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PlasmaModule 10

TransTig 800 / 2200


Service Manual
MagicWave 1700 / 2200 GB
Spare Parts List
TIG power source

42,0410,1121 012008
Contents
Foreword and safety instructions .................................................................................................................. 4
Safety ....................................................................................................................................................... 4
TechSupport National (TSN) .................................................................................................................... 4
General remarks ...................................................................................................................................... 4
Tools and measuring devices ................................................................................................................... 5
Function overview .................................................................................................................................... 5
Error location aid ...................................................................................................................................... 5
Detailed description .................................................................................................................................. 5
Replacing components ............................................................................................................................. 5
Terms and abbreviations used ................................................................................................................. 5
Spare parts list and entire circuit diagram ................................................................................................ 5
Tools and measuring devices ........................................................................................................................ 6
General remarks ...................................................................................................................................... 6
Tools required .......................................................................................................................................... 6
Measuring equipment, inspection equipment ........................................................................................... 7
Ancillary materials .................................................................................................................................... 7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 ................................................... 8
General remarks ...................................................................................................................................... 8
Block diagram .......................................................................................................................................... 8
Block diagram legend............................................................................................................................... 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 panel ....................................................................................................................... 15
Inadequate welding torch cooling (FK 2200) .......................................................................................... 19
Open circuit voltage +50 V faulty ............................................................................................................ 21
UST service codes ...................................................................................................................................... 22
Safety ..................................................................................................................................................... 22
Table of service codes ........................................................................................................................... 22
Special indications used with service codes ........................................................................................... 28
Detailed description ..................................................................................................................................... 29
General remarks .................................................................................................................................... 29
Overview ................................................................................................................................................ 29
BPS 17 - Power module PC board .............................................................................................................. 30
General remarks .................................................................................................................................... 30
Overview ................................................................................................................................................ 30
Function overview .................................................................................................................................. 30
Pin assignment ...................................................................................................................................... 31
Measuring points .................................................................................................................................... 32
LED checklist ......................................................................................................................................... 33
BPS 22 - Power module PC board .............................................................................................................. 34
General remarks .................................................................................................................................... 34
Overview ................................................................................................................................................ 34
Technical data ........................................................................................................................................ 34
Function overview .................................................................................................................................. 34
Pin assignment ...................................................................................................................................... 36
Measuring points .................................................................................................................................... 36
LED checklist ......................................................................................................................................... 37

1
HFF 22 - High frequency ignition unit, input filter ........................................................................................ 38
General remarks .................................................................................................................................... 38
Overview ................................................................................................................................................ 38
Function overview .................................................................................................................................. 39
Pin assignment ...................................................................................................................................... 40
NTFK 24 - Switched mode power supply for cooling unit ............................................................................ 42
General remarks .................................................................................................................................... 42
Function overview .................................................................................................................................. 42
Pin assignment ...................................................................................................................................... 43
Measuring points .................................................................................................................................... 44
LED checklist ......................................................................................................................................... 44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ......................................... 45
General remarks .................................................................................................................................... 45
Function overview .................................................................................................................................. 45
Pin assignment ...................................................................................................................................... 45
Measuring points .................................................................................................................................... 45
LED checklist ......................................................................................................................................... 46
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ........................................................................ 47
General remarks .................................................................................................................................... 47
Function overview .................................................................................................................................. 47
Pin assignment ...................................................................................................................................... 47
Measuring points .................................................................................................................................... 47
Important ................................................................................................................................................ 48
Technical data ........................................................................................................................................ 48
Function overview .................................................................................................................................. 48
Pin assignment ...................................................................................................................................... 48
LED checklist ......................................................................................................................................... 48
Measuring points .................................................................................................................................... 48
TP 592S temperature sensor ...................................................................................................................... 49
General remarks .................................................................................................................................... 49
Technical data ........................................................................................................................................ 49
Function overview .................................................................................................................................. 49
Pin assignment ...................................................................................................................................... 49
Measuring points .................................................................................................................................... 49
TTS 22 - IGBT driver and auxiliary power source ....................................................................................... 50
General remarks .................................................................................................................................... 50
Overview ................................................................................................................................................ 50
Technical data ........................................................................................................................................ 50
Function overview .................................................................................................................................. 50
Pin assignment ...................................................................................................................................... 51
Measuring points .................................................................................................................................... 51
LED checklist ......................................................................................................................................... 51
UST - Control and regulation unit ................................................................................................................ 52
General remarks .................................................................................................................................... 52
Function overview .................................................................................................................................. 52
Pin assignment ...................................................................................................................................... 53
Measuring points .................................................................................................................................... 54
LED checklist ......................................................................................................................................... 54
Change UST PC board .......................................................................................................................... 54
Changing modules ...................................................................................................................................... 55
General remarks .................................................................................................................................... 55
Overview ................................................................................................................................................ 55
Housing unit ................................................................................................................................................ 56
General remarks .................................................................................................................................... 56
Opening the housing .............................................................................................................................. 56
Closing the housing ................................................................................................................................ 57

