Fronius TransPuls Synergic 2700 Service Manual Download Page 49

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BPS 25/BPT 27 - power module PC board

General remarks

BPS 25 (item number 4,070,631,Z) and BPT 27 (item number 4,070,739,Z) are power
module PC boards for the TPS 2700 power source.
The BPT 27 has serial numbers of 14481582 and upwards and replaces the BPS 25.

Important!

On PC boards BPS 25/BPT 27, primary voltage is on!

BPS 25/BPT 27 consist of 2 PC boards:
-

Power module PC board BPS 25/BPT 27

PC board BPZ 25 for primary/secondary isolation

PC board BPZ 25 and BPS 25/BPT 27 form one unit. BPZ 25 and BPS 25/BPT 27
cannot be ordered separately.

Component
position in the
machine

Fig. 13 TPS 2700, position of PC board BPS 25/

BPT 27

Fig. 14 PC board BPS 25/BPT 27

Overview

PC board BPZ 25
with X1

Transistor module control LEDs

LED 15 V primary

Control LED
Boost converter

Summary of Contents for TransPuls Synergic 2700

Page 1: ...4000 5000 TransPuls Synergic 2700 TransPuls Synergic 3200 4000 5000 Service manual Spare parts list MIG MAG Power source Battery Charging Systems Welding Technology Solar Electronics EN 42 0410 1237...

Page 2: ......

Page 3: ...and welding properties with TIG welding 15 Poor weld properties with rod electrode MMA welding 16 Nothing happens on control panel TPS 2700 17 Nothing happens on control panel TPS 3200 4000 5000 19 N...

Page 4: ...position in the machine 51 Overview 51 Technical Data 52 Function overview 52 Plugs on the power module PC boards 53 Plug layout 53 LED checklist of power module PC boards 55 Measuring points 55 NT 2...

Page 5: ...echnical Data 76 Function overview 76 Plug layout 76 LED checklist 76 Measuring points 76 SR 41 Wire feed unit regulation unit 77 General remarks 77 Component position in the machine 77 Overview 77 Te...

Page 6: ...shunt 103 Changing temperature sensor TP 592S 105 Notes 105 Changing transformer TS 4000 5000 TPS 3200 4000 5000 106 Removing transformer 106 Fitting transformer 107 Changing transformer TPS 2700 109...

Page 7: ...0 Gas solenoid valve 120 Earth current watchdog 120 Test weld 120 Documentation 121 Test record 121 Test label 121 Terms and abbreviations used 122 General remarks 122 Terms and abbreviations 122 Enti...

Page 8: ...6...

Page 9: ...hed 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...

Page 10: ...g with faults whose service codes appear on the display Contains detailed descriptions of the relevant components in the power source For every component the following topics are dealt with General re...

Page 11: ...ver TX 25 or insert bit for manual torque wrench Allen key 3 mm Allen key 4 mm Allen key 5 mm Flat spanner 13 mm Flat spanner 17 mm Flat spanner 19 mm Oeteker pliers Molex extractor tool 42 0410 0290...

Page 12: ...sal control UST there is information on subsequently enabled options Information on power source functions and parameters as well as data related to the process are called up from the operating system...

Page 13: ...diagram of Trans Synergic 4000 5000 and TransPuls Synergic 2700 3200 4000 5000 power sources 3 x 400 V Block diagram legend 1 Control and regulation unit Controls regulates and monitors the welding pr...

Page 14: ...l losses due to the low inductivity required of the transformer coils can be kept to an absolute minimum 7 Welding transformer Transforms the high primary voltage into a low secondary voltage Ensures...

Page 15: ...h the service codes shown on the display as well as causes and measures for rectifying them Before starting with the fault location aid read the Function overview section and study the entire circuit...

Page 16: ...t flowcharts Poor ignition and weld properties with the selected TIG welding process Nothing happens on control panel TPS 2700 No welding current or current does not correspond to set value Service co...

