repair manual TT MW 2500 3000.pdf

TransTig 2500 / 3000 MagicWave 2500 / 3000

GB

Service manual Spare parts list TIG Power Source

Contents Foreword and safety instruction instructions s ........ ................. ................. ................. .................. ................. ................. ................. ................. ................. ................. ............... .............. .............. ...... 5 Safety ...................... ............................................... .................................................. ................................................... ......................................................... ..................................................... ...................... 5 TechSuppo echSupport rt National (TSN) ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ............... .............. .......... .. 5 General remarks ........ ................ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. .............. ................ .......... .. 5 Tools and measuring devices .................... .......................................... ............................................ ............................................ ................................................... ............................. 6 Function overview ....... ................ ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. .............. .............. ................ ........... ... 6 Error location aid ....... ................ ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ................ .............. ...... 6 Detailed description ..................... ............................................ ............................................. ............................................ .................................................... .......................................... ............ 6 Replacing components ..................... ............................................ .............................................. .............................................. ................................................... ................................... ....... 6 Terms and abbreviatio abbreviations ns used ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................ .............. ...... 6 Spare Spa re parts list and entire circuit diagram ......... ................. ................. ................. ................. ................. ................. ................. ................. ................ ............... ............ .... 6 Tools and measuring devices .................... .......................................... ............................................ ........................................... .................................................... ................................... .... 7 General remarks ........ ................ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. .............. ................ .......... .. 7 Tools required ....... ............... ................. ................. ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ............... ............... ................ .......... .. 7 Measuring equipmen equipment, t, inspection equipmen equipmentt ........ ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... ...... 7  Ancillary materials .................. ....................................... ........................................... ........................................... .......................................... .................................................. ............................. 7 Functional description MW/TT 2500/30 Functional 2500/3000 00 ....... ................ ................. ................ ................ ................ ................ ................ ................ ................ ................ ............... ............ ..... 8 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... ............... ................ .......... .. 8 Block diagram ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ .............. ...... 8 Block diagram legend ........................ ............................................... ............................................... ................................................ .................................................... ................................ .... 9 Error location aid ........ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ............... ............. ............... ................ .......... 10 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 10 Error flowchart ..................... ............................................. ............................................... ............................................... .................................................... .................................................. ...................... 11 Overview ....................... ................................................. .................................................... .................................................... ......................................................... ............................................ ............. 11 Poor ignition and weld properties with TIG welding................. welding........................... ................... .................. ................... ................... .................. ............... ........ 12 Poor ignition and weld properties with MMA welding ......... .................. ................... ................... ................... ................... ................... ................... ........... .. 13 No or incorrect welding current ........ ................ ................. .................. ................. ................. ................. ................. ................. ................. ................. .............. ............. ........... .... 14 Insufficient Insuffici ent welding torch cooling (FK 2500/FK 2500 FC/FK 2500 Rob) ......... .................. ................... ................... .................. ........... .. 15 No lights on control panel ........ ................ ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................ ............... .......... ... 17 Open circuit voltage +50 V faulty.............. faulty....................... ................. ................. .................. .................. .................. .................. .................. .................. ................. .............. ...... 19 „Err 50“ service code on the display ......... .................. .................. ................. ................. .................. .................. ................. ................. .................. .............. ............ .......... ... 20 UST service codes ........ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ................ .......... 22 Safety ...................... ............................................... .................................................. ................................................... ........................................................ ................................................... ..................... 22 Table of service codes ........ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ............... .............. ............... .......... ... 22 Speciall indication Specia indications s used with service codes............... codes....................... ................. .................. ................. ................. .................. ................. ................. ................ ....... 28 Detailed description .................... .......................................... ............................................ ............................................ .................................................... ............................................... ................. 29 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 29 Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... 29  ASU 2500 PC board .................... ......................................... ........................................... ............................................ ........................................... ............................................... .......................... 30 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 30 Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... 30 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 30 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 31 LED checklist ........ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 31 BPS 3000/MV PC board ..................... ......................................... ......................................... .......................................... ......................................... ........................................... ....................... 32 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 32 Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... 32 Technical data ...................... .............................................. ............................................... ............................................... ....................................................... ........................................... ............ 33 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 33 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 33 LED checklist ........ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 34 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ............... ........... .... 34

BSV 3000 PC board voltage doubler................. doubler......................... ................. .................. .................. .................. .................. .................. ................. ............... ............... ............. ..... 35 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 35 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 35 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 35 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 35 FKC 2500 PC board ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ............. ............ ............... ............ .... 36 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 36 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 36 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 36 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 37 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 37 FKR 2500 PC board ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ............. ............ ............... ............ .... 38 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 38 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 38 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 39 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 39 FMW 2500/30 2500/3000 00 PC board ........ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... .............. ........... .... 40 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 40 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 40 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 41 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 41 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 42 HFF 22 PC board ....... ................ ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... ............... ......... .. 43 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 43 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 43 Technical data ....................... .............................................. ............................................... ................................................ ....................................................... .......................................... ........... 44 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 44 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 45 NT 2500 PC board ....... ................ ................. ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ .............. ............. ............... ................ ........ 47 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 47 Technical data ....................... .............................................. ............................................... ................................................ ....................................................... .......................................... ........... 47 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 47 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 48 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 48 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 48 NT 60 ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ .............. .............. ............... ............... ................ ........ 49 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 49 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 49 Technical data ....................... .............................................. ............................................... ................................................ ....................................................... .......................................... ........... 49 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 49 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 50 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 51 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 51 RP 3000 PC board ....... ................ ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. ................. ............. ............. ............... .............. ....... 53 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 53 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 53 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 53 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 54 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 54 SNT 3 PC board ........ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ................. ................ ............... .............. ............... ............... .......... ... 55 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 55 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 55 Function overview ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. .............. .............. ............... ......... .. 55 Pin assignme assignment nt ........ ................ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............. ..... 55 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 56

UST PC board ..................... ............................................ ............................................... ................................................ ......................................................... ................................................. ................ 57 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 57 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 57 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 58 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ............... ........... .... 59 LED checklist ........ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 59 Changing UST PC board ........ ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ............... .............. ............. ...... 59 Line filter ....................... ............................................... ............................................... ............................................... ...................................................... ........................................................ .......................... 60 General remarks ....... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ............... ............... .......... 60 Overview ........ ................ ............... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ................ ............ .... 60 Technical data ...................... .............................................. ............................................... ............................................... ....................................................... ........................................... ............ 60 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 60 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 60 Primary rectifier ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ................. .............. .............. ................ ............... ........... .... General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ................ ........... ...

61 61 61 61 61 62

Secondary power module .................... ......................................... .......................................... .......................................... .......................................... ......................................... .................... General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... LED checklist ........ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ................ ........... ...

63 63 63 64 64 64

Shunt ........................... ...................................................... ...................................................... ...................................................... ..................................................... ............................................... ..................... 66 General remarks ....... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ............... ............... .......... 66 Overview ........ ................ ............... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ................ ............ .... 66 Technical data ...................... .............................................. ............................................... ............................................... ....................................................... ........................................... ............ 66 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 66 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 67 LED checklist ........ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 67 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ................ ........... ... 67 TP 592S temperat temperature ure sensor ....... ............... ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ............... ............... ............... ....... 68 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 68 Technical data ...................... .............................................. ............................................... ............................................... ....................................................... ........................................... ............ 68 Function overview ......... ................. ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ............... .............. ............... .......... 68 Pin assignme assignment nt ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. ...... 68 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ................ ........... ... 68 Changing modules ........ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... ................ ............... ....... 69 General remarks ....... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ............... ............... .......... 69 Overview ........ ................ ............... ............... ................ ................ ............... ............... ................ ............... ............... ................ ................ ............... ............... ................ ................ ................ ............ .... 69 Changing the transform transformer er ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............... ........... .... 70 Removing the control panel ........ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ................ .............. ............. .......... ... 70 Removing the UST PC board ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. .............. ............. ....... 70 Removing the retainin retaining g plate.............. plate....................... ................. ................. .................. ................. ................. ................. ................. ................. ................ ............... ............... ........ 70 Undoing leads on earthing socket ........ ................ ................ ................ ................. ................. ................ ................. ................. ................ ................. ............... .............. .......... 71 Undoing transformer transformer centre-tap and auxiliary power source leads ......... .................. ................... ................... .................. .................. ........... 71 Removing the HF transform transformer er ....... ............... ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ .............. ............. .......... ... 71 Removing the toroidal tape cores ........ ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. .............. ............. ....... 72 Removing the transform transformer er ........ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ .............. .............. .............. ...... 72 Installing Installin g the transform transformer er ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. .............. ............. .............. ...... 73 Securing the toroidal tape cores and transforme transformerr ......... ................. ................. ................. ................. .................. ................. ................. ................. ............. ..... 73 Fitting the secondary transform transformer er leads ........ ................. ................. ................. ................. ................. ................. ................. .................. ................. .............. ............ ...... 74 Fitting the HF transform transformer er ....... ............... ................. ................. ................ ................ ................ ................ ................ ................ ................. ................. .............. ............. ............... ........ 74 Fitting transformer centre-tap and auxiliary power source leads ........ .................. ................... .................. ................... ................... .............. ..... 74

Fitting leads to earthing socket ......... ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... ............. .......... ... 75 Fitting the retaining plate ........ ................ ................. ................. ................. .................. ................. ................. ................. ................. ................. ............... .............. ............... ............. ..... 76 Fitting the UST PC board ........ ................. ................. ................. ................. ................ ................. ................. ................ ................. ................. ................. .............. ............. ............. ..... 76 Fitting the control panel ........ ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ................ ............... ............. ..... 76 Changing the fan ........ Changing ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ................. ................ ............... .............. ............... ............... ......... .. 77 Removing the solenoid valve and fan lead ......... ................. ................. .................. .................. ................. ................. .................. .................. ................. .............. ...... 77 Removing the air baffle ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ............... ......... .. 78 Removing the fan ....... ............... ................ ................ ................ ................ ................ ................. ................. ................ ................ ................ ................ ............... .............. ............... ............. ..... 78 Installing Installin g the fan ........ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............. ..... 78 Fitting the air baffle .................... .......................................... ........................................... ........................................... ....................................................... ............................................ ........... 79 Carrying out a safety inspection ........ ................. ................. ................. .................. .................. ................. ................. .................. .................. ................. ............... ............... ............ .... 81 When is it required? ....... ............... ................ ................ ................ ................ ................ ................ ................ ............... ............... ................ ................ ............... ............... ............... .......... ... 81 Work instructio instructions ns ........ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. .............. ................ ............. ..... 81 Terms and abbreviat abbreviations ions used ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................ ............... ............... ......... .. 82 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 82 Terms and abbreviations ...................... ............................................. ............................................. ............................................ ..................................................... ............................... 82 Entire circuit diagram Spare parts lists Fronius Worldwide

Foreword and safety instructions

Safety

The following safety instructions apply to all activities described in these service manual: WARNING!  Operating the equipment incorrectly can cause serious injury and WARNING! Operating damage. All All activities described in the service manual must only be carried out by Fronius-trained service technicians. Read the „Safety rules“ chapter in the power source operating instructions.