2
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 .................................................................................................................. 60
ESD measures ....................................................................................................................................... 60
Changing the TTS 22 PC board ............................................................................................................. 60
Installing the TTS 22 PC board .............................................................................................................. 62
Changing the BSV 22 PC board .................................................................................................................. 64
ESD measures ....................................................................................................................................... 64
Removing the BSV 22 PC board ............................................................................................................ 64
Installing the BSV 22 PC board .............................................................................................................. 66
Installing UST PC board ......................................................................................................................... 67
Changing the transformer ........................................................................................................................... 68
Removing the transformer ..................................................................................................................... 68
Installing the transformer ....................................................................................................................... 72
Safety Inspection ......................................................................................................................................... 78
Requirement .......................................................................................................................................... 78
Work instruction ..................................................................................................................................... 78
Terms and abbreviations used .................................................................................................................... 79
General remarks .................................................................................................................................... 79
Terms 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 instruc-
tions:

WARNING! Work performed incorrectly can cause serious injury and damage.
All activities described in the service instructions must only be carried out by
Fronius-trained 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 electrical-
ly 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.

TechSupport If you have any questions about error analysis, your TechSupport National (TSN) sales
National (TSN) team is on hand.
mailto: welding.techsupport@fronius.com

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

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 measu- This provides an overview and description of all equipment required for servicing the
ring devices power source professionally. This equipment includes:
- Tools required
- Measuring equipment, inspection equipment
- Ancillary material

Function over- Contains a brief descriptive overview of the entire system:


view - in text form
- in block diagram form

Error location aid Serves to systematically locate and rectify the source of errors, and contains the follo-
wing 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 descrip- Contains detailed descriptions of the relevant modules in the power source.
tion
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 com- The Replacing components chapter describes how to replace components that
ponents - have no instructions of their own for replacement and
- require detailed replacement instructions

Terms and abbre- Contains a description of essential specialist terms and abbreviations for a better under-
viations used standing of the service manual

Spare parts list The Spare parts list and Entire circuit diagram chapters contain the complete spare
and entire circuit parts list and complete circuit diagram for the power source.
diagram

5
Tools and measuring devices

General remarks Tools and measuring devices provides an overview and description of all the equip-
ment 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)
- CPC extractor tool (42,0410,0677)
- Oeteker pliers
- Molex extractor tool (42,0410,0290)

6
Measuring equip- - Digital multimeter
ment, inspection - PC with MS Windows operating system
equipment (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)

Ancillary materi- - Contact spray (40,0009,0014) or alcoholic solvent


als - 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.

Block diagram

Welding torch

Workpiece
Remote control

Welding torch
control line

protective gas
shield
LocalNet

(12)
prot. gas shield solenoid valve HF transformer

Iact

(11)
HF
Welding current
Control and regulation unit

sensor

(10)
HF generator
Uact
Control panel

(9)
Inverter
Control line

*
Secondary power
module
(1)

(8)
Secondary rectifier
Control line

(7)
Welding transformer
24 V power supply
* only for MagicWave 1700 and MagicWave 2200 power sources

Power supply
** only for MagicWave 2200 and TransTig 2200 power sources

(6)

Switching
transistors
(5)
24 V

Intermediate circuit
capacitors
(4)

PFC (Power Factor


**

Control)
Primary power
module
(3)

Primary rectifier
230 V
(2)

Line filter

Fig. 1 Block diagram of the MagicWave 1700/2200, TransTig 1700/2200 and PlasmaModule 10 power sources

8
Block diagram (1) Control and regulation unit:
legend Controls, regulates and monitors the welding process and all power source func-
tions.

(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
- Supporting 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-contact 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-contact 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 No lights on control panel
position

Inadequate welding torch cooling


(FK 2200)

Open circuit voltage + 50 V faulty

Table of service codes

11
Poor ignition and
welding proper- Start
ties with TIG
welding

Correct protective gas shield Connect correct protective gas


connected, and l/min set correctly? shield and check l/min
no

yes

Gas test button: Protective gas Check protective gas shield sole-
shield flowing out? noid valve, including control
no

yes

Welding torch and grounding Check welding torch and groun-


(earthing) cable OK? ding (earthing) cable
no
yes

Parameters set correctly? - Check settings on control panel


no - Check set-up parameters
yes - Possibly reset to factory set-
tings (FAC) (see operating instruc-
tions)

Open circuit voltage with selected See Incorrect open circuit voltage
rod electrode (MMA) welding section
process = 50 V (+/- 1 V) ? no

yes

Check whether power source OK,


and check application

End

12
Poor ignition and
welding proper- Start
ties with MMA
welding

Electrodes / grounding (earthing) Connect cable correctly


cable connected / functioning no
correctly?
yes

Welding process set correctly? Select correct welding process


no
yes

Parameters set correctly? - Check settings on control panel


no - Check set-up parameters
yes - Possibly reset to factory set-
tings (FAC) (see operating instruc-
tions)

Open circuit voltage with selected See Incorrect open circuit voltage
MMA welding process = 50 V (+/- section
1 V) ? no

yes

Check whether power source OK,


and check application

End

13
No or incorrect
welding current Start

Welding torch and grounding Check welding torch and groun-


(earthing) cable connected / ding (earthing) cable
no
functioning correctly?

yes

No lights on control panel? See section entitled No lights on


yes control panel
no

Open circuit voltage with selected See Incorrect open circuit voltage
MMA welding process = 50 V (+/- section
1 V) ? no

yes

- Welding current Icomm no longer Change current sensor A1 VAC


adjustable, or yes
- Welding current is always Imax ?

no

Check whether power source OK,


and check application

End

14
No lights on
control panel Start

Is the UZWK LED on the A2 BPS Check mains cable, mains switch
17 / BPS 22 power module PC and supply voltage
no
board on constantly?

yes

Are the LEDs for supply voltage on Change A6 FP 22 control panel


the A2 BPS 17 / BPS 22 power
yes
module PC board and the A5 UST
control board on constantly?