Page 17: ...ng earthing cable OK Parameters set correctly Check shielding gas solenoid valve including control Check welding torch and groun ding earthing cable Check settings on control panel Check set up parame...

Page 18: ...arthing cable OK Parameters set correctly Check shielding gas solenoid valve including control Check welding torch and groun ding earthing cable Check settings on control panel Check set up parameters...

Page 19: ...rodes grounding earthing cable connected functioning correctly Start Parameters set correctly Check whether power source OK and check application End No No Yes Yes Check settings on control panel Chec...

Page 20: ...00V Unom and LED for mains 230V at 230V Unom Change ASU 27 On MV power sources Change BPS 24V int ext LEDs flashing on UST Switch power source off unplug plug X3 from UST switch power source on Change...

Page 21: ...heck change control panel ribbon cable Yes Unplug X4 from UST No A Steady 5V 15V 15V on UST Change VAC shunt Yes Unplug X2 from UST No Steady 5V 15V 15V on UST Check change control panel ribbon cable...

Page 22: ...heck change mains switch and cabling Change BPS Steady 24V int ext LEDs on UST Switch power source off unplug plug X3 from UST switch power source on Change NT 24 Yes Yes Steady 24V int ext LEDs on NT...

Page 23: ...on cable Yes Unplug X4 from UST No A Steady 5V 15V 15V on UST Change VAC shunt Yes Unplug X2 from UST No Steady 5V 15V 15V on UST Check change control panel ribbon cable Yes Unplug X6 from UST No Stea...

Page 24: ...ing cable connected functioning correctly Start Nothing happening on control panel See subsection Nothing happens on control panel Welding current Icomm no longer adjustable or Welding current is cons...

Page 25: ...hart No Yes BUS OK LED flashing on the SR 41 when service module unplugged Connect service module to the power source Power source entered in the service module Check VSP Change SR 41 No Yes Change US...

Page 26: ...t pump blo cked Use a screwdriver to turn the pump shaft if coolant pump is stiff change it Check securing device F1 Yes No 24V available from X1 4 X1 3 Check cable harness Change UST No Yes Fan turni...

Page 27: ...ooling unit OK Switch off unit Disconnect pump Replace fuse Switch on unit No Yes Check relay contact cable harness in cooling circuit auto transformer if avai lable and voltage on the pump Securing d...

Page 28: ...es No Change intermediate circuit electrolytic capacitors Switch off power source unplug X2 from NT 60 switch on power source Err 50 Change NT 60 No Yes Switch off power source discharge intermediate...

Page 29: ...arge intermediate circuit electrolytic capacitors unplug X7 1 X7 4 switch on power source Service code Err 50 continued A Yes Imbalance in interme diate circuit 35V No Change BPS Change intermediate c...

Page 30: ...e LHSB link dsP Cxx code no 29 Cause DSP SoftCom fault xx stands for additional entries not relevant for external service Remedy update software Change UST2 PC board dsP E05 code no 17 Cause DSP displ...

Page 31: ...codes of 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 co...

Page 32: ...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...

Page 33: ...0i Remedy check LocalNet leads Check software version UST 3 21 4 Wait for software update to finish Err 23 x code no 23 Cause config memory CFM fault on UST2B PC board x stands for 1 config memory not...

Page 34: ...ply min 2 bar 3 no or insufficient shielding gas change shielding gas solenoid valve 4 change shielding gas solenoid valve change shielding gas sensor 5 check cable harness change shielding gas soleno...

Page 35: ...ter overtemperature Remedy allow machine 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 sour...

Page 36: ...ice codes 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...

Page 37: ...ions for the relevant wire feed unit EFD 9 x Cause supply to motor x stands for 1 exceed of lower motor supply voltage limit 2 motor supply upper voltage limit exceed Remedy check VSP check change mai...