WARNING!  An electric shock can be fatal. Before opening the device WARNING! An Tur urn n the the ma main ins s swi switc tch h to to the the „O „O““ pos posit itio ion n Unpl Un plug ug th the e dev devic ice e fro from m the the ma main ins s Put up up an easy easy-to -to-un -under derst stand and warn warning ing sign sign to to stop stop anybod anybodyy inadve inadverte rtentl ntlyy switching it back on again Using Usin g a suit suitable able meas measurin uring g instru instrumen ment, t, check check to make make sure that elec electrica tricallly charged components (e.g. capacitors) have discharged WARNING!  An electric shock can be fatal. If the machine needs to be switched WARNING! An on briefly for testing while the housing is open: - Do not not touc touch h any any part parts s insid inside e the the housi housing ng - Only touc touch h using using suit suitable able meas measurin uring g or test prob probes es

CAUTION! Failure to connect a correctly-dimensioned earth lead may result in CAUTION! Failure serious injury or damage. The housing screws provide a suitable PE conductor  connection for earthing (grounding) the housing and must NOT be replaced by any other screws that do not provide a reliable PE conductor connection.

TechSupport National (TSN)

If you have any questions about error analysis, your TechSupport National (TSN) sales team will be able to help. mailto: [email protected]

General remarks

The service manual can be found in the DownloadCenter TechGuide at „www.fronius.com\downloadcenter“. Each chapter in the service manual deals with one complete topic. Use each chapter as a self-contained source of information. A short description of each chapter follows:

Tools and measuring devices

This provides an overview and description of all equipment required for servicing the power source professionally. This equipment includes: - Tools re req quir ired ed - Mea Measur suring ing equip equipmen ment, t, inspec inspectio tion n equipm equipment ent - An Anci cill llar aryy mate materi rial al

Function overview

Contains a brief descriptive overview of the entire system: - In text form - In bl bloc ock k dia diagr gram am fo form rm

Error location aid

Serves to systematically locate and rectify the source of errors, and contains the follo wing elements: The act actual ual err error or flow flowcha chart rt for for deal dealing ing wit with h gene general ral err errors ors Service Servi ce codes codes tab table le for for dealin dealing g with with error errors s whose whose servi service ce codes codes appe appear ar on on the the display

Detailed description

Contains detailed descriptions of the relevant modules in the power source. For every module, the following topics are dealt with: Genera Gen erall remar remarks ks (de (desig signa natio tion, n, item item nu numbe mberr of the the mod module ule)) Posi Po siti tion on of th the e mod modul ule e in in the the de devi vice ce Overview   Technical data Function ov overview   Pin assignment LED checklists Measuring points

Replacing components

The „Replacing components“ chapter describes how to replace components that Have Hav e no no inst instruc ructio tions ns of the their ir own own for rep replac laceme ement nt and Requ Re quir ire e deta detail iled ed rep repla lace ceme ment nt ins instr truc ucti tion ons s

Terms and abbreviations used

Contains a description of essential specialist terms and abbreviations for a better understanding of the service manual

Spare parts list and entire circuit diagram

The „Spare parts list“ and „Entire circuit diagram“ chapters contain the complete spare parts list and complete circuit diagram for the power source.

Tools and measuring devices General remarks

„Tools and measuring devices“ provides an overview and description of all the equipment required to service the device professionally. This equipment includes: - Tool ols s re req qui uire red d - Mea Measur suring ing equip equipme ment, nt, inspe inspecti ction on equipm equipment ent - An Anci cill llar aryy ma mate teri rial als s

Tools required

-

Box spanner (8 (8 mm) Larg La rge e nee needl dlee-no nose sed d pli plier ers s (app (appro rox. x. 16 160 0 mm) mm) Sma Sm all wir ire e cut utti tin ng pli lier ers s Manu Ma nual al tor torqu que e wren wrench ch (1(1-6 6 Nm, Nm, 42,0 42,041 411, 1,00 0013 13)) Slot Sl otte ted d sc scre rewd wdri rive verr (m (med ediu ium) m) Phil Ph illi lip ps scr scre ewdr driv iver er (P (PH H1) Phil Ph illi lip ps scr scre ewdr driv iver er (P (PH H2) Torx scre screwdr wdrive iverr (TX 15) 15) or inse insert rt bit bit for manu manual al torqu torque e wrench wrench Torx scre screwdr wdrive iverr (TX 25) 25) or inse insert rt bit bit for manu manual al torqu torque e wrench wrench Flat sp spanner (1 (10 mm) Flat sp spanner (1 (13 mm) Flat sp spanner (1 (17 mm) Flat sp spanner (1 (19 mm) Oeteker pliers Mole Mo lex x ex extr trac acto torr to tool ol (4 (42, 2,04 0410 10,0 ,029 290) 0) Applic App licati ation on instr instrum ument ent for for heatheat-con conduc ductiv tive e paste paste (42,04 (42,0435, 35,00 0020) 20)

Measuring equipment, inspection equipment

-

Digital mu multimeter   PC wit with h Micr Micros osof oftt Win Windo dows ws ope opera rati ting ng sys syste tem m (System requirements requirements can be found in the operating instructions for the BSL tool) „BSL to tool“ (4 (4,050,082) „Loc „L ocal alNe Nett RS RS 232 232 Co Conv nver erte ter“ r“ (4 (4,1 ,100 00,2 ,262 62)) DVD DV D Tec TechG hGui uide de (4 (40, 0,00 0006 06,2 ,291 910) 0)

-

Contact Conta ct spr spray ay (40 (40,00 ,0009, 09,001 0014) 4) or alc alcoho oholic lic sol solven ventt Heat He at-c -con ondu duct ctiv ive e pas paste te (4 (40, 0,00 0009 09,0 ,004 043) 3) Applic App licati ation on instr instrume ument nt for for heat-co heat-condu nducti ctive ve paste paste (42,0 (42,043 435,0 5,002 020) 0) Sand Sa ndpa pape perr (42, (42,04 0410 10,0 ,043 436) 6),, grad grade e 500 500 or fin finer  er 

Ancillary materials

Functional description MW/TT 2500/3000 General remarks

The „Functional description“ explains the underlying functional principle of the MagicWave 2500/3000 and TransTig 2500/3000 power sources with the help of a block diagram.

Block diagram    l   o   r    t   n   o   c   e    t   o   m   e    R

   h   c   r   o    t   g   n    i    d    l   e    W

Welding torch control line

  e   c   e    i   p    k   r   o    W

Protective gas shield

   t   e    N    l   a   c   o    L

  s   e   c   r   u   o   s   r   e   w   o   p    0    0    0    3   e   v   a    W   c    i   g   a    M    d   n   a    0    0    5    2   e   v   a    W   c    i   g   a    M   r   o    f   y    l   n   o

Output choke Protective gas shield solenoid valve

Iact

   F    H

HF transformer

   )    2    1    (

Welding current sensor

   )    1    1    (

HF generator

Uact Control line

Inverter

   *

  r   l   e   e   u   w   d   o   o   p   m   y   r   a    d   n   o   c   e    S

Secondary rectifier

Welding transformer

   )    0    1    (    )    9    (

   )    8    (

   )    7    (

   * Control line stors Transi ransistors

   )    6    (

Control panel

  n   o    i    t   a    l   u   g   e   r    d   n   a    l   o   r    t   n   t    i   o   n    C  u    )    1    (

   V    5    5

   )    5

Intermediate circuit   ( capacitors

Power supply

  y    l   p   p   u   s   r   e   w   o   p    V    4    2

   V    4    2 Power supply

   )    4

  e    l   u    d   o   m   r   e   w   o   p   y   r   a   m    i   r    P

PFC (Power    ( Factor Control)

   )    2    ( Line filter

Fig. 1

   )    3

Primary rectifier    (

Block diagram diagram of the MagicWave MagicWave 2500/3000 2500/3000 and and TransTig TransTig 2500/3000 2500/3000 power power sources

   V    0    0    4   x    3

Block diagram legend

(1) Control and regulation unit: Controls, regulates and monitors the welding process and all power source functions. (2) Line filter (EMC): Reduces unwanted high-frequency noise. (3) Primary rectifier: Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage. voltage. (4) PFC: Ensures sinusoidal current input, for  - Su Suppo pporti rting ng an opt optimu imum m degree degree of of effic efficien iency cy - Pre Preven ventin ting g react reaction ions s in the the main mains s suppl supplyy (5) Intermediate Intermediate circuit capacitors: Store and smooth the intermediate circuit voltage. (6) Transistors: the transistors carry the intermediate circuit voltage in intervals at high frequency to the primary coil on the transformer. The high frequency means that: - The transf transforme ormerr can be cons construct tructed ed to a very very light, light, comp compact act design design - Ther Thermal mal losses losses due due to the low low inductan inductance ce required required of the the transfo transformer rmer windin windings gs can be kept to an absolute minimum (7)) Weld (7 elding ing tran transfo sforme rmer: r: - Tr Transf ansforms orms the the high high primary primary voltag voltage e into a low second secondary ary volta voltage ge - Ensu Ensures res electr electrical ical isolati isolation on of primar primaryy and seco secondar ndaryy power power module modules s (8) Secondary rectifier: Converts the secondary voltage into a DC voltage (9) Inverter (only MagicWave 2500 and MagicWave 3000): Converts direct current to alternating current for “TIG AC welding” operating mode (10) HF generator: For non-contact HF ignition, the HF generator (high-frequency generator) generates the high-frequency primary voltage of the HF transformer (12). (11) Welding current sensor: Captures the actual current value for the welding process (12) HF transformer: For non-contact HF ignition, the HF transformer (high-frequency transformer) transmits high-voltage pulses to the welding circuit.

