Fronius TP 1500 Service Manual Download Page 1

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Service Manual

Summary of Contents for TP 1500

Page 2: ...in the course of inspection service and maintenance The unit will repay you by giving its users constant operational readiness for many years to come General remarks Safety Warning Work performed inco...

Page 3: ...CE marking 13 Copyright 13 Technical data Rating plate 14 Rating plate 14 Identification 14 Data regarding weld process 14 Duty cycle 15 Data regarding power supply 16 Standard characteristic 16 Set u...

Page 4: ...ircuit voltage TP 1500 VRD 41 Check the arc force and anti stick 41 Cycle test 42 Checking the transistor module 44 Checking the secondary diode 48 Checking the potentiometer ribbon cable 49 PE conduc...

Page 5: ...tting the transformer 80 Fitting the LCA15 board 80 Closing the housing 84 Installation instructions Temperature sensor 85 Safety 85 Scope of supply 85 Tools needed 85 Opening the housing 85 Removing...

Page 6: ...tion socket 103 Fitting the potentiometer and remote control unit connection socket 103 Fitting the seal for the remote control unit connection socket 104 Fitting the FPA15 board 104 Closing the housi...

Page 7: ...ed welding result and damage to the equipment Note Danger indicates an imminently hazardous situation which if not avoided will result in death or serious injury This signal word is to be limited to t...

Page 8: ...ed 25 C to 55 C Relative atmospheric humidity up to 50 at 40 C up to 90 at 20 C Ambient air Free of dust acids corrosive gases or substances etc Elevation above sea level Up to 2000 m Ambient conditio...

Page 9: ...all combustible objects well away from the welding location Welding must NEVER be performed on containers that have had gases fuels mineral oils etc stored in them Even small traces of these substanc...

Page 10: ...witch off the machine at the main switch in an emergency Hazards from mains and welding current If the following instructions are not observed vagrant welding currents may occur These can destroy eart...

Page 11: ...n of possible electromagnetic problems that may occur on equipment in the vicinity and of the degree of immunity of this equipment as per the CE Declaration of Conformity safety features mains signal...

Page 12: ...ce ensures that nobody can be endangered by your turning on the machine At least once a week check the power source for any damage that may be visible from the outside and check that the safety featur...

Page 13: ...not in perfect condition Alterations to the power source Use only original spares and wearing parts With parts sourced from other suppliers there is no certainty that these parts will have been design...

Page 14: ...ciple see Section 4 General basics Functional principle The Weld process data section gives information on the weld process for which the power source is intended here rod electrode welding and TIG we...

Page 15: ...le duty cycles are usually more than sufficient and are often prolonged in any case by the unavoidable need to change the electrode from time to time the fact that weld seams are not of unlimited leng...

Page 16: ...otection should be used 6 Apparent power computed as the product of mean power consumption 5 x mains voltage 2 here 16 A x 230 V 3 68 kVA 7 CE labelling 8 Protection class as defined in the Standard h...

Page 17: ...Note Operation with the wrong mains voltage will invalidate all warranty claims Note If the power source is designed to run on a special voltage the Technical Data shown on the rating plate apply The...

Page 18: ...90 Before the high switching frequency can be exploited the mains voltage must first be rectified in the primary rectifier The DC voltage delivered by the primary rectifier is converted to a high fre...

Page 19: ...onance converter T2 If transistor T1 becomes conductive the series resonance circuit i e coil and capacitor generates a positive sinusoidal half wave that is discharged via the resistor RL The negativ...

Page 20: ...output voltage in open circuit In the same way as with the series resonance converter the output voltage is dependent upon the addressing frequency of the switching transistors relative to the resona...

Page 21: ...ith the actual welding current that is measured by the shunt The transistors of the power pack are addressed so as to raise or lower the welding voltage to the value that is needed for keeping the pre...

Page 22: ...tches off Error indicator lights up In no load operation the power pack switches back on again 3 No load operation The sawtooth open circuit voltage see Fig 7 is applied to the output sockets Measurin...

Page 23: ...this may cause the rod electrode to burn out Sticking of the rod electrode is prevented very effectively by the Anti Stick function If a short circuit occurs the welding current is increased for a ma...

Page 24: ...defined motion of the welding torch comprises the following functional sequence The TIG Comfort Stop function is activated by lifting the torch causing the arc to become visibly longer Lowering the to...

Page 25: ...current 10 A to 150 A the gas post flow time will be between 3 and 12 seconds gas post flow time at minimum welding current 10 A 3 seconds gas post flow time at maximum welding current 150A 12 second...

