Fronius MTG 2100 S Service Manual Download | Manualshive

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Replacing modules

Safety

WARNING!

Work that is carried out incorrectly can cause serious injury and damage.

All activities described in the Service Instructions must only be carried out by Fronius-
trained service engineers.
Read the "Safety rules" chapter in the product's Operating Instructions.

WARNING!

An electric shock can be fatal.

Before opening the device, observe the discharge time for electrically-charged compon-
ents (e.g. capacitors) specified in the Service Instructions, the Operating Instructions or
on the device itself.

▶

Follow the five safety rules:

▶

Disconnect completely

▶

Ensure the device cannot be switched back on

▶

Check that the device is de-energised

▶

Carry out earthing and short-circuiting

▶

Cover nearby live components or make them inaccessible

General

The "Replacing modules" section explains how to replace components that:
-

Have no instructions of their own for replacement and

-

Require detailed replacement instructions

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EN

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Summary of Contents for MTG 2100 S

Page 1: ...elemental chlorine free paper ECF sourced from certified sustainable forests FSC Perfect Charging Perfect Welding Solar Energy TransSteel 2200 MTG 2100S EN Service manual MIG MAG power source 42 0426 0273 EN 007 01042021 ...

Page 2: ......

Page 3: ...PC board 27 Removing the LSTMAG20 PC board 27 Installing the LSTMAG20 PC board 28 Replacing secondary diodes 30 Replacing the secondary diode 30 Replacing the fan 32 Replacing the fan 32 Replacing the transformer 33 Removing the transformer 33 Fitting the transformer 33 Replacing the solenoid valve 35 Replacing the solenoid valve 35 Replacing the drive 37 Removing the drive 37 Installing the drive...

Page 4: ...ions 58 General 58 Mains supply and connecting lines 58 Housing and covers 58 Adjustment and display devices 58 Rating plate and warning stickers 58 Electrical tests 59 Ground conductor resistance 59 Insulation resistance 59 Open circuit voltage 60 Documentation 61 Documentation 61 Function tests 62 Mains on off devices 62 Indicators and control elements 62 Gas solenoid valve 62 Test weld 62 4 ...

Page 5: ...General information 5 ...

Page 6: ...6 ...

Page 7: ...fatal If the device needs to be switched on briefly for testing while the housing is open Do not touch any parts inside the housing Only touch using suitable measuring or test probes WARNING An inadequate ground conductor connection can cause serious injury or damage The housing screws provide a suitable ground conductor connection for earthing the housing and must NOT be replaced by any other scr...

Page 8: ... PZ2 Phillips screwdriver PH2 Torque wrench 1 5 Nm BT1 fitting tool item number 42 0411 0039 Torque wrench item number 42 0411 9040 Adjustable spanner insertion tool item number 42 0435 0229 Measuring and testing equip ment Digital multimeter Insulation tester Metriso 5000 Torch flow rate testbox 4 078 016 Flow and leak tester Manual welding torch testbox 4 045 998 Apparatus tester e g Fluke 6200 ...

Page 9: ...Error location aid 9 ...

Page 10: ...10 ...

Page 11: ...f 15 V 24Vint Lights up when there is an internal primary supply voltage of 24 V 24VMotor Lights up when there is a supply voltage of 24 V for the motor TXD A Lights up when data is being transferred to the control panel RXD A Lights up when data is being transferred to the control panel TXD B Flashes in normal operation lights up when data is being sent to the LocalNet update interface RXD B Ligh...

Page 12: ...ched on PFC Flashes when there are no errors on the PFC Error Lights up when the PFC is faulty or is not configured Temperature sensor Description ntc 1 PC board wirefeeder ntc 2 Temperature sensor of the motor controller voltage doubler ntc 3 Temperature sensor of the motor controller secondary circuit ntc 4 Temperature sensor of the motor controller PFC 12 ...

