Fronius TransSynergic 4000 Service Manual
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Fronius TransSynergic 4000 Service Manual

Mig/mag power source
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See also: Operating Instructions & Spare Parts
/ Battery Charging Systems /
TransSynergic 4000/5000
TransPuls Synergic 2700
TransPuls Synergic 3200/4000/5000
42,0410,1237
Welding Technology
/ Solar Electronics
011-28062017
Service manual
Spare parts list
MIG/MAG Power source

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Summary of Contents for Fronius TransSynergic 4000

  • Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Service manual TransSynergic 4000/5000 Spare parts list MIG/MAG Power source TransPuls Synergic 2700 TransPuls Synergic 3200/4000/5000 42,0410,1237 011-28062017...

  • Page 3: Table Of Contents

    Table of contents Foreword and safety instructions ........................6 Safety ............................... 6 Fronius Technical Support Center (TSC) ....................6 General remarks ............................6 Function overview ............................ 7 Fault location aid ............................7 Detailed description ..........................7 Changing components ..........................7 Terms and abbreviations used .........................
  • Page 4 Technical Data ............................39 Function overview ..........................40 Plug layout ............................. 40 LED checklist ............................41 Measuring points ........................... 41 ASU 40 - additional PC board ........................42 General remarks ............................ 42 Component position in the machine ...................... 42 Overview ..............................42 Technical Data ............................
  • Page 5 Measuring points ........................... 69 Changing UST PC board ........................69 NF 3160 - Line filter ............................ 70 General remarks ............................ 70 Component position in the machine ...................... 70 Overview ..............................70 Technical Data ............................70 Function overview ..........................71 Plug layout ............................. 71 LED checklist ............................
  • Page 6 Primary rectifier ............................88 General remarks ............................ 88 Component position in the machine ...................... 88 Overview ..............................88 Function overview ..........................88 Plug layout ............................. 89 Measuring points ........................... 89 Changing components ..........................90 Safety ..............................90 General remarks ............................ 90 Overview ..............................
  • Page 7 Test record ............................121 Test label .............................. 121 Terms and abbreviations used ........................122 General remarks ..........................122 Terms and abbreviations ........................122 Entire circuit diagram ..........................124 Storage location ........................... 124 Spare parts list / Circuit diagram Fronius Worldwide...

  • Page 9: Foreword And Safety 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 personnel. Take note of the „Safety rules“ chapter in the power source operating instructions. WARNING! An electric shock can be fatal. Before opening up the machine Move the mains switch to the “O”...

  • Page 10: Function Overview

    Tools and This provides an overview and description of all equipment required for servicing the measuring power source professionally. This equipment includes: instruments Tools required Measuring and inspection equipment Ancillary materials Function over- Contains a brief descriptive overview of the entire system: view in text form in block diagram form...

  • Page 11: Tools And Measuring Instruments

    Tools and measuring instruments General remarks „Tools and measuring instruments“ offers an overview and description of all equipment needed to service the machine professionally. This equipment includes: Tools required Measuring and inspection equipment Ancillary materials Tools required Box spanner (8 mm) Large needle nosed pliers (approx.

  • Page 12: Function Overview

    Function overview Principle of the The machines are totally digitized, microprocessor-controlled inverter power sources. A digital family of universal control regulates the entire welding process. The actual data are measured machines continuously, and the machine responds immediately to any changes. Special control algorithms ensure that the target status is maintained at all times.

  • Page 13: Block Diagram

    Block diagram Remote control unit Wire-feed unit Control panel Regulation unit Local Welding torches Wire Valve Workpiece Control and Local Welding current regulation unit (10) 55 V sensor 24 V Power Output choke supply 24 V 55 V Secondary Rectifer 3 x 400 V Primary power module Fig.
  • Page 14 Block diagram (6) Transistors: legend The transistors carry the intermediate circuit voltage in intervals at high frequency (continued) to the primary coil on the transformer. The high frequency means that The transformer can be built very easily and compactly. Thermal losses due to the low inductivity required of the transformer coils can be kept to an absolute minimum.

  • Page 15: Fault Location Aid

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

  • Page 16: Fault Flowcharts

    Fault flowcharts Overview The overview will help you to find the relevant (section of) flowchart. The positions and meanings of the LEDs for the components/PC boards can be found in the „Detailed description“ section. The „Detailed description“ section contains an „LED checklist“...

  • Page 17: Poor Ignition And Welding Properties With „Mig/Mag Welding

    Poor ignition and Start welding proper- ties with „MIG/ MAG welding“ Correct shielding gas connected, Connect correct shielding gas and and l/min set correctly? check l/min Gas-test button: Shielding gas Check shielding gas solenoid flowing out? valve, including control Welding torch and grounding Check welding torch and groun- (earthing) cable OK? ding (earthing) cable...

  • Page 18: Poor Ignition And Welding Properties With „Tig Welding

    Poor ignition and Start welding proper- ties with „TIG welding“ Correct shielding gas connected, Connect correct shielding gas and and l/min set correctly? check l/min Gas-test button: Shielding gas Check shielding gas solenoid flowing out? valve, including control Welding torch and grounding Check welding torch and groun- (earthing) cable OK? ding (earthing) cable...

  • Page 19: Poor Weld Properties With „Rod Electrode (Mma) Welding

    Poor weld pro- Start perties with „rod electrode (MMA) welding“ Connect cable correctly Electrodes/grounding (earthing) cable connected/functioning correctly? Check settings on control panel Parameters set correctly? Check set-up parameters Possibly reset to factory set- tings (FAC) (see operating instruc- tions) Check whether power source OK, and check application...