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 Change power module PC board
the A2 BPS 17 / BPS 22 on the A2 BPS 17 / BPS 22
no
power module PC board on con-
stantly?
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

15
No lights on
A
control panel
(continued)

LEDs for supply voltage on A5 UST Change power module PC board


control board constantly illumina- A2 BPS 17 / BPS 22
yes
ted?

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 Change the A5 UST control board
control board constantly illumina- no
ted?

yes

Connect plug X1 to the A5 UST


control board

LEDs for supply voltage on A5 UST Change A4 TTS22 PC board


control board constantly illumina- (driver for inverter)
no
ted?

yes

16
No lights on
B
control panel
(continued)

Connect plug X2 to the A5 UST


control board

LEDs for supply voltage on A5 UST Change A6 FP22 control panel


control board constantly illumina-
no
ted?

yes

Connect plug X4 to the A5 UST


control board

LEDs for supply voltage on A5 UST Change current sensor A1 VAC


control board constantly illumina- no
ted?

yes

Connect plug X7 to the A5 UST


control board

LEDs for supply voltage on UST Test FK 2200 cooling unit


control board constantly illumina- no
ted?

yes

17
No lights on
C
control panel
(continued)

Connect plugs X9, X10 to the A5


UST control board

LEDs for supply voltage on A5 UST Change A7 HFF22 PC board (HF


control board constantly illumina- generator / filter)
ted? no

yes

Check whether power source OK,


and check application

End

18
Inadequate
welding torch Start
cooling (FK 2200)

Cooling unit set-up parameters Switch set-up parameters to Auto


switched to Off? or On
yes
no

Switch off power source

Sufficient coolant? Top up coolant, then vent cooling


no unit
yes

Fuse for coolant pump OK? Change fuse (check rating is same
as original)
no
yes

Coolant pump blocked? Use a screwdriver to turn the


yes cooling unit pump shaft.
If the pump is difficult to move,
change the pump to avoid overloa-
ding the power module.
no

Unplug X4 from power module A1


NTFK24, switch on power supply,
change cooling units set-up
parameter to On

19
Inadequate
A
welding torch
cooling (FK 2200)
(continued)

Power LED on the A1 NTFK24 Check fuse F1 and 230 VAC power
power module illuminated con- supply on the A1 NTFK24 X2
no power module. Change A1
stantly ?
yes NTFK24 power module

On LED on the A1 NTFK24 power Voltage at the A1 NTFK24 X3/2,


module illuminated? X3/8 power module < 1 V DC
no

yes no yes

Check cable harness, change A5


UST controller in the power source

LEDs +15V, +24V, + 24V OK on Change A1 NTFK24 power module


the A1 NTFK24 power module
illuminated constantly ? no

yes

Change coolant pump and/or fan

End

20
Open circuit
voltage +50 V Start
faulty

Open circuit voltage present for - Change TTS 22 PC board


selected MMA welding process ? (MW 1700 / 2200)
- Change BSV XX PC board
yes
(TT 2200)
no

- Steady +5 V, +18V, +24V LEDs - Change TTS 22 PC board


on TTS 22?
- If the polarity is changed using no
the Process button: neg./pos.
ignition LED lit ?

yes

Check inverter (see detailed


explanation - secondary power
supply)

End

21
UST service codes

Safety
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

Table of service For every service code there is information on


codes - 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: DSP displays a general error, xx stands for additional entries not required
for external service
Remedy: Update software. Change UST PC board.

dsP | A21 (code no.20)


Cause: The power source is configured for either parallel operation (set-up parame-
ter P-C is set to ON) or for TimeTwin Digital (set-up parameter T-C is set
to ON). However, the LHSB link has been disconnected, or has become
faulty, while the power source was switched on.
Remedy: 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: DSP SoftCom error, xx stands for additional entries not relevant for external
service
Remedy: Update software. Change UST PC board.

dsP | E05 (code no.17)


Cause: DSP displays internal error
Remedy: Update software. Change UST PC board.

dsP | Exx (code no.21)


Cause: 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
Remedy: Update software. Change UST PC board.

dsP | Sy (code no.35)


Cause: Internal error (version conflict)
Remedy: Update software. Change UST PC board.

dsP | nSy (code no.36)


Cause: Internal error (version conflict)
Remedy: Update software. Change UST PC board.