Page 13: ...e diode 1 Other measuring results indicate a defect in the diode meaning it needs to be replaced Temperature sensor X2 Cooling element transformer connection X2 2 pin Microfit connector Pin 1 Temperature signal Pin 2 5 V A temperature dependent resistance as per the table below must be measured between pins 1 and 2 of the X2 connector Temp C R Nom W Temp C R Nom W Temp C R Nom W 0 32 650 35 6531 7...

Page 14: ... Tamb 10 000 ohm 498 ohm 25 23 10 996 ohm The individual symbols stand for the following variables Tamb ambient temperature of the temperature sensor in C Rlow resistance in ohm according to the table for the next temperature down from the ambient temperature Rhigh resistance in ohm according to the table for the next temperature up from the ambient temperature Thigh temperature in C for resistanc...

Page 15: ... 12 ESr 0 14 Et 0 3 Etb 0 1 If the service codes shown above appear on the display it may be possible to resolve the problem by updating the database software and the firmware for details see Software update If the problem is not resolved by a software update please contact Fronius Technical Support TSN TSI When contacting them please provide the following information Service code displayed Config...

Page 16: ...13 Illegal welding process change during welding Do not make illegal welding process changes acknowledge service code Cause Remedy Err 11 5 V power supply on power module faulty Replace LSTMAG20 PC board Cause Remedy Err 12 15 V power supply on power module faulty Replace LSTMAG20 PC board Cause Remedy Err 51 Mains undervoltage mains voltage has fallen below the tolerance range Check mains voltage...

Page 17: ... high Replace LSTMAG20 PC board Cause Remedy EPS 8 The voltage offset for welding voltage measurement is too high Replace LSTMAG20 PC board Cause Remedy EFd 4 Motor is not supported Perform software update replace motor Cause Remedy EFd 7 Motor current sensor faulty Replace LSTMAG20 PC board Cause Remedy EFd 8 PC board LSTMAG20 overtemperature Allow power source to cool down check that fan is runn...

Page 18: ...place motor Cause Remedy EFd 83 Short circuit in wirefeeder motor or on LSTMAG20 PC board Unplug motor start function test if there is no error EFd 83 replace motor otherwise replace LSTMAG20 PC board Cause Remedy EFd 84 Fault on the PC board no command is send to the motor Check 24V motor power supply replace PC board Cause Remedy to0 TMP Overtemperature on the PC board LSTMAG20 secondary circuit...

Page 19: ...t Operate power source within the permitted temperature range Cause Remedy tu3 TMP Undertemperature on the PC board LSTMAG20 motor controller TMP is the temperature indicator Operate power source within the permitted temperature range Cause Remedy tu6 TMP Undertemperature on the PC board LSTMAG20 voltage doubler TMP is the temperature indicator Operate power source within the permitted temperature...

Page 20: ... LSTMAG20 PC board PFC module Replace LSTMAG20 PC board Cause Remedy Err tfA Temperature sensor fault on PC board PFC Replace LSTMAG20 PC board Cause Remedy no Prg No saved program selected Select saved program Cause Remedy No IGn Ignition time out function is active current did not start flowing before the length of wire specified in the set up menu had been fed The power source safety cut out ha...

Page 21: ... PFC firmware Switch power source off and on again if the error persists replace LST MAG20 PC board Cause Remedy ECC 3 Communication error on LSTMAG20 PC board Switch power source off and on again replace LSTMAG20 PC board Cause Remedy PFC Upd Firmware is being installed on the PFC Wait for the firmware update to finish Cause Remedy 21 EN ...

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Page 23: ...Replacing modules 23 ...

Page 24: ...24 ...

Page 25: ...he discharge time for electrically charged compon ents e g capacitors specified in the Service Instructions the Operating Instructions or on the device itself Follow the five safety rules Disconnect completely Ensure the device cannot be switched back on Check that the device is de energised Carry out earthing and short circuiting Cover nearby live components or make them inaccessible General The ...