Page 26: ...nce smaller than 200 ohms VRD is inactive No limitation of the output voltage so as to ensure sufficient welding power Example Start of welding Important Within 0 3 seconds of the end of welding VRD i...

Page 27: ...th different potentials approach one another The charge equalisation e g between the work surface and the pin of a component leads to uncontrolled currents that can damage the component ESDS are compo...

Page 28: ...s to servicing the TP 1500 power source the secondary diode and the transistor module on the LCA 15 board are especially critical components Both the secondary diode and the transistor module are powe...

Page 29: ...completely and evenly covered with heat transfer compound Once there is an even thin layer of compound on the roller of the application tool lift the tool out of the compound Heat transfer compound To...

Page 30: ...riginal packaging The inside packaging consists of one supporting element at the underside of the power source and one at the top The outside packaging is a coated corrugated cardboard box with a carr...

Page 31: ...en made to the TP 1500 series Modification Tools and appliances Designation 1 Manual torque screwdriver 1 to 6 Nm 2 Bit insert TX 20 for torque screwdriver 3 Bit insert hexagon socket width across 3 f...

Page 32: ...supplied with a filter attachment A 42 0405 0303 This removes the dust particles out of the cooling air sucked in by the fan Mount the filter attachment over the air intake slots as shown in the pictu...

Page 33: ...ding on the machine location but no less often than twice a year remove the housing and blow the inside of the power source clean with dry oil free reduced blow compressed air Do not aim air jets at e...

Page 34: ...g machine Ensure sufficient supply of cooling air Dust filter is dirty Remove the filter attachment and clean or change filter insert Power module is very dirty e g Operation without filter atachmnet...

Page 35: ...y Replace the secondary diode see Installation instructions for LCG 15 board LCG11 board is faulty Replace LCG15 board see Installation instructions for LCG 15 board and sec diode Welding voltage meas...

Page 36: ...eplace LCA 15 board see the section headed Installa tion instructions for LCA 15 board Gas solenoid valve is faulty even when the Gas test function is activated there is still 15 V on the white Gas va...

Page 37: ...d Resharpen the tungsten elec trode Welding torch is damaged Torch body protective hose etc are defective Change the damaged parts or replace the whole torch Mains fuse and or safety cut out has tripp...

Page 38: ...e this may mean that the LCA15 board or the potentiometer are faulty or that Imax is not set correctly If the maximum welding current Imax is too high or too low set the maximum welding current Genera...

Page 39: ...nimum welding amperage Load resistor load 4 Ohm P 400 W S h u n t V Amp meter TP 1500 If Imin is not within the tolerance range this may mean that the LCA15 board or the potentiometer are faulty or th...

Page 40: ...O and unplug the machine from the mains Connect the measuring circuit together with the voltmeter to the welding sockets Plug the machine back into the mains and shift the mains switch to I Set the we...

Page 41: ...n circuit voltage continued Fig 7 Check Arc force and Anti stick Check the arc force and anti stick Variant 2 Measuring the RMS value N B The RMS value can only be of any help in detecting a defect in...

Page 42: ...jumps to around 180 A arc force Condition 2 After approx 5 seconds the welding current automatically switches off anti stick function Lift the rutile electrode off the workpiece Condition 3 Power sour...

Page 43: ...omatically switches back on once the heat sink has cooled down to 60 C Condition 6 The Fault indicator goes out Set the welding current dial to Minimum After a few more minutes the fan cuts out once t...

Page 44: ...g direction as shown in the illustration with a diode testing device e g multimeter with diode testing function Measure the diode paths in the non conducting direction as well Replace the transistor m...

Page 45: ...the conducting direction of the diode path Checking the Transistor module continued 0 2 0 7 V 1 0 2 0 7 V 2 Fig 12 First diode path Intermediate circuit potential primary side transformer cable Fig 13...

Page 46: ...cond diode path GND potential primary side transformer cable Fig 14 Second diode path Intermediate circuit potential primary side transformer cable 0 2 0 7 V 3 0 2 0 7 V 4 Checking the transistor modu...

Page 47: ...47 Fig 16 Diode path Rectifier rectifier Fig 17 Diode path Rectifier AC 0 4 1 V 5 0 2 0 7 V 6 Checking the transistor module continued...

Page 48: ...de testing function Measure the diode paths in the non conducting direction as well Replace the secondary diode if the measurements in the conducting direction show that the measured voltage drop is s...

Page 49: ...lows constantly Potentiometer has a short circuit LCA15 board is faulty Replace potentiometer or LCA15 board LED Isoll remains dark Potentiometer has an interruption there is a break in the ribbon cab...

