changing inverter module (Refer to the installation instructions for the inverter module) Changing the TP 592S temperature sensor Changing the TTS 22 PC board Changing the BSV 22 PC board Changing earth current watchdog Changing the transformer
55
Housing unit General remarks
The section headed „Housing“ covers the opening and closing of the housing for the replacement operations described below.
-
Opening the housing
-
(1)
(1)
Undo screws (1) on both sides of the power source for the side s. Take off side s
(1)
Fig. 1 Removing housing side s
(2)
NOTE! After removing the screws (2), ensure that the control does not fall out of the frame.
(2)
-
Undo front screws (2)
-
Undo rear screws (3)
Fig. 2 Removing front screws
(3)
(3)
Fig. 3 Undoing rear screws
56
Opening the housing (continued)
(7) (4)
(4)
If handle is present, remove holder on one side as follows: Undo screws (4) on the holder for the handle
Fig. 4 Removing screws for handle holder
(5) (6)
Remove the cover as follows: Lift the handle (5) and holder (6) slightly Remove the cover (7) (Fig. 4)
Fig. 5 Removing handle holder
Closing the housing
(7) (4)
(6)
(4)
-
Fit cover (7) If present, replace handle (6) with holder (5) and fasten with two screws (4).
-
Tighten front screws (2)
Fig. 6 Replacing cover and fastening handle
(2)
(2)
Fig. 7 Tightening front screws
57
Closing the housing (continued)
(3)
Tighten rear screws (3)
(3)
Fig. 8 Tightening rear screws
WARNING!Danger of electric shock due to insufficient insulation of the housing. Every electric shock is potentially life threatening. Before fitting the side , lay down the sheet for insulating the PC boards behind the side on the side of BPS 17/22 PC board. -
(1)
(1)
(1)
Fig. 9 Fastening the housing side s
58
On both sides of the power source replace side s and fasten with screws (1)
Changing BPS 17 PC board Instructions
When changing the BPS 17 PC board, always follow the installation instructions supplied with the board.
Changing BPS 22 PC board Instructions
When changing the BPS 22 PC board, always follow the installation instructions supplied with the board.
Changing inverter module Instructions
When changing the inverter module, always follow the installation instructions supplied with the module.
Changing the TP 592S temperature sensor Instructions
The temperature sensor is plugged in but can be lifted out by carefully using an ordinary screwdriver or pulled out with flat pliers. Before inserting the new temperature sensor, fill the hole for the sensor with heat conductive paste to ensure perfect heat transfer. If the temperature sensor is covered by other parts, please refer to instructions for removing the part concerned, and see the special instructions in the „Changing components“ section, if available.
59
Changing the TTS 22 PC board ESD measures
NOTE! There is danger of damage to the TTS 22 PC board from electrical discharge. When changing the TTS 22, take appropriate ESD (electrostatic discharge) measures. These include: -
-
The workspace used when removing the board must be equipped with the following ESD-appropriate protective measures: - Work surfaces - Floors - Conductive wristband - Seating In addition to the ESD-appropriate workspace, use a suitable transport container
Changing the TTS 22 PC board
(2)
(1) (2) (1)
(11)
(1) Fig. 1 UST: remove plug connections and unscrew spacers
UST PC board: Remove plug connections (1) Unscrew the 5 spacers (2) and metal spacer (11) Remove UST PC board
60
Changing the TTS 22 PC board (continued)
(4)
-
Unscrew the two spacers (4) on the insulating sheet
-
Remove Molex plug (5) and blade terminal (6) from the TTS 22 PC board
-
Undo two spacers (3) and four screws (9)
-
Remove TTS 22 PC board (7) complete with retaining plate (10) Undo five spacers (8) on TTS 22 PC board Remove TTS 22 PC board (7) from retaining plate (10)
(4)
Fig. 2 Loosening the spacers
(6)
(5)
Fig. 3 Removing plug connections from sockets
(9) (3)
(9)
(9)
(3)
(9)
Fig. 4 Undoing screws and spacers
(8)
(10)
(7) Fig. 5 Removing TTS 22 PC board and spacers
61
Installing the TTS 22 PC board
-
Place the TTS 22 (7) on the spacers (8) on the retaining plate -
Screw in the five spacers (8) on TTS 22 PC board Replace TTS 22 PC board (7) complete with retaining plate
(8)
(7) Fig. 6 Fasten TTS 22 PC board with spacers
-
Fasten the TTS 22 PC board complete with retaining plate using the two spacers (3) and four screws (9)
-
Insert Molex plug (5) on TTS 22 PC board
(9) (3)
(9)
(9)
(3)
(9)
Fig. 7 Tighten screws and spacers
Important: When inserting the five blade terminals (6), proceed as follows: Insert the individual blade terminals to „Common X1“ slot The remaining blade terminals bound in pairs with silicone tubing can be inserted arbitrarily into the remaining slots. The only requirement is that blade terminals are inserted in pairs into either X2/X3 or X4/X5. (5)
(6)
Fig. 8 Inserting plugs into sockets
-
(4)
(4)
Fig. 9 Tightening spacers
62
Screw in the two spacers (4) on the insulating sheet
Installing the TTS 22 PC board (continued)
-
Lay down UST PC board
Fig. 10 Laying down UST PC board
(2)
(1)
(2)
(1)
(11)
(1) Fig. 11 UST: reinserting plug connections and tightening spacers
UST PC board: - reinsert plug connections (1) NOTE! When tightening the spacers (2), screw metal spacer into position (11). -
Tighten the 5 spacers (2) and metal spacer (11)
63
Changing the BSV 22 PC board ESD measures
NOTE! There is danger of damage to the BSV 22 PC board from electrical discharge. When changing the BSV 22, take appropriate ESD (electrostatic discharge) measures. This includes: -
-
The workspace used when removing the board must be equipped with the following ESD-appropriate protective measures: - Work surfaces - Floors - Conductive wristband - Seating In addition to the ESD-appropriate workspace, use a suitable transport container
Removing the BSV 22 PC board
(2)
(1) (2) (1)
(11)
(1) Fig. 1 UST: remove plug connections and unscrew spacers
UST PC board: Remove plug connections (1) Unscrew the 5 spacers (2) and metal spacer (11) Remove UST PC board
64
Removing the BSV 22 PC board (continued)
(4)
-
Unscrew the two spacers (4) on the insulating sheet
-
Remove Molex plug (5) and blade terminal (6) from the BSV 22 PC board
-
Undo two spacers (3) and four screws (9)
-
Remove BSV 22 PC board (7) complete with retaining plate (10) Undo the four spacers (8) on BSV 22 PC board Remove BSV 22 PC board (7) from retaining plate (10)
(4)
Fig. 2 Loosening the spacers
(5)
(6)
Fig. 3 Removing plug connections from sockets
(9) (3)
(9)
(9)
(3)
(9)
Fig. 4 Undoing screws and spacers
(8)
(7) (8)
(10)
-
(8)
(8)
Fig. 5 Removing BSV 22 PC board and spacers
65
Installing the BSV 22 PC board
-
Place the BSV 22 (7) on the spacers (8) on the retaining plate (8)
(7) (8)
(10)
-
(8)
Tighten the four spacers (8) on BSV 22 PC board (7) Replace BSV 22 PC board (7) complete with retaining plate
(8)
Fig. 6 Fasten BSV 22 PC board with spacers
-
Fasten the BSV 22 PC board complete with retaining plate using the two spacers (3) and four screws (9)
-
Insert Molex plug (5) into BSV 22 PC board X9 Insert blade terminals X1 to X4 (6) as labelled on the cables and on BSV 22 PC board.
(9) (3)
(9)
(9)
(3)
(9)
Fig. 7 Tightening screws and spacers
(5)
(6)
-
Fig. 8 Inserting plugs into sockets
-
(4)
(4)
Fig. 9 Tightening spacers
66
Screw in the two spacers (4) on the insulating sheet
Installing the BSV 22 PC board (continued)
-
Lay down UST PC board
Fig. 10 Laying down UST PC board
Installing UST PC board
(2)
(1)
(2)
(1)
(11)
(1) Fig. 11 UST: reinserting plug connections and tightening spacers
UST PC board: - reinsert plug connections (1) NOTE! When tightening the spacers (2), screw metal spacer into position (11). -
Tighten the 5 spacers (2) and metal spacer (11)
67
Changing the transformer Removing the transformer
(1)
-
Undo two front screws (1) for the device frame
-
Disconnect the ribbon cable (2) for the control at X2 on the UST PC board Remove the control
(1)
Fig. 1 Undoing screws on front of device frame
(2)
Fig. 2 UST: Disconnecting the ribbon cable
-
(3)
Fig. 3 BPS: Disconnecting the ribbon cable
68
Disconnect ribbon cable (3) from BPS PC board
Removing the transformer (continued)
-
Undo the two screws (4) on HF transformer (5)
-
Lift high frequency (HF) transformer (5) and undo two screws (6) behind the HF transformer.
-
Remove secondary transformer leads (7): Unscrew the two screws with serrated washers (not shown)
-
Cut cable tie on the secondary transformer lead (7) (cable tie no shown) Remove toroidal tape cores (8) from the transformer leads
(5) (4)
Fig. 4 HF transformer: removing screws
(5)
(6) Fig. 5 Loosening the two screws behind the HF transformer
(7)
Fig. 6 Removing the secondary transformer leads
-
(8)
(7)
Fig. 7 Removing toroidal tape cores
69
Removing the transformer (continued)
(12) (10)
Undo hexagon bolt (9) using a size 19 spanner Remove hexagon bolt (9) with serrated washer and shim
The following leads are now disconnected: Middle tap transformer lead (10) Measuring line (11) - white cable with „Massebuchse“ written on it Secondary wiring lead (12) - white cable with no writing
(11) (9)
Fig. 8 Removing the middle tap transformer lead
(13)
-
Undo spacers (13)
-
Remove blade terminals X2 to X5 (15) Remove blade terminal „X1 common“ (16) from the measuring line for welding voltage. Cut cable tie for the measuring line (16) - Fig. 11
(13)
Fig. 9 Loosening the spacers
(15)
(16)
-
-
Fig. 10 Removing blade terminal for the measuring lines
70
Removing the transformer (continued)
(18)
-
(16)
Remove measuring lead (16) for the welding voltage Feed out the middle tap transformer lead (17) on the current sensor (18)
(17)
Fig. 11 Feeding out the middle tap transformer lead
-
Loosen the two screws (19) on the luster terminal Remove primary leads (20) Undo screw (21)
-
Undo screws (22)
(20) (21) (19)
Fig. 12 Disconnect primary transformer leads
Important: undo the three screws (22) on earth wire, if present.
(22)
Fig. 13 Undo screws on transformer
(24) (23)
(25)
(22) Fig. 14 Removing the transformer
71
Remove transformer (22) Cut through cable ties (23) and (24) on transformer
Removing the transformer (continued)
-
Unthread the middle tap transformer lead (17) on the EP rings (25) (see also Fig. 14)
-
Undo the four screws (26) on the transformer and remove the side plates (27)
(25) (17) Fig. 15 Feeding out the middle tap transformer lead
(27)
(26)
(27) Fig. 16 Removing the plates on the transformer
Installing the transformer
-
Fasten side plates (27) to the transformer using the four screws (26) (24) (23)
(25)
(22) Fig. 17 Routing the middle tap transformer lead
72
Thread EP rings (25) onto the middle tap transformer lead (17) and make two winds Fasten EP rings (25) and middle tap transformer lead (17) with cable ties
Installing the transformer (continued)
-
Installing the transformer (22) into the power source -
Tighten screws (22)
Important: If earth wire is present tighten the three screws (22) and fasten earth wire using the central screw (22).