Error location aid General remarks

The chapter „Error location aid“ consists of the following parts - Er Erro rorr flo low wcha hart rt - Tab able le of se serv rvic ice e cod codes es The error flowchart is for the systematic location and rectifying of errors. In the „Table of  service codes“ chapter, there is also a table which deals with the service codes shown on the display, as well as the causes of errors and how to rectify them. Before using the error location aid, read the „Function overview“ chapter and study the entire circuit diagram in order to understa understand nd how the power source is constructed and how it operates. Important! The following applies to those with even less experience of troubleshooting Important! The and fault diagnosis on the MagicWave 2500/3000 and TransTig 2500/3000 power  sources. Before using the error location aid, read the following chapters: - „F „Fun unct ctio ion n ov over ervi view ew““ - “E “Ent ntir ire e ci circ rcui uitt di diag agra ram” m”

Error flowchart Overview

The overview will help you to find the relevant sections of the flowchart from among those listed below. The positions and meanings of the measuring points and LEDs for the modules/PC boards can be found in the „Detailed description“ chapter. which contains an „LED checklist“ or a „Measuring points“ sub-section for each of the modules/PC boards (with LEDs). Poor ignition and weld properties with TIG welding

Poor ignition and weld properties with MMA welding

No or incorrect welding current

Move the mains switch to the „I“ position

Insufficient welding torch cooling (FK  Insufficient 2500/FK 2500 FC/FK 2500 Rob)

No lights on control panel

Open circuit voltage + 50 V faulty

„Err 50“ service code on the display

Table of service codes

Poor ignition and weld properties with TIG welding

Start

Correct protective gas shield connected, and l/min set correctly?

no

Connect correct protective gas shield and check l/min

yes

Gas test button: Protective gas shield flowing out?

no

Check protective gas shield solenoid valve, including control

yes

Welding torch and grounding (earthing) cable OK?

no

Check welding torch and grounding (earthing) cable

yes

Parameters set correctly? no yes

Open circuit voltage with selected „rod electrode (MMA) welding“ process = 50 V (+/- 1 V) ? yes

Check whether power source OK, and check application

End

no

Check settings on control panel, check set-up parameters, possibly reset to factory settings (FAC) (see operating instructions)

See „Incorrect open circuit voltage“ section

Poor ignition and weld properties with MMA welding

Start

Electrodes/grounding (earthing) cable connected/functioning correctly?

Connect cable correctly no

yes

Welding process set correctly?

Select correct welding process no

yes

Parameters set correctly? no yes

Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ? yes

Check whether power source OK, and check application

End

no

- Ch Chec eck k set setti ting ngs s on on con contr trol ol pa pane nell Check set-up parameters Poss Po ssib ibly ly re rese sett to fac acto tory ry se setttings (FAC) (see operating instructions)

See „Incorrect open circuit voltage“ section

No or incorrect welding current

Start

Welding torch and grounding (earthing) cable connected/ connected/functiofunctiono ning correctly?

Check welding torch and grounding (earthing) cable

yes

No lights on control panel? yes

See section entitled „No lights on control panel“

no

Open circuit voltage with selected „MMA welding“ process = 50 V (+/1 V) ?

no

See „Incorrect open circuit voltage“ section

yes

-

Welding current Iset no longer  adjustable, or  Wel eldi ding ng cu curr rren entt is is alw alway ays s Imax ? no

Check whether power source OK, and check application

End

yes

Change current sensor A1 VAC

Insufficient welding torch cooling (FK 2500/ FK 2500 FC/FK 2500 Rob)

Start

Cooling unit set-up parameters switched to „OFF“?

yes

Switch „C-C“ set-up parameter to „On“

no

Sufficient coolant?

Top up coolant; vent cooling unit no

yes Change pump

no Pump rotating?

Pump pressure OK? yes yes

no

Check cooling system (flow rate) and change defective components

Coolant pump jammed? yes

Turn pump using a screwdriver, if it  will not turn change the pump, pump , check fuse F1

no

FKC/FKR 2500 PC board: „Cooler  ON signal“ 24V X2/4 - X2/3 and 24V X2/8 - X2/3 present?

Check cable harness, if OK  change UST PC board no

yes FKC/FKR 2500 PC board: Mains voltage present on plug X1/1 - X1/ 2?

yes

 A 

Check cable harness and fuse F1 no

Insufficient welding torch cooling (FK 2500/ FK 2500 FC/FK 2500 Rob) (continued)

 A 

Replace fans

Fans rotating? no yes

400 VAC present on FKR 2500 PC board X5 - X6?

Change water pump yes

no

FK 2500 Standard Check/change fuse on FK 2500 PC board Change FKR 2500 PC board

End

FK 2500 MV   Check/change fuse on FK 2500 PC board, check/change autotransformer, change FKC 2500 PC board

No lights on control panel

Start

Steady HS LED on the  A2 BPS 3000/MV  power module board?

no

Check mains cable, mains switch, line filter and supply voltage

yes Steady +24V int/ext LEDs on UST? no yes

Switch power source off, unplug X3 plug from the UST PC board, switch power  source on

Steady +24V int/ext LEDs on A3 NT 2500 power module board?

no

Change the A3 NT 2500 power module board

yes Switch power source off, plug X3 plug into the UST PC board and unplug X7, switch power source on

Steady +24V int/ext LEDs on UST PC board? no Check cooling unit

Steady +5V, +15V, 15V LEDs on UST PC board? no Unplug X4 from UST PC board

 A 

yes

Check/change control panel/ribbon cable

yes

Change A2 BPS 3000/ MV power module board

No lights on control panel (continued)

 A 

Steady +5V, +15V, 15V LEDs on UST PC board?

Change VAC shunt yes

no

Unplug X2 from UST PC board

Steady +5V, +15V, 15V LEDs on UST PC board?

Check/change control panel/ribbon cable yes

no

Unplug X6 from UST PC board

Steady +5V, +15V, 15V LEDs on UST PC board? no

Change UST PC board

End

Change BPS yes

Open circuit voltage +50 V faulty

Start

Open circuit voltage for selected „MMA welding“ process not equal to 50 V?

yes

Change FMW 2500/3000 PC board, Change BSVXX PC board

no From here onwards, troubleshooting only applies to MagicWave 2500/3000

Steady +5 V, +18V, +18V, +24V LEDs LED s on FMW 2500/3000 PC board? If the polarity changes using the „Process“ button: „neg./pos. ignition“ LED lit ? yes

Check secondary power module (see detailed explanation - secondary power module)

End

no

Change FMW 2500/3000 PC

„Err 50“ service code on the display

Start

Does service code Err  50 appear directly after switching on, although the primary no power module is not operating?

Select „Rod electrode“ mode Change UST

yes yes Imbalance in intermediate circuit > 35V? no yes

+5V voltage available on UST from X6/26 X7/8? no Change BPS

Does Err 50 disappear after a short

yes

no

Change UST

Switch off power  source; unplug X2 from NT 60; switch on power source

Change NT 60 no

Switch off power  source; discharge intermediate intermediat e circuit electrolytic capacitors; unplug X1 from NT 24; switch on power  source

Imbalance in intermediate circuit > 35V? yes

 A 

no

On the BPS, the brightness of the control LEDs remains unchanged when the BPS is activated yes

Err 50? yes

Change intermediate circuit electrolytic capacitors

no

Change NT 24

„Err 50“ service code on the display (continued)

 A 

Switch off power  source; discharge intermediate intermediat e circuit electrolytic capacitors; unplug X7/1 - X7/4; switch on power  source

Imbalance in intermediate circuit > 35V? yes Change intermediate circuit electrolytic capacitors

End

no

Change BPS

UST service codes Safety

Table of service codes

WARNING! An electric shock can be fatal. Before opening the device WARNING! An Tur urn n the the ma main ins s swi switc tch h to to the the „O „O““ pos posit itio ion n Unpl Un plug ug th the e dev devic ice e fro from m the the ma main ins s Ensure Ensu re that elect electrical rically ly charg charged ed comp componen onents ts (e.g (e.g.. capac capacitors itors)) have have been discharged

For every service code there is information on - Ser Servic vice e code code indi indicat cator or (e.g (e.g.. „Err „Err | Arc Arc“) “) - Code no. (e.g. (e.g. when when service service code is is displaye displayed d by a robot robot interf interface) ace) - Rea Reason son for the the serv service ice code code bei being ng disp display layed ed - The corre correspo spond nding ing troub troubles lesho hooti oting ng measu measure re dsP | Axx (code no.20) Cause Ca use:: Reme Re medy dy::

DSP dis displa plays ys a gene general ral err error, or, xx stan stands ds for ad addit dition ional al en entri tries es no nott requ require ired d for external service Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

dsP | A21 (code no.20) Cause Ca use::

Remedy: Reme dy:

The pow power er sou source rce is conf configu igured red for eit either her pa paral rallel lel ope operat ration ion (se (set-u t-up p para parame me-ter P-C is set to “ON”) or for TimeTwin Digital (set-up parameter T-C is set to “ON”). However, the LHSB link has been disconnected, or has become faulty, while the power source was switched on. Resett the Rese the service service code code:: Switch Switch the pow power er source source off and back on again again.. If  necessary, restore or repair the LHSB link.

dsP | Cxx (code no.29) Cause Ca use:: Reme Re medy dy::

DSP SoftC DSP SoftCom om err error, or, xx stan stands ds for for addi additio tional nal en entri tries es not not rele relevan vantt for for exte externa rnall service Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

dsP | E05 (code no.17) Cause: Reme Re medy dy::

DSP displays internal error  Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

dsP | Exx (code no.21) Caus Ca use: e:

Reme Re medy dy::

DSP di DSP disp spla lays ys ge gene nera rall err error or,, xx st stan ands ds fo for  r  1 timeout during charging 2 EOF during charging 3 error on data channel (LT selection) 4 error on com channel (LT selection) 5 timeout at EM stop command Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

dsP | Sy (code no.35) Caus use: e: Reme Re medy dy::

Inte tern rnal al err rro or (ve (vers rsio ion n con conffli lic ct) Update Upda te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

dsP | nSy (code no.36) Caus use: e: Reme Re medy dy::

Inte tern rnal al err rro or (ve (vers rsio ion n con conffli lic ct) Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

Table of service codes (continued)

EcF | xxx (code no.32) Caus Ca use: e:

BPS BP S co conf nfig igur urat atio ion n er erro ror, r, x st stan ands ds fo for: r:

Reme Re medy dy::

1 TPS TP S 270 700 0 wit ith h inc nco orr rre ect po pow wer mod odu ule 2 TS/T TS /TPS PS/T /TP P 40 4000 00 wi with th in inco corr rrec ectt pow power er mo modu dule le 3 TS/T TS /TPS PS/T /TP P 50 5000 00 wi with th in inco corr rrec ectt pow power er mo modu dule le 4 TT 22 2200 00,, MW MW 22 2200 00 wi with th in inco corr rrec ectt pri prima mary ry po powe werr mod modul ule e 5 MW 17 1700 00 wi with th in inco corr rrec ectt pri prima mary ry po powe werr mod modul ule e 253 This confi configura guration tion func function tions s only only from from UST2A UST2A V1.3 V1.3 A onwar onwards ds 254 This config configurat uration ion functi functions ons only only from from UST PC PC board, board, version version UST2 UST2A  A  255 25 5 Un Unkn know own n prim primar aryy powe powerr modu module le Fitt cor Fi corre rect ct pr prim imar aryy po powe werr mod modul ule e

EFD | xx.y (code no.30) Cause: Cau se: Reme Re medy dy::

Error in Error in wire wirefe feed ed sys system tem,, xx xx and and y can be fo found und in the lis listt of ser servic vice e code codes s for the wirefeed system. Chec Ch eck k wi wire refe feed ed sy syst stem em

EIF | xx.y (code no.63) Cause: Cau se: Remedy: Reme dy:

Error in con Error conjun juncti ction on wit with h a rob robot ot int interf erface ace,, xx an and d y can be fou found nd in the the lis listt of service codes for your robot interface. Check Che ck robo robott inter interface face,, updat update e softw software, are, chan change ge robo robott inter interface face

Err | Arc (code no.61) Cause: Caus e: Remed edyy:

DPS 500 DPS 5000 0 onl only: y: DP DPS S det detec ecte ted d arc arc fo form rmat atio ion n Chec eck k app ppli lic cati tio on

Err | bPS (code no.18) Cause: Remedy Rem edy::

DSP displays internal error  Updat Up date e softwa software. re. Chan Change ge UST UST PC board board.. Change Change BPS BPS PC boar board. d.