Page 50: ...n test Fig 23 Insulation test Primary circuit secondary circuit Fig 24 Insulation test Primary circuit earth PE conductor test continued Warning An electric shock can be fatal The testing unit works w...

Page 51: ...inst the protective contact of the mains plug Fig 25 Carry out the measurement Insulation resistance must be 2 5 MOhm If the insulation resistance is less than 2 5 MOhm the power source must be inspec...

Page 52: ...bly 1 Installation instructions FPA 15 board Assembly 5 Installation instructions Varistor Assembly 2 Installation instructions Transformer Assembly 8 Installation instructions Temperature sensor Asse...

Page 53: ...53 Overall circuit diagram...

Page 54: ...54...

Page 55: ...et width across 3 for torque screwdriver Molex extractor tool 42 0410 0290 Grinding paper grain P 500 or finer Contact spray Opening the housing Take off the carrying strap Undo the 5x25 TX20 screw 34...

Page 56: ...element 21 Remove the board insulator 37 Removing the LCG15 board Disconnect the ribbon cable 42 from the FPA15 board 5 Cut through the cable binder 33 Disconnect the 10 pole Molex plug 41 from the LC...

Page 57: ...0 screws 52 from the LCG 15 board 3 52 59 Fig 6 3 Carefully detach the LCG15 board 3 3 Fig 7 Undo the 2 M4x14 TX20 screws 31 on the diode holder 50 Detach the secondary diode together with the diode h...

Page 58: ...t spray and a non linting cloth Remove any contamination or unevenness from the heat sink with fine abrasive paper grain P 500 or finer Clean the heat sink with contact spray and a non linting cloth N...

Page 59: ...please proceed according to the following procedure 1 Place the LCG15 board 3 onto the spacers on the diode holder in the correct position N B Before inserting the 4 hexagon socket screws M4x22 width...

Page 60: ...54 56 57 41 Fig 16 64 64 Mounting the shunt and connecting the leads Plug the 10 pole Molex plug 41 onto board LCA15 1X10 Fix the cable harness for Molex plugs 40 and 41 using a cable binder 33 Note B...

Page 61: ...housing box Screw the 5x25 TX20 screw 35 back onto the rear of the housing Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Closing the housing 21 3...

Page 62: ...1 to 6 Nm 42 0411 0013 Bit insert TX 20 for torque screwdriver Grinding paper grain P 500 or finer Contact spray Additional tools needed Socket spanner holder with 1 4 external hexagonal socket drive...

Page 63: ...Disconnect the 10 pole Molex plug 41 from the LCA15 board Removing the LCA15 board Remove the housing stiffening element 21 Remove the board insulator 37 21 37 Fig 2 Fig 3 Fig 4 Note Undo the two M4x1...

Page 64: ...or finer Clean the heat sink with contact spray and a non linting cloth Peel off the protective film 46 from the transistor module 47 Fitting the LCA15 board 46 47 Note Before mounting the LCA15 boar...

Page 65: ...e that the LCA15 board transformer leads 44 are not trapped between the transistor module and the heat sink All parts must be kept clean Any contamination between the transistor module and the heat si...

Page 66: ...WAGO connectors 45 Carefully place the LCA15 board 1 underside first onto the heat sink 1 To position the LCA15 board 1 gently screw the M4 screw 43 into the M4x17 earthing stud 48 see Fig 10 by hand...

Page 67: ...il you start to feel gentle resistance Note Before you tighten the M4x14 TX20 screws 31 the transistor module must be lying completely flat on the heat sink without any gaps Pre mount the M4x14 TX20 s...

Page 68: ...Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Insert the board insulator 37 Insert the housing stiffening element 21 Closing the housing 34 36 3...

Page 69: ...ove the housing stiffening element 21 Remove the board insulator 37 Additional tools needed Socket spanner holder with 1 4 external hexagonal socket drive and 1 4 external square socket drive to fit t...

Page 70: ...etting dial 6 Note When undoing the fixing nut for the Welding amperage setting dial hold the dial 6 firmly Undo the fixing nut of the setting dial 6 with the socket spanner width across 7 Detach the...

Page 71: ...1500 TIG Apply gentle pressure to the seal of the remote control socket 7 to prevent it being forced out when you press on the FPA15 board Snap the FPA15 board 5 onto the rear alignment pin first Swin...

Page 72: ...bbon cable 42 above the cable harness as shown in Fig 17 Plug the ribbon cable 42 to board FPA15 5 Fitting the FPA15 board continued Replace the setting dial 6 Note When thigthening the fixing nut for...

Page 73: ...housing box Screw the 5x25 TX20 screw 35 back onto the rear of the housing Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Insert the board insulat...