  • Page 20: Nothing Happens On Control Panel (Tps 2700)

    Nothing happens Start on control panel (TPS 2700) Voltage OK on prima- Check mains cable, ry rectifier V1=320V/ mains switch, line 560V DC? filter, rectifier and supply voltage Voltage on intermedi- ate circuits 1 and 2 > Change BPS 250V DC? On MV power sources Are LEDs +5V, +12V flashing on the ASU 27,...
  • Page 21 Nothing happens on control panel (TPS 2700) (continued) Steady +5V, +15V, - Check/change control 15V on UST? panel/ribbon cable Unplug X4 from UST Steady +5V, +15V, - 15V on UST? Change VAC shunt Unplug X2 from UST Steady +5V, +15V, - Check/change control 15V on UST? panel/ribbon cable...

  • Page 22: Nothing Happens On Control Panel (Tps 3200/4000/5000)

    Nothing happens Start on control panel (TPS 3200/4000/ 5000) 3x230V/3x400V on Check mains cable, the terminal strip X7/5 line filter and supply - X7/7 OK? voltage MV power sources LED 230V flashing on with U nom 230V ASU 40 at U nom Change ASU 40 230V? Voltage on intermedi-...
  • Page 23 Nothing happens on control panel (TPS 3200/4000/ 5000) (continued) Steady +5V, +15V, - Check/change control 15V on UST? panel/ribbon cable Steady +24V int/ext LEDs on UST? Check cooling unit Unplug X4 from UST Change BPS Steady +5V, +15V, - 15V on UST? Change VAC shunt Unplug X2 from UST Steady +5V, +15V, -...

  • Page 24: No Or Incorrect Welding Current

    No or incorrect Start welding current Welding torch and grounding Check welding torch and groun- ding (earthing) cable (earthing) cable connected/ functioning correctly? Nothing happening on control See subsection „Nothing happens panel? on control panel“ Welding current I no longer Change current sensor A1 VAC comm adjustable, or...

  • Page 25: No Or Incorrect Wirefeed Speed

    No or incorrect Start wirefeed speed Service code display- see service codes See „Nothing hap- table pens on control panel“ flowchart Wire-feed unit entered +24V LED flashing Steady +24V ext LED in the service module? on SR 41? on UST? Check cable harness/ „BUS OK“...

  • Page 26: Insufficient Torch Cooling (Fk 4000/Fk 4000 R)

    No or incorrect wirefeed speed (continued) BRT LED flashes Check torch trigger/ when torch trigger cabling pressed? Change SR 41 Insufficient torch Start cooling (FK 4000/ FK 4000 R) Cooling unit set-up Switch set-up settings settings switched to to AUTO or ON OFF? Sufficient coolant? Top up coolant;...
  • Page 27 Insufficient torch cooling (FK 4000/ FK 4000 R) (continued) 400V AC available Check cable harness from plug X10/6 - to power source X10/8? Securing device F1 in Switch off unit; the cooling unit OK? Disconnect pump; Replace fuse; Switch on unit; Check relay contact, Securing device F1 Change auto-transfor-...

  • Page 28: Service Code Err 50

    Service code Err Start Does service code Err 50 appear directly after switching on, Select „Rod electro- although the primary de“ mode power module is not Change UST operating? Imbalance in interme- +5V available on UST diate circuit > 35V? from X6/26 - X7/8? Change BPS Does Err 50 disappear...
  • Page 29 Service code Err (continued) Switch off power source; discharge intermediate circuit electrolytic capacitors; unplug X7/1 - X7/4 switch on power source Imbalance in interme- Change BPS diate circuit > 35V? Change intermediate circuit electrolytic capacitors...

  • Page 30: Ust Service Codes

    UST service codes Safety WARNING! An electric shock can be fatal. Before opening up the machine Move the mains switch to the “O” position Unplug machine from the mains Ensure that electrically charged components (e.g. capacitors) have been discharged Table of service For every service code there is information on codes Service code indicator (e.g.
  • Page 31 Table of service EcF | xxx (code no.32) codes Cause: BPS configuration fault, x stands for: (continued) 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...
  • Page 32 Table of service Err | PE (code no.53) codes Cause: Ground (earth) fault (continued) Remedy: remove earth fault. Configure machine in insulated state. Check earth current watchdog and change if necessary. Err | tF1 (code no.11), Err | tF2 (code no.12), Err | tF3 (code no.13), Err | tF4 (code no.14), Err | tF5 (code no.15) Cause: temperature sensor fault (short circuit or interruption)
  • Page 33 Table of service Err | 059 (code no.59) codes Cause: overvoltage in the secondary circuit: safety cut-out has tripped (continued) Remedy: check secondary circuit, including TP4CEL40 Err | 060 (code no.60) Cause: DPS5000 only: Due to an opened door contact, SITRE1A has triggered safety disconnection Remedy: safety cut-out: close door contact...
  • Page 34 Table of service Err | 26.x (code no.26) codes Cause: config memory (CFM) „machine“ fault, x stands for: (continued) 1 config memory not found 2 checksum error 3 CFM undescribed 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Remedy: check cable harness.
  • Page 35 Table of service no | H2O (code no.39) codes Cause: flow watchdog reporting water deficiency (continued) Remedy: check cooling system hosepipes. Check pump pressure and flow rate. Check flow watchdog. no | Ign (code no.55) Cause: „Ignition time-out“ fault: no ignition within the value set in the set-up menu. The safety cut-out has tripped.

  • Page 36: Special Displays Used With Service Codes

    Level 3 (e.g. „IP 3456“): instruction pointer (press parameter selection button again) Important! Please make a note of the displays in levels 1, 2, and 3, and pass them on to Fronius. Using this data, Fronius can locate the precise cause of the fault.

  • Page 37: Service Codes Sr 4Xa

    Service codes SR 4xA Safety WARNING! An electric shock can be fatal. Before opening up the machine Move the mains switch to the “O” position Unplug machine from the mains Ensure that electrically charged components (e.g. capacitors) have been discharged Table of service EFD 1.x codes...