Err | Cfg (code no.72) Cause: Cau se: Remedy Rem edy::

Power sou Power source rce con config figura uratio tion n chan changed ged (e. (e.g. g. con connec nected ted in par parall allel el wit with ha second power source) Reset Re set ser servic vice e cod code e by by pre pressi ssing ng set set-up -up but butto ton n

Err | EPF (code no.22) Cause: Reme Re medy dy::

Error du during ch charging of of flflex Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

Err | IP (code no.19) Cau ause se:: Remed Rem edy: y:

DSP dis ispl pla ays pri rim mar aryy ov over ercu curr rren entt Check seco Check seconda ndary ry power power modu module. le. Cha Change nge prim primary ary pow power er modu module. le.

Err | Jo (code no.67) Cau ause se:: Reme Re medy dy::

JobMa JobM ast ster er te tempe pera ratu ture re se senso sorr fau fault ltyy Chan Ch ange ge Jo JobM bMas aste terr we weld ldin ing g to torc rch h

Err | Lic (code no.40) Cause: Remed Rem edy: y:

Faulty/incorrect lilicence ke key Check Ch eck lic licen ence ce key key.. Check Check and upd update ate ena enable ble cod codes. es.

Table of service codes (continued)

Err | PE (code no.53) Cause: Remedy: Rem edy:

Earth-fault error   Remove Remo ve earth earth faul fault. t. Conf Configure igure devi device ce in in insula insulated ted stat state. e. Chec Check k earth earth current watchdog and change if necessary.

Err | tF1 (code no.11), Err | tF2 (code no.12), Err | tF3 (code no.13), Err | tF4 (code no.14), Err | tF5 (code no.15) Cause Ca use::

Remed Re medy: y:

Temperat Temper ature ure sen sensor sor err error or (sho (short rt circ circuit uit or bre break ak)) - exam example ples: s: tF1 tF1 - tem tempe pe-rature sensor error on secondary rectifier, tF2 - temperature sensor error on primary power module, tF4 - temperature sensor error on primary power  module PFC (power factor control) Check Che ck cable cable harn harness ess and and chang change e the relev relevant ant tem temper peratu ature re senso sensor  r 

Err | tF6 (code no.16) Cause: Caus e: Reme Re medy dy::

Errorr on Erro on BPS BPS PC bo boar ard d or or on on the the co conn nnec ecti tion on to th the e BPS BPS PC bo boar ard d Chec Ch eck k ribb ribbon on cab cable le.. Chan Change ge BPS BPS PC PC boar board. d.

Err | tF7 (code no.34) Cause se:: Remed edyy:

Tempe Tem pera ratture se sen nso sorr er erro rorr on UST Cha han nge US UST PC PC boar ard d

Err | tF8 (code no.64) Cause:: Cause Remed Re medy: y:

In con conjun juncti ction on wit with h therm thermost ostat at opt option ion:: cool cooling ing un unit it tem temper perat ature ure sen sensor sor err error  or  Check cab Check cable le harn harness ess.. Chang Change e tempe temperat rature ure sen sensor sor..

Err | 027 (code no.27) Cause: Caus e: Remedy:

One of One of the the su supp pply ly vo volt ltag ages es is ou outs tsid ide e the the to tole lera ranc nce e ran range ge Change US UST

Err | 049 (code no.49) Cause: Remed Re medy: y:

Phase fa failure Check Ch eck the ma mains ins fus fuse, e, the the main mains s lead lead and and the the main mains s plug plug

Err | 050 (code no.50) Cause: Caus e: Reme Re medy dy::

Voltag Volt age e int inter erme medi diat ate e cir circu cuit it sy symm mmet etry ry er erro ror  r  See Se e erro errorr flow flowch char artt Err Err 50 ifif avai availa labl ble. e. If there is a voltage of +5V on the UST from X6/26 - X7/8, change UST. If there is a voltage of 0 V on the UST from X6/26 - X7/8 0V, change BPS.

Err | 051 (code no.51) Cause: Cau se: Remedy dy::

Mains Mai ns und underv ervolt oltage age:: The mai mains ns vol volta tage ge ha has s fall fallen en bel below ow the tol tolera erance nce range Check main ins s vo volt lta age

Err | 052 (code no.52) Cause:: Cause Remedy dy::

Mains ove Mains overvo rvolta ltage: ge: The mai mains ns vol volta tage ge ha has s rise risen n abo above ve the tol tolera erance nce ran range ge Check main ins s vo volt lta age

Err | 054 (code no.54) Cause se:: Reme Re medy dy::

Wir ire e st stic ick k con onttro roll has tr trip ipp ped Remo Re move ve sho short rt cir circu cuit it on on wel weldi ding ng wi wire re

Table of service codes (continued)

Err | 056 (code no.56) Cause: Cau se: Rem eme edy:

In con conjun juncti ction on wit with h wire wire-fe -feed ed uni unitt and and „wi „wirere-end end che check“ ck“ opt option ion:: no no wir wire e available Ins nser ertt ne new wir wire esp spo ool

Err | 059 (code no.59) Cause: Caus e: Remed Rem edy: y:

Overvo Over volt ltag age e in the the sec secon onda dary ry cir circu cuit it:: safe safety ty cut cut-o -out ut has has tri tripp pped ed Check Ch eck sec second ondary ary cir circui cuit, t, incl includ uding ing TPC TPCEL4 EL40 0 PC boa board rd

Err | 060 (code no.60) Caus Ca use: e: Reme Re medy dy::

DPS500 DPS5 000 0 only only:: Due Due to an an open opened ed doo doorr cont contac act, t, SIT SITRE RE1A 1A has has tri trigg gger ered ed safety disconnection Safe Sa fety ty cu cutt-ou out: t: clo close se do door or co cont ntac actt

Err | 062 (code no.62) Cause: Caus e: Reme Re medy dy::

Remote Remo te co cont ntro roll TP TP08 08 ov over erte temp mper erat atur ure e Allo Al low w TP08 TP08 to to cool cool dow down. n. Cha Chang nge e TP08 TP08..

Err | 068 (code no.68) Cause: Caus e: Remed edyy:

Second Seco ndar aryy cir circu cuit it sa safe fety ty cu cutt-ou outt has has tr trip ippe ped d Chan ang ge TT TTS PC PC bo boar ard d

Err | 069 (code no.69) Cause: Caus e: Remedy:

Illega Ille gall cha chang nge e of of mod mode e or or pro proce cess ss du duri ring ng we weld ldin ing g Reignite ar arc

Err | 23.x (code no.23) Caus Ca use: e:

Reme Re medy dy::

Config Conf ig me memo mory ry (C (CFM FM)) err error or on US UST T PC PC boa board rd,, x st stan ands ds fo for: r: 1 config memory not found 2 checksum error  3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Upda Up date te sof softw twar are. e. Cha Chang nge e UST UST PC boa board rd..

Err | 24.x (code no.24) Caus Ca use: e:

Reme Re medy dy::

Config Conf ig me memo mory ry (C (CFM FM)) err error or on BP BPS S PC PC boa board rd,, x st stan ands ds fo for: r: 1 config memory not found 2 checksum error  3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Chec Ch eck k ribb ribbon on cab cable le.. Chan Change ge BPS BPS PC PC boar board. d.

Err | 25.x (code no.25) Caus Ca use: e:

Remedy:

Config Conf ig me memo mory ry (C (CFM FM)) “al “alte tern rnat ator or”” err error or,, x st stan ands ds fo for: r: 1 config memory not found 2 checksum error  3 never tested 4 test not OK  5 unknown board type 8 invalid identifier (identifier UST1 to UST2) Change TT TTS

Table of service codes (continued)

Err | 26.x (code no.26) Caus Ca use: e:

Remed Re medy: y:

Config Conf ig me memo mory ry (C (CFM FM)) „ma „mach chin ine“ e“ er erro ror, r, x sta stand nds s for for:: 1 config memory not found 2 checksum error  3 CFM empty 5 unknown PC board type 8 invalid identifier (identifier UST1 to UST2) Check Che ck cable cable harn harness ess.. Change Change con config fig mem memory ory on on power power sourc source e cable cable harness.

Err | 31.x (code no.31) Cause: Reme Re medy dy::

EEProm save error   Upda Up date te sof softw twar are. e. Cha Chang nge e UST2 UST2 PC PC boar board. d.

Err | 70.x (code no.70) Caus Ca use: e:

Remedy:

Erro Er rorr wit with h the the di digi gita tall gas gas co cont ntro roll opt optio ion, n, x sta stand nds s for for:: 1 no sensor found 2 no protective gas shield 3 alignment error  4 protective gas shield solenoid valve break or short circuit 5 no protective gas shield solenoid valve found For ca cause x 1 check cable harness, change protective gas shield sensor  2 check shielding gas supply (min. 2 bar) 3 no or insufficient protective protective gas shield, change protective gas shield solenoid valve 4 change protective gas shield solenoid valve, change protective gas shield sensor  5 check cable harness, change protective gas shield solenoid valve

Err | 71.x (code no.71) Cause:

Reme Re medy dy::

Limit error, x stands for: 1 exceed of upper current limit 2 exceed of lower current limit 3 exceed of upper voltage limit 4 exceed of lower voltage limit Chec Ch eck k appli applica cati tion on.. Chec Check k param paramet eter ers. s.

hot | H2O (code no.65) Cause:: Cause Remedy: Reme dy:

In con conjun juncti ction on wit with h the thermo rmosta statt opti option: on: Ove Overte rtempe mperat rature ure in coo coolin ling g syst system em Allow cool cooling ing unit unit to to cool cool down. down. Open cooli cooling ng unit unit and clean heat excha exchannger. Check whether fan is functioning properly.

no | Arc (code no.58) Cause: Caus e: Remedy: Rem edy:

Arc Ar c is is bro broke ken, n, ar arcc-br brea eak k mon monit itor or ha has s tri tripp pped ed Check weldi Check welding ng para paramete meters. rs. Reig Reignite nite arc. Chec Check k ground grounding ing (ear (earthin thing) g) connection.

no | GAS (code no.57) Cause: Cau se: Reme Re medy dy::

In con conjun juncti ction on wit with h the the dig digita itall gas gas con contro troll opti option: on: no pro protec tectiv tive e gas gas shi shield eld available Chec Ch eck k shi shiel eldi ding ng ga gas s sup suppl plyy

Table of service codes (continued)

no | H2O (code no.39) Cause: Caus e: Remedy: Reme dy:

Flow wa Flow watc tchd hdog og re repo port rtin ing g wa wate terr def defic icie ienc ncyy Check Chec k coolin cooling g system system hose lines lines.. Check Check pump pres pressure sure and flow rate rate.. Check flow watchdog.

no | Ign (code no.55) Cause: Cau se: Remedy: Rem edy:

“Ignition “Ignit ion tim time-o e-out” ut” err error: or: No ign igniti ition on with within in the the valu value e set set in the set set-up -up men menu. u. The safety cut-out has tripped. Clean Clea n workp workpiece iece surf surface. ace. Che Check ck param parameter eters s in setset-up up menu menu.. Check Check grounding (earthing) connection.

no | Prg (code no.1) Cause: Rem eme edy:

No saved program selected Sele Se lect ct sav aved ed pro rog gra ram m

off (code no.150) Cause: Cau se: Remedy: Reme dy:

No com commun munica icatio tion n betw betwee een n the the Lo Local calNet Net pa parti rticip cipan ants ts (e. (e.g. g. po power wer sou source rce,,  wire feed unit, remote remot e control or welding torch) tor ch) Check Chec k Local LocalNet Net cabl cables. es. Chan Change ge remo remote te contr control/w ol/weldi elding ng torch torch.. Wait Wait for  for  software update to finish.