22
Table of service
EcF | xxx (code no.32)
codes
(continued) Cause: BPS configuration error, x stands for:
1 TPS 2700 with incorrect power module
2 TS/TPS/TP 4000 with incorrect power module
3 TS/TPS/TP 5000 with incorrect power module
4 TT 2200, MW 2200 with incorrect primary power module
5 MW 1700 with incorrect primary power module
253 This configuration functions only from UST2A V1.3 A onwards
254 This configuration functions only from UST PC board, version
UST2A
255 Unknown primary power module
Remedy: Fit correct primary power module

EFD | xx.y (code no.30)


Cause: Error in wirefeed system, xx and y can be found in the list of service codes
for the wirefeed system.
Remedy: Check wirefeed system

EIF | xx.y (code no.63)


Cause: Error in conjunction with a robot interface, xx and y can be found in the list
of service codes for your robot interface.
Remedy: Check robot interface, update software, change robot interface

Err | Arc (code no.61)


Cause: DPS 5000 only: DPS detected arc formation
Remedy: Check application

Err | bPS (code no.18)


Cause: DSP displays internal error
Remedy: Update software. Change UST PC board. Change BPS PC board.

Err | Cfg (code no.72)


Cause: Power source configuration changed (e.g. connected in parallel with a
second power source)
Remedy: Reset service code by pressing set-up button

Err | EPF (code no.22)


Cause: Error during charging of flex
Remedy: Update software. Change UST PC board.

Err | IP (code no.19)


Cause: DSP displays primary overcurrent
Remedy: Check secondary power module. Change primary power module.

Err | Jo (code no.67)


Cause: JobMaster temperature sensor faulty
Remedy: Change JobMaster welding torch

Err | Lic (code no.40)


Cause: Faulty/incorrect licence key
Remedy: Check licence key. Check and update enable codes.

23
Table of service
Err | PE (code no.53)
codes
(continued) Cause: Earth-fault error
Remedy: 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: Temperature sensor error (short circuit or break) - examples: tF1 - tempe-
rature sensor error on secondary rectifier, tF2 - temperature sensor error on
primary power module
Remedy: Check cable harness and change the relevant temperature sensor

Err | tF6 (code no.16)


Cause: Error on BPS PC board or on the connection to the BPS PC board
Remedy: Check ribbon cable. Change BPS PC board.

Err | tF7 (code no.34)


Cause: Temperature sensor error on UST
Remedy: Change UST PC board

Err | tF8 (code no.64)


Cause: In conjunction with thermostat option: cooling unit temperature sensor error
Remedy: Check cable harness. Change temperature sensor.

Err | 027 (code no.27)


Cause: One of the supply voltages is outside the tolerance range
Remedy: Change UST

Err | 049 (code no.49)


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

Err | 050 (code no.50)


Cause: Voltage intermediate circuit symmetry error
Remedy: 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: Mains undervoltage: The mains voltage has fallen below the tolerance
range
Remedy: Check mains voltage

Err | 052 (code no.52)


Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check mains voltage

Err | 054 (code no.54)


Cause: Wire stick control has tripped
Remedy: Remove short circuit on welding wire

24
Table of service
Err | 056 (code no.56)
codes
(continued) Cause: In conjunction with wire-feed unit and wire-end check option: no wire
available
Remedy: Insert new wirespool

Err | 059 (code no.59)


Cause: Overvoltage in the secondary circuit: safety cut-out has tripped
Remedy: Check secondary circuit, including TPCEL40

Err | 060 (code no.60)


Cause: DPS5000 only: Due to an opened door contact, SITRE1A has triggered
safety disconnection
Remedy: Safety cut-out: close door contact

Err | 062 (code no.62)


Cause: Remote control TP08 overtemperature
Remedy: Allow TP08 to cool down. Change TP08.

Err | 068 (code no.68)


Cause: Secondary circuit safety cut-out has tripped
Remedy: Change TTS PC board

Err | 069 (code no.69)


Cause: Illegal change of mode or process during welding
Remedy: Reignite arc

Err | 23.x (code no.23)


Cause: 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)
Remedy: Update software. Change UST PC board.

Err | 24.x (code no.24)


Cause: 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)
Remedy: Check ribbon cable. Change BPS PC board.

Err | 25.x (code no.25)


Cause: 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)
Remedy: Change TTS

25
Table of service
Err | 26.x (code no.26)
codes
(continued) Cause: 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)
Remedy: Check cable harness. Change config memory on power source cable
harness.

Err | 31.x (code no.31)


Cause: EEProm save error
Remedy: Update software. Change UST2 PC board.

Err | 70.x (code no.70)


Cause: 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
Remedy: 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: 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
Remedy: Check application. Check parameters.

hot | H2O (code no.65)


Cause: In conjunction with thermostat option: Overtemperature in cooling system
Remedy: Allow cooling unit to cool down. Open cooling unit and clean heat exchan-
ger. Check whether fan is functioning properly.

no | Arc (code no.58)


Cause: Arc is broken, arc-break monitor has tripped
Remedy: Check welding parameters. Reignite arc Check grounding (earthing)
connection.

no | GAS (code no.57)


Cause: In conjunction with the digital gas control option: no protective gas shield
available
Remedy: Check protective gas shield supply

26
Table of service
no | H2O (code no.39)
codes
(continued) Cause: Flow watchdog reporting water deficiency
Remedy: Check cooling system hose lines. Check pump pressure and flow rate.
Check flow watchdog.

no | Ign (code no.55)


Cause: Ignition time-out error: No ignition within the value set in the set-up menu.
The safety cut-out has tripped.
Remedy: Clean workpiece surface. Check parameters in set-up menu. Check
grounding (earthing) connection.

no | Prg (code no.1)


Cause: No saved program selected
Remedy: Select saved program

off (code no.150)


Cause: No communication between the LocalNet participants (e.g. power source,
wire feed unit, remote control or welding torch)
Remedy: Check LocalNet cables. Change remote control/welding torch. Wait for
software update to finish.