Page 38: ...the error message re appears check the actual value pick up and the cable connections to and from it St1 E 4 Cause At minimum wirefeed speed the motor of the push pull unit does not deliver any actua...

Page 39: ...the push pull unit does not deliver any actual rotational speed value Remedy Repeat the push pull calibration If the error message re appears check the actual value pick up and the cable connections t...

Page 40: ...her wirefeed problems Remedy Engage the drive units of both wire feed unit motors arrange the hose pack in as straight a line as possible check the inner liner for kinks or soiling check the contact p...

Page 41: ...itional PC board ASU 40 additional PC board BPS 25 BPT 27 power module PC board BPS 32 40 42 50 power module PC board NT 24 24 V switched mode power supply for control and regulation unit NT 60 60 V s...

Page 42: ...s for switching between 230 V and 400 V Component position in the machine Fig 5 TPS 2700 MV Position of ASU 27 PC board Overview Fig 6 ASU 27 PC board Technical Data Input voltage 230 400 V AC Input v...

Page 43: ...age 12 V and 5 V from the input voltage When switching on the switching mechanism on the PC board detects the input voltage a With an input voltage of 400 V AC the ASU 27 PC board switches both power...

Page 44: ...42 Measuring points LED checklist Fig 8 LED indicators on ASU 27 PC board There are no measuring points available on the ASU 27 PC board LED 5 V LED 12 V LED 230 V AC LED 400 V AC...

Page 45: ...5000 MV and is for switching the input voltage between 230 V AC and 400 V AC Component position in the machine Fig 9 TPS 3200 MV TS TPS 4000 5000 Position of ASU 40 PC board Overview Fig 10 ASU 40 PC...

Page 46: ...es on BPS 32 40 42 43 50 53 in series b With an input voltage of 230 V AC the ASU 40 PC board switches both power modules on BPS 32 40 42 43 50 53 in parallel High charging connection by means of resi...

Page 47: ...ectifer L2 Pin 12 NC Pin 13 NC Pin 14 NC Pin 15 NC Pin 16 NC Pin Function X2 Connection to 2nd line filter L1 out X3 Connection to 2nd line filter L2 out X4 Connection to 3rd line filter L3 out X5 Con...

Page 48: ...points There are no measuring points available on the ASU 40 PC board LED checklist continued LED charge unit flashes once the intermediate circuit has been charged LED 230 V flashes at an input volt...

Page 49: ...S 25 BPT 27 primary voltage is on BPS 25 BPT 27 consist of 2 PC boards Power module PC board BPS 25 BPT 27 PC board BPZ 25 for primary secondary isolation PC board BPZ 25 and BPS 25 BPT 27 form one un...

Page 50: ...d range Switching with boost converter for increasing the intermediate circuit voltage from approx 282 V DC to 320 Volt DC per circuit at 400 V AC input voltage Controlling the transistor module via d...

Page 51: ...t 2 Pin 6 NC Pin 7 Intermediate circuit 2 GNDP Pin 8 15 V primary Pin 9 Intermediate circuit 1 Pin 10 NC Pin 11 Intermediate circuit 1 Pin 12 NC Pin 13 Intermediate circuit 2 Pin 14 NC Pin 15 Intermed...

Page 52: ...OS FETs metal oxide semiconductor field effect transistors with diode This diode provides information about the state of the transistor using a diode tester a diffusion potential of 0 4 0 5 V must be...

Page 53: ...le M1 M1 TP1 TP2 0 46 V M1 TP1 TP4 0 46 V M1 TP3 TP2 0 46 V M1 TP3 TP4 0 46 V Diode check module M2 M2 TP5 TP6 0 46 V M2 TP5 TP8 0 46 V M2 TP7 TP6 0 46 V M2 TP7 TP8 0 46 V Diode check module M3 M3 TP9...

Page 54: ...617 Z BPS 42 item number 4 070 738 Z BPS 43 item number 4 070 771 Z TS TPS 5000 BPS 50 item number 4 070 658 Z BPS 53 item number 4 070 772 Z Important On the power module PC boards primary voltage is...

