Fronius TransSynergic 5000

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101

1. Insert lead (4) into earth current

watchdog luster terminal

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

current watchdog

(continued)

(4)

(1)

(2)

Fig. 8 Fitting earth current watchdog

Main Page

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

Fronius TransSynergic 5000 - Page 103

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