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Copyright to this service manual remains the property of Fronius
International GmbH.

Text and illustrations are all technically correct at the time of going to print.

The right to effect modifications is reserved. The contents of the service
manual shall not provide the basis for any claims whatever on the part of the
purchaser. If you have any suggestions for improvement, or can point out to
us any mistakes which you may have found in the manual, we should be
most grateful to you.

Copyright

Do not make any alterations, installations or modifications to the welding
machine without getting permission from the manufacturer first.

Replace immediately any components that are 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 designed and
manufactured to cope with the stressing and safety requirements that will be
made of them.

When ordering spare parts, please state the exact designation and the
relevant part number, as given in the spare parts list. Please also quote the
serial number of your power source.

Spares and
wearing parts

In view of international standards, regular calibration of power sources is
advisable. Fronius recommends a 12-month calibration interval. For more
information, please contact your Fronius partner!

Calibration of
power sources

The power source fulfils the fundamental requirements of the Low-Voltage
and Electromagnetic Compatibility Directive and is thus CE-marked.

CE-marking

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Содержание TP 1500

Страница 1: ...1 Service Manual...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 53: ...53 Overall circuit diagram...

Страница 54: ...54...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 114: ...114...

Страница 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...

Страница 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...

Страница 117: ...00 PLZE Bo kov Letkovsk 38 Tel 420 377 183 411 Fax 420 377 183 419 E Mail sales plzen fronius com 500 04 HRADEC KR LOV Pra sk 293 12 Tel 420 495 070 011 Fax 420 495 070 019 E Mail sales h kralove fron...

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