Page 55: ...r modules for BPS 42 V1 4A BPS 50 and BPS 53 Each transistor module has a temperature sensor Temperature analysed by a PWM signal electrically isolated the temperature of the warmest transistor module...

Page 56: ...t GND T2 Pin 6 Transistor control Pin 8 Transistor control Pin 10 Transistor control Pin 12 Transistor control Pin 14 GNDD Pin 16 15 V Pin 18 Main switch detection 0 V off 5 V on Pin 20 Signal for hig...

Page 57: ...cuit 1 red cable Plug layout continued Pin 1 Intermediate circuit 1 Pin 2 NC Pin 3 Intermediate circuit 1 Pin 4 NC Pin 5 Intermediate circuit 2 Pin 6 NC Pin 7 Intermediate circuit 2 GNDP Pin 8 15 V pr...

Page 58: ...A BPS 43 BPS 42 V1 4A Main switch LED Intermediate circuit imbalance LED LED 15 V primary High charging relay LED Measuring points In every transistor module there are 4 MOS FETs metal oxide semicondu...

Page 59: ...EN Fig 23 Measuring points on PC board BPS 50 V1 4A BPS 42 V1 4A BPS 40 BPS 32 4 x diode 4 x diode Measuring points continued Fig 23a Measuring points on PC board BPS 53 BPS 50 V1 4A BPS 43 BPS 42 V1...

Page 60: ...diate circuit voltage 2 TP5 TP7 320 V DC Diode check module M1 TP1 TP2 0 46 V TP1 TP4 0 46 V TP3 TP2 0 46 V TP3 TP4 0 46 V TP5 TP6 0 46 V TP5 TP8 0 46 V TP7 TP6 0 46 V TP7 TP8 0 46 V Important No cont...

Page 61: ...and external components Important On NT 24 switched mode power supply the primary voltage is on Component position in the machine Fig 24 TPS 2700 position of NT 24 Fig 26 NT 24 Overview Fig 25 TPS 320...

Page 62: ...or supplying other components Supply voltages are electrically isolated and protected by PTC Electrically isolated measurement of intermediate circuit voltage evaluation on UST PC board Plug layout X1...

Page 63: ...13 12 11 10 9 Plug layout continued LED 24 V internal LED 15 V primary LED 24 V external X2 Fig 29 Plug X1 and X2 on mains adapter NT 24 A X1 Pin function X2 Secondary connection 24 V Pin 1 24 V exte...

Page 64: ...400 V AC approx 320 V DC at a nominal voltage of 230 V AC Intermediate circuit voltage 2 X1 5 X1 7 approx 280 V DC at a nominal voltage of 400 V AC approx 320 V DC at a nominal voltage of 230 V AC 15...

Page 65: ...voltage is on Fig 30 TPS 2700 position of NT 60 Fig 32 NT 60 Fig 31 TPS 3200 TS TPS 4000 5000 Position of NT 60 Primary voltage Secondary voltage X1 X2 Intermediate circuit 1 supply LED Error LED PTC...

Page 66: ...rent limit until the PTC resistors have reached the switch off temperature In the case of a short circuit the 55 V supply LED does not flash As soon as the PTC resistors trip the Error LED flashes Plu...

Page 67: ...pply LED Intermediate circuit 2 supply LED Error LED PTC highly resistive 55 V supply LED Measuring points Plug layout continued Pin 7 Intermediate circuit 2 GND P Pin 8 15 V primary Fig 35 Plug X1 an...

Page 68: ...a nominal voltage of 400 V AC approx 320 V DC at a nominal voltage of 230 V AC Intermediate circuit voltage 2 X2 5 X2 7 approx 280 V DC at a nominal voltage of 400 V AC approx 320 V DC at a nominal v...