-Stop- (code no.38) Cause: Remedy: Reme dy:

Robot not ready When using a robot robot inte interfac rface e or or field field bus bus coupl coupler, er, init initialis ialise e the the “Robot “Robot ready” and “Source error reset” signals.

tJo | xxx (code no.66) Cause: Remedy Rem edy::

JobMaster ov overtemperature Allow All ow devi device ce to to cool cool down down.. Chec Check k cooli cooling ng syst system em..

tp1 | xxx (code no.5), tp2 | xxx (code no.6), tp3 | xxx (code no.7), tp4 no.7), tp4 | xxx (code no.8), tp5 | xxx (code no.9) Cause: Cau se:

Remedy Rem edy::

Overtempe Overte mperat rature ure in pow power er sou source rce pri primar maryy circ circuit uit (XX (XXX X stan stands ds for tem temper peraature indicator) - Example: tp1 - overtemperature on primary power module, tp2 - overtemperat overtemperature ure on primary power module PFC (power factor control) Allow All ow the the powe powerr source source to to cool cool down. down. Che Check ck that that fan fan is run runnin ning. g.

tp6 | xxx (code no.10) Cause: Cau se: Remedy Rem edy::

Overtemp Overte mpera eratu ture re in pow power er sou source rce pri prima mary ry cir circui cuit, t, tem temper peratu ature re sen sensor sor on BPS PC board has tripped (XXX stands for temperature indicator) Allow All ow the the powe powerr source source to to cool cool down. down. Chec Check k that that fan fan is runn running ing..

tp7 | Hot Cause: Remedy Rem edy::

Duty cycle exceeded Allow All ow the the powe powerr source source to to cool cool down. down. Chec Check k that that fan fan is runn running ing..

ts1 | xxx (code no.2), no.2), tS2 | xxx (code no.3), no.3), tS3 | xxx (code no.4) Cause: Cau se:

Remedy Rem edy::

Overtempe Overte mperat rature ure in pow power er sou source rce sec second ondary ary cir circui cuitt (XXX (XXX sta stands nds for te tempe mpe-rature indicator) - Examples: ts1 - overtemperature at secondary rectifier, ts2 - overtemperat overtemperature ure at the auxiliary voltage source, tst - overtemperat overtemperature ure at UST PC board Allow All ow the the powe powerr source source to to cool cool down. down. Che Check ck that that fan fan is run runnin ning. g.

Table of service codes (continued)

tSt | xxx (code no.33) Cause:: Cause Remed Re medy: y:

Overtemp Overte mpera eratu ture re in in cont control rol cir circui cuit, t, xxx xxx sta stands nds for th the e tempe temperat rature ure ind indica icator  tor  Allow All ow the po power wer sou source rce to coo cooll down. down. Ch Check eck fan fan..

US | POL (code no.37) Caus Ca use: e: Remed Re medy: y:

Special indications used with service codes

Measur Meas urin ing g de devi vice ce fo forr sec secon onda dary ry vo volt ltag age e (U (Usec) incorrectly connected, or  defective for some other reason Check Ch eck cab cable le har harne ness. ss. Ch Chang ange e UST2 UST2 PC bo board ard..

The following service codes are special indications for software problems: -

And | Opc Prt | Flt Ill | Opa Ill | Ina Ill | Bus Err | 105

-

ST K | O V L ST K | U VL Err | Dog AS S | E r t Ed g | 1

If the service codes shown above appear, more detailed information can be requested at the power source control panel. Using the parameter selection buttons (left/right arrows), you can switch between the following display levels: Leve Le vell 1 (e. (e.g. g. „An „And d | Opc Opc“) “):: serv servic ice e code code dis displ play ay (appears automatica automatically) lly) Leve Le vell 2 (e (e.g .g.. “CS “CS 01 01”): ”): se segm gmen entt dis displ play ay (press parameter selection button once) Leve Le vell 3 (e.g (e.g.. “IP “IP 3456 3456”) ”):: inst instru ruct ctio ion n poin pointe ter  r  (press parameter selection button again) Important! Please make a note of the indications in levels 1, 2, and 3, and pass them on Important! Please to Fronius. Using this data, Fronius can locate the precise cause of the error.

Detailed description General remarks

This section contains a detailed description of the electronic modules with regard to the following points: Gene Ge nera rall (des (desig igna nati tion on,, item item num numbe ber) r) Posi Po siti tion on of th the e mod modul ule e in in the the de devi vice ce Overview   Technical data Function overview   Pin assignment LED checklist Measuring points

Overview

„Detailed description“ is composed of the following sections: ASU 2500 PC board BPS 3000/MV PC board BSV 3000 PC board FKC 2500 PC board FKR 2500 PC board FMW 2500/3000 PC PC bo board HFF 22 PC board NT 2500 PC board NT 60 PC board RP 3000 PC board SNT 3 PC board UST US T PC PC boa board rd - con contr trol ol an and d reg regul ulat atio ion n uni unitt Line filter   Primary rectifier   Secondary po power mo module Shunt Tem emp pera rattur ure e sen senso sorr AD AD59 592 2

ASU 2500 PC board General remarks

The ASU 2500 PC board (item number 4,071,075,Z) supplies the KD Supply 2500

Overview LED LE D +5V +5V OK LE LED D +12 +12V V OK OK

LED 230V OK

LED 400V OK

LED high charging relay active

(X3) Fig. Fi g. 2

Function overview

(X2)

(X1)

ASU 25 2500 00 PC bo board  ard 

The ASU 2500 PC board supplies the NT60 power supply in the KD Supply 2500 and performs the following tasks: 5 V an and d 12 12 V po powe werr sup suppl plyy for for th the e boa board rd Generatio Gene ration n of inte intermed rmediate iate circu circuit it volta voltage ge from from the powe powerr source source suppl supplyy voltag voltage e for  for  supplying the NT 60 power supply Glas Gl ass s tub tube e fus fuse e on on inp input ut si side de 10 A/ A/50 500 0 V  Automati Auto matic c voltag voltage e switchin switching g using using relay relay enab enables les opera operation tion in all all voltag voltage e ranges ranges (200 - 560V)

Pin assignment

LED checklist

Plug

Function

X1 .... ........ ...... Pin 1 Pin 3 Pin 5 Pin 7

Mains Main s voltage voltage supply to FK 2500 2500 PE 0 V AC/L1 PE NC

Pin 2 Pin 4 Pin 6 Pin 8

NC NC NC 400V AC/L2

X2 ......... Mains voltage voltage supply supply to power supply Pin 1 PE Pin 2 Pin 3 0 V AC/L1 Pin 4 Pin 5 PE Pin 6 Pin 7 NC Pin 8

NC NC NC 400V AC/L2

X3 .... ........ ...... Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13 Pin 15

NC NC NC NC NC NC NC NC

Supply to NT 60 Supply ZWK1+ ZWK1ZWK2+ ZWK2ZWK1+ ZWK1ZWK2+ ZWK2-

LED +12V +12V ....... LED +5V ......... LED 230V 230V ..... ....... .. LED 400V 400V ..... ....... .. LED Hochl Hochl .... ...... ..

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14 Pin 16

Control voltage voltage 12 V OK (must always always be lit) lit) Control voltage voltage 5 V OK (must always always be lit) lit) Supply Supp ly voltage voltage is 230 230 V  Supply Supp ly voltage voltage is 400 400 V  High charging charging connec connection tion active active

BPS 3000/MV PC board General remarks

BPS 3000/MV (item no. 4,071,63/64,Z) is the power module board for the power source. Important! The primary voltage is on the power module board.

Overview LED +17V 

Power supply plug

(X9)

(X4) (X8)

(X6)

(X1) LED PFC (X10) LED HLSX LED HS (X3)

(X2)

(X5)

(X7)

Plug to RP 3000 PC board and cooling circuit supply

Fig. Fi g. 3 BPS 30 3000 00/MV /MV PC boa board  rd 

LED +5V  Power module Control plug to UST2C PC board

Technical data

Input voltage of BPS 3000

380 - 480 V AC (3-phase)

Input voltage tolerance of BPS 3000

(+/-15%)

Input voltage of BPS 3000 MV

200 - 480 V AC (1- and 3-phase)

Input voltage tolerance of BPS 3000 MV

(+/-10%)

Supply voltage from NT 2500

15 V DC primary

Transistor module switching frequency

70 kHz

Intermediate circuit voltage

Function overview

-

Pin assignment

720 V DC

Inputs Input s and outp output uts s are elec electri trical cally ly isola isolated ted usin using g optica opticall couple couplers rs Monitori Mon itoring ng of both inte intermed rmediate iate circu circuits its for imbala imbalance: nce: a signal signal is is transmi transmitted tted to the the UST board if there is any deviation from a permitted range PFC boos boostt convert converter er for for steppin stepping g up the inte intermed rmediate iate circu circuit it volta voltage ge to to 720 720 VDC VDC Contr Co ntroll olling ing the the trans transist istor or modul module e via driv driver er stage stages s from from the UST UST boar board d Activatio Acti vation n of boos boostt conver converter ter only once the high char charging ging time is compl completed eted Quick Quic k shutdo shutdown wn of of power power modul module e in the event event of a modu module le fault fault due to perman permanent ent primary current measurement Contr Co ntroll olling ing the the trans transist istor or modul module e via driv driver er stage stages s from from the UST UST PC PC board board High charg charging ing conn connectio ection n via resis resistors, tors, the time for bridg bridging ing the the resisto resistors rs by mean means s of relays is specified by the UST board Quick Quic k shutdo shutdown wn of of power power modul module e in the event event of a modu module le fault fault due to perman permanent ent primary current measurement The powe powerr full full bridge bridge break breaks s down down the the rectifi rectified ed interm intermedia ediate te circuit circuit volt voltage age into a 40 kHz signal. The bridge circuit is controlled via driver stages from the UST board.