  • Page 38: Service Codes For Push-Pull Calibration

    Service codes for push-pull calibration Safety WARNING! An electric shock can be fatal. Before opening up the machine Move the mains switch to the “O” position Unplug machine from the mains Ensure that electrically charged components (e.g. capacitors) have been discharged Checking actual- The actual-value pick-up is checked by measuring the direct voltage on the actual-value...

  • Page 39: Error Codes Shown When The Drive Units Are Engaged („Engaged" Calibration)

    Error codes St1 | E 5 shown when the Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any drive units are actual rotational speed value. engaged („enga- ged“ calibration) Remedy: Repeat the push-pull calibration. If the error message re-appears: check the actual-value pick-up and the cable connections to and from it St1 | E 6 Cause:...
  • Page 40 Error codes St2 | E 12 shown when the Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any drive units are engaged („enga- actual rotational speed value. ged“ calibration) Remedy: Repeat the push-pull calibration. If the error message re-appears: check the actual-value pick-up and the cable connections to and from it (continued) St2 | E 13...

  • Page 41: Detailed Description

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

  • Page 42: Asu 27 - Additional Pc Board

    ASU 27 - additional PC board General remarks The ASU 27 PC board (item number 4,070,691,Z) is an additional PC board for the TPS 2700 MV power sources and is for switching between 230 V and 400 V. Component position in the machine Fig.5 TPS 2700 MV: Position of ASU 27 PC board...

  • Page 43: Function Overview

    Function over- For switching between 230 V AC and 400 V AC view For generating control voltage +12 V and +5 V from the input voltage When switching on, the switching mechanism on the PC board detects the input voltage: a) With an input voltage of 400 V AC, the ASU 27 PC board switches both power modules on BPS 25/BPT 27 in series b) With an input voltage of 230 V AC, the ASU 27 PC board switches both power...

  • Page 44: Led Checklist

    LED checklist LED +5 V LED +12 V LED 230 V AC LED 400 V AC Fig. 8 LED indicators on ASU 27 PC board Measuring points There are no measuring points available on the ASU 27 PC board.

  • Page 45: Asu 40 - Additional Pc Board

    ASU 40 - additional PC board General remarks The ASU 40 PC board (item number 4,070,685) is an additional PC board for TPS 3200 TS/TPS 4000/5000 MV, and is for switching the input voltage between 230 V AC and 400 V AC. Component position in the machine...

  • Page 46: Technical Data

    Technical Data Input voltage 230/400 V AC Input voltage tolerance +/- 15 % Function over- For switching between 230 V AC and 400 V AC view For generating control voltage +12 V and +5 V from the input voltage When switching on, the switching mechanism on the PC board detects the input voltage: a) With an input voltage of 400 V AC, the ASU 40 PC board switches both power modules on BPS 32/40/42/43/50/53 in series...

  • Page 47: Led Checklist

    Plug layout Function (continued) Connection to 2nd line filter L1 out Connection to 2nd line filter L2 out Connection to 3rd line filter L3 out Connection to 2nd rectifer L1 Connection to 2nd rectifer L2 Connection to 2nd rectifer L3 not connected Connection to cooling unit 230 V Connection to cooling unit L2...

  • Page 48: Measuring Points

    LED checklist LED charge unit ..... flashes once the intermediate circuit has been charged (continued) LED 230 V ...... flashes at an input voltage of 230 V Measuring points There are no measuring points available on the ASU 40 PC board.

  • Page 49: Bps 25/Bpt 27 - Power Module Pc Board

    BPS 25/BPT 27 - power module PC board BPS 25 (item number 4,070,631,Z) and BPT 27 (item number 4,070,739,Z) are power General remarks module PC boards for the TPS 2700 power source. The BPT 27 has serial numbers of 14481582 and upwards and replaces the BPS 25. Important! On PC boards BPS 25/BPT 27, primary voltage is on! BPS 25/BPT 27 consist of 2 PC boards: Power module PC board BPS 25/BPT 27...

  • Page 50: Technical Data

    Technical Data Input voltage 3 x 230/400 V AC Input voltage tolerance (+/-15%) Supply voltage (from NT 24A) 15 V DC primary Boost converter work frequency 47 kHz Transistor module switching frequency 100 kHz Function over- Basic composition: two individual power modules (advantage: power modules can view be switched in series as well as parallel) Suitable for a 3 x 400 V AC and 3 x 230 V AC mains supply...
  • Page 51 Plug layout BPS Function 25/BPT 27 Ribbon cable connection to UST PC board (on BPZ 25 PC board) (continued) Pin 1 Primary current measurement Pin 2 Primary current measurement GND T1 Pin 3 Primary current measurement Pin 4 Primary current measurement GND T2 Pin 5 Transistor control...

  • Page 52: Led Checklist

    LED checklist 1 x 15 V primary supply LED 2 control LEDs 8 transistor module control LEDs Boost converter Fig. 16 LED indicators on PC board BPS 25/BPT 27 Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor field effect transistors) with diode.
  • Page 53 Measuring points Measuring points Plug/pin Measuring result command (continued) value Intermediate circuit voltage 1 M1/TP1-TP3 320 V DC Intermediate circuit voltage 2 M2/TP5-TP7 320 V DC Diode check module M1 M1/TP1-TP2 (+) 0.46 V M1/TP1-TP4 (+) 0.46 V M1/TP3 (+) - TP2 0.46 V M1/TP3 (+) - TP4 0.46 V...

  • Page 54: Bps 32/40/42/43/50/53 - Power Module Pc Board

    BPS 32/40/42/43/50/53 - power module PC board BPS 32/40/42/43/50/53 are power module PC boards: General remarks TPS 3200 ....BPS 32 (item number 4,070,681,Z) BPS 42 >/= V1.4A (item number 4,070,738,Z) BPS 43 (item number 4,070,771,Z) TS/TPS 4000..... BPS 40 (item number 4,070,617,Z) BPS 42 (item number 4,070,738,Z) BPS 43 (item number 4,070,771,Z) TS/TPS 5000.....