Page 69: ...sources Following versions are available UST 2C 4 070 960 Z UST Pipe 4 070 963 Z Component position in the machine Fig 36 TPS 2700 position of UST PC board Fig 37 TPS 3200 TS TPS 4000 5000 position of...

Page 70: ...not cool sufficiently e g because the duty cycle was excee ded the power source switches off and displays an appropriate service code Ventilator control subject to temperature and firmware Data trans...

Page 71: ...l Pin 1 Primary current T1 Pin 3 Primary current T2 Pin 5 OUT A1 Pin 7 OUT A2 Pin 9 OUT B1 Pin 11 OUT B2 Pin 13 GND D Pin 15 5 V Pin 17 24 V Pin 19 PWM temperature Pin 21 SCL CLOCK Pin 23 FAST OUT 1 P...

Page 72: ...anging the UST the enabled options must be clarified with the customer the enable codes must be supplied by the customer Measuring points See plug layout Measuring points Plug pin Measuring result com...

Page 73: ...d by the power source and which can affect other consumer loads that come from the mains supply and which can affect the power source Important On the NF 3160 PC board the mains voltage is on Componen...

Page 74: ...ivert disturbances to earth and also between the phases Resistors discharge the line filter capacitors Plug layout LED checklist Measuring points Fig 43 Connections on NF 3160 PC board X1 X2 X3 X4 X5...

Page 75: ...C board NF 3400 serial number 14280747 upwards has been replaced by line filter 40 A item number 43 0001 1199 The line filter 40 A is used with TS 4000 5000 TPS 3200 3200 MV 4000 5000 The line filter...

Page 76: ...Resistors discharge the line filter capacitors The earth current watchdog is integrated on line filter 40 A 80 A Plug layout NF 3400 Technical Data Attenuation of parasitic frequencies 60 Hz Fig 48 C...

Page 77: ...A 80 A Plug layout line filter 40 A 80 A Line filter 40 A Fig 49 Connections on line filter 40 A and 80 A Line filter 80 A Pin Function X1 Mains supply U1 L1 in V1 L2 in W1 L3 in PE PE conductor X2 Co...

Page 78: ...which permits the isolated capture of the welding current Shunt General remarks Component position in the machine Fig 50 TPS 2700 position of shunt Fig 52 Shunt Overview Fig 51 TPS 3200 TS TPS 4000 5...

Page 79: ...es do not apply Based on the principle of compensation of magnetic fields the current transducers provide a measured current proportional to the primary current Function over view There are no LED ind...

Page 80: ...the regulation unit for powering and controlling the wire feed unit Component position in the machine Fig 53 TPS 2700 position of SR 41 PC board Fig 54 SR 41 PC board Overview X9 X2 X1 X3 X4 X5 X6 X7...

Page 81: ...y for any connected peripheral devices with voltages of 15 V 15 V and 5 V Controls the gas magnet valve blow off signal Controls a push pull system via the X12 plug Analyses the torch trigger signal A...

Page 82: ...no buttons pressed Pin 5 Gun Trigger torch trigger Pin 6 GND D Euro Pin 7 GND Pullmig potentiometer Pin 8 Torch detection Pin 9 GND torch Pin 10 15 V X4 Robot sensors feeder inching and gas test Pin...

Page 83: ...n for PMR 4000 push pull option and RobactaDrive LED BRT Pin function X7 LocalNet power source connection Pin 1 24 V Pin 2 RXDL 485 Pin 3 RXDH 485 Pin 4 GND Pin 5 TXDL 485 Pin 6 TXDH 485 X8 Wire feed...

Page 84: ...24 V flashes when the supply voltage is OK LED 15 V flashes when the supply voltage is OK LED 5 V flashes when the supply voltage is OK LED forwards flashes when the wire is moved forwards by the driv...

Page 85: ...ntegrated into the plastic housing and provided with a pluggable Molex connection Fig 57 Temperature sensor TP 592S Component position in the machine Fig 58 TPS 2700 position of temperature sensor TP...