(22)
Fig. 18 Securing the transformer
(16) (17)
Fig. 19 Routing leads
Route leads as follows and fix with cable tie: Along route 16 (fig. 19): Measuring line (16) for the blade terminal „X1 common“ (single lead) Along route 17 (fig. 19 and 20): Feed in auxiliary power source leads for the blade terminals X2 to X5 (leads bound in pairs)
(17)
Fig. 20 Routing auxiliary power source leads
Important: The position of the primary transformer leads (20) on the luster terminals is not important.
(20) (21)
(19) Fig. 21 Connecting primary transformer leads
73
-
Insert transformer leads (20) into the luster terminals and fix with screws (19) Fix luster terminals and insulation with screws (21) Bind leads with cable tie
Installing the transformer (continued)
(18) -
(16)
Feed middle tap transformer lead (17) in direction of arrow through the current sensor (18) Route measuring line (16) for the blade terminal „X1 common“ (see fig. 19)
(17)
Fig. 22 Routing transformer lead
(15)
(16)
When inserting the five blade terminals (15, 16), proceed as follows: Insert the individual blade terminals (16) to „Common X1“ slot The remaining blade terminals (15) bound in pairs with silicone tubing can be inserted arbitrarily into the remaining slots. The only requirement is that blade terminals are inserted in pairs into either X2/X3 or X4/X5.
Fig. 23 Removing blade terminal for the measuring lines
-
(13)
(13)
Fig. 24 Tightening spacers
74
Tighten the two spacers (13) on the insulating sheet
Installing the transformer (continued) (12) (10) (11) (9)
(9)
(29) (30) (11) (12) (10) Fig. 25 Fitting the middle tap transformer lead
Align the following components on the hexagon bolt (9) in the numbered order: Serrated washer (29) Shim (30) Measuring line (11) - white cable with „Massebuchse“ written on it Secondary wiring lead (12) - white cable with no writing Middle tap transformer lead (10) Tighten hexagon bolt (9) using a size 19 spanner NOTE! When aligning the secondary transformer leads (7), ensure that the toroidal tape cores are in the airstream (for correct position in airstream see fig. 28) and that they are held in place with cable ties.
(8)
(7)
Fig. 26 Fitting toroidal tape cores
(31) (7)
Fig. 27 Fastening secondary transformer leads
NOTE!When tightening the screws with serrated washers for the secondary voltage of the transformer, maintain the tightening torque given below. -
Slide the serrated washers onto the fastening screws (not shown). Fasten the secondary transformer leads (7): Tighten the screws (31) including serrated washers (not shown) with a torque of 4 Nm.
75
Installing the transformer (continued)
(5)
-
Lift high frequency (HF) transformer (5) and tighten two screws (6) behind the HF transformer
-
Replace HF transformer and tighten the two screws (4)
-
Connect ribbon cable (3) from BPS PC board
(6) Fig. 28 Tightening the two screws behind the HF transformer
(4)
Fig.29 HF transformer: tightening screws
(3)
Fig. 30 BPS: connecting the ribbon cable
NOTE! Danger of malfunction during high frequency welding. When routing the ribbon cable (2), ensure that there is enough distance between it and the HF leads (32).
(32)
(2)
Fig. 31 shows the correct routing of the ribbon cable (2). X2 Fig. 31 UST: connecting the ribbon cable
-
Connect the ribbon cable (2) for the control at X2 on the UST PC board Insert the operating
76
Installing the transformer (continued)
-
(1)
(1)
Fig. 32 Screws on front of device frame
77
Press front of frame on Tighten two front screws (1) for the device frame
Safety Inspection Requirement
A safety inspection must be carried out - after every repair - after every modification - at specified intervals (at least once every 12 months)
Work instruction
The work instruction „Safety Inspection of Arc Welding and Cutting Equipment“ is available in the TechGuide Center under „Safety, Environment & Health“.
78
and abbreviations used General remarks
„ and abbreviations“ is a glossary of specific technical essential for an understanding of the service manual.
and abbreviations
BSL tool: The BSL tool is a special tool for updating the power source with new firmware. A PC or notebook is required for the update. Config memory (CFM): The CFM component supplements the UST PC board firmware (central control and regulation unit) with individual, device-specific data. DSP: Digital SignalProcessor. Part of the UST PC board (central control and regulation unit). The DSP captures digitised actual values on the part of the welding process, and ensures constant regulation and optimisation of the welding current and voltage, on the basis of the parameters set the saved firmware the actual values measured EMI: ElectroMagnetic Interference. Electromagnetic interference is high-frequency noise in the mains voltage. The line filter absorbs this noise and thereby ensures optimum welding results and trouble-free operation of the power source. FAC: Factory resets the settings in the setup menu. The original factory settings are restored by pressing and holding the „Store“ button for two seconds. The welding machine has been reset when the display reads „PrG“. Jobs and parameters in the second level of the set-up menu are not deleted. Hall shunt: Ensures electrically isolated measuring of the welding current. The UST (central control and regulation unit) analyses the signal. IGBT: Insulated Gate Bipolar Transistor. This is a special bipolar transistor for switching to high power settings. IGBTs are used in the power source as modules. On the TT/MW 1700/ 2200 power sources, IGBT modules are used in a secondary role to prepare the welding current for AC welding. Instruction pointer: When a software error appears: the third level of the display contains more detailed information on the cause of the error (see „Error location aid“ chapter) LocalNet RS232 converter: For connecting the power source to the serial interface on a PC, for: ing software options transmitting data from the power source using PC-based software (Fronius Backup, Fronius Service Module, Job-Explorer, etc.)
79
80
TransTig 800
TransTig 2200
MagicWave 1700
MagicWave 2200
PlasmaModule 10
FK 2200
MagicWave 2200 Job G/F MagicWave 2200 Job G/F/US TransTig 800 Job G/F TransTig 2200 Job G/F TransTig 2200 Job G/F/US MagicWave 1700 Job G/F MagicWave 1700 Job G/F/US
4,075,119 4,075,119,800 4,075,159 4,075,120 4,075,120,800 4,075,121 4,075,121,800
MagicWave 2200 G/F MagicWave 2200 G/F/US TransTig 2200 G/F TransTig 2200 G/F/US MagicWave 1700 G/F MagicWave 1700 G/F/US
4,075,125 4,075,125,800 4,075,126 4,075,126,800 4,075,127 4,075,127,800
12,0405,0369 42,0201,1328 42,0406,0320
43,0004,1993 - US 43,0004,0519
AM2,0201,1327 43,0002,0295 42,0300,0648
45,0200,1151
42,0409,2979 - US 42,0409,2911 42,0001,3541 - US 43,0013,0015 BE2,0201,1329
42,0407,0273 40,0001,0310 - *
12,0405,0365 33,0005,4146 - TT800 33,0005,4130 - MW1700 33,0005,4129 - MW/TT2200
43,0006,0152 - MW2200 43,0006,0134 - MW1700/TT800/2200
42,0405,0421 41,0003,0282,Z - MW 1700/2200
2IS W2 FM
4,070,949 - FMW22IS 41,0003,0279 12,0405,0365
41,0003,0203
33,0010,0326
43,0001,0600
43,0001,1177 43,0001,1176 - TT 43,0001,3280 - TT 2200 43,0001,3279 - MW1700/2200 43,0001,3258 - TT800/2200 Job 43,0001,3259 - MW1700/2200 Job 42,0406,0315 42,0406,0093
42,0409,3211 - TT800 42,0409,2935 - TT2200 42,0409,2934 - MW1700 42,0409,2882 - MW2200
43,0001,1178 43,0001,1273 TT800
42,0405,0398 - MW1700/2200 42,0405,0399 - TT2200
42,0001,1501
43,0004,2328
42,0001,5477
43,0004,2330
* gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée * Indicar la longitud deseada * Indicare la lunghezza desiderat * indicar o comprimento desejado
XYHG WHSRåDGRYDQRXGpONX
32,0405,0183 42,0404,0024
TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_wi_00545
1/2 012007
4,070,798,Z - BPS17 MW 1700/TT 800 4,070,799,Z - BPS22 TT/MW 2200
4,070,813 - BSV22 TT2200 4,070,804,Z - TTS22 MW1700/2200 41,0001,0627 41,0009,0057
S
2 S2 TT 22 V BS
33,0024,0032 33,0010,0325 - MW/TT2200
BP
43,0006,0168
43,0001,1191 42,0405,0420 4,070,960,Z - UST2C HF
F2
2
43,0004,1122 - 26pol.
US
T2
4,070,812 - HFF22
TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_wi_00545
2/2 012007
FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: [email protected] www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations.
ud_fr_st_so_00082
012008
GB
Service Manual Spare Parts List TIG power source
42,0410,1121
012008
Contents Foreword and safety instructions .................................................................................................................. Safety ....................................................................................................................................................... Tech National (TSN) .................................................................................................................... General remarks ...................................................................................................................................... Tools and measuring devices ................................................................................................................... Function overview .................................................................................................................................... Error location aid ...................................................................................................................................... Detailed description .................................................................................................................................. Replacing components ............................................................................................................................. and abbreviations used ................................................................................................................. Spare parts list and entire circuit diagram ................................................................................................
4 4 4 4 5 5 5 5 5 5 5
Tools and measuring devices ........................................................................................................................ General remarks ...................................................................................................................................... Tools required .......................................................................................................................................... Measuring equipment, inspection equipment ........................................................................................... Ancillary materials ....................................................................................................................................
6 6 6 7 7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 ................................................... General remarks ...................................................................................................................................... Block diagram .......................................................................................................................................... Block diagram legend...............................................................................................................................
8 8 8 9
Error location aid ......................................................................................................................................... 10 General remarks .................................................................................................................................... 10 Error flowchart .............................................................................................................................................. 11 Overview ................................................................................................................................................. 11 Poor ignition and welding properties with TIG welding ........................................................................... 12 Poor ignition and welding properties with MMA welding ......................................................................... 13 No or incorrect welding current .............................................................................................................. 14 No lights on control ....................................................................................................................... 15 Inadequate welding torch cooling (FK 2200) .......................................................................................... 19 Open circuit voltage +50 V faulty ............................................................................................................ 21 UST service codes ...................................................................................................................................... Safety ..................................................................................................................................................... Table of service codes ........................................................................................................................... Special indications used with service codes ...........................................................................................
22 22 22 28
Detailed description ..................................................................................................................................... 29 General remarks .................................................................................................................................... 29 Overview ................................................................................................................................................ 29 BPS 17 - Power module PC board .............................................................................................................. General remarks .................................................................................................................................... Overview ................................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
30 30 30 30 31 32 33
BPS 22 - Power module PC board .............................................................................................................. General remarks .................................................................................................................................... Overview ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
34 34 34 34 34 36 36 37
1
HFF 22 - High frequency ignition unit, input filter ........................................................................................ General remarks .................................................................................................................................... Overview ................................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ......................................................................................................................................
38 38 38 39 40
NTFK 24 - Switched mode power supply for cooling unit ............................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
42 42 42 43 44 44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ......................................... General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
45 45 45 45 45 46
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ........................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... Important ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... LED checklist ......................................................................................................................................... Measuring points ....................................................................................................................................
47 47 47 47 47 48 48 48 48 48 48
TP 592S temperature sensor ...................................................................................................................... General remarks .................................................................................................................................... Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points ....................................................................................................................................
