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TransSynergic 5000
Fronius TransSynergic 5000 Service Manual
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T
ransSynergic 4000/5000
T
ransPuls Synergic 2700
T
ransPuls Synergic 3200/4000/5000
Service manual
S
pare p
arts list
MIG/MAG Power source
/ Ba
ttery Charging Systems /
W
el
d
ing T
echnol
ogy
/ Sol
ar El
ectronics
EN
42,0410,1237
011-28062017
2
Table of Contents
Table of Contents
3
Foreword and Safety Instructions
9
Safety
9
Fronius Technical Support Center (TSC)
9
General Remarks
9
Function Overview
10
Fault Location Aid
10
Detailed Description
10
Changing Components
10
Terms and Abbreviations Used
10
Spare Parts List and Entire Circuit Diagram
10
Tools and Measuring Instruments
10
Tools and Measuring Instruments
11
General Remarks
11
Tools Required
11
Measuring and Inspection Equipment
11
Ancillary Materials
11
Function Overview
12
Principle of the Digital Family of Machines
12
Useful Information
12
Block Diagram
13
Block Diagram Legend
13
Fault Location Aid
15
General Remarks
15
Fault Flowcharts
16
Overview
16
Poor Ignition and Welding Properties with „MIG/MAG Welding
17
Poor Ignition and Welding Properties with „TIG Welding
18
Poor Weld Properties with „Rod Electrode (MMA) Welding
19
Nothing Happens on Control Panel (TPS 2700)
20
Nothing Happens on Control Panel (TPS 3200/4000/5000)
22
No or Incorrect Welding Current
24
No or Incorrect Wirefeed Speed
25
Insufficient Torch Cooling (FK 4000/FK 4000 R)
26
Service Code Err 50
28
UST Service Codes
30
Safety
30
Table of Service Codes
30
Special Displays Used with Service Codes
36
Service Codes SR 4Xa
37
Safety
37
Table of Service Codes
37
Service Codes for Push-Pull Calibration
38
Safety
38
Checking Actual-Value Pick-Up
38
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 Description
41
General Remarks
41
Position of Electronic Components
41
Overview
41
ASU 27 - Additional PC Board
42
General Remarks
42
Component Position in the Machine
42
Overview
42
Technical Data
42
Function Overview
43
Plug Layout
43
LED Checklist
44
Measuring Points
44
ASU 40 - Additional PC Board
45
General Remarks
45
Component Position in the Machine
45
Overview
45
Technical Data
46
Function Overview
46
Plug Layout
46
LED Checklist
47
Measuring Points
48
BPS 25/BPT 27 - Power Module PC Board
49
General Remarks
49
Component Position in the Machine
49
Overview
49
Technical Data
50
Function Overview
50
Plug Layout BPS 25/BPT 27
50
LED Checklist
52
Measuring Points
52
BPS 32/40/42/43/50/53 - Power Module PC Board
54
General Remarks
54
Component Position in the Machine
54
Overview
54
Technical Data
55
Function Overview
55
Plugs on the Power Module PC Boards
56
Plug Layout
56
LED Checklist of Power Module PC Boards
58
Measuring Points
58
NT 24 - Switched Mode Power Supply 24 V
61
General Remarks
61
Component Position in the Machine
61
Overview
61
Technical Data
62
Function Overview
62
Plug Layout
62
LED Checklist
63
Measuring Points
63
NT 60 - Switched Mode Power Supply 60 V
65
General Remarks
65
Component Position in the Machine
65
Overview
65
Technical Data
66
Function Overview
66
Plug Layout
66
LED Checklist
67
Measuring Points
67
UST - Control and Regulation Unit
69
General Remarks
69
Component Position in the Machine
69
Overview
69
Technical Data
70
Plug Layout
70
Function Overview
70
LED Checklist
72
Measuring Points
72
Changing UST PC Board
72
NF 3160 - Line Filter
73