  • Page 55: Technical Data

    Overview Main switch LED LED +15 V primary (continued) Intermediate circuit imbalance LED High charging relay LED Fig. 20 PC board BPS 53 / 50 >/= V1.4A / 43 / 42 >/= V1.4A *) ... not on PC board BPS 42 >/= V1.4A and BPS 43 Technical Data Input voltage 3 x 230/400 V AC...

  • Page 56: Plugs On The Power Module Pc Boards

    Plugs on the power module (X18) (X7) (X19) (X1) (X20) (X21) (X4) (X12) (X11) (X2) (X10) PC boards (X6) (X15) (X14) (X17) (X16) (X5) (X13) (X9) (X8) (X3) Fig. 21 Plugs and connections on power module PC board, e.g. BPS 50 < V1.4A The position of the plug and connections is identical for all power module PC boards.
  • Page 57 Plug layout Function (continued) Intermediate circuits 1 and 2 primary connection Pin 1 Intermediate circuit 1 + Pin 9 Intermediate circuit 1 + Pin 2 Pin 10 Pin 3 Intermediate circuit 1 - Pin 11 Intermediate circuit 1 - Pin 4 Pin 12 Pin 5 Intermediate circuit 2 +...

  • Page 58: Led Checklist Of Power Module Pc Boards

    LED checklist of power module PC boards Fig. 22 LED indicators on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32 Main switch LED LED +15 V primary Intermediate circuit imbalance LED High charging relay LED Fig.
  • Page 59 Measuring points (continued) Fig. 23 Measuring points on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32 4 x diode 4 x diode Fig. 23a Measuring points on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A...
  • Page 60 Measuring points Measuring points Plug/pin Measuring result command value (continued) Intermediate circuit voltage 1 TP1-TP3 320 V DC Intermediate circuit voltage 2 TP5-TP7 320 V DC Diode check module M1 TP1-TP2 (+) 0.46 V TP1-TP4 (+) 0.46 V TP3 (+) - TP2 0.46 V TP3 (+) - TP4 0.46 V...

  • Page 61: Nt 24 - Switched Mode Power Supply 24 V

    NT 24 - switched mode power supply 24 V General remarks NT 24 switched mode power supply (item number 4,070,626,Z) for internal and external components. Important! On NT 24 switched mode power supply, the primary voltage is on! Component position in the machine Fig.

  • Page 62: Technical Data

    Technical Data Input voltages 2 x 230 - 380 V DC from intermediate circuit Output voltages 15 V DC primary 24 V DC internal 24 V DC external Fuse protection from PTC 15 V primary 24 V internal 24 V external Function over- Internal and external components supplied with +24 V DC view...

  • Page 63: Led Checklist

    Plug layout function (continued) Secondary connection +24 V Pin 1 +24 V external Pin 5 GND EXT Pin 2 Pin 6 Pin 3 Intermediate circuit voltage UZW Pin 7 GND UZW Pin 4 +24 V internal Pin 8 GND INT LED checklist LED 24 V internal LED 15 V primary...
  • Page 64 Measuring points Measuring points Plug/pin Measuring result command value (continued) Intermediate circuit voltage 1 X1/1 - X1/3 approx. 280 V DC at a nominal voltage of 400 V AC approx. 320 V DC at a nominal voltage of 230 V AC Intermediate circuit voltage 2 X1/5 - X1/7 approx.

  • Page 65: Nt 60 - Switched Mode Power Supply 60 V

    NT 60 - switched mode power supply 60 V The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feed General remarks unit motor. Important! On NT 60 switched mode power supply, the primary voltage is on! Component position in the machine Fig.30 TPS 2700, position of NT 60...

  • Page 66: Technical Data

    Technical Data Supply voltage from intermediate circuit 2 x 230 - 380 V DC Output voltage Idle 59 (+/- 2) V at a load of 4 A 55 (+/- 2) V Function over- Output voltage is electrically isolated and protected by 2 parallel switched PTC view resistors.

  • Page 67: Led Checklist

    Plug layout Pin 7 Intermediate circuit 2- GND P Pin 15 Intermediate circuit 2- GND P (continued) Pin 8 + 15 V primary Pin 16 + 15 V primary LED checklist Intermediate circuit 2 supply LED „Error“ LED (PTC highly resistive) 55 V supply LED Intermediate circuit 1 supply LED Fig.
  • Page 68 Measuring points Measuring points Plug/pin Measuring result command value (continued) Intermediate circuit voltage 1 X2/1 - X2/3 approx. 280 V DC at a nominal voltage of X2/9 - X2/11 400 V AC approx. 320 V DC at a nominal voltage of 230 V AC Intermediate circuit voltage 2 X2/5 - X2/7 approx.

  • Page 69: Ust - Control And Regulation Unit

    UST - Control and regulation unit General remarks The UST PC board is a universal control, regulation and monitoring unit for fully digiti- sed Fronius power sources. Following versions are available: UST 2C (4,070,960,Z) UST-Pipe (4,070,963,Z) Component position in the machine Fig.37 TPS 3200, TS/TPS 4000/5000:...

  • Page 70: Technical Data

    Technical Data Supply voltage (from NT 24A) 24 V DC Function over- Power module control (driver switches on UST PC board) view Operating panel control in the form of a databus connection (LocalNet) Evaluation of the mains switch signal coming from the BPS PC board: a) Mains switch ON: Once the intermediate circuit voltage reaches a certain value, the relays on the BPS PC board are controlled by the UST PC board b) Mains switch OFF: UST stores present settings and activates the ventilators for...
  • Page 71 Plug layout Function (continued) Temperature transmission; voltage command value, current command value Pin 1 Voltage actual value Pin 13 Voltage actual value + Pin 2 Pin 14 Pin 3 Shunt C 4000, Pin 15 Shunt D 5000, Pin 4 Shunt A 3000, Pin 16 Pin 5 Shunt B 2000,...