Page 26: ... 1 1 1 Undo the five TX25 screws 1 on the side panel and remove the side panel 2 1 2 Disconnect the ribbon cable 2 for the control panel on the LSTMAG20 PC board 3 3 3 Remove the two TX25 screws 3 on the control panel 4 Remove the control panel 26 ...

Page 27: ... 3 3 3 3 Undo the five TX25 screws 2 and remove the leads 4 Undo the four TX20 screws 3 and remove the leads 5 6 5 5 5 5 4 7 5 Undo the eight TX20 screws 4 6 Undo the five TX20 screws 5 7 Undo the four TX20 screws 6 8 Insert the screwdriver into the hole 7 on the LSTMAG20 PC board and turn to detach the PC board from the heat sink 9 Remove the LSTMAG20 PC board 10 Clean the heat sink 27 EN ...

Page 28: ...nk 3 Fit 13 M4x8 TX20 screws 1 to 0 5 Nm Tightening torque 1 5 Nm 4 Fit four M4x13 TX20 screws 2 to 1 0 Nm then secure Tightening torque 1 9 Nm 5 6 6 6 5 4 4 3 3 5 Fit leads 3 4 and 5 using an M4x8 2 TX20 screw Tightening torque 1 5 Nm 6 Fit the transformer leads using M5x12 TX25 screws 6 Tightening torque 3 0 Nm 7 7 7 Plug in all connectors 7 on the PC board 28 ...

Page 29: ... 8 8 Configure the jumper 8 on the LST MAG20 PC board Standard no jumper connection open MV jumper connected closed 9 Close housing as described in section Closing the housing 29 EN ...

Page 30: ...d 3 Undo the two M4x10 mm TX20 screws 1 on the faulty diode 4 Clean the heat sink and modules on the LSTMAG20 PC board NOTE Observe the direction of installation 5 Place the new diode on the heat sink as shown and secure with two M4x10 mm TX20 screws 1 Pre tighten with 0 5 Nm Tightening torque green screws 2 1 Nm Tightening torque red screws 1 3 Nm 2 2 6 Bend the tabs 2 on the thermal foil 90 degr...

Page 31: ...he thermal foil 3 to the modules on the LSTMAG20 PC board as shown 8 Install the PC board as described in section Installing the LSTMAG20 PC board 9 Close housing as described in section Closing the housing 31 EN ...

Page 32: ...over 2 4 3 3 Remove the fan 3 and unplug the connector 4 4 Connect and install the new fan IMPORTANT Install the fan with the air flow towards the inside The arrow on the fan should point inwards 6 5 5 Insert the cover 5 and fit an M5x12 mm TX25 screw 6 Tightening torque 3 0 Nm 6 Close left side panel 32 ...

Page 33: ...oard 3 Unscrew the two TX25 screws 3 from the primary transformer leads on the LSTMAG20 PC board 4 Unscrew the 17 mm screw from the transformer lead 3 on the current socket 5 Disconnect the two flat connectors 4 5 5 6 Undo the two TX25 screws 5 7 Remove the transformer Fitting the trans former 2 2 1 1 Insert the transformer 1 2 Fit the transformer 1 using two PT 5x14 mm TX25 screws 2 Tightening to...

Page 34: ... leads 4 to the LST MAG20 PC board 5 Fit the primary transformer leads to the LSTMAG20 PC board using two M4x8 mm TX25 screws 5 Tightening torque 1 5 Nm 6 Fit the secondary transformer leads to the LSTMAG20 PC board using three M5x12 mm TX20 screws 6 Tightening torque 3 0 Nm 7 Close housing as described in section Closing the housing 34 ...

Page 35: ...nd swing the back panel to one side 2 3 2 Unplug the cable 2 from the PC board 2 3 Undo size 17mm nut 3 from the solenoid valve 4 5 7 6 4 Unplug cable 4 5 Remove the hose clamp 5 and the hose 6 6 Remove the solenoid valve 7 7 Fitt the hose 6 with the hose clamp 5 to the new solenoid valve and plug in the cables 4 again 35 EN ...