Plug

Function

X1 ......... Ribbon cable cable from UST (power (power module control) control) Further information on pin assignments can be found in the chapter entitled „Detailed description“ - „UST“. X2/11 X2/1 1 .... Prim Primary ary recti rectifier fier + X3 .... ........ ...... Prim Primary ary transforme transformer  r  X4 .... ........ ...... Prim Primary ary transforme transformer  r  X5/6 X5/ 6 ... ...... ... PFC choke choke X7 ......... Connection to RP RP 3000 PC board board Pin 1 L1 Pin 3 L2 Pin 5 L3 Pin 7 Rel+ Pin 9 NC Pin 11 NC Pin 13 NC

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14

NC NC NC L1 cooling unit L2 cooling unit L3 Rel-

X8 ......... Earthing (screw connection connection on the PC board) X9 .... ........ ...... Pin 1 Pin 3 Pin 5 Pin 7 Pin 9

Connection Connecti on to NT 2500 2500 U ZWK   NC GND primary NC +17V  

X10/12 X10/ 12 .. Prima Primary ry rectif rectifier ier -

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10

NC GND primary U ZWK   NC GND primary

LED checklist

LEDs for supply voltages (green) LED +17V +17V ....... light up when power power supply is functioning functioning correctly LED +5V ......... light up when when power supply on UST PC board board is functioning functioning correctly Signal LEDs (red) LED PFC ........ lights up or flashes with varying degrees degrees of brightness brightness depending on power drawn from the power source (the brighter the LED the higher the power) HLSX LED ...... lights up when the high charging charging relays are activated activated HS LED .......... lights up when mains mains switch is in - l - position position

Measuring points

Measurement on each of the diode regions depicted below must produce a result of  0.34 V.

Fig.. 4 Fig

Measuri Mea suring ng points points on BPS BPS 3000/MV 3000/MV PC PC board  board 

Measuring points

Plug/pin

Measuring result set value

Intermediate circuit voltage

X9/1 - X9/4

720 V DC

17 V primary

X9/9 - X9/10

17 V DC

BSV 3000 PC board voltage doubler  General remarks

The BSV 3000 (item number 4,071,071,Z) is an additional PC board for TransTig 2500/ 3000 and is used for raising the output voltage

Overview (X1)

(X2)

(X4)

(X3)

(X9)

(X11)

Fig. Fi g. 5

BSV BS V 30 3000  00 

Function overview

The BSV 3000 PC board raises the open circuit voltage for optimised ignition properties during MMA and TIG welding.

Pin assignment

Plug

Function

X1 .... ....... ..... .. AC from transfor transformer  mer  X2 .... ....... ..... .. AC from transfor transformer  mer  X3 .... ........ ...... Weld Welding ing voltage voltage X4 .. ..... ...... ..... GND X9 .... ....... ..... .. AC from transfor transformer  mer  Pin 1 Welding voltage X11 .... ....... ... PE (earthin (earthing g screws) screws)

Pin 2

GND

FKC 2500 PC board General remarks

FKC 2500 (item number 4,071,073,Z) is the interface board for the MV variants of the FK  2500 cooling unit.

Overview LED +10V  LED +5V  (X5)

(X6) LED +5V_L1 LED PIC_OK

(X9)

(X7)

(X2)

(X1) Fig. Fi g. 6

Function overview

(X3) (X4)

FKC FK C 250 2500 0 PC PC boar board  d 

The FKC 2500 PC board performs the following functions: Electr Ele ctrica ically lly iso isolat lated ed con contro troll of of the the coo coolan lantt pump pump Allows Allow s the the combinin combining g of cool coolant ant pump, pump, main mains s voltag voltage, e, UST UST,, flow flow sensor sensor and two fans Automati Auto matic c switchi switching ng of of the the mains mains volta voltage ge using using powe powerr transist transistors, ors, no manua manuall switswitching required

Pin assignment

Plug

Function

X1 .... ........ ...... 400 V AC supp supply ly Pin 1 L1 (400 V) Pin 3 NC

Pin 2 Pin 4

NC L2 (400 V)

X2 .... ....... ..... .. Pin 1 Pin 3 Pin 5 Pin 7

Pin 2 Pin 4 Pin 6 Pin 8

Water control Cooler on NC 24 V  

X3 .. .... ..... ..... .. Fan Pin 1 Cooler on

Pin 2

24 V  

X4 .. .... ..... ..... .. Fan Pin 1 Cooler on

Pin 2

24 V  

Control from Control from UST UST NC GND secondary NC NC

X5 .... ........ ...... L2 Pump Pump motor  motor  X6 .... ........ ...... L1 Pump Pump motor  motor 

LED checklist

X7 .... ........ ...... Pin 1 Pin 3 Pin 5

Flow sens sensor  or  GND secondary NC NC

Pin 2 Pin 4 Pin 6

Water control 24 V   NC

X9 .... ....... ..... .. Pin 1 Pin 3 Pin 5 Pin 7 Pin 9

Auto-transf Auto-tra nsforme ormer  r  230 V   L2 200 V   480 V   440 V  

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10

NC NC NC NC 400 V  

LEDs for supply voltages (green) LED +10V ....... for the switched switched mode power supply supply,, must be on all the time LED +5V ......... for the PIC (microcontroller) (microcontroller) supply supply,, must be on all the time LED PIC_OK PIC_OK .. flash flashes es when when the PIC is is working working LED +5V_L1 +5V_L1 ... for the PIC supply supply,, must be on all the time

FKR 2500 PC board General remarks

FKR 2500 (item number 4,071,074,Z) is the interface board for the standard variants of  the FK 2500 cooling unit.

Overview

(X2)

(X4)

(X3)

(X7)

(X1) (X5)

Fig. Fi g. 7

FKR FK R 25 2500  00 

Function overview

The FKR 2500 PC board performs the following functions: Electrically isolated control of the coolant pump Electr Ele ctrica ically lly iso isolat lated ed con contro troll of of the the coo coolan lantt pump pump Allows Allow s the comb combinin ining g of cool coolant ant pump, pump, main mains s voltag voltage, e, UST UST,, flow flow sensor sensor and and two two fans

Pin assignment

Plug

Function

X1 .... ........ ...... 400 V AC supp supply ly Pin 1 L1 (400 V) Pin 3 NC

Pin 2 Pin 4

NC L2 (400 V)

X2 .... ....... ..... .. Pin 1 Pin 3 Pin 5 Pin 7

Pin 2 Pin 4 Pin 6 Pin 8

Water control Cooler on NC 24 V  

X3 .. .... ..... ..... .. Fan Pin 1 Cooler on

Pin 2

24 V  

X4 .. .... ..... ..... .. Fan Pin 1 Cooler on

Pin 2

24 V  

Pin 2 Pin 4 Pin 6

Water control 24 V   NC

Control from Control from UST UST NC GND secondary NC NC

X5 .... ........ ...... L2 Pump Pump motor  motor  X6 .... ........ ...... L1 Pump Pump motor  motor  X7 .... ........ ...... Pin 1 Pin 3 Pin 5

Flow sens sensor  or  GND secondary NC NC

FMW 2500/3000 PC board General remarks

On the MagicWave 2500/3000 power sources, the FMW 2500/3000 PC board (item no. 4,071,065/66,Z) 4,071,065/6 6,Z) is used to control the inverter transistors and the auxiliary voltage source, as well as to measure the open circuit voltage.

Overview (X1)

(X2)

(X3)

(X4)

(X5)

(X6)

(X10) (X9)

(X7)

Fig. Fi g. 8

FMW FM W 25 2500  00 

(X8)

Function overview

On the MagicWave 4000/5000 power sources, the FMW 2500/3000 PC board is used for the AC output voltage and performs the following tasks: Generatin Gene rating g a DC volt voltage age of 300V 300V for charg charging ing the elect electrolyt rolyte e capaci capacitors tors in the the secondary intermediate circuit The elec electroly trolyte te capa capacitor citors s on the FMW 300 boar board d are are used used to store store exce excess ss energ energyy from the welding circuit during AC welding. In order to keep the electrolyte capacitors free from AC voltage, which is connected shortly before zero-crossing during  AC welding, the electrolyte elect rolyte capacitors capacit ors receive a charge char ge of approx. 300 V. V. Limiti Lim iting ng the the seco second ndary ary inte interme rmedia diate te circu circuit it to to a maxim maximum um of of 400 400 V  Cont Co ntro roll llin ing g th the e in inve vert rter er tr tran ansi sist stor ors s Power Pow er suppl supplyy for gene generat rating ing the the 5 V and and 18 V volt voltage ages s requir required ed by the the PC boar board d Generatin Gene rating g an auxi auxiliary liary volt voltage, age, in order order to allow allow ignit ignition ion aft after er zero-cro zero-crossing ssing durin during g  AC welding. The auxiliary auxili ary voltage passes through an additional addit ional winding on the  welding transformer transf ormer in the welding circuit. circ uit. Measuring Meas uring the open circu circuit it volta voltage: ge: If there there is no volt voltage age on pins pins X6/1 X6/1 and X6/4 X6/4,, the the DC voltage is increased to 113 V. The device is then shut down and the “Err | 068” service code appears.

Pin assignment

Plug

Function

X2 .... ........ ...... Pin 1 Pin 3 Pin 5 Pin 7 Pin 9 Pin 11 Pin 13

Connection Connecti on to UST 24 V   NC SC L NC HQ-ON NC Temp5+

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10 Pin 12 Pin 14

X3 ........ .......... Common (centre-ta (centre-tap) p) transform transformer  er  Pin 1 Common Pin 2

Polarity Error   Temp5GND NC SDA   NC Common

X4 ......... Auxiliary voltage source transformer winding Pin 1 IN1.1 Pin 2 IN1.2 Pin 3 IN1.2 Pin 4 IN1.2 X5 ......... Auxiliary voltage source transformer winding Pin 2 IN2.2 Pin 1 IN2.1 Pin 4 IN2.2 Pin 3 IN2.2 X6... Voltage measurement Pin 1 VOWI1.1 (U-act +) +) Pin 3 NC Pin 5 VOWI1.2 (U-act +) +) Pin 7 NC X7 ......... Cable to copper copper busbar busbar (top (top left) left) X8 .... ........ ...... Cabl Cable e to middle copper copper plate X9 ......... Cable to copper copper plate (outside right) X10 .... ....... ... Cabl Cable e to middle copper copper plate plate

Pin 2 Pin 4 Pin 6 Pin 8

NC VOWI2.1 (U-act -) NC VOWI2.2 (U-act -)

LED checklist

LED 24V  LED 18V  LED 5V  Err 

LED Help

LED pos LED neg

LED PosHelp LED NegHelp

Fig.. 9 LED indi Fig indicato cators rs on on FMW FMW 2500  2500 

LEDs for supply voltages (green) LED 24V ......... control voltage, voltage, must must be on all the time time LED 18V ......... IGBT voltage supply supply,, electrically isolated, isolated, must be on all the time time LED 5V .......... ............ for the processor processor voltage supply supply,, must be on all the time Error ........... ............... .... lights up if overvoltage overvoltage - 18 18 V supply for for IGBTs IGBTs and power module module are shut off immediately LED pos ......... lights up if transistors transistors for positive positive welding current are being actuated actuated LED neg ......... lights up if transistors for for negative welding welding current are are being actuated actuated LED pos and LED neg light up alternately if AC is present and with increasing brightness as frequency increases. LED PosHelp.. auxiliary voltage, voltage, must be on on all the time - lights up at positive positive zero crossing peak LED NegHelp NegHelp . auxiliary voltage, voltage, must be on all all the time - lights up at negative negative zero crossing peak LED PosHelp and LED NegHelp light up alternately if AC is present and with increasing brightness as frequency increases.

