Fronius TransSynergic 4000 - Page 2

Fronius TransSynergic 4000

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Table of Contents

Table of Contents3
Foreword and Safety Instructions9
- Safety9
- Fronius Technical Support Center (TSC)9
- General Remarks9
- Function Overview10
- Fault Location Aid10
- Detailed Description10
- Changing Components10
- Terms and Abbreviations Used10
- Spare Parts List and Entire Circuit Diagram10
- Tools and Measuring Instruments10
Tools and Measuring Instruments11
- General Remarks11
- Tools Required11
- Measuring and Inspection Equipment11
- Ancillary Materials11
Function Overview12
- Principle of the Digital Family of Machines12
- Useful Information12
- Block Diagram13
- Block Diagram Legend13
Fault Location Aid15
- General Remarks15
Fault Flowcharts16
- Overview16
- Poor Ignition and Welding Properties with „MIG/MAG Welding17
- Poor Ignition and Welding Properties with „TIG Welding18
- Poor Weld Properties with „Rod Electrode (MMA) Welding19
- Nothing Happens on Control Panel (TPS 2700)20
- Nothing Happens on Control Panel (TPS 3200/4000/5000)22
- No or Incorrect Welding Current24
- No or Incorrect Wirefeed Speed25
- Insufficient Torch Cooling (FK 4000/FK 4000 R)26
- Service Code Err 5028
UST Service Codes30
- Safety30
- Table of Service Codes30
- Special Displays Used with Service Codes36
Service Codes SR 4Xa37
- Safety37
- Table of Service Codes37
Service Codes for Push-Pull Calibration38
- Safety38
- Checking Actual-Value Pick-Up38
- Error Codes Shown When the Drive Units Are Engaged („Engaged" Calibration)38
- Error Codes Shown When the Drive Units Are Engaged („Engaged" Calibration)39
Detailed Description41
- General Remarks41
- Position of Electronic Components41
- Overview41
ASU 27 - Additional PC Board42
- General Remarks42
- Component Position in the Machine42
- Overview42
- Technical Data42
- Function Overview43
- Plug Layout43
- LED Checklist44
- Measuring Points44
ASU 40 - Additional PC Board45
- General Remarks45
- Component Position in the Machine45
- Overview45
- Technical Data46
- Function Overview46
- Plug Layout46
- LED Checklist47
- Measuring Points48
BPS 25/BPT 27 - Power Module PC Board49
- General Remarks49
- Component Position in the Machine49
- Overview49
- Technical Data50
- Function Overview50
- Plug Layout BPS 25/BPT 2750
- LED Checklist52
- Measuring Points52
BPS 32/40/42/43/50/53 - Power Module PC Board54
- General Remarks54
- Component Position in the Machine54
- Overview54
- Technical Data55
- Function Overview55
- Plugs on the Power Module PC Boards56
- Plug Layout56
- LED Checklist of Power Module PC Boards58
- Measuring Points58
NT 24 - Switched Mode Power Supply 24 V61
- General Remarks61
- Component Position in the Machine61
- Overview61
- Technical Data62
- Function Overview62
- Plug Layout62
- LED Checklist63
- Measuring Points63
NT 60 - Switched Mode Power Supply 60 V65
- General Remarks65
- Component Position in the Machine65
- Overview65
- Technical Data66
- Function Overview66
- Plug Layout66
- LED Checklist67
- Measuring Points67
UST - Control and Regulation Unit69
- General Remarks69
- Component Position in the Machine69
- Overview69
- Technical Data70
- Plug Layout70
- Function Overview70
- LED Checklist72
- Measuring Points72
- Changing UST PC Board72
NF 3160 - Line Filter73
- General Remarks73
- Component Position in the Machine73
- Overview73
- Technical Data73
- Function Overview74
- Plug Layout74
- LED Checklist74
- Measuring Points74
NF 3400 - Line Filter/Line Filter 40 A/80 a75
- General Remarks75
- Component Position in the Machine75
- Overview75
- Technical Data76
- Function Overview76
- Plug Layout NF 340076
- Plug Layout Line Filter 40 A/80 a77
- LED Checklist77
- Measuring Points77
Shunt78
- General Remarks78
- Component Position in the Machine78
- Overview78
- Technical Data79
- Function Overview79
- Plug Layout79
- LED Checklist79
- Measuring Points79
SR 41 - Wire-Feed Unit Regulation Unit80
- General Remarks80
- Component Position in the Machine80
- Overview80
- Technical Data81
- Function Overview81
- Plug Layout81
- LED Checklist83
- Measuring Points84
Temperature Sensor TP 592S85
- General Remarks85
- Component Position in the Machine85
- Technical Data86
- Function Overview86
- Plug Layout86
- Measuring Points86
Secondary Power Module TPS 270087
- General Remarks87
- Component Position in the Machine87
- Overview87
- Function Overview88
- Measuring Points88
Secondary Power Module TS 4000/5000, TPS 3200/4000/500089
- General Remarks89
- Component Position in the Machine89
- Overview90
- Function Overview90
- Measuring Points90
Primary Rectifier91
- General Remarks91
- Component Position in the Machine91
- Overview91
- Function Overview91
- Plug Layout92
- Measuring Points92
Changing Components93
- Safety93
- General Remarks93
- Overview93
Changing Throttle (TS 4000/5000, TPS 3200/4000/5000)94
- Removing Throttle94
- Fitting Throttle95
Changing Throttle (TPS 2700)97
- Removing Throttle97
- Fitting Throttle98
Changing Earth Current Watchdog101
- Removing Earth Current Watchdog101
- Fitting Earth Current Watchdog102
Changing PC Board ASU 27 (TPS 2700 MV)104
- Removing ASU 27104
- Fitting ASU 27104
Changing Shunt (TPS 2700)105
- Removing Shunt105
- Fitting Shunt106
Changing Temperature Sensor TP 592S108
- Notes108
Changing Transformer (TS 4000/5000, TPS 3200/4000/5000)109
- Removing Transformer109
- Fitting Transformer110
Changing Transformer (TPS 2700)112
- Removing Transformer112
- Fitting Transformer113
Changing Intermediate Circuit Capacitors (TS 4000/5000, TPS 3200/4000/5000)115
- Removing Intermediate Circuit Capacitors115
- Fitting Intermediate Circuit Capacitors116
Safety Inspection118
- General118
- Responsibility118
Visual Inspections119
- General119
- General Conditions119
- Welding Torch/Electrode Holder/Welding Current Return Terminal119
- Mains Supply and Connecting Lines119
- Welding Circuit119
- Housing and Covers120
- Adjustment and Display Devices120
Electrical Tests121
- Ground Conductor Resistance121
- Insulation Resistance122
- Open Circuit Voltage U0122
Function Tests123
- General123
- Mains Power On/Off Equipment123
- Indicators and Controls123
- Gas Solenoid Valve123
- Earth Current Watchdog123
- Test Weld123
Documentation124
- Test Record124
- Test Label124
Terms and Abbreviations Used125
- General Remarks125
- Terms and Abbreviations125
Entire Circuit Diagram127
- Storage Location127
Spare Parts List Circuit Diagram129

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