Page 74: ...ion Bit insert TX 20 Soldering iron Soldering tin Solder absorption strand Suction pump as an alternative to the solder absorption strand Remove the housing stiffening element 21 Remove the board insu...

Page 75: ...ce to detach the varistor 2 from the LCA 15 board Before any work involving the soldering iron always clean the tip of the soldering iron Completely remove the solder from the soldering points 76 usin...

Page 76: ...oints 77 Carefully insert the varistor into the soldering points 76 and hold it in place Note Only use special electronics soldering tin for soldering on the varistor 76 77 Solder the varistor to the...

Page 77: ...rive and 1 4 external square socket drive to fit torque screwdriver Socket spanner insert width across 7 with 1 4 internal square socket drive Heat transfer compound Foamed plastic roller Smooth clean...

Page 78: ...e from 2A 39 Disconnect the ribbon cable 42 from the FPA15 board 5 Unplug the 2 pole Molex plug 40 from the LCA15 board Disconnect the 10 pole Molex plug 41 from the LCA15 board Note Undo the two M4x1...

Page 79: ...rs 45 completely together Disconnect the LCA15 board transformer leads 44 Removing the transformer Removing the LCA15 board continued Undo the M4x20 TX20 screws 52 from the secondary diode transformer...

Page 80: ...spaced as far apart as possible Tighten the M4x20 TX20 screws 52 with a torque of 1 5 Nm Fasten the centre tap transformer lead 59 and the measuring lead 78 with the M5x12 TX20 screw 56 Tighten the M...

Page 81: ...heat transfer compound Once there is an even thin layer of compound on the roller of the application tool lift the tool out of the compound Note If the heat transfer compound is not applied to the co...

Page 82: ...board 1 gently screw the M4 screw 43 into the M4x17 earthing stud 48 see Fig 10 by hand Fitting the LCA15 board continued Arrange the transformer leads 44 for the LCA 15 board as shown in Fig 15 and...

Page 83: ...ntle resistance Note Before you tighten the M4x14 TX20 screws 31 the transistor module must be lying completely flat on the heat sink without any gaps Pre mount the M4x14 TX20 screws 31 with a torque...

Page 84: ...Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Insert the board insulator 37 Insert the housing stiffening element 21 Closing the housing Plug th...

Page 85: ...rth conductor 36 Tools needed Designation Manual torque screwdriver 1 to 6 Nm 42 0411 0013 Bit insert TX 20 for torque screwdriver Remove the housing stiffening element 21 Remove the board insulator 3...

Page 86: ...0 Fig 5 Plug the 2 pole Molex plug 40 onto the LCA15 board Fix the cable harness for the 2 pole Molex plug 40 and the 10 pole Molex plug 41 with the cable binder 33 Mount the temperature sensor 9 and...

Page 87: ...housing box Screw the 5x25 TX20 screw 35 back onto the rear of the housing Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Insert the board insula...

Page 88: ...ng earth conductor 36 Tools needed Designation Molex extractor tool 42 0410 0290 Remove the housing stiffening element 21 Remove the board insulator 37 34 36 35 Fig 1 21 37 Fig 2 Note Follow the safet...

Page 89: ...the 10 pole Molex plug 41 from the LCA15 board 33 Fig 4 80 Remove the following cables from the 10 pole Molex plug 41 Fan lead red 80 Pin 1 Fan lead black 81 Pin 2 TP 1500 TIG Loosen the hexagon nut 8...

Page 90: ...g the fan Note When inserting the fan make sure that it snaps into the catches 83 83 Fig 8 16 TP 1500 TIG Pivot the gas solenoid valve 16 back into its original position Fix the cables with cable bind...

Page 91: ...41 onto board LCA15 Plug the 2 pole Molex plug 40 onto board LCA15 Fix the cable harness for 2 pole Molex plug 40 and 10 pole Molex plug 41 with a cable binder Note Before plugging in the ribbon cable...

Page 92: ...X 20 for torque screwdriver General remarks These installation instructions apply to both the mains switch and the mains cable If the mains switch is to be dismounted but not the mains cable the follo...

Page 93: ...ug the mains leads for the mains cable from the mains switch L brown 84 from 1 N blue 85 from 2 84 85 12 Fig 4 Press in the catch on the side of the mains switch 12 and prise out the mains switch 12 F...

Page 94: ...cable Fig 5 Fig 6 On the heat sink disconnect the mains cable earthing conductor 87 and detach it from the air guide film 49 87 49 At the rear of the machine loosen the M5x25 TX20 screws 34 for the m...