49 49 49 49 49 49
TTS 22 - IGBT driver and auxiliary power source ....................................................................................... General remarks .................................................................................................................................... Overview ................................................................................................................................................ Technical data ........................................................................................................................................ Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist .........................................................................................................................................
50 50 50 50 50 51 51 51
UST - Control and regulation unit ................................................................................................................ General remarks .................................................................................................................................... Function overview .................................................................................................................................. Pin assignment ...................................................................................................................................... Measuring points .................................................................................................................................... LED checklist ......................................................................................................................................... Change UST PC board ..........................................................................................................................
52 52 52 53 54 54 54
Changing modules ...................................................................................................................................... 55 General remarks .................................................................................................................................... 55 Overview ................................................................................................................................................ 55 Housing unit ................................................................................................................................................ General remarks .................................................................................................................................... Opening the housing .............................................................................................................................. Closing the housing ................................................................................................................................
2
56 56 56 57
Changing BPS 17 PC board ........................................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing BPS 22 PC board ........................................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing inverter module ........................................................................................................................... 59 Instructions ............................................................................................................................................. 59 Changing the TP 592S temperature sensor ................................................................................................ 59 Instructions ............................................................................................................................................. 59 Changing the TTS 22 PC board .................................................................................................................. ESD measures ....................................................................................................................................... Changing the TTS 22 PC board ............................................................................................................. Installing the TTS 22 PC board ..............................................................................................................
60 60 60 62
Changing the BSV 22 PC board .................................................................................................................. ESD measures ....................................................................................................................................... Removing the BSV 22 PC board ............................................................................................................ Installing the BSV 22 PC board .............................................................................................................. Installing UST PC board .........................................................................................................................
64 64 64 66 67
Changing the transformer ........................................................................................................................... 68 Removing the transformer ..................................................................................................................... 68 Installing the transformer ....................................................................................................................... 72 Safety Inspection ......................................................................................................................................... 78 Requirement .......................................................................................................................................... 78 Work instruction ..................................................................................................................................... 78 and abbreviations used .................................................................................................................... 79 General remarks .................................................................................................................................... 79 and abbreviations ........................................................................................................................ 79 Entire circuit diagram Spare parts lists Fronius Worldwide
3
Foreword and safety instructions
Safety
The following safety instructions apply to all activities described in these service instructions: 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 service technicians. Read the „Safety rules“ chapter in the power source operating instructions.
WARNING! An electric shock can be fatal. Before opening the device Turn the mains switch to the „O“ position Unplug the device from the mains Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument, check to make sure that electrically charged components (e.g. capacitors) have discharged 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 that do not provide a reliable PE conductor connection.
Tech National (TSN)
If you have any questions about error analysis, your Tech National (TSN) sales team is on hand. mailto: [email protected]
General remarks
The service instructions can be found in the Center TechGuide at „www.fronius.com\center“. Each chapter in the service manual deals with one complete topic. Use each chapter as a self-contained source of information. A short description of each chapter follows:
4
Tools and measuring devices
This provides an overview and description of all equipment required for servicing the power source professionally. This equipment includes: - Tools required - Measuring equipment, inspection equipment - Ancillary material
Function overview
Contains a brief descriptive overview of the entire system: - in text form - in block diagram form
Error location aid
Serves to systematically locate and rectify the source of errors, and contains the following elements: The actual error flowchart for dealing with general errors Service codes table for dealing with errors whose service codes appear on the display
Detailed description
Contains detailed descriptions of the relevant modules in the power source. For every module, the following topics are dealt with: General remarks (designation, item number of the module) Position of the module in the device Overview Technical data Function overview Pin assignment LED checklists Measuring points
Replacing components
The „Replacing components“ chapter describes how to replace components that have no instructions of their own for replacement and require detailed replacement instructions
and abbreviations used
Contains a description of essential specialist and abbreviations for a better understanding of the service manual
Spare parts list and entire circuit diagram
The „Spare parts list“ and „Entire circuit diagram“ chapters contain the complete spare parts list and complete circuit diagram for the power source.
5
Tools and measuring devices General remarks
„Tools and measuring devices“ provides an overview and description of all the equipment required to service the device professionally. This equipment includes: - Tools required - Measuring equipment, inspection equipment - Ancillary materials
Tools required
-
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 (4) Torx screwdriver (TX 25) or insert bit for manual torque wrench (4) Allen key (3 mm) Allen key (4 mm) Allen key (5 mm) Flat spanner (10 mm) Flat spanner (13 mm) Flat spanner (17 mm) Flat spanner (19 mm) Flat spanner (32 mm) C extractor tool (42,0410,0677) Oeteker pliers Molex extractor tool (42,0410,0290)
6
Measuring equipment, inspection equipment
Ancillary materials
-
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) DVD TechGuide (40,0006,2910)
-
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), grade 500 or finer
7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 General remarks
The „Function overview“ section explains the underlying functional principle of the MagicWave 1700/2200 and TransTig 800/2200 power sources as well as PlasmaModule 10 with the help of a block diagram.
Welding torch control line
Workpiece
Welding torch
Remote control
Block diagram
prot. gas shield solenoid valve
HF transformer
(12)
LocalNet
protective gas shield
Fig. 1
Block diagram of the MagicWave 1700/2200, TransTig 1700/2200 and PlasmaModule 10 power sources
230 V
Line filter
Primary power module
**
Intermediate circuit capacitors
Primary rectifier
8
(11) (8)
(9)
Switching transistors
(7)
Welding transformer
(6)
Secondary rectifier
24 V
PFC (Power Factor Control)
Inverter
(5)
* Secondary power module
Control line
Uact
HF generator
(10)
Welding current sensor
Power supply
24 V power supply
(4) (3) (2)
* only for MagicWave 1700 and MagicWave 2200 power sources ** only for MagicWave 2200 and TransTig 2200 power sources
Control line
(1)
Control
Control and regulation unit
HF
Iact
Block diagram legend
(1) Control and regulation unit: Controls, regulates and monitors the welding process and all power source functions. (2) Line filter (EMC): Reduces unwanted high-frequency noise. (3) Primary rectifier: Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage. (4) PFC (Power Factor Control, MagicWave 2200 and TransTig 2200 only): Ensures sinusoidal current input, for - ing an optimum degree of efficiency - Preventing perturbations in the mains supply (5) Intermediate circuit capacitors: store and smooth the intermediate circuit voltage. (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 constructed to a very light, compact design - Thermal losses due to the low inductance required of the transformer windings 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) Inverter (only MagicWave 1700 and MagicWave 2200): Converts direct current to alternating current for “TIG AC welding” operating mode (10) HF generator: For non- HF ignition, the HF generator (high-frequency generator) generates the high-frequency primary voltage of the HF transformer (12). (11) Welding current sensor: Captures the actual current value for the welding process (12) HF transformer: For non- HF ignition, the HF transformer (high-frequency transformer) transmits high-voltage pulses to the welding circuit.
9
Error location aid General remarks
The chapter „Error location aid“ consists of the following parts - Error flowchart - Table of service codes The error flowchart is for the systematic locating and rectifying of errors. In the „Table of service codes“ chapter, there is also a table which deals with the service codes shown on the display, as well as the causes of errors and how to rectify them. Before using the error location aid, read the „Function overview“ chapter and study the entire circuit diagram in order to understand how the power source is constructed and how it operates. Important: The following applies to those who do not yet have much experience of troubleshooting and fault diagnosis on the MagicWave 1700 / 2200, TransTig 800 / 2200 and PlasmaModule 10 power sources. Before using the error location aid, read the following chapters: „Function overview“ „Entire circuit diagram“
10
Error flowchart Overview
The overview will help you to find the relevant sections of the flowchart from among those listed below. The positions and meanings of the measuring points and LEDs for the modules / PC boards can be found in the „Detailed description“ chapter, which contains an „LED checklist“ or a „Measuring points“ sub-section for each of the modules / PC boards (with LEDs). Poor ignition and welding properties with TIG welding
Poor ignition and welding properties with MMA welding
No or incorrect welding current
Move the mains switch to the „I“ position
No lights on control
Inadequate welding torch cooling (FK 2200)
Open circuit voltage + 50 V faulty
Table of service codes
11
Poor ignition and welding properties with TIG welding
Start
Correct protective gas shield connected, and l/min set correctly?
no
Connect correct protective gas shield and check l/min
yes
Gas test button: Protective gas shield flowing out?
no
Check protective gas shield solenoid valve, including control
yes
Welding torch and grounding (earthing) cable OK?
no
Check welding torch and grounding (earthing) cable
yes
Parameters set correctly? no yes
Open circuit voltage with selected „rod electrode (MMA) welding“ process = 50 V (+/- 1 V) ? yes
Check whether power source OK, and check application
End
12
no
- Check settings on control Check set-up parameters Possibly reset to factory settings (FAC) (see operating instructions)
See „Incorrect open circuit voltage“ section
Poor ignition and welding properties with MMA welding
Start
Electrodes / grounding (earthing) cable connected / functioning correctly?
Connect cable correctly no
yes
Welding process set correctly?
Select correct welding process no
yes
Parameters set correctly? no yes
Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ? yes
Check whether power source OK, and check application
End
13
no
- Check settings on control Check set-up parameters Possibly reset to factory settings (FAC) (see operating instructions)
See „Incorrect open circuit voltage“ section
No or incorrect welding current
Start
Welding torch and grounding (earthing) cable connected / functioning correctly?
no
Check welding torch and grounding (earthing) cable
yes
No lights on control ? yes
See section entitled „No lights on control “
no
Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ?
no
See „Incorrect open circuit voltage“ section
yes
-
Welding current Icomm no longer adjustable, or Welding current is always Imax ? no
Check whether power source OK, and check application
End
14
yes
Change current sensor A1 VAC
No lights on control
Start
Is the UZWK LED on the A2 BPS 17 / BPS 22 power module PC board on constantly?
no
Check mains cable, mains switch and supply voltage
yes
Are the LEDs for supply voltage on the A2 BPS 17 / BPS 22 power yes module PC board and the A5 UST control board on constantly?
Change A6 FP 22 control
no
-
Turn the mains switch to the „O“ position Remove connectors A5 UST.X3, X6 from the control board - Turn the mains switch to the „I“ position
Are the LEDs for supply voltage on the A2 BPS 17 / BPS 22 on the no power module PC board on constantly? yes
-
Turn the mains switch to the „O“ position Connect plug to the A5 UST:X3 control board Turn the mains switch to the „I“ position
A
15
Change power module PC board A2 BPS 17 / BPS 22
No lights on control (continued)
A
LEDs for supply voltage on A5 UST control board constantly illuminated?
yes
Change power module PC board A2 BPS 17 / BPS 22
no
-
Turn the mains switch to the „O“ position - Connect plug X6 to the A5 UST control board Disconnect plugs X1, X2, X4, X7, X9 and X10 from the UST control board - Turn the mains switch to the „I“ position
LEDs for supply voltage on A5 UST control board constantly illuminated?
Change the A5 UST control board no
yes
Connect plug X1 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminated? yes
B
16
no
Change A4 TTS22 PC board (driver for inverter)
No lights on control (continued)
B
Connect plug X2 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminano ted?
Change A6 FP22 control
yes
Connect plug X4 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illumina- no ted?