HFF 22 PC board General remarks

HFF 22 (item number 4,070,812,Z) is used for high frequency ignition in the MW 2500 and MW 3000 power sources and is also a filter assignment for remote controls and torch triggers.

Overview

HF module

Filter module

Fig.. 10 HFF 22 Fig

Technical data

Supply voltage Output voltage

Function overview

+ 24 VDC (+/  20 %) 1000 VDC  

The HFF 22 PC board includes the following components:

(1) HF module From the +24 V supply (24 V LED green), the HF module generates a +15 V supply (+15  V LED green) for the internal inter nal control module. module . A flyback converter conver ter charging circuit ci rcuit charges the impulse capacitor from +24 V to 1000 V. Immediately after charging the ignition thyristor is activated and the impulse capacitor discharges the HF launch coil via the primary coil. The HF launch coil transforms the charging voltage of the impulse capacitor  from 1000 V to approx. 10 kV. Each charging process of the impulse capacitor is indicated by the SIG LED (red) lighting up.

(2) Filter module The filter module comprises two 6-pin, current-compensated filter chokes (one choke each for remote control and torch trigger). The filter chokes eliminate high-frequency impulses on the data lines caused by parasitic capacities. A circuit layout of capacitors and Transil arrays (protective diodes) is used for discharging overvoltage of the data lines.

Pin assignment (X3)

(X1)

(X2)

(X5)

(X4)

(X6)

(X7)

Fig. 11 11 Pin assignment assignment on HFF HFF 22 PC board  board 

Pin assignment (continued)

X1 ...... HF pulse positive pole (blade (blade terminal connection connection to primary voltage voltage of the HF launch coil) X2 ...... HF pulse negative pole pole (blade terminal connection connection to primary voltage of the HF HF launch coil)

X3 ...... High frequency frequency control control cables (connection to UST) Pin

Designation

1

NC

2

+ 24 V

 

Pin

Designation

3

SIGNAL

4

GND

X4 ...... Torch trigger cables (connection (connection to UST) Pin

Designation

Pin

Designation

1

NC

6

NC

2

DOWN

7

NC

3

CRATERFILL

8

IDENTIF

4

UP

9

GND

5

MAIN CURR

10

NC

X5 ...... Torch trigger cables cables (connection (connection to welding torch) Pin

Designation

Pin

Designation

1

NC

6

NC

2

DOWN

7

NC

3

CRATERFILL

8

IDENTIF

4

UP

9

GND

5

MAIN CURR

10

NC

X6 ...... Remote control control cables (connection to remote control) control) Pin

Designation

Pin

Designation

1

+24 V-EXT

4

GND 485

2

RXDL 485

5

TXDL 485

3

RXDH 485

6

TXDH 485

X7 ...... Remote control cables cables (connection (connection to UST) Pin

Designation

Pin

Designation

1

+24 V-EXT

4

GND 485

2

TXDL 485

5

RXDL 485

3

TXDH 485

6

RXDH 485

NT 2500 PC board General remarks

The NT 2500 switched mode power supply is used to supply internal and external components

Technical data

Input voltage

max. 800 V DC from the intermediate circuit

Output voltages

Fuse protection by PTC 24 V internal 24 V external 15 V primary

Function overview

-

24 V internal 24 V external 17 V primary 4.2 A 2A 0 .2 5 A

Internal Inter nal and ext extern ernal al com compo ponen nents ts sup suppli plied ed wit with h 24 24 V  Powe Po werr mod modul ule e sup suppl plie ied d wit with h 17 17 V pr prim imar aryy WARNING!  An electric shock can be fatal. 17 V configured in primary. Do not WARNING! An use for supplying other components components..

-

Supply vol Supply voltag tages es are are elec electri trical cally ly isol isolate ated d and and prote protecte cted d by PTC Electrical Elect rically ly isolat isolated ed measu measureme rement nt of inte intermed rmediate iate circu circuit it voltag voltage, e, evalua evaluation tion on UST UST PC board

     

Overview  X1 LED 24 V  internal LED 24 V  external

Supply LED

 X2

LED 17 V 

Fig. 12 Pin assignment assignment on HFF HFF 22 PC board  board 

Pin assignment

LED checklist

Plug

Function

X1 Pin 1 Pin 3 Pin 5 Pin 7

24 V external UZW GND EXT GND

Pin 2 Pin 4 Pin 6 Pin 8

NC 24 V internal NC GND INT

X2 Pin 1 Pin 3 Pin 5 Pin 7 Pin 9

+ UZWK   NC GNDP NC 17 V primary

Pin 2 Pin 4 Pin 6 Pin 8 Pin 10

NC GNDP UZWK   NC GNDP

Supply LED LED ............. ............... .. lights up if no error is present and the power power supply is being fed by the intermediate circuit .................... .......... .................... .............. .... flashes or does not light up if the power supply is defective LED 24V external external ...... ......lights lights up if the 24 V external external voltage is present LED 24V internal internal ....... .......lights lights up if the 24 V internal internal voltage is present LED 17V primary ....... .......lights lights up if the 17 V primary voltage voltage is present Important! The 24 V internal/external and 17 V primary LEDs go out or become dimmer  Important! The if there is a short circuit.

NT 60 General remarks

The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feed unit motor. Important! The primary voltage is on the NT 60 switched mode power supply.

Overview

Primary voltage

Secondary voltage

Intermediate circuit 2 supply LED  X1

 X2

Intermediate circuit 1 supply LED

„Error“ LED (PTC active)

Supply LED 55 V 

Fig. Fi g. 13 NT 60  60 

Technical data

Supply voltage from intermediate circuit Output voltage

Function overview

-

Open circuit at a load of 4 A

2 x 230 - 380 V DC 5 9 ( + /- 2 ) V   5 5 ( + /- 2 ) V  

Output Outp ut voltag voltage e is elec electrica trically lly isola isolated ted and prot protecte ected d by 2 parall parallel el connec connected ted PTC resistors. The 1 V/A V/A falling falling outp output ut chara characteri cteristic stic of the the NT NT 60 circu circuit it enabl enables es severa severall NT 60 power supplies to be connected in parallel. If there there is is a short short circu circuit, it, the the NT NT 60 rest restrict ricts s to max. 15 A, using using the the intern internal al current current 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 light up. As soon as the PTC resistors trip, the „Error“ LED flashes.

Pin assignment

(X2)

(X1)

Fig. 14 Plug on NT NT 60 power power supply 

Plug

Function

X1 ......... Connection to wire-feed wire-feed unit (secondary (secondary voltage) voltage) Pin 1 + 55 V   Pin 2 + 55 V   X2 ......... Primary connection connection intermediate intermediate circuits 1 and 2 Pin 1 Intermediate ci circuit 1+ 1+ Pin 9 Interm rme ediate ci circuit Pin 2 NC Pin 10 NC Pin 3 Intermediate ci circuit 1 Pin Pi n 11 11 In Inte term rmed edia iate te ci circ rcui uitt Pin 4 NC Pin 12 NC Pin 5 Intermediate ci circuit 2+ 2+ Pin Pi n 13 13 In Inte term rmed edia iate te ci circ rcui uitt Pin 6 NC Pin 14 NC Pin Pi n7 Inte In term rme edi dia ate ci circ rcu uit 2- GN GND P Pin Pi n 15 In Inte term rmed edia iate te ci circ rcui uitt Pin 8 +15 V primary Pin 16 +15 V primary

1+ 1+ 12+ 2+ 2- GND 2GND P

LED checklist

Intermediate circuit 2 supply LED „Error“ LED (PTC highly resistant) 55 V supply LED Intermediate circuit 1 supply LED Fig. 15 LED indicators indicators on power power supply NT 60 

Measuring points

 X2

Fig. 16 Plug X1 and X2 X2 on power supply supply NT 60 

 X1

Measuring points (continued)

Measuring points

Plug/pin

Measuring result set value

Intermediate circuit voltage 1 X2/1 - X2/3 X2/9 - X2/11

approx. 280 V DC at 400 V AC approx. 320 V DC at 230 V AC

Intermediate circuit voltage 2 X2/5 - X2/7 X2/13 - X2/15

approx. 280 V DC at 400 V AC approx. 320 V DC at 230 V AC

55 V circuit

approx. 57-61 V DC in open-

X1/1 - X1/3 X1/2 - X1/4

RP 3000 PC board General remarks

The RP 3000 PC board (item no. 4,071,068) is used to charge the intermediate circuit capacitors.

Overview (X6)

(X5) (X7) (X4)

(X3)

(X2)

(X1)

Fig.17 RP 3000 

Function overview

-

-

PTC resi resisto stors rs for for limiti limiting ng the the sta starti rting ng curr curren entt of the the powe powerr source source PTC resist resistors ors are are bridge bridged d by the relay relays s after after a pred predeter etermine mined d period period of time time and after having reached a predefined intermediate circuit voltage (controlled by the UST via the BPS 3000) Limiting Limit ing of of the the startin starting g current current occu occurs rs at and above above an input input volt voltage age of appro approx. x. 240 240  VDC Unde Un derv rvol olta tage ge sh shut ut-o -off ff at ap appr prox ox.. 165 165 V 

Pin assignment

Plug

Function

X1 .... ........ ...... L1 from from line filter  filter  X2 .... ........ ...... L1 to recti rectifier  fier  X3 .... ........ ...... L2 from from line filter  filter  X4 .... ........ ...... L2 to recti rectifier  fier  X5 .... ........ ...... L3 from from line filter  filter  X6 .... ........ ...... L3 to recti rectifier  fier  X7 .... ........ ...... Pin1 Pin3 Pin5 Pin7 Pin9 Pin11 Pin13

Measuring points

Connecting Connecti ng leads to BPS 3000 3000 L1 L2 L3 Rel+ NC NC NC

Pin2 Pin4 Pin6 Pin8 Pin10 Pin12 Pin14

NC NC NC NC NC L3 Rel-

Measuring points

Plug/pin

Measuring result set value

PTC resistor parallel)

X 1 - X2

approx. 75 Ohm (2 PTCs in

X3 - X 4 X5 - X 6

at approx. 20 °C Short circuit - relay sticks Remedy: Change PC board

SNT 3 PC board General remarks

The SNT 3 PC board (item no. 4,070,730) is an active LocalNet distributor for digital power sources and peripheral devices.