General Remarks
73
Component Position in the Machine
73
Overview
73
Technical Data
73
Function Overview
74
Plug Layout
74
LED Checklist
74
Measuring Points
74
NF 3400 - Line Filter/Line Filter 40 A/80 a
75
General Remarks
75
Component Position in the Machine
75
Overview
75
Technical Data
76
Function Overview
76
Plug Layout NF 3400
76
Plug Layout Line Filter 40 A/80 a
77
LED Checklist
77
Measuring Points
77
Shunt
78
General Remarks
78
Component Position in the Machine
78
Overview
78
Technical Data
79
Function Overview
79
Plug Layout
79
LED Checklist
79
Measuring Points
79
SR 41 - Wire-Feed Unit Regulation Unit
80
General Remarks
80
Component Position in the Machine
80
Overview
80
Technical Data
81
Function Overview
81
Plug Layout
81
LED Checklist
83
Measuring Points
84
Temperature Sensor TP 592S
85
General Remarks
85
Component Position in the Machine
85
Technical Data
86
Function Overview
86
Plug Layout
86
Measuring Points
86
Secondary Power Module TPS 2700
87
General Remarks
87
Component Position in the Machine
87
Overview
87
Function Overview
88
Measuring Points
88
Secondary Power Module TS 4000/5000, TPS 3200/4000/5000
89
General Remarks
89
Component Position in the Machine
89
Overview
90
Function Overview
90
Measuring Points
90
Primary Rectifier
91
General Remarks
91
Component Position in the Machine
91
Overview
91
Function Overview
91
Plug Layout
92
Measuring Points
92
Changing Components
93
Safety
93
General Remarks
93
Overview
93
Changing Throttle (TS 4000/5000, TPS 3200/4000/5000)
94
Removing Throttle
94
Fitting Throttle
95
Changing Throttle (TPS 2700)
97
Removing Throttle
97
Fitting Throttle
98
Changing Earth Current Watchdog
101
Removing Earth Current Watchdog
101
Fitting Earth Current Watchdog
102
Changing PC Board ASU 27 (TPS 2700 MV)
104
Removing ASU 27
104
Fitting ASU 27
104
Changing Shunt (TPS 2700)
105
Removing Shunt
105
Fitting Shunt
106
Changing Temperature Sensor TP 592S
108
Notes
108
Changing Transformer (TS 4000/5000, TPS 3200/4000/5000)
109
Removing Transformer
109
Fitting Transformer
110
Changing Transformer (TPS 2700)
112
Removing Transformer
112
Fitting Transformer
113
Changing Intermediate Circuit Capacitors (TS 4000/5000, TPS 3200/4000/5000)
115
Removing Intermediate Circuit Capacitors
115
Fitting Intermediate Circuit Capacitors
116
Safety Inspection
118
General
118
Responsibility
118
Visual Inspections
119
General
119
General Conditions
119
Welding Torch/Electrode Holder/Welding Current Return Terminal
119
Mains Supply and Connecting Lines
119
Welding Circuit
119
Housing and Covers
120
Adjustment and Display Devices
120
Electrical Tests
121
Ground Conductor Resistance
121
Insulation Resistance
122
Open Circuit Voltage U0
122
Function Tests
123
General
123
Mains Power On/Off Equipment
123
Indicators and Controls
123
Gas Solenoid Valve
123
Earth Current Watchdog
123
Test Weld
123
Documentation
124
Test Record
124
Test Label
124
Terms and Abbreviations Used
125
General Remarks
125
Terms and Abbreviations
125
Entire Circuit Diagram
127
Storage Location
127
Spare Parts List Circuit Diagram
129
Other manuals for Fronius TransSynergic 5000
Operating Instructions
212 pages
Operating Instructions & Spare Parts
212 pages
5
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Fronius TransSynergic 5000 Specifications
General
Brand
Fronius
Model
TransSynergic 5000
Category
Power Supply
Language
English
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