-Stop- (code no.38)


Cause: Robot not ready
Remedy: When using a robot interface or field bus coupler, initialise the Robot
ready and Source error reset signals.

tJo | xxx (code no.66)


Cause: JobMaster overtemperature
Remedy: Allow 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: Overtemperature in power source primary circuit (XXX stands for tempera-
ture indicator) - Example: tp1 - overtemperature at primary power module
Remedy: Allow the power source to cool down. Check that fan is running.

tp6 | xxx (code no.10)


Cause: Overtemperature in power source primary circuit, temperature sensor on
BPS PC board has tripped (XXX stands for temperature indicator)
Remedy: Allow the power source to cool down. Check that fan is running.

tp7 | Hot
Cause: Duty cycle exceeded
Remedy: 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: Overtemperature in power source secondary circuit (XXX stands for tempe-
rature indicator) - Examples: ts1 - overtemperature at secondary rectifier,
ts2 - overtemperature at the auxiliary voltage source, tst - overtemperature
at UST PC board
Remedy: Allow the power source to cool down. Check that fan is running.
Remedy: Check cable harness. Change UST2 PC board.

27
Table of service
tSt | xxx (code no.33)
codes
(continued) Cause: Overtemperature in control circuit, xxx stands for the temperature indicator
Remedy: Allow the power source to cool down. Check fan.

US | POL (code no.37)


Cause: Measuring device for secondary voltage (Usec) incorrectly connected, or
defective for some other reason

Special indicati- The following service codes are special indications for software problems:
ons used with
service codes - And | Opc - STK | OVL
- Prt | Flt - STK | UVL
- Ill | Opa - Err | Dog
- Ill | Ina - ASS | Ert
- Ill | Bus - Edg | 1
- Err | 105

If the service codes shown above appear, more detailed information can be requested at
the power source control panel. Using the parameter selection buttons (left/right arrows),
you can switch between the following display levels:
- Level 1 (e.g. And | Opc): service 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 pass 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 over-
Input voltage 230 VAC (+15 % / -20 %)
view
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 over- The BPS 17 PC board includes the following components:
view (1) Line filter
(continued) (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 joining 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 intermedi-
ate 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 intermedi-
ate 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 X28 .... (secondary voltage), voltage supply internal/external
(continued)
Pin Designation Pin Designation
1 +24 V-EXT, +24 V remote 5 GND-EXT, remote control
control connection connection GND
2 NC 6 NC
3 UZW, intermediate circuit 7 GND-UZW, intermediate
voltage measuring circuit voltage measuring
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply

Measuring points 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
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

Function over- Components on the BPS 22 PC board


view

(1)

(2)
(8)

(3)

(4)

(7)
(5)

(6)

Fig. 9 Components on the BPS 22 power module PC board

34
Function over- The BPS 22 PC board includes the following components:
view (1) Line filter
(continued) (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 intermedi-
ate 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 supports 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 intermedi-
ate 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 Designation Pin Designation


1 +24 V-EXT, +24 V remote 5 GND-EXT, remote control
control connection connection GND
2 NC 6 NC
3 UZW, intermediate circuit 7 GND-UZW, intermediate
voltage measuring circuit voltage measuring
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply

Measuring points 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 over-
Supply voltage + 24 VDC (+/- 20 %)
view
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 char-
ges 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 indica-
ted 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 X1 ...... HF pulse positive pole (blade terminal connection to primary voltage of the HF
(continued) 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 NTFK 24 (item number 4,070,819,Z) is the switched mode power supply for the FK 2200
cooling unit.

Function over-
Range of input voltage 140 VAC... 280 VAC
view
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 over- (4) Flow controller and undervoltage control
view
(continued) 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 Designation Pin 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 Designation Pin Designation


1 Phase 2 Neutral conductor

X3 ...... Connection to power source


Pin Designation Pin Designation
1 NC 6 NC
2 /Cooler on 0 V = cooling 7 + 24 V - Control supply
unit on voltage from the power
source
3 /Watercontrol 0 V = coolant 8 GND water control - GND of
flow and supply voltage of the supply voltage from the
the cooling unit OK power source
4 NC 9 NC
5 NC 10 GND (+ 24 V) - GND of the
supply voltage from the
power source

43
Pin assignment X4 ...... Connection for fan and coolant pump of the cooling unit
(continued)
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

Measuring points See pin assignment

LED checklist
+15 VP

Power

+24 VOK
+24 V

ON
Fig. 31 Control LEDs on NTFK 24 PC board

Power ............. Mains voltage present


+ 15 VP ........... Supply for PWM IC present
+24 VOK ......... The supply voltage to the coolant pump is greater than 20 V
+24 V .............. Pump and fan voltage present
ON .................. 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 over- The rectifier generates DC from the AC from the welding transformer.
view
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 0.15 V
(B) (B)