  • Page 72: Led Checklist

    Plug layout function (continued) Control for gas solenoid valve and TIG welding torch (optional) Pin 1 High frequency on/off HF Pin 7 GND (HF) Pin 2 Gas 1 Pin 8 +24 V (Gas 1) Pin 3 Gas 2 Pin 9 +24 V (Gas 2) Pin 4 Crater fill BRT...

  • Page 73: Nf 3160 - Line Filter

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

  • Page 74: Function Overview

    Function over- Varistors provide protection against momentary overvoltage of the mains view Capacitors and coils form an LC low-pass filter that moderates the parasitic fre- quencies over 60 Hz Capacitors divert disturbances to earth and also between the phases Resistors discharge the line filter capacitors Plug layout Fig.

  • Page 75: Nf 3400 - Line Filter/Line Filter 40 A/80 A

    NF 3400 - Line filter/line filter 40 A/80 A The NF 3400 PC board (item number 4,070,664) is used with the TPS 3200, TS/TPS General remarks 4000/5000 power sources and is for filtering out parasitic frequencies: generated by the power source and which can affect other consumer loads that come from the mains supply and which can affect the power source PC board NF 3400 (serial number 14280747 upwards) has been replaced by line filter 40 A (item number 43,0001,1199).

  • Page 76: Technical Data

    Overview (continued) Line filter 40 A Line filter 80 A Fig. 47 Line filter 40 A and 80 A Technical Data Attenuation of parasitic frequencies > 60 Hz Function over- Varistors provide protection against momentary overvoltage of the mains view Capacitors and coils form an LC low-pass filter that moderates the parasitic fre- quencies over 60 Hz Capacitors divert disturbances to earth and also between the phases...

  • Page 77: Plug Layout Line Filter 40 A/80 A

    Plug layout line filter 40 A/80 A Line filter 40 A Line filter 80 A Fig. 49 Connections on line filter 40 A and 80 A Function Mains supply L1 in L2 in L3 in PE conductor Connection to BPS 42/50/53 L1 out L2 out L3 out...

  • Page 78: Shunt

    Shunt General remarks The shunt (item number 43,0001,1138) is a current sensor which permits the isolated capture of the welding current. Component Shunt position in the (behind the motor plate) machine Shunt Fig. 50 TPS 2700, position of shunt Fig. 51 TPS 3200, TS/TPS 4000/5000: position of shunt Overview Fig.

  • Page 79: Technical Data

    Technical Data Supply voltage +15 V /- 15 V Nominal current 500 A Output current at nominal current 250 mA Transformation ratio 1 : 2000 Function over- The shunt operates according to the compensation principle, where a magnetically soft, view probe functions as a magnetic field detector.

  • Page 80: Sr 41 - Wire-Feed Unit Regulation Unit

    SR 41 - Wire-feed unit regulation unit General remarks On the TPS 2700 power source, the SR 41 PC board (item number 4,070,677,Z) is the regulation unit for powering and controlling the wire-feed unit. Component position in the machine Fig. 53 TPS 2700, position of SR 41 PC board Overview LED BUS OK LED +15 V...

  • Page 81: Technical Data

    Technical Data Supply voltage (from NT 24) + 24 V DC Supply voltage (from NT 60) + 55 V DC Function over- Digital adjuster with power module (flow converter) for the wire-feed unit motor view two-stage adjustment for permanent stabilisation of the motor: a) Stabilisation of fast, dynamic changes, using a voltage/current regulator b) Stabilisation of slow, dynamic changes, using a speed controller via the actual- value pick-up...
  • Page 82 Plug layout function (continued) Connection to control panel Pin 1 GND for power potentiometer Pin 5 GND (arc correction) Pin 2 +5 V for power potentiometer Pin 6 +5 V (arc correction Pin 3 Power+ (actual value of power Pin 7 ARC-CORR + (arc correction potentiometer) actual value)

  • Page 83: Led Checklist

    Plug layout function (continued) LocalNet power source connection Pin 1 +24 V Pin 4 Pin 2 RXDL-485 Pin 5 TXDL-485 Pin 3 RXDH-485 Pin 6 TXDH-485 Wire-feed unit motor connection Pin 1 Motor + (red) Pin 2 Motor - (blue) BSL tool (20 pin) connection + 55 V (NT 60) supply Pin 1...

  • Page 84: Measuring Points

    LED checklist LED BUS OK ....flashes when connection with Bus master (power source) is OK (continued) LED FLEX OK ....flashes when there is no fault LED µP OK ..... flashes when the processor is working LED BRT ......flashes when the torch trigger is pressed LED + 55 V .....

  • Page 85: Temperature Sensor Tp 592S

    Temperature sensor TP 592S General remarks The TP 592S temperature sensor (item number 43,0001,0600) is an electronic temperature sensor. It has an integrated temperature/current converter chip. The chip is integrated into the plastic housing and provided with a pluggable Molex connection. Fig.57 Temperature sensor TP 592S Component position in the...

  • Page 86: Technical Data

    Technical Data Check supply 4 - 30 V DC Output current 1 µA/K Function over- The temperature sensor is fitted to the cooling element and measures the view 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.

  • Page 87: Secondary Power Module Tps 2700

    Secondary power module TPS 2700 General remarks On the TPS 2700, the secondary power module consists of two diode modules (item number 41,0003,0215 ), each of which has two integral diodes. Component position in the machine Secondary power module Fig.61 TPS 2700, position of secondary power module Overview PC board BPS 25/BPT 27...