Page 36: ...is not trapped in any way 8 Insert the solenoid valve 7 into the holder 9 Fit the nut 8 size 17 mm Tighten ing torque 3 Nm 9 10 Plug in the cables 9 to the PC board 11 Insert the back panel 10 10 10 10 12 Fit the back panel using 6 screws 10 Tightening torque 3 Nm 36 ...

Page 37: ...the drive 1 1 Open housing as described in section Opening the housing 2 Remove the driver roller and pressure roller 3 Unplug the motor lead 1 from the LSTMAG20 PC board 2 4 Undo the three PH2 screws 2 3 5 Remove the drive 3 37 EN ...

Page 38: ...ue 2 1 Nm 1 3 Plug in the motor lead 3 on the LST MAG 20 PC board 4 Fit the driver roller and pressure roller 5 Calibrating the motor 6 Close housing as described in section Closing the housing Calibrating the motor Access the Service menu à Select the 2nd parameter and access the second Service menu 38 ...

Page 39: ...ng button or the torch trigger Display shows 1 St 3 0 an 5 Press the Wire threading button or the torch trigger Display shows AdJ 6 Measure the speed at the drive roller and set to 3 m min 42 3 U min using the right adjusting dial Display shows rdY The values have been stored internally 7 Press the Wire threading button or the torch trigger Display shows 2 nd 15 0 8 Press the Wire threading button...

Page 40: ...in section Opening the housing 2 Remove the wearing parts from the motor plate 3 Undo the TX25 screw 1 on the polar ity reverser lead 2 2 4 Undo the two TX25 screws 2 3 4 5 Undo the three PH2 screws 3 6 Undo the three TX25 screws 4 7 Swivel the motor plate outwards and remove it 40 ...

Page 41: ... the motor plate 1 in until it engages 5 4 3 Fit the motor plate using three TX25 screws 4 Tightening torque 1 5 Nm 4 Position the drive in the motor plate and fit using three M5x12 mm PH2 countersunk screws 5 Tightening torque 2 1 Nm 5 Fit the wearing parts and close the cover 6 6 6 Fit two TX25 screws 6 Tightening torque 2 1 Nm 41 EN ...

Page 42: ... 7 7 Fit the polarity reverser lead to the motor plate using a TX25 screw 7 Tightening torque 3 0 Nm 8 Close housing as described in section Closing the housing 42 ...

Page 43: ...l 2 Fit the control panel using two PT 5x14 mm TX25 screws 2 Tightening torque 1 5 Nm 2 1 3 Connect the ribbon cable 2 for the control panel to the LSTMAG20 PC board 3 3 3 3 3 4 Insert the side panel and secure using five M5x12 TX25 screws 3 Tightening torque 2 1 Nm 43 EN ...

Page 44: ...Insert the trigger into the grip 4 5 5 5 7 Undo the coaxial cable using 2x15 mm flat spanner 4 8 Remove the torch body coaxial cable 9 Apply Loctite 243 thread sealant to the bottom third of the torch connector 10 Fit the new torch body coaxial cable FSC using a 15 mm flat spanner and torque wrench 42 0411 9040 with insertion tool 42 0435 0229 4 Tightening torque 15 Nm 11 Fit the three 2 5x12 TX 8...

Page 45: ...pinning the control line note the position of the tool to fully undo the locking hooks 4 5 4 Fit the new coaxial cable FSC using a torque wrench 42 0411 9040 with insertion tool 42 0435 0229 4 Tightening torque 15 Nm 5 Allow the control line to engage using a pinning tool or flat screwdriver 5 Brown A Blue B NOTE Pull to check that the locking hooks on the control line are engaged 45 EN ...