Change current sensor A1 VAC
yes
Connect plug X7 to the A5 UST control board
LEDs for supply voltage on UST control board constantly illuminated? yes
C
17
Test FK 2200 cooling unit no
No lights on control (continued)
C
Connect plugs X9, X10 to the A5 UST control board
LEDs for supply voltage on A5 UST control board constantly illuminano ted? yes
Check whether power source OK, and check application
End
18
Change A7 HFF22 PC board (HF generator / filter)
Inadequate welding torch cooling (FK 2200)
Start
Cooling unit set-up parameters switched to „Off“?
yes
Switch set-up parameters to „Auto“ or „On“
no
Switch off power source
Sufficient coolant? no
Top up coolant, then vent cooling unit
yes
Fuse for coolant pump OK? no
Change fuse (check rating is same as original)
yes
Coolant pump blocked?
yes
no
Unplug X4 from power module A1 NTFK24, switch on power supply, change cooling unit’s set-up parameter to „On“
A
19
Use a screwdriver to turn the cooling unit pump shaft. If the pump is difficult to move, change the pump to avoid overloading the power module.
Inadequate welding torch cooling (FK 2200) (continued)
A
Power LED on the A1 NTFK24 power module illuminated constantly ?
no
yes
On LED on the A1 NTFK24 power module illuminated?
no
Check fuse F1 and 230 VAC power supply on the A1 NTFK24 X2 power module. Change A1 NTFK24 power module
Voltage at the A1 NTFK24 X3/2, X3/8 power module < 1 V DC
yes
no
yes
Check cable harness, change A5 UST controller in the power source
LEDs +15V, +24V, + 24V OK on the A1 NTFK24 power module illuminated constantly ? yes
Change coolant pump and/or fan
End
20
Change A1 NTFK24 power module no
Open circuit voltage +50 V faulty
Start
-
Open circuit voltage present for selected „MMA welding“ process ? yes
-
Change TTS 22 PC board (MW 1700 / 2200) Change BSV XX PC board (TT 2200)
no
-
Steady +5 V, +18V, +24V LEDs on TTS 22? - If the polarity is changed using the „Process“ button: „neg./pos. ignition“ LED lit ? yes
Check inverter (see detailed explanation - secondary power supply)
End
21
no
Change TTS 22 PC board
UST service codes Safety
Table of service codes
WARNING! An electric shock can be fatal. Before opening the device Turn the mains switch to the „O“ position Unplug the device from the mains Ensure that electrically charged components (e.g. capacitors) have been discharged
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 - The corresponding troubleshooting measure dsP | Axx (code no.20) Cause: Remedy:
DSP displays a general error, xx stands for additional entries not required for external service Update software. Change UST PC board.
dsP | A21 (code no.20) Cause:
Remedy:
The power source is configured for either parallel operation (set-up parameter 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. Acknowledge 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: Remedy:
DSP SoftCom error, xx stands for additional entries not relevant for external service Update software. Change UST PC board.
dsP | E05 (code no.17) Cause: Remedy:
DSP displays internal error Update software. Change UST PC board.
dsP | Exx (code no.21) Cause:
Remedy:
DSP displays general error, xx stands for 1 timeout during charging 2 EOF during charging 3 error on data channel (LT selection) 4 error on com channel (LT selection) 5 timeout at EM stop command Update software. Change UST PC board.
dsP | Sy (code no.35) Cause: Remedy:
Internal error (version conflict) Update software. Change UST PC board.
dsP | nSy (code no.36) Cause: Remedy:
Internal error (version conflict) Update software. Change UST PC board. 22
Table of service codes (continued)
EcF | xxx (code no.32) Cause:
BPS configuration error, x stands for: 1 2 3 4 5 253 254
Remedy:
TPS 2700 with incorrect power module TS/TPS/TP 4000 with incorrect power module TS/TPS/TP 5000 with incorrect power module TT 2200, MW 2200 with incorrect primary power module MW 1700 with incorrect primary power module This configuration functions only from UST2A V1.3 A onwards This configuration functions only from UST PC board, version UST2A 255 Unknown primary power module Fit correct primary power module
EFD | xx.y (code no.30) Cause: Remedy:
Error in wirefeed system, xx and y can be found in the list of service codes for the wirefeed system. Check wirefeed system
EIF | xx.y (code no.63) Cause: Remedy:
Error in conjunction with a robot interface, xx and y can be found in the list of service codes for your robot interface. Check robot interface, update software, change robot interface
Err | Arc (code no.61) Cause: Remedy:
DPS 5000 only: DPS detected arc formation Check application
Err | bPS (code no.18) Cause: Remedy:
DSP displays internal error Update software. Change UST PC board. Change BPS PC board.
Err | Cfg (code no.72) Cause: Remedy:
Power source configuration changed (e.g. connected in parallel with a second power source) Reset service code by pressing set-up button
Err | EPF (code no.22) Cause: Remedy:
Error during charging of flex Update software. Change UST PC board.
Err | IP (code no.19) Cause: Remedy:
DSP displays primary overcurrent Check secondary power module. Change primary power module.
Err | Jo (code no.67) Cause: Remedy:
JobMaster temperature sensor faulty Change JobMaster welding torch
Err | Lic (code no.40) Cause: Remedy:
Faulty/incorrect licence key Check licence key. Check and update enable codes.
23
Table of service codes (continued)
Err | PE (code no.53) Cause: Remedy:
Earth-fault error Remove earth fault. Configure device 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:
Remedy:
Temperature sensor error (short circuit or break) - examples: tF1 - temperature sensor error on secondary rectifier, tF2 - temperature sensor error on primary power module Check cable harness and change the relevant temperature sensor
Err | tF6 (code no.16) Cause: Remedy:
Error on BPS PC board or on the connection to the BPS PC board Check ribbon cable. Change BPS PC board.
Err | tF7 (code no.34) Cause: Remedy:
Temperature sensor error on UST Change UST PC board
Err | tF8 (code no.64) Cause: Remedy:
In conjunction with thermostat option: cooling unit temperature sensor error Check cable harness. Change temperature sensor.
Err | 027 (code no.27) Cause: Remedy:
One of the supply voltages is outside the tolerance range Change UST
Err | 049 (code no.49) Cause: Remedy:
Phase failure Check the mains fuse, the mains supply lead and the mains plug
Err | 050 (code no.50) Cause: Remedy:
Voltage intermediate circuit symmetry error See error flowchart Err 50 if available. If there is a voltage of +5V on the UST from X6/26 - X7/8, change UST. If there is a voltage of 0 V on the UST from X6/26 - X7/8 0V, change BPS.
Err | 051 (code no.51) Cause: Remedy:
Mains undervoltage: The mains voltage has fallen below the tolerance range Check mains voltage
Err | 052 (code no.52) Cause: Remedy:
Mains overvoltage: The mains voltage has risen above the tolerance range Check mains voltage
Err | 054 (code no.54) Cause: Remedy:
Wire stick control has tripped Remove short circuit on welding wire
24
Table of service codes (continued)
Err | 056 (code no.56) Cause: Remedy:
In conjunction with wire-feed unit and „wire-end check“ option: no wire available Insert new wirespool
Err | 059 (code no.59) Cause: Remedy:
Overvoltage in the secondary circuit: safety cut-out has tripped Check secondary circuit, including TPCEL40
Err | 060 (code no.60) Cause: Remedy:
DPS5000 only: Due to an opened door , SITRE1A has triggered safety disconnection Safety cut-out: close door
Err | 062 (code no.62) Cause: Remedy:
Remote control TP08 overtemperature Allow TP08 to cool down. Change TP08.
Err | 068 (code no.68) Cause: Remedy:
Secondary circuit safety cut-out has tripped Change TTS PC board
Err | 069 (code no.69) Cause: Remedy:
Illegal change of mode or process during welding Reignite arc
Err | 23.x (code no.23) Cause:
Remedy:
Config memory (CFM) error on UST PC board, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Update software. Change UST PC board.
Err | 24.x (code no.24) Cause:
Remedy:
Config memory (CFM) error on BPS PC board, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Check ribbon cable. Change BPS PC board.
Err | 25.x (code no.25) Cause:
Remedy:
Config memory (CFM) „alternator“ error, 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) Change TTS
25
Table of service codes (continued)
Err | 26.x (code no.26) Cause:
Remedy:
Config memory (CFM) „machine“ error, x stands for: 1 config memory not found 2 checksum error 3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Check cable harness. Change config memory on power source cable harness.
Err | 31.x (code no.31) Cause: Remedy:
EEProm save error Update software. Change UST2 PC board.
Err | 70.x (code no.70) Cause:
Remedy:
Error with the digital gas control option, x stands for: 1 no sensor found 2 no protective gas shield 3 alignment error 4 protective gas shield solenoid valve break or short circuit 5 no protective gas shield solenoid valve found For cause x 1 check cable harness, change protective gas shield sensor 2 check protective gas shield supply (min. 2 bar) 3 no or insufficient protective gas shield, change protective gas shield solenoid valve 4 change protective gas shield solenoid valve, change protective gas shield sensor 5 check cable harness, change protective gas shield solenoid valve
Err | 71.x (code no.71) Cause:
Remedy:
Limit error, x stands for: 1 exceed of upper current limit 2 exceed of lower current limit 3 exceed of upper voltage limit 4 exceed of lower voltage limit Check application. Check parameters.
hot | H2O (code no.65) Cause: Remedy:
In conjunction with thermostat option: Overtemperature in cooling system Allow cooling unit to cool down. Open cooling unit and clean heat exchanger. Check whether fan is functioning properly.
no | Arc (code no.58) Cause: Remedy:
Arc is broken, arc-break monitor has tripped Check welding parameters. Reignite arc Check grounding (earthing) connection.
no | GAS (code no.57) Cause: Remedy:
In conjunction with the digital gas control option: no protective gas shield available Check protective gas shield supply
26
Table of service codes (continued)
no | H2O (code no.39) Cause: Remedy:
Flow watchdog reporting water deficiency Check cooling system hose lines. Check pump pressure and flow rate. Check flow watchdog.
no | Ign (code no.55) Cause: Remedy:
„Ignition time-out“ error: No ignition within the value set in the set-up menu. The safety cut-out has tripped. Clean workpiece surface. Check parameters in set-up menu. Check grounding (earthing) connection.
no | Prg (code no.1) Cause: Remedy:
No saved program selected Select saved program
off (code no.150) Cause: Remedy:
No communication between the LocalNet participants (e.g. power source, wire feed unit, remote control or welding torch) Check LocalNet cables. Change remote control/welding torch. Wait for software update to finish.
-Stop- (code no.38) Cause: Remedy:
Robot not ready When using a robot interface or field bus coupler, initialise the „Robot ready“ and „Source error reset“ signals.
tJo | xxx (code no.66) Cause: Remedy:
JobMaster overtemperature Allow device 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: Remedy:
Overtemperature in power source primary circuit (XXX stands for temperature indicator) - Example: tp1 - overtemperature at primary power module Allow the power source to cool down. Check that fan is running.
tp6 | xxx (code no.10) Cause: Remedy:
Overtemperature in power source primary circuit, temperature sensor on BPS PC board has tripped (XXX stands for temperature indicator) Allow the power source to cool down. Check that fan is running.
tp7 | Hot Cause: Remedy:
Duty cycle exceeded Allow the power source to cool down. Check that fan is running.
ts1 | xxx (code no.2), tS2 | xxx (code no.3), tS3 | xxx (code no.4) Cause:
Remedy:
Overtemperature in power source secondary circuit (XXX stands for temperature indicator) - Examples: ts1 - overtemperature at secondary rectifier, ts2 - overtemperature at the auxiliary voltage source, tst - overtemperature at UST PC board Allow the power source to cool down. Check that fan is running.
Remedy:
Check cable harness. Change UST2 PC board.