Page 86: ...corresponds to 273 15 K 273 15 K corresponds to 273 15 A Pin function X1 2 pin Molex plug Plug layout Measure the current flowing through the temperature sensor as follows Remove lead at pin 1 from Mo...

Page 87: ...o diode modules item number 41 0003 0215 each of which has two integral diodes Component position in the machine Fig 61 TPS 2700 position of secondary power module Fig 62 Secondary power module Overvi...

Page 88: ...irect current which is fed to the welding sockets Measuring points There are two diodes in every diode module Measurement on the diode regions must produce a result of approx 0 2 V Fig 63 Diode module...

Page 89: ...er module consists of four diode modules item number 41 0003 0203 each of which has two integral diodes Component position in the machine Fig 64 TPS 2700 position of secondary power module Secondary p...

Page 90: ...current which is fed to the welding sockets Measuring points There are two diodes in every diode module Measurement on the diode regions must produce a result of approx 0 2 V Fig 66 Diode module Fig 6...

Page 91: ...in the machine Primary rectifier Primary rectifier Fig 68 TS 4000 5000 TPS 3200 4000 5000 position of primary rectifier Fig 67 TPS 2700 position of primary rectifier Overview Fig 69 Primary rectifier...

Page 92: ...L1 Mains voltage input L1 L2 Mains voltage input L2 L3 Mains voltage input L3 Intermediate circuit voltage output Intermediate circuit voltage output L3 Measuring points Fig 73 Measuring points on pri...

Page 93: ...Changing components General remarks Overview In the Changing components section there is a description of how to change compon ents which have no instructions of their own regarding changing and requi...

Page 94: ...m the shunt 3 1 On the transformer loosen hexagon nut 4 using a size 13 spanner 2 Remove protective element 5 and throttle lead 2 1 Remove screw 6 from the front of the housing NOTE When removing the...

Page 95: ...11 Fitting throttle 1 Put throttle 9 in place and fix in place with 4 screws 10 and sheet nuts 11 Fig 6 Fitting throttle 1 On the transformer fit the following components in the order they are listed...

Page 96: ...els Fitting throttle continued Fig 10 Fitting front of the housing NOTE When fitting the control panel 7 take care not to bend stretch or strain the ribbon cable 1 Plug ribbon cable into control panel...

Page 97: ...l 3 Loosen two screws 1 on front aperture 1 Loosen two screws 3 on the drive unit 2 NOTE When lifting the drive unit 2 do not pinch bend or strain the cables 2 Carefully raise the entire drive unit 2...

Page 98: ...2 Feed out the throttle lead 9 from the shunt 8 Removing throttle continued Fig 4 Loosening hexagon bolt 1 Loosen three screws 13 on throttle 14 2 Carefully remove throttle 14 and throttle lead 15 to...

Page 99: ...clips 11 and 10 as shown in Fig 9 Fig 8 Fitting throttle 13 13 14 Fig 9 Connecting throttle 11 10 12 1 Feed throttle lead 9 through shunt 8 2 Push following components onto hexagon bolt 5 Lock washer...

Page 100: ...ontinued Fig 13 Fitting drive unit NOTE When putting the drive unit 2 in place do not pinch bend or strain the cables 1 Fit the drive unit 2 using two screws 3 2 3 Fig 14 Screws on the front aperture...

Page 101: ...g earth current watch dog 1 Loosen screw 3 on luster terminal 2 Remove lead 4 Fig 1 Removing earth current watchdog Fig 2 Loosening luster terminal on earth current watchdog Fig 3 Removing fan and exp...

Page 102: ...x plug 7 from UST X4 PC board 2 Remove leads 8 and 9 of the watchdog cable 6 from the following pins on the 24 pin Molex plug 7 X4 10 X4 22 Use Molex extractor tool Fig 4 Detaching watchdog cable Remo...