0.4 V
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 connec-
ting 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 0.15
(B) (B) V33 0.15 V

0.15 V

0.15 V 0.15 V
(B) 0.15 V

Fig.40 Diode regions on secondary power module, new version

LED checklist See Measuring points section

46
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 over- The shunt operates according to the compensation principle, where a magnetically soft
view probe functions as a magnetic field detector. The shunt is characterised by the following
features:
- Compact design
- Low offset current
- Low hysteresis
- High temperature stability
- Integrated electronics

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

Pin assignment X1 ...... Molex plug from adapter cable


Pin Designation Pin 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

Measuring points 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 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.
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 +15 V Pin 3 I Real -


Pin 2 -15 V Pin 4 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

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 has a plug-in Molex connec-
tion.

Fig. 45 TP 592S temperature sensor

Technical data Supply voltage 4 - 30 V DC


Output current 1 A/K

Function over- - The temperature sensor is fitted to the cooling element and measures the elements
view temperature.
- The temperature sensor emits a current of exactly 1 A per K (Kelvin), provided that
there is a voltage of 4 - 30 V DC.

0 K corresponds to a temperature of -273.15C


0C corresponds to 273.15 K
273.15 K corresponds to 273.15 A

Pin assignment Plug Function


X1 2-pin Molex plug

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

Measuring points 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 24 V DC

Function over- The TTS 22 controls the polarity of the welding current and the auxiliary power source.
view The auxiliary power source allows the arc to be reignited. The TTS 22 and FMW PC
boards work in tandem.

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 Designation Pin Designation


1 Uact- 2 Uact+

X9 ...... Connection to control (UST PC board)


Pin Designation Pin Designation
1 Uact- 2 Uact+

Measuring points See pin assignment

LED checklist See overview

51
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 over- The UST PC board performs the following functions:


view
(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 panel


The UST controls the control panel 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 swit-
ched 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 panel (10-pin ribbon cable)

X3 ...... Supply

Pin Designation Pin Designation


1 +24 V-EXT, +24 V remote 5 GND-EXT, remote control
control connection connection GND
2 NC 6 NC
3 UZW, intermediate circuit 7 GND-UZW, intermediate
voltage measuring circuit voltage measuring
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply 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 GND (SUPPLY)

53
Pin assignment X8 ...... Programming interface for updating firmware via BSL tool
(continued)
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 NOTE! Options enabled via service module software are stored on the UST,
board 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 - Undo screws (1) on both sides of the


housing power source for the side panels.
- Take off side panels

(1) (1) (1)


Fig. 1 Removing housing side panels

NOTE! After removing the screws


(2) (2) (2), ensure that the control panel
does not fall out of the frame.

- Undo front screws (2)

Fig. 2 Removing front screws

- Undo rear screws (3)


(3) (3)

Fig. 3 Undoing rear screws

56
Opening the If handle is present, remove holder on one
housing (7) (4) (4) side as follows:
(continued) - Undo screws (4) on the holder for the
handle

Fig. 4 Removing screws for handle holder

Remove the cover as follows:


- Lift the handle (5) and holder (6)
(5)
slightly
(6) - Remove the cover (7) (Fig. 4)

Fig. 5 Removing handle holder

Closing the - Fit cover (7)


(7) (4) (6) (4)
housing - If present, replace handle (6) with
holder (5) and fasten with two screws
(4).

Fig. 6 Replacing cover and fastening handle

- Tighten front screws (2)


(2) (2)

Fig. 7 Tightening front screws

57
Closing the - Tighten rear screws (3)
housing (3) (3)
(continued)

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 panel,
lay down the sheet for insulating the PC boards behind the side panel on the
side of BPS 17/22 PC board.

- On both sides of the power source


replace side panels and fasten with
screws (1)

(1) (1) (1)


Fig. 9 Fastening the housing side panels

58
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 con-
ductive 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 compon-
ents 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 (2)


TTS 22 PC board

(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 - Unscrew the two spacers (4) on the
TTS 22 PC board insulating sheet
(continued)

(4) (4)
Fig. 2 Loosening the spacers

- Remove Molex plug (5) and blade


terminal (6) from the TTS 22 PC
board

(5) (6)
Fig. 3 Removing plug connections from sockets

- Undo two spacers (3) and four screws


(9)

(9)

(3) (9) (9) (3) (9)

Fig. 4 Undoing screws and spacers

- Remove TTS 22 PC board (7) com-


plete with retaining plate (10)
- Undo five spacers (8) on TTS 22 PC
board
- Remove TTS 22 PC board (7) from
(8) (10) retaining plate (10)

(7)
Fig. 5 Removing TTS 22 PC board and spacers

61
Installing the TTS - Place the TTS 22 (7) on the spacers (8) on the retaining plate
22 PC board
- Screw in the five spacers (8) on TTS
22 PC board
- Replace TTS 22 PC board (7) com-
plete with retaining plate

(8)