27
Table of service codes (continued)
tSt | xxx (code no.33) Cause: Remedy:
Overtemperature in control circuit, xxx stands for the temperature indicator Allow the power source to cool down. Check fan.
US | POL (code no.37) Cause:
Special indications used with service codes
Measuring device for secondary voltage (Usec) incorrectly connected, or defective for some other reason
The following service codes are special indications for software problems: -
-
And | Opc Prt | Flt Ill | Opa Ill | Ina Ill | Bus Err | 105
STK | OVL STK | UVL Err | Dog ASS | Ert Edg | 1
If the service codes shown above appear, more detailed information can be requested at the power source control . Using the parameter selection buttons (left/right arrows), you can switch between the following display levels: Level 1 (e.g. „And | Opc“): service code 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 indications in levels 1, 2, and 3, and them on to Fronius. Using this data, Fronius can locate the precise cause of the error.
28
Detailed description General remarks
This section contains a detailed description of the electronic modules with regard to the following points: General (designation, item number) Position of the module in the device Overview Technical data Function overview Pin assignment LED checklist Measuring points
Overview
„Detailed description“ is composed of the following sections: BPS 17 - Power module PC board BPS 22 - Power module PC board HFF 22 - High frequency ignition unit, input filter NTFK 24 - 24 V switched mode power supply for supplying KK 2200 cooling unit Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 TP 592S temperature sensor TTS 22 - IGBT driver and auxiliary power source UST - Control and regulation unit
29
BPS 17 - Power module PC board General remarks
BPS 17 (item no. 4,070,798,Z) is the power module PC board for power sources TT 800, MW 1700 and PlasmaModule 10.
Overview
Still required
Function overview
Input voltage
230 VAC (+15 % / -20 %)
Supply voltage from the power module
24 Vint (+/-20 %), 2.5 A 24 Vext (+/-20 %), 1.5 A 15 Vp (+10 %), 0.2 A
Components on the BPS 17 PC board (5)
(1)
(3)
(4)
(6)
(2)
Fig. 6 Components on the BPS 17 power module PC board
30
Function overview (continued)
The BPS 17 PC board includes the following components: (1) Line filter (2) Rectifier (3) High-charging circuit (4) Intermediate circuit capacitors (5) Switched mode power supply (+24 V internal, +24 V external) (6) Power full bridge The BPS 17 PC board also contains a safety-related primary/secondary ing point. (1) Line filter The line filter is located in the AC branch, and has a two-stage structure. The line filter serves to reduce the interference produced in the device for the for the mains lead. (2) Rectifier The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the intermediate circuit. (3) Switched-mode power supply The switched mode power supply is a flyback converter that is supplied by the intermediate circuit capacitors. The switched-mode power supply is synchronised at 65 kHz and provides the output voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); where the 15 Vp coil is for primary and only supplies the power for the PWM ICs of the power supply. The output voltages are electrically isolated from one another and fused with a PTC each. (4) High-charging circuit PTC resistors limit the starting current. The controller (UST PC board) dictates the high charging time. The expiry of a preset length of time plus a preset value for the intermediate circuit voltage are prerequisites for bridging the high charging resistors with relays. Bridging the high charging resistors using relays is done after: - the high charging time has expired - the preset value for the intermediate voltage has been reached (5) Intermediate circuit capacitors The intermediate circuit capacitors are used to smooth out and stabilise the rectified input voltage. (6) Power full bridge The power full bridge breaks the rectified intermediate circuit voltage into a 100kHz signal. The bridge circuit (with 4 power MOSFETs) is controlled with driver stages.
Pin assignment
X1 ...... (secondary), ribbon cable from UST (X6) Details on the pin assignment can be found in the chapter entitled „Detailed description“ - „UST“ in the section „Pin assignment X6“. X3 ...... TRANSF2 (primary voltage), connecting lead to welding transformer X4 ...... TRANSF1 (primary voltage), connecting lead to welding transformer X9 ...... (L1 - phase - primary voltage), connecting lead to mains switch X10 .... (N - neutral conductor - primary voltage), connecting lead to mains switch
31
Pin assignment (continued)
Measuring points
X28 .... (secondary voltage), voltage supply internal/external Pin
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
Measurement on each of the diode regions depicted below must produce a result of 0.4 V. The picture also shows the HS LED and the HLS LED (see following section „Control LEDs“).
HS LED
HLS LED
Fig. 7 Diode regions on the BPS 17 power module PC board
Further measuring points can be found in the chapter entitled „Detailed description“ „UST“ in the section „Pin assignment“.
32
LED checklist
Control LEDs on BPS 17 PC board
Uzwk
+15 Vp
HLS LED
+24 Vext
+24 Vint
HS LED
Fig. 8 Control LEDs on BPS 17 power module PC board
Uzwk ................. lights up when there is supply from the intermediate circuit LEDs for supply voltage: +15 Vp ............. lights up when switched mode power supply is working correctly +24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint ............ lights up when switched mode power supply is working correctly HS LED .......... lights up when the mains switch is in the „I“ position HLS LED ........ lights up when the high charging relay is activated
33
BPS 22 - Power module PC board General remarks
BPS 22 (item no. 4,070,799,Z) is the power module PC board for TT 2200 and MW 2200 power sources.
Overview
Still required
Technical data
Function overview
Input voltage
230 VAC (+15 % / -30 %)
Supply voltage from the power module
24 Vint (+/-20 %), 2.5 A 24 Vext (+/-20 %), 1.5 A 15 Vp (+10 %), 0.2 A
Components on the BPS 22 PC board
(1)
(2) (8)
(3)
(4)
(7)
(5)
(6)
Fig. 9 Components on the BPS 22 power module PC board
34
Function overview (continued)
The BPS 22 PC board includes the following components: (1) Line filter (2) High-charging circuit (3) Intermediate circuit capacitors (4) Rectifier (5) PFC (Power Factor Control) (6) Shunt (7) Power full bridge (8) Switched mode power supply (+24 V internal, +24 V external) (1) Line filter The line filter is located in the AC branch, and has a two-stage structure. The line filter serves to reduce the interference produced in the device for the for the mains lead. (2) High-charging circuit PTC resistors limit the starting current. The controller (UST PC board) dictates the high charging time. The expiry of a preset length of time plus a preset value for the intermediate circuit voltage are prerequisites for bridging the high charging resistors with relays. (3) Intermediate circuit capacitors The intermediate circuit capacitors are used to smooth out and stabilise the rectified input voltage. (4) Rectifier The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the intermediate circuit. (5) PFC (Power Factor Control) The Power Factor Control s a sinusoidal mains current input. Therefore, so that almost no reactive current occurs, the largest current input possible is possible from the single phase mains. (6) Shunt Measures the mains current for the PFC. (7) Power full bridge The power full bridge generates a 100kHz signal from the rectified intermediate circuit voltage. The bridge circuit (with 4 power MOSFETs) is controlled with driver stages. (8) Switched mode power supply The switched mode power supply is a flyback converter that is supplied by the intermediate circuit capacitors. The switched-mode power supply is synchronised at 65 kHz and provides the output voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); where the 15 Vp coil is for primary and only supplies the power for the PWM ICs of the power supply. The output voltages are electrically isolated from one another and fused with a PTC each.
35
Pin assignment
X1 ...... (secondary), ribbon cable from UST (X6) Details on the pin assignment can be found in the chapter entitled „Detailed description“ - „UST“ in the section „Pin assignment X6“. X3 ...... TRANSF2 (primary voltage), connecting lead to welding transformer X4 ...... TRANSF1 (primary voltage), connecting lead to welding transformer X9 ...... (L1 - phase - primary voltage), connecting lead to mains switch X10 .... (N - neutral conductor - primary voltage), connecting lead to mains switch X28 .... (secondary voltage), voltage supply internal/external Pin
Measuring points
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
Measurement on each of the diode regions depicted below must produce a result of 0.4 V.
Fig. 10 Diode regions on the BPS 22 power module PC board
Further measuring points can be found in the chapter entitled „Detailed description“ „UST“ in the section „Pin assignment“.
36
LED checklist
Control LEDs on BPS 22 PC board
PFC LED
Uzwk +15 Vp
HLS LED HS LED
+24 Vext
+24 Vint
Fig. 11 Control LEDs on BPS 22 power module PC board
Uzwk ................. lights up when there is supply from the intermediate circuit LEDs for supply voltage: +15 Vp ............. lights up when switched mode power supply is working correctly +24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint ............ lights up when switched mode power supply is working correctly HS LED .......... lights up when the mains switch is in the „I“ position HLS LED ........ lights up when the high charging relay is activated PFC LED ........ lights up or flashes with varying degrees of brightness depending on power drawn. High brightness equals high power.
37
HFF 22 - High frequency ignition unit, input filter General remarks
HFF 22 (item number 4,070,812,Z) is used for high frequency ignition in the MW 1700 and MW 2200 power sources and is also a filter assignment for remote controls and torch triggers.
Overview
HF module
Filter module
Fig. 25 HFF 22
38
Function overview
Supply voltage
+ 24 VDC (+/- 20 %)
Output voltage
1000 VDC
The HFF 22 PC board includes the following components:
(1) HF module From the +24 V supply (24 V LED green), the HF module generates a +15 V supply (+15 V LED green) for the internal control module. A flyback converter charging circuit charges the impulse capacitor from +24 V to 1000 V. Immediately after charging the ignition thyristor is activated and the impulse capacitor discharges the HF launch coil via the primary coil The HF launch coil transforms the charge voltage of the impulse capacitor from 1000 V to approx. 10 kV. Each charging process of the impulse capacitor is indicated by the SIG LED (red) lighting up.
(2) Filter module The filter module comprises two 6-pin, current-compensated filter chokes (one choke each for remote control and torch trigger). The filter chokes eliminate high-frequency impulses on the data lines caused by parasitic capacities. A circuit layout of capacitors and Transil arrays (protective diodes) is used for discharging overvoltage of the data lines.
39
Pin assignment (X3)
(X1)
(X2)
(X5)
(X4)
(X6)
(X7)
Fig. 26 Pin assignment on HFF 22 PC board
40
Pin assignment (continued)
X1 ...... HF pulse positive pole (blade terminal connection to primary voltage of the HF launch coil X2 ...... HF pulse negative pole (blade terminal connection to primary voltage of the HF launch coil)
X3 ...... High frequency control cables (connection to UST) Pin
Designation
Pin
Designation
1
NC
3
SIGNAL
2
+ 24 V
4
GND
X4 ...... Torch trigger cables (connection to UST) Pin
Designation
Pin
Designation
1
NC
6
NC
2
DOWN
7
NC
3
CRATERFILL
8
IDENTIF
4
UP
9
GND
5
MAIN CURR
10
NC
X5 ...... Torch trigger cables (connection to welding torch) Pin
Designation
Pin
Designation
1
NC
6
NC
2
DOWN
7
NC
3
CRATERFILL
8
IDENTIF
4
UP
9
GND
5
MAIN CURR
10
NC
X6 ...... Remote control cables (connection to remote control) Pin
Designation
Pin
Designation
1
+24 V EXT
4
GND 485
2
RXDL 485
5
TXDL 485
3
RXDH 485
6
TXDH 485
X7 ...... Remote control cables (connection to UST) Pin
Designation
Pin
Designation
1
+24 V EXT
4
GND 485
2
TXDL 485
5
RXDL 485
3
TXDH 485
6
RXDH 485
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NTFK 24 - Switched mode power supply for cooling unit General remarks
Function overview
NTFK 24 (item number 4,070,819,Z) is the switched mode power supply for the FK 2200 cooling unit.