Page 103: ...l 2 Tighten screw 3 on luster terminal 1 Fix earth current watchdog 1 in place using two screws 2 2 Fitting the side panels 3 Fig 7 Connecting earth current watchdog luster terminal Fitting earth curr...

Page 104: ...hing leads from BPT BPS Fig 2 Removing ASU 27 PC board X3 X4 X6 X5 1 2 4 4 4 4 3 Put ASU 27 X4 PC board in place and fit using four spacers 4 Fig 2 Plug in 16 pin Molex plug ASU 27 X4 3 Fig 2 Feed cab...

Page 105: ...pen wire feed unit cover 2 Remove side panel 3 Loosen two screws 1 on front aperture 1 Loosen two screws 3 on the drive unit 2 NOTE When lifting the drive unit 2 do not pinch bend or strain the cables...

Page 106: ...itting shunt Fig 5 Fitting shunt 5 6 7 7 8 9 1 Feed throttle lead 9 through shunt 2 Fit shunt 8 using two screws 7 3 Plug in 8 pin Molex plug 6 4 Push following components onto hexagon bolt 5 Lock was...

Page 107: ...ce do not pinch bend or strain the cables 1 Put entire drive unit 2 in place 2 Fit the drive unit 2 using two screws 3 Fig 8 Fitting drive unit 2 3 1 Tighten two screws 1 on front aperture 2 Fit side...

Page 108: ...w temperature sensor in place fill the hole for the sensor with heat conductive paste to ensure perfect heat transfer If the temperature sensor is covered by other parts please refer to instructions f...

Page 109: ...tie on toroidal tape cores 3 and 4 Important If necessary cut open any other cable ties near the toroidal tape cores as well Removing trans former 1 1 2 2 Fig 1 Removing transformer leads Fig 2 Loosen...

Page 110: ...7 8 9 10 11 11 Fig 4 Removing transformer 12 14 Fig 5 Putting transformer in place 13 7 7 8 9 10 11 11 Fig 6 Fitting transformer 12 1 Fit transformer holder 12 using 4 screws 11 2 Using 4 screws 7 fi...

Page 111: ...eads ensure that they are assigned to the correct terminals e g screw transformer lead 1 to terminal N1 1 Fit the following to the BPS 42 50 PC board using 4 screws 1 Primary transformer leads as desc...

Page 112: ...ps 7 and 8 2 Loosen screw 9 on middle tap connection and remove throttle lead 10 3 4 2 2 2 5 6 Fig 2 Exposing transformer 2 1 Loosen four screws 11 on the transformer holder 12 2 Remove transformer ho...

Page 113: ...the transformer arrange the primary leads as follows 1 Feed the blue lead through the upper sensor 16 2 Feed the orange lead through the lower sensor 17 1 Fit transformer holder 12 including transfor...

Page 114: ...rew 19 3 Feed outer orange primary lead through cut outs 20 on PC board and clamp in place with terminal screw 21 4 Clamp inner blue primary lead using terminal screw 22 5 Clamp inner orange primary l...

Page 115: ...ate circuit capacitors 1 Loosen two screws 3 on cover sheet 4 2 Remove cover sheet 4 Fig 1 Removing rear of housing 1 1 2 Fig 2 Removing cover sheet 1 Loosen four capacitor screws 5 NOTE When loosenin...

Page 116: ...citor 7 remain on the partition 9 inside the power source be disposed of NOTE When fitting the capaci tors ensure that the grommets 8 are arranged correctly as shown in Fig 5 Fig 6 Putting capacitors...

Page 117: ...er sheet 4 using two screws 3 3 3 4 Fitting intermedi ate circuit capa citors continued Fig 10 Fitting cover sheet 1 Fasten rear of housing 2 with three screws 1 2 Fit side panels Fig 11 Fitting rear...