  • Page 88: Function Overview

    Function over- The diode modules go together to make up the secondary rectifier. The secondary view rectifier transforms the welding transformer’s alternating current into a direct current, which is fed to the welding sockets Measuring points There are two diodes in every diode module.

  • Page 89: Secondary Power Module Ts 4000/5000, Tps 3200/4000/5000

    Secondary power module TS 4000/5000, TPS 3200/ 4000/5000 General remarks On the TS 4000/5000 and TPS 3200/4000/5000, the secondary power module consists of four diode modules (item number 41,0003,0203), each of which has two integral diodes. Important! In the course of replacement, the diodes must not be interchanged.

  • Page 90: Overview

    Overview Copper busbar Diode module Copper busbar Diode module Temperature sensor Diode module Diode module Cooling element Copper busbar Welding transformer Fig.65 Secondary power module Function over- The diode modules go together to make up the secondary rectifier. The secondary view rectifier transforms the welding transformer’s alternating current into a direct current, which is fed to the welding sockets...

  • Page 91: Primary Rectifier

    Primary rectifier General remarks The following primary rectifiers are used: TPS 2700: rectifier with item number 41,0002,0059 TS 4000/5000, TPS 3200/4000/5000: rectifier with item number 42,0001,0060 Component position in the Primary rectifier Primary rectifier machine Fig.67 TPS 2700: position of primary rectifier Fig.68 TS 4000/5000, TPS 3200/4000/5000: position of primary rectifier Overview...

  • Page 92: Plug Layout

    Plug layout Fig.71 Connections on the primary rectifier Fig.72 Connections on the primary rectifier TPS 2700 TS 4000/5000, TPS 3200/4000/5000 function Mains voltage input L1 Mains voltage input L2 Mains voltage input L3 Intermediate circuit voltage output + Intermediate circuit voltage output - Measuring points Fig.74 Measuring points on primary rectifier TS Fig.73 Measuring points on primary rectifier TPS...

  • Page 93: Changing Components

    Changing components Safety WARNING! An electric shock can be fatal. Before opening up the machine Move the mains switch to the “O” position Unplug machine from the mains Put up an easy-to-understand warning sign to stop anybody inadvertently switching it back on again Using a suitable measuring instrument, check to make sure that electrical- ly charged components (e.g.

  • Page 94: Changing Throttle (Ts 4000/5000, Tps 3200/4000/5000)

    Changing throttle (TS 4000/5000, TPS 3200/4000/5000) Remove side panels Removing throttle On the minus socket, loosen hexagon bolt (1) using a size 19 spanner Feed out the throttle lead (2) from the shunt (3) Fig. 1 Preparing throttle lead for removal On the transformer, loosen hexagon nut (4) using a size 13 spanner Remove protective element (5) and...

  • Page 95: Fitting Throttle

    Removing throttle Loosen 2 screws (8) (continued) Remove front of housing Fig.4 Removing front of housing Unscrew 4 screws (10) and remove sheet nuts (11) from throttle (11) Remove throttle (9) (10) (11) Fig.5 Removing throttle Fitting throttle Put throttle (9) in place and fix in place with 4 screws (10) and sheet (11) nuts (11)
  • Page 96 Fitting throttle Place front of housing onto base (continued) plate and press upwards and inwards Tighten 2 screws (8) Fig.9 Putting front of housing in place NOTE! When fitting the control panel (7), take care not to bend, stretch or strain the ribbon cable. Plug ribbon cable into control panel (7) Carefully put control panel (7) in place...

  • Page 97: Changing Throttle (Tps 2700)

    Changing throttle (TPS 2700) Removing throttle Open wire-feed unit cover Remove side panel Loosen two screws (1) on front aperture Fig.1 Screws on the front aperture Loosen two screws (3) on the drive unit (2) NOTE! When lifting the drive unit (2), do not pinch, bend or strain the cables.

  • Page 98: Fitting Throttle

    Removing throttle Loosen hexagon bolt (5) on minus (continued) socket using size 19 spanner Feed out the throttle lead (9) from the shunt (8) Fig.4 Loosening hexagon bolt Remove both upper copper clips (10) (11) and (11) from the transformer Loosen screw (12) on the middle tap connection (10)
  • Page 99 Fitting throttle Fit throttle (14) using three screws (continued) (13) (13) (13) (14) Fig.8 Fitting throttle Fasten throttle lead (9) - Fig.8 - onto (11) middle tap connection using screw (12) - Fig.9. Fit copper clips (11) and (10) as shown in Fig.9 (10) (12)
  • Page 100 Fitting throttle (continued) Fig.12 Connecting drive unit Reconnect two-pin Molex plug (4) NOTE! When putting the drive unit (2) in place, do not pinch, bend or strain the cables. Fit the drive unit (2) using two screws Fig.13 Fitting drive unit Fit two screws (1) on front aperture Fit side panel Close wire-feed unit cover...

  • Page 101: Changing Earth Current Watchdog

    Changing earth current watchdog Removing earth Remove side panels current watch- Loosen two screws (2) on earth current watchdog (1) Fig. 1 Removing earth current watchdog Loosen screw (3) on luster terminal Remove lead (4) Fig. 2 Loosening luster terminal on earth current watchdog Fig.

  • Page 102: Fitting Earth Current Watchdog

    Removing earth Unplug 24-pin Molex plug (7) from current watch- UST:X4 PC board Remove leads (8) and (9) of the (continued) watchdog cable (6) from the following pins on the 24-pin Molex plug (7): X4:10 X4:22 Use Molex extractor tool Fig.
  • Page 103 Fitting earth Insert lead (4) into earth current current watchdog watchdog luster terminal (continued) Tighten screw (3) on luster terminal Fig. 7 Connecting earth current watchdog luster terminal Fix earth current watchdog (1) in place using two screws (2) Fitting the side panels Fig.