Range of input voltage
140 VAC... 280 VAC 200 VDC... 400 VDC
Output voltage
24 V (+/- 1 V), 5.5 A (max. 30 V in idle)
Max. current
5.5 A (fused with PTCs)
The NTFK 22 PC board includes the following components:
(1) Charging circuit When switched on, NTC resistors limit the charging current. The resistors R58 and R59 are NTCs and have a high ohm rating during operation. An external glass-tube fuse of 4 A (slow-blow fuse) is required, as NTCs do not limit fault current when it occurs.
(2) Control If the pin X3:2 (=/cooler on) is set to signal ground, the cooling unit starts.
(3) Control of the fan and coolant pump The +24 V supply is fused with PTCs. The PTCs become highly resistant when there is a overcurrent. This process depends on the level of overload and the ambient temperature (5.5 A at 60 °C).
42
Function overview (continued)
(4) Flow controller and undervoltage control If no flow monitor is present, pin X1/2 (/water ctrl.sig.) is switched to signal ground (GND) via a short circuit jumper. The undervoltage detector of the coolant pump is also coupled to the flow controller. If the supply voltage of the coolant pump is lower than 20 V, (e.g the pump is blocked), a message to the UST controller board is sent (service code). The flow monitor is powered from the power source. The signal voltages at pins X3 and X1, as well as the supply voltage of the coolant pump are electrically isolated from one another.
Pin assignment
X1 ...... Flow monitor connection Pin
Pin
Designation
Designation
1
+24V flow monitor supply
3
GND
2
Flow monitor signal (low active)
4
GND
X2 ...... Mains voltage (fused with external glass-tube F1, 4 A - slow blow) Pin 1
Designation
Pin
Phase
2
Designation Neutral conductor
X3 ...... Connection to power source Pin
Designation
Pin
Designation
1
NC
6
NC
2
/Cooler on 0 V = cooling unit on
7
+ 24 V - Control supply voltage from the power source
3
/Watercontrol 0 V = coolant flow and supply voltage of the cooling unit OK
8
GND water control - GND of the supply voltage from the power source
4
NC
9
NC
5
NC
10
43
GND (+ 24 V) - GND of the supply voltage from the power source
Pin assignment (continued)
Measuring points
X4 ...... Connection for fan and coolant pump of the cooling unit Pin
Designation
Pin
Designation
1
+ 24 V coolant pump
4
GND coolant pump
2
+24 V Fan
5
GND fan
3
LED+, external control LED
6
GND LED
See pin assignment
LED checklist +15 VP
Power
+24 VOK +24 V
ON Fig. 31 Control LEDs on NTFK 24 PC board
Power ............. + 15 VP ........... +24 VOK ......... +24 V .............. ON ..................
Mains voltage present Supply for PWM IC present The supply voltage to the coolant pump is greater than 20 V Pump and fan voltage present External signal for switching on the coolant pump is present
44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 General remarks
The secondary power module for the TransTig 800 / 2200, MagicWave 1700 / 2200 and PlasmaModule 10 power sources contains the following number(s) of diode modules (item number 41,0003,0203): Secondary rectifier 1 diode module (PlasmaModule 10) 2 diode modules (TT 800 / 2200) 4 diode modules (MW 1700 / 2200) Inverter previous version consisting of MW 2200 inverter checked (item number 41,0003,0282,Z) new version from serial number 17352516 comprising 4 IGBT transistor modules (item number 41,0003,0279) and PC board FMW22IS (item number 4,070,949,Z)
Function overview
The rectifier generates DC from the AC from the welding transformer. Important: The following description only applies to MagicWave 1700 / 2200 power sources. The transistor modules on the inverter module convert the DC to AC, which is then sent to the welding sockets. The transistor modules are controlled by the TTS 22 PC board. On the FMW 22 IS PC board the integrated suppressor diodes protect the inverter transistors from excessive voltages from the welding circuit.
Pin assignment
Important: The following description only applies to MagicWave 1700 / 2200 power sources. X8 ...... Connection from inverter module to TTS 22.
Measuring points
Measurements taken on the diode regions depicted below must produce approximately the following results: approx. 0.4 V at the suppressor diodes on the inverter module (A) (measuring points can be found in the following picture). approx. 0.15 V at the rectifier diodes (B) (measuring points can be found in „Pin assignment“ section). Torques: - Copper clips and PC board on power semiconductors: 1.5 Nm - Power semiconductors on heat sink: 2.1 Nm
45
Measuring points (continued)
(B)
(B)
(A)
Welding current LED Welding current LED 0.15 V
(B)
0.15 V
0.4 V
(B)
0.15 V
0.15 V
Fig. 39 Diode regions on secondary power module, previous version
Important: TransTig 800 / 2200 power sources only offer two diode modules and the PlasmaModule 10 only offers one. On the TransTig 800 and PM 10 power sources the single diode is fitted on the top left. On the TransTig 2200 the two diodes are fitted on the left. On the MagicWave 1700 / 2200 power sources all 4 diodes are fitted. The temperature sensor can be found between the diode modules, where the connecting leads of the temperature sensor run off to the left. Welding current LED Welding current LED
(B)
(B)
(B) 0.15 V (B) (B)
0.15 V (B)
0.15 V33 (B)
0.15 V 0.15 V
0.15 V
0.15 V (B)
Fig.40 Diode regions on secondary power module, new version
LED checklist
See „Measuring points“ section
46
0.15 V
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 General remarks
The shunt (item number 43,0001,1191) is a current sensor and is used on the TransTig and MagicWave 1700 / 2200 power sources for electrically isolated capture of the welding current.
Fig.43 Shunt for capturing welding current
Function overview
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 welding current transmission ratio is 1:2000.
Pin assignment
X1 ...... Molex plug from adapter cable Pin
Measuring points
Pin
Designation
Designation
1
NC
5
NC
2
NC
6
NC
3
Iact 100 A gives 0.33 V
7
GND
4
- 15 V
8
+ 15 V
The welding current can be captured indirectly using by measuring the voltage. With a welding current of 100 A for example, there should be a voltage of 0.33 V measured: - Either on the Molex plug of the adapter cable, pin 3 and pin 7 - On UST PC board, Molex plug X4, pin 5 and pin 17
47
Important
Various versions of the shunt are in use. NOTE! To prevent malfunctions, and to exclude the possibility of damage to other parts in the power source, use only the adapter cable supplied.
Technical data
Supply voltage
+15 V /- 15 V
Nominal current
Function overview
500 A
Output current at nominal current
250 mA
Transformation ratio
1 : 2000
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 welding current transmission ratio is 1:2000. Other functions: Electric isolation between power 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
Pin assignment
Plug
Function
X1
Molex plug from adapter cable
Pin 1 Pin 2
+15 V -15 V
Pin 3 Pin 4
I Real GND
LED checklist
There are no LED indicators on the shunt.
Measuring points
The welding current can be captured indirectly using by measuring the voltage. 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 set value
Welding current
X4/5 - X4/17
0.33 V at a welding current of 100 A
NOTE! To prevent malfunctions, and to exclude the possibility of damage to other parts in the power source, use only the adapter cable supplied.
48
TP 592S temperature sensor 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 has a plug-in Molex connection.
General remarks
Fig. 45 TP 592S temperature sensor
Technical data
Function overview
Supply voltage
4 - 30 V DC
Output current
1 µA/K
-
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 assignment
Measuring points
Plug
Function
X1
2-pin Molex plug
Pin 1
Temp. 1+
Pin 2
Temp. 1-
Measure the current flowing through the temperature sensor as follows: Remove lead at pin 1 from Molex plug using Molex extractor tool. Connect 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 „Functional description“.
49
TTS 22 - IGBT driver and auxiliary power source General remarks
The TTS 22 PC board (item number 4,070,804) fulfills the function of an IGBT driver and an auxiliary power source.
Overview Negative ignition
Positive ignition
Error + 24 V + 18 V +6V
Fig. 46 TTS 22
Technical data
Supply voltage
Function overview
The TTS 22 controls the polarity of the welding current and the auxiliary power source. The auxiliary power source allows the arc to be reignited. The TTS 22 and FMW PC boards work in tandem.
24 V DC
The TTS 22 generates two independent voltages (+5V and +18V) for PC board control from the +24V supply voltage. The control unit conditions the control signals (polarity of welding current and reignition) and is used to electrically isolate and forward the signals to the relevant transistor module (IGBT). The process is displayed: - On the „neg ignition“ and „pos. ignition“ LEDs for the auxiliary power source - On the FMW PC board „LED +“ and „LED -“ for the polarity of the welding current The welding voltage is also measured. If the welding voltage should fall outside the permitted range, the following occurs: - Inverter control signal goes to „Stop“ - 18V PC board supply stopped: „+18 V“ LED goes out - Error LED (red) lights up - Error signal „X7:4“ to UST PC board active (low signal)
50
Pin assignment
X1 ...... Common X2 ...... AC, alternating voltage for positive half wave X3 ...... AC, alternating voltage for positive half wave X4 ...... AC, alternating voltage for negative half wave X5 ...... AC, alternating voltage for negative half wave X6 ...... Connection to FMW22 PC board X7 ...... Connection to UST PC board X8 ...... Measurement of welding voltage Pin 1
Designation
Pin
Uact-
2
Designation Uact+
X9 ...... Connection to control (UST PC board) Pin 1
Designation
Pin
Uact-
Measuring points
See pin assignment
LED checklist
See overview
2
51
Designation Uact+
UST - Control and regulation unit General remarks
The UST PC board (item number 4,070,860,Z) is a universal control, regulation and monitoring unit for fully digitised Fronius power sources.
Function overview
The UST PC board performs the following functions: (1) Power module control The control of the power module is performed by the UST via plug X6; the driver circuits are on the UST. (2) Control of control The UST controls the control via a 10-pin ribbon cable (X2). The control is handled via a databus connection (LocalNet) (3) Mains switch evaluation The UST evaluates the incoming mains switch signal from the BPS PC board. If the intermediate circuit voltage reaches a certain level, the relays close after a specified time. The UST uses the mains switch signal to detect when the power source is switched off. The UST stores the current settings and activates the fans to discharge the intermediate circuit. (4) Temperature evaluation The UST evaluates the signals from the temperature sensors and controls the fans. If the temperature continues to rises and the fans cannot cool sufficiently (e.g. because the duty cycle is exceeded), the power source switches off and outputs an appropriate service code. (5) Control of fan The UST controls the fan (X5) depending on temperature and firmware. (6) LocalNet interface The LocalNet interface is used to transmit data from the plug connection (X9) to the peripheral devices via the filter PC board (e.g. HFF22). (7) Regulation of welding current and voltage The welding current and voltage is regulated by the DSP (digital signal processor) and the firmware integrated in the UST. (8) Control of inverter The UST PC board controls the inverter module via the plug (X1).