(7)
Fig. 6 Fasten TTS 22 PC board with spacers

- Fasten the TTS 22 PC board comple-


te with retaining plate using the two
spacers (3) and four screws (9)
(9)

(3) (9) (9) (3) (9)

Fig. 7 Tighten screws and spacers

- Insert Molex plug (5) on TTS 22 PC


board

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

- Screw in the two spacers (4) on the


insulating sheet

(4) (4)
Fig. 9 Tightening spacers

62
Installing the TTS - Lay down UST PC board
22 PC board
(continued)

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 (2)


BSV 22 PC board

(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 - Unscrew the two spacers (4) on the
BSV 22 PC board insulating sheet
(continued)

(4) (4)
Fig. 2 Loosening the spacers

(5) (6) - Remove Molex plug (5) and blade


terminal (6) from the BSV 22 PC
board

Fig. 3 Removing plug connections from sockets

- Undo two spacers (3) and four screws


(9)

(9)

(3) (9) (9) (3) (9)

Fig. 4 Undoing screws and spacers

- Remove BSV 22 PC board (7) com-


(8) (7) (8) (10)
plete with retaining plate (10)
- Undo the four spacers (8) on BSV 22
PC board
- Remove BSV 22 PC board (7) from
retaining plate (10)

(8) (8)
Fig. 5 Removing BSV 22 PC board and spacers

65
Installing the - Place the BSV 22 (7) on the spacers (8) on the retaining plate
BSV 22 PC board
- Tighten the four spacers (8) on BSV
(8) (7) (8) (10)
22 PC board (7)
- Replace BSV 22 PC board (7) com-
plete with retaining plate

(8) (8)
Fig. 6 Fasten BSV 22 PC board with spacers

- Fasten the BSV 22 PC board comple-


te with retaining plate using the two
spacers (3) and four screws (9)
(9)

(3) (9) (9) (3) (9)

Fig. 7 Tightening screws and spacers

(5) (6) - 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.

Fig. 8 Inserting plugs into sockets

- Screw in the two spacers (4) on the


insulating sheet

(4) (4)
Fig. 9 Tightening spacers

66
Installing the BSV - Lay down UST PC board
22 PC board
(continued)

Fig. 10 Laying down UST PC board

Installing UST PC (2)


board

(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 - Undo two front screws (1) for the


transformer device frame

(1) (1)
Fig. 1 Undoing screws on front of device frame

- Disconnect the ribbon cable (2) for


the control panel at X2 on the UST
PC board
- Remove the control panel

(2)

Fig. 2 UST: Disconnecting the ribbon cable

- Disconnect ribbon cable (3) from BPS


PC board

(3)

Fig. 3 BPS: Disconnecting the ribbon cable

68
Removing the - Undo the two screws (4) on HF
transformer transformer (5)
(continued)
(5)

(4)

Fig. 4 HF transformer: removing screws

(5) - Lift high frequency (HF) transformer


(5) and undo two screws (6) behind
the HF transformer.

(6)

Fig. 5 Loosening the two screws behind the HF


transformer

- Remove secondary transformer leads


(7): Unscrew the two screws with
serrated washers (not shown)

(7)

Fig. 6 Removing the secondary transformer leads

- Cut cable tie on the secondary trans-


former lead (7) (cable tie no shown)
- Remove toroidal tape cores (8) from
the transformer leads

(8) (7)
Fig. 7 Removing toroidal tape cores

69
Removing the - Undo hexagon bolt (9) using a size 19
transformer spanner
(continued) - Remove hexagon bolt (9) with serra-
(12) ted washer and shim
(10)
The following leads are now disconnected:
(11) - Middle tap transformer lead (10)
(9) - Measuring line (11) - white cable with
Massebuchse written on it
- Secondary wiring lead (12) - white
cable with no writing

Fig. 8 Removing the middle tap transformer lead

- Undo spacers (13)

(13) (13)
Fig. 9 Loosening the spacers

- Remove blade terminals X2 to X5


(15) (16)
(15)
- Remove blade terminal X1 common
(16) from the measuring line for
welding voltage.
- Cut cable tie for the measuring line
(16) - Fig. 11

Fig. 10 Removing blade terminal for the measuring


lines

70
Removing the - Remove measuring lead (16) for the
transformer welding voltage
(continued) (18) - Feed out the middle tap transformer
lead (17) on the current sensor (18)

(16) (17)

Fig. 11 Feeding out the middle tap transformer lead

- Loosen the two screws (19) on the


(20) luster terminal
- Remove primary leads (20)
(21) - Undo screw (21)

(19)

Fig. 12 Disconnect primary transformer leads

- Undo screws (22)

Important: undo the three screws (22) on


(22) earth wire, if present.