  • Page 104: Changing Pc Board Asu 27 (Tps 2700 Mv)

    Changing PC board ASU 27 (TPS 2700 MV) Removing ASU Remove side panel Unplug leads (for cable harness (1), Fig.2) from the following slots on the BPT/BPS PC board: Fig. 1 Detaching leads from BPT/BPS Cut open cable tie on cable harness (1) Feed cable harness (1) out through bushing (2) Unplug 16-pin Molex plug ASU 27:X4...

  • Page 105: Changing Shunt (Tps 2700)

    Changing shunt (TPS 2700) Open wire-feed unit cover Removing shunt Remove side panel Loosen two screws (1) on front aperture Fig.1 Screws on the front aperture Loosen two screws (3) on the drive unit (2) NOTE! When lifting the drive unit (2), do not pinch, bend or strain the cables.

  • Page 106: Fitting Shunt

    Removing shunt Loosen hexagon bolt (5) on minus (continued) socket using size 19 spanner Unplug 8-pin Molex plug (6) Loosen two screws (7) on shunt (8) Remove shunt (8) and feed out throttle lead (9) Fig.4 Removing shunt Fitting shunt (10) (13) (11) (12)
  • Page 107 Fitting shunt NOTE! When putting the drive (continued) unit (2) in place, do not pinch, bend or strain the cables. Put entire drive unit (2) in place Fit the drive unit (2) using two screws Fig.8 Fitting drive unit Tighten two screws (1) on front aperture Fit side panel Close wire-feed unit cover...

  • Page 108: Changing Temperature Sensor Tp 592S

    Changing temperature sensor TP 592S Notes The temperature sensor is fixed and can be lifted out by carefully using a simple scre- wdriver or removed with flat pliers. Before putting the new temperature sensor in place, fill the hole for the sensor with heat conductive paste to ensure perfect heat transfer.

  • Page 109: Changing Transformer (Ts 4000/5000, Tps 3200/4000/5000)

    Changing transformer (TS 4000/5000, TPS 3200/4000/ 5000) Removing trans- Remove side panels former On BPS 42/50 PC board, loosen 4 screws (1) for primary transformer leads Remove protective elements (2) Fig. 1 Removing transformer leads Cut open cable tie on toroidal tape cores (3) and (4) Important! If necessary, cut open any other cable ties near the toroidal tape...

  • Page 110: Fitting Transformer

    Removing trans- Loosen 4 screws (7) for secondary (11) former transformer leads on copper sheet (continued) Loosen hexagon nut (8) using a size 13 spanner Remove protective element (9) and throttle lead (10) Loosen 4 screws (11) on the transfor- mer holder (12) (10) Remove transformer holder (12)
  • Page 111 Fitting transfor- NOTE! When fitting the primary transformer leads, ensure that (continued) they are assigned to the correct terminals: e.g. screw transformer lead „1+“ to terminal „N1+“ Fit the following to the BPS 42/50 PC board using 4 screws (1): Primary transformer leads, as described on labelling Protective elements (2)

  • Page 112: Changing Transformer (Tps 2700)

    Changing transformer (TPS 2700) Removing trans- Remove side panel former Loosen terminal screws (2) and remove primary transformer leads (3) Cut open cable tie (4) Remove copper clips (5) and (6) Fig. 1 Exposing transformer 1 Remove copper clips (7) and (8) Loosen screw (9) on middle tap connection and remove throttle lead (10)

  • Page 113: Fitting Transformer

    Fitting transfor- Push insulators (15) onto secondary (15) connections Wind both of the middle primary leads twice around the ferrite core and fasten with cable tie (14) (15) (14) Fig.5 Fastening insulators and ferrite core Before fitting the transformer, arrange the primary leads as follows: Feed the „blue lead“...
  • Page 114 Fitting transfor- (continued) (19) (18) (22) (23) (20) (21) Fig. 9 Connecting transformer 2 Fit copper clips (5) and (6) Feed „outer blue primary lead“ through cut-outs (18) on PC board and clamp in place with terminal screw (19) Feed „outer orange primary lead“ through cut-outs (20) on PC board and clamp in place with terminal screw (21) Clamp „inner blue primary lead“...

  • Page 115: Changing Intermediate Circuit Capacitors (Ts 4000/5000, Tps 3200/4000/5000)

    Changing intermediate circuit capacitors (TS 4000/ 5000, TPS 3200/4000/5000) Removing inter- Remove side panels mediate circuit Loosen three screws (1) on rear of capacitors housing (2) Remove rear of housing (2) Fig. 1 Removing rear of housing Loosen two screws (3) on cover sheet (4) Remove cover sheet (4) Fig.

  • Page 116: Fitting Intermediate Circuit Capacitors

    Fitting intermedi- Important! After removing a capacitor (7), its grommets (8) - Fig.5 - can either ate circuit capa- adhere to the front of the capacitor (7) citors remain on the partition (9) inside the power source be disposed of NOTE! When fitting the capaci- tors, ensure that the grommets (8) are arranged correctly, as...
  • Page 117 Fitting intermedi- Fit cover sheet (4) using two screws ate circuit capa- citors (continued) Fig. 10 Fitting cover sheet Fasten rear of housing (2) with three screws (1) Fit side panels Fig. 11 Fitting rear of housing...

  • Page 118: Safety Inspection

    This section outlines the safety inspection of the welding systems described in this service manual. This section is fully compliant with IEC 60974-4. Extracts of the requisi- te measuring methods are documented in Fronius work instruction PMÜ-01. Please also be aware of the requirements and standards relevant to your country, as the measured values or steps taken during the tests may vary.

  • Page 119: Visual Inspections

    Visual inspections General The following must be visually inspected without any further dismantling of the system. Obvious defects in any safety-related device components are unacceptable. Any defects that could cause other hazards must be repaired immediately or restrictions placed on the further use of the system until repairs have been effected. General conditi- Markings and stickers (rating plate, warning stickers) must be present and legible There must be no damage or indications of improper use...