Page 46: ... e g Metriso 5000 Test voltage 500 V DC Measuring points Between the outer pipe of the torch body and contact tip insulation resist ance min 1 MW Test equipment Torch flow rate testbox 4 078 016 Perform the tests as described in the Torch Flow Rate Operating Instructions For the limit values refer to the PP SER 2001 Welding torch flow rates ser vice test schedule 46 ...

Page 47: ...lements are working properly for details see the Manual torch testbox Operating Instructions NOTE While the control elements are being tested the hosepack should be flexed and twisted along its entire length so that any breaks in the control line can be detected 47 EN ...

Page 48: ...48 ...

Page 49: ...Software 49 ...

Page 50: ...50 ...

Page 51: ...aded from the DownloadCenter To update the software on the power source the TSt2500c remote control cable harness 43 0004 4850 is required in addition to the LocalNet USB converter The cable harness must be connected between the LocalNet USB converter and the LSTMAG20 PC board 1 1 Connect the TSt2500c remote control cable harness 43 0004 4850 to the update interface 1 2 Connect the LocalNet USB co...

Page 52: ...same time Description of the menu contents Sequence Menu item display Description 1 Numerical value Firmware version 2 Numerical value Number of welding program database 3 Numerical value Number of the currently selected welding program 4 Numerical value Arc time in hours 5 2nd Open menu level 2 To open menu level 2 press the two para meter selection keys arrow keys at the top at the same time 5 1...

Page 53: ...e month 1 to 12 To change the value press the right hand control dial 5 5 dAY Date setting for the day 1 to 31 To change the value press the right hand control dial 5 6 Hou Time setting for the hour 0 to 24 To change the value press the right hand control dial 5 7 Min Time setting for the minute 0 to 59 To change the value press the right hand control dial 53 EN ...

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Page 55: ...Safety Inspections 55 ...

Page 56: ...56 ...

Page 57: ... such defects have been rectified The following tests must be performed in the prescribed sequence Each test must be passed before the next test is started If it is not possible to perform a particular test the examiner must decide whether the safety of the device can nevertheless still be verified The examiner bears full responsibility and liability for this decision Justifications for the result...

Page 58: ...nd cur rent capacity of mains cables As the current capacity can vary depending on how the cables are routed and the differ ent ambient temperatures the requirements set out in the standard must be observed when changing mains cables Also refer to the applicable requirements and standards in your country Housing and cov ers All housing components insulation components and protective covers must be...

Page 59: ...afety precautions Only perform the measurement if a ground conductor resistance test has been car ried out successfully Do not touch any other person while performing the test and take measures to pre vent other people touching any metallic surfaces Ensure that the polarity is correct while conducting the insulation resistance test to avoid unreliable test results The device to be tested must be s...

Page 60: ... the tested potentials or via the discharge function on the insu lation tester Open circuit voltage Peak value measurement of open circuit voltage at the power source current sock ets The measurement must be performed using the Measuring circuit for U0 measure ment 43 0001 0945 The measurement must be performed in MIG MAG mode The open circuit voltage must not exceed the value specified on the rat...

Page 61: ...bration data used If an individual test cannot be performed the resulting decision must be justified and documented by the examiner Any device that fails a test must be clearly marked as unsafe and the operator informed The device may no longer be used Once a device passes the test an inspection sticker 42 200 101 must be affixed to it The Safety inspection test record is available from the Froniu...

Page 62: ... operation of the gas solenoid valve must be tested by activating the torch trigger several times To check the gas solenoid valve and the gas lines for leaks the gas line to the gas solenoid valve must be subjected to pressure Disable the gas feed at the gas cylinder and observe the pressure gauge for any drop in pressure over a period of 2 minutes There must be no noticeable drop in pressure on t...

Page 63: ...63 EN ...

Page 64: ...S INTERNATIONAL GMBH Froniusstraße 1 A 4643 Pettenbach AUSTRIA contact fronius com www fronius com Under www fronius com contact you will find the addresses of all Fronius Sales Service Partners and locations ...

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