Page 118: ...rried out General The repair engineer is responsible for carrying out and documenting the safety inspec tion properly and for making the correct decision regarding the outcome of the inspec tion Shoul...

Page 119: ...ctrode holder welding current return terminal Line must not be damaged or faulty do not use insulation or adhesive tapes to repair damage Connectors and plug socket devices must not be damaged or defo...

Page 120: ...y or blocked and an air filter must be present There must be no signs of overloading or improper use Protection devices e g gas cylinder holder must be present Rollers transportation devices brackets...

Page 121: ...nduc tor resistance 1 Measuring device 2 Welding system 9 Instrument leads Furthermore measurements must be taken from the ground conductor contact of the mains cable or from a reliable earthing point...

Page 122: ...ble resistance e g 10 k 5 W Measurement Limit value Primary Secondary Mains plug L1 L2 L3 N Current sockets 5 M Primary Earth PE Mains plug L1 L2 L3 N Earth 2 5 M Secondary Earth PE Current sockets Ea...

Page 123: ...the gas solenoid valve and the gas pipes for leaks the gas pipe to the gas solenoid valve must be subjected to pressure Turn off the gas feed at the gas cylinder and observe any fall in pressure with...

Page 124: ...The latest version is available to download from EnergyNet DownloadCenter The test record must be completed in full and archived according to national regulations Test record After a positive inspect...

Page 125: ...s optimum welding results and trouble free operation of the power source FAC Factory resets settings in the setup menu By pressing and holding the Store button for two seconds the original factory set...

Page 126: ...ltage doubling contributes considerably to optimum ignition properties and a stable arc Segment display When a software fault appears Second display level displays more detailed information on localis...

Page 127: ...125 EN The circuit diagram is located inside the power source attached to the inside of the right side panel Entire circuit diagram Storage location...

Page 128: ...126...

Page 129: ...e Parts List Circuit Diagram Lista parti di ricambio Schema Lista de repuestos Esquema de cableado Lista de pe as sobresselen tes Esquema de conex es Onderdelenlijst Bedradingsschema Reservdelsliste K...

Page 130: ...eben xx Specify the length required xx Indiquer la longueur d sir e xx Indicar la longitud deseada xx Indicare la lunghezza desiderat xx indicar o comprimento desejado XYHG WH SR DGRYDQRX GpONX 9 0mm...

Page 131: ...R 4 075 138 630 R TransPuls Synergic 5000 CMT MV R 4 075 139 630 R TransPulsSynerg 3200 CMT MV US R 4 075 137 800 R TransPulsSynerg 4000 CMT MV US R 4 075 138 800 R TransPulsSynerg 5000 CMT MV US R 4...

Page 132: ...04 40 0009 0043 33 0005 4112 43 0001 1139 43 0001 1103 43 0001 1187 43 0001 1092 41 0009 0187 12 0405 0208 12 0405 0208 33 0005 4120 4 100 413 43 0006 0152 33 0010 0335 33 0010 0345 45 0200 0918 45 02...

Page 133: ...1 1355 43 0004 0586 43 0004 0664 42 0407 0437 BE2 0201 1593 43 0004 2324 42 0407 0534 42 0407 0533 43 0013 0015 BE2 0201 1934 42 0400 0132 32 0409 2740 43 0003 0485 32 0405 0229 32 0405 0183 42 0300 1...

Page 134: ...TPS 2700...

Page 135: ...TPS 2700 MV...

Page 136: ...TS 4000 5000 TPS 3200 4000 5000...

Page 137: ...TPS 3200 MV Teil 1...

Page 138: ...TPS 3200 MV Teil 2...

Page 139: ...TS 4000 MV 5000 MV TPS 4000 MV 5000 MV...

Page 140: ...roniusplatz 1 A 4600 Wels Austria Tel 43 0 7242 241 0 Fax 43 0 7242 241 3940 E Mail sales fronius com www fronius com www fronius com addresses Under http www fronius com addresses you will find all a...

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