  • Page 120: Housing And Covers

    Housing and Housing components/insulation components must be present and undamaged (do covers not use insulation or adhesive tapes to repair damage) No unauthorised modifications must have been made (e.g. installations, conversi- ons that have not been approved by the manufacturer) Cooling openings must not be dirty or blocked and an air filter must be present There must be no signs of overloading or improper use Protection devices (e.g.

  • Page 121: Electrical Tests

    Electrical tests Ground conduc- All housing components must be tor resistance fitted The ground conductor resistance may not exceed < 0.3 Ω (for mains cables up to 5 m; extra 0.1Ω for each additional 7.5 m; max. 1Ω) The measuring current must be no lower than 200 mA (recommendation: 10 A) Mains cable: the measurement must...

  • Page 122: Insulation Resistance

    Insulation resis- WARNING! Danger of electric shock! The test voltage is 500 V DC. Do not tance touch the test piece during the test. Following the test, discharge the capaci- tors between secondary / earth and primary / earth using a suitable resistance (e.g.: 10 kΩ...

  • Page 123: Function Tests

    Function tests General Under normal circumstances, function tests are only mandatory following repair work. However, we recommend that the following function tests are carried out on a regular basis to ensure that the welding system is safe and working properly at all times. Mains power on/ Mains switch - check the switch is fully operational by turning the mains switch on off equipment...

  • Page 124: Documentation

    Documentation Test record The „Safety Inspection / Maintenance Test Record“ must be used to document the safety inspection. The latest version is available to download from EnergyNet / DownloadCenter. The test record must be completed in full and archived according to national regulations.

  • Page 125: Terms And Abbreviations Used

    (see „fault location aid“ section) LocalNet RS232 converter: For connecting the power source to the serial interface on a PC, for: uploading software options communicating data from the power source using PC-based software (Fronius Backup, Fronius Service Module, Job-Explorer, etc.)
  • Page 126 Terms and abbre- NTC resistors: viations NTC = negative temperature coefficient. These resistors have high resistance at low (continued) temperatures. As long as the operating temperature has not been reached, the high resistance ensures the limitation of the starting current. Shortly after switching on, the current limit is raised as a result of the rapid heating of the NTC resistors.

  • Page 127: Entire Circuit Diagram

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

  • Page 129: Spare Parts List Circuit Diagram

    Ersatzteilliste Schaltplan Spare Parts List Circuit Diagram Liste de pièces de rechange Schéma de connexions Lista parti di ricambio Schema Lista de repuestos Esquema de cableado Lista de peças sobresselen- Esquema de conexões Onderdelenlijst Bedradingsschema Reservdelsliste Koblingsplan Seznam náhradních dílù Schéma zapojení...
  • Page 130 42,0407,0284 ø9,0mm (.354inch) 40,0001,0310 40,0001,0062 xx) T.I.M.E 43,0004,0116 - 1,5m ( 4,1ft) 43,0004,0272 - 2,5m ( 8,2ft) 43,0004,2025 - 3,0m (9.75ft) 43,0004,0105 - 3,5m (11.5ft) 43,0004,0106 - 4,5m (14,8ft) 43,0004,1086 T.I.M.E - 3,5m (11.5ft) T.I.M.E - 4,5m (14.8ft) 43,0004,1087 42,0400,0308 42,0405,0559 42,0100,1366 42,0100,1058...
  • Page 131 TransPuls Synergic 3200 4,075,124 TransSynergic 4000 C 4,075,097 TransPuls Synergic 3200 MV 4,075,124,800 TransSynergic 5000 C 4,075,098 TransSynergic 4000 C MV 4,075,097,800 TransSynergic 4000 4,075,099 TransSynergic 5000 C MV 4,075,098,800 TransSynergic 5000 4,075,101 TransPuls Synergic 4000 MV 4,075,100,800 TransPuls Synergic 4000...
  • Page 132 42,0200,8860 32,0405,0164 AM2,0200,8819 32,0405,0164 45,0200,0918 45,0200,0918 45,0200,1186 - CrNi 45,0200,1186 - CrNi 45,0200,1201 - CMT 45,0200,1201 - CMT 45,0200,1307 - YARD 45,0200,1307 - YARD 41,0003,0203 12,0405,0208 43,0001,0600 40,0009,0043 43,0001,1103 43,0001,1139 41,0003,0203 33,0005,4112 33,0005,4120 - MV 33,0005,4120 - 460V/US 33,0010,0335 43,0001,1186 43,0001,1187 43,0006,0152 43,0001,1092...
  • Page 133 43,0004,0664 - MV 43,0004,0987 43,0004,0586 - 460V 43,0004,2727 - TIME 5000 43,0004,2324 - US AWG 6 43,0004,2955 - US AWG 10 43,0001,1213 - MV/US 80A 42,0407,0437 - MV 42,0407,0533 - US AWG 6 42,0407,0534 - US AWG 10 43,0013,0015 BE2,0201,1934 - MV BE2,0201,1355 - US...
  • Page 134 TPS 2700...
  • Page 135 TPS 2700 MV...
  • Page 136 TS 4000 / 5000, TPS 3200 / 4000 / 5000...
  • Page 137 TPS 3200 MV (Teil 1)
  • Page 138 TPS 3200 MV (Teil 2)
  • Page 139 TS 4000 MV / 5000 MV, TPS 4000 MV / 5000 MV...
  • Page 140 FRONIUS INTERNATIONAL GMBH Froniusplatz 1, A-4600 Wels, Austria Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940 E-Mail: sales@fronius.com 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 012011...

This manual is also suitable for:

Transsynergic 5000Transpuls synergic 2700Transpuls synergic 3200

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