52
Pin assignment
X1 ...... Inverter control (connection to TTS 22) X2 ...... Connection to control (10-pin ribbon cable) X3 ...... Supply Pin
Designation
Pin
Designation
1
+24 V-EXT, +24 V remote control connection
5
GND-EXT, remote control connection GND
2
NC
6
NC
3
UZW, intermediate circuit voltage measuring
7
GND-UZW, intermediate circuit voltage measuring
4
+24 V-INT, internal voltage supply
8
GND-INT, internal voltage supply
X4 ...... Temperature; Uact, Iact Pin
Designation
Pin
Designation
1
Uact -
13
U ACT +
2
NC
14
NC
3
LEM C 4000, Shunt
15
LEM D 5000
4
LEM A 3000, Shunt
16
NC
5
LEM B 2000, Shunt
17
GNDD LEM
6
- 15 V LEM
18
+ 15 V LEM
7
TH - ERROR 1
19
TH - ERROR 2
8
GND A (UP 400)
20
UP 400
9
CFM-
21
CFM+
10
ESC 1
22
ESC 2
11
TEMP 2 -
23
TEMP 2 +
12
TEMP 1 -
24
TEMP 1 +
X5 ...... Fan Pin
Designation
Pin
Designation
1
+ 24 V
3
+ 24 V
2
FAN, fan power module
4
FAN, fan control unit
X6 ...... Powersource - connection to power module (BPS), 26-pin ribbon cable X7 ...... Cooling unit Pin
Designation
Pin
Designation
1
Temp 6 +
6
TEMP 6 -
2
COOLER ON
7
+ 24 V
3
WAT. CONTR.
8
GND (WAT. CONTR.)
4
CFM+
9
CFM-
5
NC
10
53
GND (SUPPLY)
Pin assignment (continued)
X8 ...... Programming interface for updating firmware via BSL tool NOTE! Risk of damage to electronic components. Switch off the power supply before connecting or removing BSL tools. X9 ...... RS485 connection to remote control via a filter PC board
Measuring points
See pin assignment
LED checklist
+24 Vext +24 Vint + 5V +15 V - 15 V
STAT
+ 5V
Fig.47 Control LEDs on UST PC board
+24 Vext ........... lights up when switched mode power supply is working correctly +24 Vint + 5V ................ RS 485 +15 V - 15 V + 5V STAT .............. Status LED lights up if no firmware is present if it does not light up: process OK
Change 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.
54
Changing modules General remarks
The „Changing modules“ chapter describes how to replace components that have no instructions of their own for replacement and require detailed replacement instructions NOTE! Danger of damage to threads, especially when fastening screws with power tools (e.g. power screwdrivers). In order to avoid damage to threads, proceed as follows: - Turn screws slightly to the left to guarantee optimum centring. - Screw in at least two full turns by hand. This prevents the screw from forming a new thread: - Carefully tighten the screw
Overview
The „Replacing components“ section contains the following subsections: Housing unit Changing BPS 17 PC board (Refer to the installation instructions for the BPS 17 PC board) Changing BPS 22 PC board (Refer to the installation instructions for the BPS 22 PC board) Changing inverter module (Refer to the installation instructions for the inverter module) Changing the TP 592S temperature sensor Changing the TTS 22 PC board Changing the BSV 22 PC board Changing earth current watchdog Changing the transformer
55
Housing unit General remarks
The section headed „Housing“ covers the opening and closing of the housing for the replacement operations described below.
-
Opening the housing
-
(1)
(1)
Undo screws (1) on both sides of the power source for the side s. Take off side s
(1)
Fig. 1 Removing housing side s
(2)
NOTE! After removing the screws (2), ensure that the control does not fall out of the frame.
(2)
-
Undo front screws (2)
-
Undo rear screws (3)
Fig. 2 Removing front screws
(3)
(3)
Fig. 3 Undoing rear screws
56
Opening the housing (continued)
(7) (4)
(4)
If handle is present, remove holder on one side as follows: Undo screws (4) on the holder for the handle
Fig. 4 Removing screws for handle holder
(5) (6)
Remove the cover as follows: Lift the handle (5) and holder (6) slightly Remove the cover (7) (Fig. 4)
Fig. 5 Removing handle holder
Closing the housing
(7) (4)
(6)
(4)
-
Fit cover (7) If present, replace handle (6) with holder (5) and fasten with two screws (4).
-
Tighten front screws (2)
Fig. 6 Replacing cover and fastening handle
(2)
(2)
Fig. 7 Tightening front screws
57
Closing the housing (continued)
(3)
Tighten rear screws (3)
(3)
Fig. 8 Tightening rear screws
WARNING!Danger of electric shock due to insufficient insulation of the housing. Every electric shock is potentially life threatening. Before fitting the side , lay down the sheet for insulating the PC boards behind the side on the side of BPS 17/22 PC board. -
(1)
(1)
(1)
Fig. 9 Fastening the housing side s
58
On both sides of the power source replace side s and fasten with screws (1)
Changing BPS 17 PC board Instructions
When changing the BPS 17 PC board, always follow the installation instructions supplied with the board.
Changing BPS 22 PC board Instructions
When changing the BPS 22 PC board, always follow the installation instructions supplied with the board.
Changing inverter module Instructions
When changing the inverter module, always follow the installation instructions supplied with the module.
Changing the TP 592S temperature sensor Instructions
The temperature sensor is plugged in but can be lifted out by carefully using an ordinary screwdriver or pulled out with flat pliers. Before inserting the new temperature sensor, fill the hole for the sensor with heat conductive paste to ensure perfect heat transfer. If the temperature sensor is covered by other parts, please refer to instructions for removing the part concerned, and see the special instructions in the „Changing components“ section, if available.
59
Changing the TTS 22 PC board ESD measures
NOTE! There is danger of damage to the TTS 22 PC board from electrical discharge. When changing the TTS 22, take appropriate ESD (electrostatic discharge) measures. These include: -
-
The workspace used when removing the board must be equipped with the following ESD-appropriate protective measures: - Work surfaces - Floors - Conductive wristband - Seating In addition to the ESD-appropriate workspace, use a suitable transport container
Changing the TTS 22 PC board
(2)
(1) (2) (1)
(11)
(1) Fig. 1 UST: remove plug connections and unscrew spacers
UST PC board: Remove plug connections (1) Unscrew the 5 spacers (2) and metal spacer (11) Remove UST PC board
60
Changing the TTS 22 PC board (continued)
(4)
-
Unscrew the two spacers (4) on the insulating sheet
-
Remove Molex plug (5) and blade terminal (6) from the TTS 22 PC board
-
Undo two spacers (3) and four screws (9)
-
Remove TTS 22 PC board (7) complete with retaining plate (10) Undo five spacers (8) on TTS 22 PC board Remove TTS 22 PC board (7) from retaining plate (10)
(4)
Fig. 2 Loosening the spacers
(6)
(5)
Fig. 3 Removing plug connections from sockets
(9) (3)
(9)
(9)
(3)
(9)
Fig. 4 Undoing screws and spacers
(8)
(10)
(7) Fig. 5 Removing TTS 22 PC board and spacers
61
Installing the TTS 22 PC board
-
Place the TTS 22 (7) on the spacers (8) on the retaining plate -
Screw in the five spacers (8) on TTS 22 PC board Replace TTS 22 PC board (7) complete with retaining plate
(8)
(7) Fig. 6 Fasten TTS 22 PC board with spacers
-
Fasten the TTS 22 PC board complete with retaining plate using the two spacers (3) and four screws (9)
-
Insert Molex plug (5) on TTS 22 PC board
(9) (3)
(9)
(9)
(3)
(9)
Fig. 7 Tighten screws and spacers
Important: When inserting the five blade terminals (6), proceed as follows: Insert the individual blade terminals to „Common X1“ slot The remaining blade terminals bound in pairs with silicone tubing can be inserted arbitrarily into the remaining slots. The only requirement is that blade terminals are inserted in pairs into either X2/X3 or X4/X5. (5)
(6)
Fig. 8 Inserting plugs into sockets
-
(4)
(4)
Fig. 9 Tightening spacers
62
Screw in the two spacers (4) on the insulating sheet
Installing the TTS 22 PC board (continued)
-
Lay down UST PC board
Fig. 10 Laying down UST PC board
(2)
(1)
(2)
(1)
(11)
(1) Fig. 11 UST: reinserting plug connections and tightening spacers
UST PC board: - reinsert plug connections (1) NOTE! When tightening the spacers (2), screw metal spacer into position (11). -
Tighten the 5 spacers (2) and metal spacer (11)
63
Changing the BSV 22 PC board ESD measures
NOTE! There is danger of damage to the BSV 22 PC board from electrical discharge. When changing the BSV 22, take appropriate ESD (electrostatic discharge) measures. This includes: -
-
The workspace used when removing the board must be equipped with the following ESD-appropriate protective measures: - Work surfaces - Floors - Conductive wristband - Seating In addition to the ESD-appropriate workspace, use a suitable transport container
Removing the BSV 22 PC board
(2)
(1) (2) (1)
(11)
(1) Fig. 1 UST: remove plug connections and unscrew spacers
UST PC board: Remove plug connections (1) Unscrew the 5 spacers (2) and metal spacer (11) Remove UST PC board
64
Removing the BSV 22 PC board (continued)
(4)
-
Unscrew the two spacers (4) on the insulating sheet
-
Remove Molex plug (5) and blade terminal (6) from the BSV 22 PC board
-
Undo two spacers (3) and four screws (9)
-
Remove BSV 22 PC board (7) complete with retaining plate (10) Undo the four spacers (8) on BSV 22 PC board Remove BSV 22 PC board (7) from retaining plate (10)
(4)
Fig. 2 Loosening the spacers
(5)
(6)
Fig. 3 Removing plug connections from sockets
(9) (3)
(9)
(9)
(3)
(9)
Fig. 4 Undoing screws and spacers
(8)
(7) (8)
(10)
-
(8)
(8)
Fig. 5 Removing BSV 22 PC board and spacers
65
Installing the BSV 22 PC board
-
Place the BSV 22 (7) on the spacers (8) on the retaining plate (8)
(7) (8)
(10)
-
(8)
Tighten the four spacers (8) on BSV 22 PC board (7) Replace BSV 22 PC board (7) complete with retaining plate
(8)
Fig. 6 Fasten BSV 22 PC board with spacers
-
Fasten the BSV 22 PC board complete with retaining plate using the two spacers (3) and four screws (9)
-
Insert Molex plug (5) into BSV 22 PC board X9 Insert blade terminals X1 to X4 (6) as labelled on the cables and on BSV 22 PC board.
(9) (3)
(9)
(9)
(3)
(9)
Fig. 7 Tightening screws and spacers
(5)
(6)
-
Fig. 8 Inserting plugs into sockets
-
(4)
(4)
Fig. 9 Tightening spacers
66
Screw in the two spacers (4) on the insulating sheet
Installing the BSV 22 PC board (continued)
-
Lay down UST PC board
Fig. 10 Laying down UST PC board
Installing UST PC board
(2)
(1)
(2)
(1)
(11)
(1) Fig. 11 UST: reinserting plug connections and tightening spacers
UST PC board: - reinsert plug connections (1) NOTE! When tightening the spacers (2), screw metal spacer into position (11). -
Tighten the 5 spacers (2) and metal spacer (11)
67
Changing the transformer Removing the transformer
(1)
-
Undo two front screws (1) for the device frame
-
Disconnect the ribbon cable (2) for the control at X2 on the UST PC board Remove the control
(1)
Fig. 1 Undoing screws on front of device frame
(2)
Fig. 2 UST: Disconnecting the ribbon cable
-
(3)
Fig. 3 BPS: Disconnecting the ribbon cable
68
Disconnect ribbon cable (3) from BPS PC board
Removing the transformer (continued)
-
Undo the two screws (4) on HF transformer (5)
-
Lift high frequency (HF) transformer (5) and undo two screws (6) behind the HF transformer.