Fig. 13 Undo screws on transformer

- Remove transformer (22)


- Cut through cable ties (23) and (24)
(24) on transformer

(23)

(25)

(22)

Fig. 14 Removing the transformer

71
Removing the - Unthread the middle tap transformer
transformer lead (17) on the EP rings (25)
(continued) (see also Fig. 14)

(25)
(17)

Fig. 15 Feeding out the middle tap transformer lead

(27) - Undo the four screws (26) on the


transformer and remove the side
plates (27)

(26)

(27)
Fig. 16 Removing the plates on the transformer

Installing the - Fasten side plates (27) to the transformer using the four screws (26)
transformer
- Thread EP rings (25) onto the middle
tap transformer lead (17) and make
(24) two winds
- Fasten EP rings (25) and middle tap
(23) transformer lead (17) with cable ties

(25)

(22)

Fig. 17 Routing the middle tap transformer lead

72
Installing the - Installing the transformer (22) into the power source
transformer
(continued) - Tighten screws (22)

Important: If earth wire is present tighten


(22) the three screws (22) and fasten earth
wire using the central screw (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
(17) (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)

Fig. 20 Routing auxiliary power source leads

Important: The position of the primary


(20) transformer leads (20) on the luster
terminals is not important.
(21)
- Insert transformer leads (20) into the
(19) luster terminals and fix with screws
(19)
- Fix luster terminals and insulation with
screws (21)
Fig. 21 Connecting primary transformer leads - Bind leads with cable tie

73
Installing the - Feed middle tap transformer lead (17)
transformer in direction of arrow through the
(continued) (18) current sensor (18)
- Route measuring line (16) for the
blade terminal X1 common
(see fig. 19)

(16) (17)

Fig. 22 Routing transformer lead

When inserting the five blade terminals


(15) (16)
(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

- Tighten the two spacers (13) on the


insulating sheet

(13) (13)
Fig. 24 Tightening spacers

74
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 se-


condary 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 (5) - Lift high frequency (HF) transformer
transformer (5) and tighten two screws (6) behind
(continued) the HF transformer

(6)

Fig. 28 Tightening the two screws behind the HF


transformer

- Replace HF transformer and tighten


the two screws (4)

(4)

Fig.29 HF transformer: tightening screws

- Connect ribbon cable (3) from BPS


PC board

(3)

Fig. 30 BPS: connecting the ribbon cable

NOTE! Danger of malfunction


(32) during high frequency welding.
When routing the ribbon cable
(2), ensure that there is enough
distance between it and the HF
(2) leads (32).

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 panel at X2 on the UST PC board
- Insert the operating panel

76
Installing the - Press front of frame on
transformer - Tighten two front screws (1) for the
(continued) device frame

(1) (1)

Fig. 32 Screws on front of device frame

77
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 avai-
lable in the TechGuide DownloadCenter under Safety, Environment & Health.

78
Terms and abbreviations used

General remarks Terms and abbreviations is a glossary of specific technical terms essential for an
understanding of the service manual.

Terms and abbre- BSL tool:


viations 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 ensu-
res 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:
- uploading 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 4,075,119 MagicWave 2200 G/F 4,075,125
MagicWave 2200 Job G/F/US 4,075,119,800 MagicWave 2200 G/F/US 4,075,125,800
TransTig 800 Job G/F 4,075,159 TransTig 2200 G/F 4,075,126
TransTig 2200 Job G/F 4,075,120 TransTig 2200 G/F/US 4,075,126,800
TransTig 2200 Job G/F/US 4,075,120,800 MagicWave 1700 G/F 4,075,127
MagicWave 1700 Job G/F 4,075,121 MagicWave 1700 G/F/US 4,075,127,800
MagicWave 1700 Job G/F/US 4,075,121,800
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
42,0407,0273 BE2,0201,1329

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

2IS 41,0003,0282,Z - MW 1700/2200


W2
FM

4,070,949 - FMW22IS

41,0003,0279

41,0003,0203
12,0405,0365 33,0010,0326
43,0001,1177 43,0001,0600
43,0001,1176 - TT
43,0001,1178
43,0001,3280 - TT 2200 42,0409,3211 - TT800 43,0001,1273 TT800
43,0001,3279 - MW1700/2200 42,0409,2935 - TT2200
43,0001,3258 - TT800/2200 Job 42,0409,2934 - MW1700
43,0001,3259 - MW1700/2200 Job 42,0409,2882 - MW2200
42,0406,0315 * gewnschte Lnge angeben
42,0405,0398 - MW1700/2200 * Specify the length required
42,0406,0093 42,0405,0399 - TT2200 * Indiquer la longueur dsire
* Indicar la longitud deseada
42,0001,1501 43,0004,2328 * Indicare la lunghezza desiderat
* indicar o comprimento desejado
42,0001,5477 43,0004,2330 XYHG
WHSRDGRYDQRXGpONX

32,0405,0183
42,0404,0024

TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200


Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2

el_fr_st_wi_00545 012007
4,070,813 - BSV22 TT2200
4,070,798,Z - BPS17 MW 1700/TT 800
4,070,804,Z - TTS22 MW1700/2200
4,070,799,Z - BPS22 TT/MW 2200
41,0001,0627

41,0009,0057

33,0024,0032
2
S2
TT 22 33,0010,0325 - MW/TT2200
V
BS
S
BP 43,0006,0168

43,0001,1191
42,0405,0420

4,070,960,Z - UST2C

T2
2 US
F2
HF

4,070,812 - HFF22
43,0004,1122 - 26pol.

TT 800/2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200


Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2

el_fr_st_wi_00545 012007
FRONIUS INTERNATIONAL GMBH
Buxbaumstrae 2, 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 012008