Page 95: ...hing conductor 87 can be stowed away well 87 88 Mounting the mains cable At the rear of the machine tighten the M5x25 TX20 screws 34 for the mains cable strain relief device with a torque of 1 5 Nm 34...

Page 96: ...e outside insert the mains switch 12 into the rear of the housing and press it in until it snaps into the catches 12 Plug the housing earth conductor 36 onto the housing box in the correct position Re...

Page 97: ...Undo the 5x25 TX20 screw 35 on the rear of the housing Carefully lift the housing box and disconnect the housing earth conductor 36 Remove the housing stiffening element 21 Remove the board insulator...

Page 98: ...gon nut 82 width across 17 to the gas connector 82 Fig 5 16 18 89 88 Fig 4 17 Note Use a new hose clamp 18 to fasten the gas hose 17 Push the gas hose 17 onto the magnet valve and fasten it with a hos...

Page 99: ...housing box Screw the 5x25 TX20 screw 35 back onto the rear of the housing Screw the 5x25 TX20 screw 34 back onto the front of the housing Fit the carrying strap back on again Remove the board insula...

Page 100: ...plete with potentiometer connection socket for the remote control unit and seal for the connection socket If you intend to replace either the potentiometer the remote control unit connection socket or...

Page 101: ...ket spanner width across 7 Detach the setting dial 6 Disconnect the ribbon cable 42 from the FPA15 board 5 Unplug the 2 pole Molex plug 40 from the LCA15 board Disconnect the 10 pole Molex plug 41 fro...

Page 102: ...00 1500 RC In the socket loosen the M5x12 TX20 screw 70 Swing the copper bracket 55 to one side Note First carefully detach the FPA15 board 5 from the front alignment pins 89 and 90 Carefully lift the...

Page 103: ...or the remote control unit connection socket Completely remove the solder from the soldering points 91 using a solder absorption strand or suction pump Carefully detach the remote control unit connect...

Page 104: ...r alignment pin first Fig 13 Carefully insert the seal 7 for the remote control unit connection socket into the front of the housing 7 Swing the copper bracket 55 back into its original position Caref...

Page 105: ...cable 42 above the cable harness as shown in Fig 19 Plug the ribbon cable 42 to board FPA15 5 Plug the housing earth conductor 36 onto the housing box in the correct position Replace the housing box S...

Page 106: ...uctions describe the entire procedure for removing and fitting the front of the housing complete with welding sockets and adhesive label If you only intend to exchange the welding sockets then it is o...

Page 107: ...r 37 Take off the cap from the Welding amperage setting dial 6 Note When undoing the fixing nut for the Welding amperage setting dial hold the dial 6 firmly Undo the fixing nut of the setting dial 6 w...

Page 108: ...the copper bracket 55 TP 1500 TIG Loosen the hexagon nut 69 width across 13 for the screw fixing of the socket TP 1500 1500 RC In the socket loosen the M5x12 TX20 screw 70 Undo and remove the round nu...

Page 109: ...RC In the socket and in the socket loosen the M5x12 TX20 screw 70 Working from the inside of the housing towards the outside push the welding sockets 13 or 14 out of the front of the housing Removing...

Page 110: ...ackets in the inside of the housing using M5x12 TX20 screws 70 Tighten the M5x12 TX20 screws 70 with a torque of 2 Nm holding the copper brackets firmly as you do so Note Before affixing the adhesive...

Page 111: ...15 5 into place on the rear alignment pin Carefully insert the seal 7 for the remote control unit connection socket into the front of the housing Fitting the seal for the remote control unit connectio...

Page 112: ...15 board Swing the copper bracket 55 back into its original position Carefully press the FPA15 board until all the alignment pins have snapped into place TP 1500 TIG Tighten the hexagon nut 69 width a...

Page 113: ...42 to board FPA15 5 Plug the housing earth conductor 36 onto the housing box in the correct position Replace the housing box Screw the 5x25 TX20 screw 35 back onto the rear of the housing Screw the 5x...

Page 114: ...114...

Page 115: ...43 0001 1084 40 0001 0352 12 0405 0298 4 070 778 Z LCG15 4 100 319 4 070 831 Z LCA15HD 4 070 718 Z LCA15 41 0001 0627 Varistor 4 070 782 Z TP1500 4 070 783 Z TP1500 RC TIG 22 0405 0275 45 0200 0924 43...

Page 116: ...e angeben Specify the length required Indiquer la longueur d sir e Indicar la longitud deseada Indicare la lunghezza desiderat indicar o comprimento desejado 43 0006 0177 42 0406 0295 43 0001 1084 40...

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