-
Remove secondary transformer leads (7): Unscrew the two screws with serrated washers (not shown)
-
Cut cable tie on the secondary transformer lead (7) (cable tie no shown) Remove toroidal tape cores (8) from the transformer leads
(5) (4)
Fig. 4 HF transformer: removing screws
(5)
(6) Fig. 5 Loosening the two screws behind the HF transformer
(7)
Fig. 6 Removing the secondary transformer leads
-
(8)
(7)
Fig. 7 Removing toroidal tape cores
69
Removing the transformer (continued)
(12) (10)
Undo hexagon bolt (9) using a size 19 spanner Remove hexagon bolt (9) with serrated washer and shim
The following leads are now disconnected: Middle tap transformer lead (10) Measuring line (11) - white cable with „Massebuchse“ written on it Secondary wiring lead (12) - white cable with no writing
(11) (9)
Fig. 8 Removing the middle tap transformer lead
(13)
-
Undo spacers (13)
-
Remove blade terminals X2 to X5 (15) Remove blade terminal „X1 common“ (16) from the measuring line for welding voltage. Cut cable tie for the measuring line (16) - Fig. 11
(13)
Fig. 9 Loosening the spacers
(15)
(16)
-
-
Fig. 10 Removing blade terminal for the measuring lines
70
Removing the transformer (continued)
(18)
-
(16)
Remove measuring lead (16) for the welding voltage Feed out the middle tap transformer lead (17) on the current sensor (18)
(17)
Fig. 11 Feeding out the middle tap transformer lead
-
Loosen the two screws (19) on the luster terminal Remove primary leads (20) Undo screw (21)
-
Undo screws (22)
(20) (21) (19)
Fig. 12 Disconnect primary transformer leads
Important: undo the three screws (22) on earth wire, if present.
(22)
Fig. 13 Undo screws on transformer
(24) (23)
(25)
(22) Fig. 14 Removing the transformer
71
Remove transformer (22) Cut through cable ties (23) and (24) on transformer
Removing the transformer (continued)
-
Unthread the middle tap transformer lead (17) on the EP rings (25) (see also Fig. 14)
-
Undo the four screws (26) on the transformer and remove the side plates (27)
(25) (17) Fig. 15 Feeding out the middle tap transformer lead
(27)
(26)
(27) Fig. 16 Removing the plates on the transformer
Installing the transformer
-
Fasten side plates (27) to the transformer using the four screws (26) (24) (23)
(25)
(22) Fig. 17 Routing the middle tap transformer lead
72
Thread EP rings (25) onto the middle tap transformer lead (17) and make two winds Fasten EP rings (25) and middle tap transformer lead (17) with cable ties
Installing the transformer (continued)
-
Installing the transformer (22) into the power source -
Tighten screws (22)
Important: If earth wire is present tighten the three screws (22) and fasten earth wire using the central screw (22).
(22)
Fig. 18 Securing the transformer
(16) (17)
Fig. 19 Routing leads
Route leads as follows and fix with cable tie: Along route 16 (fig. 19): Measuring line (16) for the blade terminal „X1 common“ (single lead) Along route 17 (fig. 19 and 20): Feed in auxiliary power source leads for the blade terminals X2 to X5 (leads bound in pairs)
(17)
Fig. 20 Routing auxiliary power source leads
Important: The position of the primary transformer leads (20) on the luster terminals is not important.
(20) (21)
(19) Fig. 21 Connecting primary transformer leads
73
-
Insert transformer leads (20) into the luster terminals and fix with screws (19) Fix luster terminals and insulation with screws (21) Bind leads with cable tie
Installing the transformer (continued)
(18) -
(16)
Feed middle tap transformer lead (17) in direction of arrow through the current sensor (18) Route measuring line (16) for the blade terminal „X1 common“ (see fig. 19)
(17)
Fig. 22 Routing transformer lead
(15)
(16)
When inserting the five blade terminals (15, 16), proceed as follows: Insert the individual blade terminals (16) to „Common X1“ slot The remaining blade terminals (15) bound in pairs with silicone tubing can be inserted arbitrarily into the remaining slots. The only requirement is that blade terminals are inserted in pairs into either X2/X3 or X4/X5.
Fig. 23 Removing blade terminal for the measuring lines
-
(13)
(13)
Fig. 24 Tightening spacers
74
Tighten the two spacers (13) on the insulating sheet
Installing the transformer (continued) (12) (10) (11) (9)
(9)
(29) (30) (11) (12) (10) Fig. 25 Fitting the middle tap transformer lead
Align the following components on the hexagon bolt (9) in the numbered order: Serrated washer (29) Shim (30) Measuring line (11) - white cable with „Massebuchse“ written on it Secondary wiring lead (12) - white cable with no writing Middle tap transformer lead (10) Tighten hexagon bolt (9) using a size 19 spanner NOTE! When aligning the secondary transformer leads (7), ensure that the toroidal tape cores are in the airstream (for correct position in airstream see fig. 28) and that they are held in place with cable ties.
(8)
(7)
Fig. 26 Fitting toroidal tape cores
(31) (7)
Fig. 27 Fastening secondary transformer leads
NOTE!When tightening the screws with serrated washers for the secondary voltage of the transformer, maintain the tightening torque given below. -
Slide the serrated washers onto the fastening screws (not shown). Fasten the secondary transformer leads (7): Tighten the screws (31) including serrated washers (not shown) with a torque of 4 Nm.
75
Installing the transformer (continued)
(5)
-
Lift high frequency (HF) transformer (5) and tighten two screws (6) behind the HF transformer
-
Replace HF transformer and tighten the two screws (4)
-
Connect ribbon cable (3) from BPS PC board
(6) Fig. 28 Tightening the two screws behind the HF transformer
(4)
Fig.29 HF transformer: tightening screws
(3)
Fig. 30 BPS: connecting the ribbon cable
NOTE! Danger of malfunction during high frequency welding. When routing the ribbon cable (2), ensure that there is enough distance between it and the HF leads (32).
(32)
(2)
Fig. 31 shows the correct routing of the ribbon cable (2). X2 Fig. 31 UST: connecting the ribbon cable
-
Connect the ribbon cable (2) for the control at X2 on the UST PC board Insert the operating
76
Installing the transformer (continued)
-
(1)
(1)
Fig. 32 Screws on front of device frame
77
Press front of frame on Tighten two front screws (1) for the device frame
Safety Inspection Requirement
A safety inspection must be carried out - after every repair - after every modification - at specified intervals (at least once every 12 months)
Work instruction
The work instruction „Safety Inspection of Arc Welding and Cutting Equipment“ is available in the TechGuide Center under „Safety, Environment & Health“.
78
and abbreviations used General remarks
„ and abbreviations“ is a glossary of specific technical essential for an understanding of the service manual.
and abbreviations
BSL tool: The BSL tool is a special tool for updating the power source with new firmware. A PC or notebook is required for the update. Config memory (CFM): The CFM component supplements the UST PC board firmware (central control and regulation unit) with individual, device-specific data. DSP: Digital SignalProcessor. Part of the UST PC board (central control and regulation unit). The DSP captures digitised actual values on the part of the welding process, and ensures constant regulation and optimisation of the welding current and voltage, on the basis of the parameters set the saved firmware the actual values measured EMI: ElectroMagnetic Interference. Electromagnetic interference is high-frequency noise in the mains voltage. The line filter absorbs this noise and thereby ensures optimum welding results and trouble-free operation of the power source. FAC: Factory resets the settings in the setup menu. The original factory settings are restored by pressing and holding the „Store“ button for two seconds. The welding machine has been reset when the display reads „PrG“. Jobs and parameters in the second level of the set-up menu are not deleted. Hall shunt: Ensures electrically isolated measuring of the welding current. The UST (central control and regulation unit) analyses the signal. IGBT: Insulated Gate Bipolar Transistor. This is a special bipolar transistor for switching to high power settings. IGBTs are used in the power source as modules. On the TT/MW 1700/ 2200 power sources, IGBT modules are used in a secondary role to prepare the welding current for AC welding. Instruction pointer: When a software error appears: the third level of the display contains more detailed information on the cause of the error (see „Error location aid“ chapter) LocalNet RS232 converter: For connecting the power source to the serial interface on a PC, for: ing software options transmitting data from the power source using PC-based software (Fronius Backup, Fronius Service Module, Job-Explorer, etc.)
79
80
TransTig 800
TransTig 2200
MagicWave 1700
MagicWave 2200
PlasmaModule 10
FK 2200
MagicWave 2200 Job G/F MagicWave 2200 Job G/F/US TransTig 800 Job G/F TransTig 2200 Job G/F TransTig 2200 Job G/F/US MagicWave 1700 Job G/F MagicWave 1700 Job G/F/US
4,075,119 4,075,119,800 4,075,159 4,075,120 4,075,120,800 4,075,121 4,075,121,800
MagicWave 2200 G/F MagicWave 2200 G/F/US TransTig 2200 G/F TransTig 2200 G/F/US MagicWave 1700 G/F MagicWave 1700 G/F/US
4,075,125 4,075,125,800 4,075,126 4,075,126,800 4,075,127 4,075,127,800
12,0405,0369 42,0201,1328 42,0406,0320
43,0004,1993 - US 43,0004,0519
AM2,0201,1327 43,0002,0295 42,0300,0648
45,0200,1151
42,0409,2979 - US 42,0409,2911 42,0001,3541 - US 43,0013,0015 BE2,0201,1329
42,0407,0273 40,0001,0310 - *
12,0405,0365 33,0005,4146 - TT800 33,0005,4130 - MW1700 33,0005,4129 - MW/TT2200
43,0006,0152 - MW2200 43,0006,0134 - MW1700/TT800/2200
42,0405,0421 41,0003,0282,Z - MW 1700/2200
2IS W2 FM
4,070,949 - FMW22IS 41,0003,0279 12,0405,0365
41,0003,0203
33,0010,0326
43,0001,0600
43,0001,1177 43,0001,1176 - TT 43,0001,3280 - TT 2200 43,0001,3279 - MW1700/2200 43,0001,3258 - TT800/2200 Job 43,0001,3259 - MW1700/2200 Job 42,0406,0315 42,0406,0093
42,0409,3211 - TT800 42,0409,2935 - TT2200 42,0409,2934 - MW1700 42,0409,2882 - MW2200
43,0001,1178 43,0001,1273 TT800
42,0405,0398 - MW1700/2200 42,0405,0399 - TT2200
42,0001,1501
43,0004,2328
42,0001,5477
43,0004,2330
* gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée * Indicar la longitud deseada * Indicare la lunghezza desiderat * indicar o comprimento desejado
XYHG WHSRåDGRYDQRXGpONX
32,0405,0183 42,0404,0024
TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_wi_00545
1/2 012007
4,070,798,Z - BPS17 MW 1700/TT 800 4,070,799,Z - BPS22 TT/MW 2200
4,070,813 - BSV22 TT2200 4,070,804,Z - TTS22 MW1700/2200 41,0001,0627 41,0009,0057
S
2 S2 TT 22 V BS
33,0024,0032 33,0010,0325 - MW/TT2200
BP
43,0006,0168
43,0001,1191 42,0405,0420 4,070,960,Z - UST2C HF
F2
2
43,0004,1122 - 26pol.
US
T2
4,070,812 - HFF22
TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200 Ersatzteilliste / Spare parts list / Listes de pièces de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi el_fr_st_wi_00545
2/2 012007
FRONIUS INTERNATIONAL GMBH Buxbaumstraße 2, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: [email protected] www.fronius.com www.fronius.com/addresses Under http://www.fronius.com/addresses you will find all addresses of our Sales & service partners and Locations.
ud_fr_st_so_00082
012008
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