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10

Fig. 1 Function outline

Function overview

Principle of the
digital family of
machines

Useful informati-
on

The machines are totally digitized, microprocessor-controlled inverter power sources. A
universal control regulates the entire welding process. The actual data are measured
continuously, and the machine responds immediately to any changes. Special control
algorithms ensure that the target status is maintained at all times. A decisive factor for
the power source welding properties is the software system, instead of a rigid, barely
alterable hardware system. This gives the weld process an unrivalled degree of precisi-
on, with exact reproducibility of welding results and excellent operating properties.

BSL-Tool

OS

DB

UST

Local Net

CFM

In the universal 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 (OS) by the universal control. The
welding program database (DB) contains welding-engineering know-how. Welding
characteristics for different materials and their parameter settings are called up from
this database.

Important!

The operating system and the welding process database are constantly

being enhanced. Use „Update“ to bring the software up to date. The BSL tool is used for
this purpose. Enabled options need only be reactivated after the UST PC board has
been changed.

Communication with system components takes place via a serial databus (LocalNet).
The LocalNet connection socket is the interface for system components, e.g. wire-feed
unit or remote control. Establishing a connection and disconnecting takes place accor-
ding to the „plug and play“ principle.

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Содержание TransPuls Synergic 2700

Страница 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...

Страница 2: ......

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 8: ...6...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 128: ...126...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 134: ...TPS 2700...

Страница 135: ...TPS 2700 MV...

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

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

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

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

Страница 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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