Overview

X11_1 X11_2 X11_3 X10 X7

X6_1 LED 1 X6_2 LED 2 X6_3 LED 3

Fig.18 SNT 3

Function overview

SNT 3 is used to automatically connect and disconnect the LocalNet nodes in line with the Hot Plug and Play principle.

Pin assignment

Plug

Function

X6_1 .... ...... Loca LocalNet lNet plug 1 X6_2 .... ...... Loca LocalNet lNet plug 2 X6_3 .... ...... Loca LocalNet lNet plug 3 X7 .... ........ ...... Loca LocalNet lNet in X10 .... ....... ... 55 V DC input input X11_1 X11 _1 ... 55 V DC DC X11_2 X11 _2 ... 55 V DC DC X11_3 X11 _3 ... 55 V DC DC

LED checklist

LED 1 ........... ..................... ............. ... flashes when a node is connected connected to LocalNet LocalNet plug 1 and the connection is OK  LED 2 ........... ..................... ............. ... flashes when a node node is connected to LocalNet LocalNet plug 2 and the connection is OK  LED 3 ........... ..................... ............. ... flashes when a node node is connected to LocalNet LocalNet plug 3 and the connection is OK 

UST PC board General remarks

The UST PC board (item number 4,070,860,Z) is a universal control, regulation and monitoring unit for fully digitised Fronius power sources.

Function overview

The UST PC board performs the following functions: (1) Power module control The control of the power module is performed by the UST via plug X6; the driver circuits are on the t he UST. (2) Control of control panel The UST controls the control panel via a 10-pin ribbon cable (X2). The control is handled via a databus connection (LocalNet). (LocalNet). (3) Mains switch switch evaluation evaluation The UST evaluates the incoming mains switch signal from the BPS PC board. If the intermediate circuit voltage reaches a certain level, the relays close after a specified time. The UST uses the mains switch signal to detect when the power source is switched off. The UST stores the current settings and activates the fans to discharge the intermediate intermediat e circuit. (4) Temperature evaluation The UST evaluates the signals from the temperature sensors and controls the fans. If  the temperature continues to rises and the fans cannot cool sufficiently (e.g. because the duty cycle is exceeded), the power source switches off and outputs an appropriate service code. (5) Contr Control ol of fan The UST controls the fan (X5) depending on temperature and firmware. (6) LocalNet interface The LocalNet interface is used to transmit data from the plug connection (X9) to the peripheral devices via the filter PC board (e.g. HFF22). (7) Regulation of welding current current and voltage The welding current and voltage is regulated by the DSP (digital signal processor) and the firmware integrated in the UST. (8) Control of inverter  The UST PC board controls the inverter module via the plug (X1).

Pin assignment

X1 ...... Inverter control (connection (connection to TTS TTS 22) X2 ...... Connecting lead to control control panel panel (10-pin ribbon ribbon cable) X3 .. ..... ..... Sup Supply ply Pi n

Designation

Pin

Designation

1

+24 V-EXT, +24 V remote control connection

5

GND-EXT, remote control connection GND

2

NC

6

NC

3

UZW, intermediate circuit voltage measuring

7

GND-UZW, in intermediate circuit voltage measuring

4

+24 V-INT, internal voltage supply

8

GND-INT, internal voltage supply

X4 .... ...... .. Temp emperat erature; ure; Uact, Iact Pin

Designation

Pin

Designation

1

Uist -

13

U IS T +

2

NC

14

NC

3

LEM C 4000, Shunt

15

LEM D 5000

4

LEM A 3000, Shunt

16

NC

5

LEM B 2000, Shunt

17

GNDD LEM

6

- 1 5 V L EM

18

+ 15 V LEM

7

TH - ERROR 1

19

TH - ERROR 2

8

GND A (UP 400)

20

UP 400

9

CFM -

21

CFM +

10

ES C 1

22

ESC 2

11

T E MP 2 -

23

T E MP 2 +

12

T E MP 1 -

24

T E MP 1 +

X5..... X5... .... Fa Fan n Pin

Designation

1

+ 24 V

 

2

FAN, fan power module

Pin

Designation

3

+ 24 V

 

4

FAN, fan control

X6 ...... Power source - connection to to power module module (BPS), 26-pin ribbon cable X7 ... ...... ... Coo Coolin ling g uni unitt Pin

Designation

Pin

Designation

1

Temp 6 +

6

T EM P 6 -

2

COOLER ON

7

+ 24 V

3

WAT. CONTR.

8

GND (WAT. CONTR.)

4

CFM +

9

CFM -

5

NC

10

 

GND (SUPPLY)

Pin assignment (continued)

X8 ...... Programming interface for for updating firmware via BSL tool NOTE! Risk of damage to electronic components. Switch off the power supply NOTE! Risk before connecting or removing BSL tools. X9 ...... RS485 connecting connecting lead to remote control control via a filter PC board board

Measuring points

See pin assignment

LED checklist

+24 V ext +24 V int + 5 V  +15 V  - 15 V 

STAT

+ 5V 

Fig. 19 Control LEDs on UST UST PC board  board 

+24 V ext ........... lights up when switched switched mode power power supply is working correctly correctly +24 V int + 5V .... ........ ....... ....... ...... RS 485 485 +15 V  - 15 V  + 5V  STA ST AT .... ........ ........ ...... .. St Status atus LED LED lights up if no firmware is present if it does not light up: process OK 

Changing UST PC board

NOTE! Options enabled via the „Service module“ software are stored on the NOTE! Options UST and must be re-enabled after changing the UST. Before changing the UST, the enabled options must be clarified with the customer - the enable codes must be supplied by the customer.

Line filter  General remarks

The 29 A line filter (item no. 43,0001,3320) is a part of the TransTig and MagicWave 2500/3000 power sources and is used to filter out parasitic frequencies that: are gene generat rated ed by the the power power sour source ce and and could could affec affectt other other consu consume merr loads loads come com e from from th the e grid grid an and d could could af affec fectt the the pow power er sou source rce

Overview X2

L1' L3'

X6

L2'

X4

PECONTR2 PECONTR1 X1 X3 X5

L1 L2 L3

Fig.. 20 Lin Fig Line e filter  filter 

Technical data

 Attenuation of parasitic parasit ic frequencies

Function overview

-

Pin assignment

> 60 Hz

Vari aristo stors rs provid provide e protect protection ion agai against nst mome moment ntary ary main mains s overvol overvolta tages ges Capacito Cap acitors rs and and coils coils form form an LC low-p low-pass ass filte filterr that that attenua attenuates tes the the paras parasitic itic frequ frequenencies over 60 Hz Capaci Cap acito tors rs diver divertt distur disturban bances ces to to earth earth and and also also betwe between en the the phase phases s Integrat Inte grated ed earth earth curre current nt watch watchdog: dog: used to prote protect ct the the weldin welding g machin machine e and and the the ininhouse installation from vagabond currents that are conducted via the earthing

Plug

Function

X1 .......... ................... ......... Mains voltage input L1 X2 ........... ................... ........ Mains voltage input L1' X3 .......... ................... ......... Mains voltage input L2 X4 ........... ................... ........ Mains voltage input L2' X5 .......... ................... ......... Mains voltage input L3 X6 ........... ................... ........ Mains voltage input L3' PECONTR1.... Earth current watchdog reed reed contact (normally closed) closed) PECONTR2.... Earth current watchdog reed reed contact (normally closed) closed)

Primary rectifier  General remarks

Three-phase bridge rectifier with item number 42,0001,0060

Overview

L1 (+)

L2

L3 (-)

Fig. 21 Primary rectifier rectifier TS 4000/5000, 4000/5000, TPS 3200/  3200/  4000/5000 

Function overview

The primary rectifier converts the input voltage (mains voltage) into a rectified voltage for  the intermediate circuit.

Pin assignment

Plug

Function

L1

Mains voltage input L1

L2

Mains voltage input L2

L3

Mains voltage input L3

( +)

Intermediate circuit voltage output +

(-)

Intermediate ci circuit vo voltage ou output -

Measurement on each of the diode regions must produce a result of 0.4 V.

Measuring points

Fig. 22 Measuring Measuring points on primary primary rectifier TS 4000/5000, TPS 3200/4000/5000 

Secondary power module General remarks

The secondary power module for the TransTig 2500/3000 and MagicWave 2500/3000 power sources contains the following components: - Tr TransT ansTig ig 2500: 2500: 2 diode diode modul modules es (item (item number number 41,00 41,0003,0 03,0203) 203) - Tr TransT ansTig ig 3000: 3000: 3 diode diode modul modules es (item (item number number 41,00 41,0003,0 03,0203) 203) - Magi MagicW cWave ave 2500: 2500: 4 diode diode modul modules es (item (item numbe numberr 41,0003, 41,0003,020 0203) 3) 6 transistor modules (item number 41,0003,0279) - Magi MagicW cWave ave 3000: 3000: 6 diode diode modul modules es (item (item number number 41,0 41,0003, 003,029 0291) 1) 10 transistor modules (item number 41,0003,0279) - Tr TransT ansTig ig 2500/30 2500/3000, 00, Magic MagicWa Wave ve 2500: 2500: 4 toroida toroidall tape tape cores cores - Mag MagicW icWave ave 3000: 3000: 10 toroida toroidall tape cores cores (item (item number number 41,001 41,0012,00 2,0030) 30) 2 HXP 200 1kOhm resistors (item number 43,0001,1274) - 1 ther thermoe moeleme lement nt (ite (item m numb number er 43, 43,0001 0001,06 ,0600) 00)

Overview

Fig. 23 Seconda Secondary ry power module module

Function overview

The diode modules form the secondary rectifier, which is executed as a centre-tap connection. The secondary rectifier generates DC from the AC of the welding transformer. An output choke smoothes the direct current. The diodes are protected from overvoltage by toroidal tape cores on the transformer leads. The transistors on the inverter  convert the DC of the secondary rectifier to AC, which is then sent to the welding sockets. The transistor module is controlled by the UST PC board via the FMW PC board.

LED checklist

This information is the same as the contents of the „LED checklist“ section of the „FMW 2500/3000 PC board“ section.

Measuring points

Measuring point

Measuring result set value

Diode regions (1)

0.15 V  

Diode regions (1)

0.15 V  

Diode regions (1) Diode regions (2)

0.15 V   0.4 V  

Diode regions (1) Diode regions (2) Resistance (3)

0.15 V   0.4 V   1.8 kOhm

(1)

(1)

(1) (1) (1) (1)

(1) Fig. 24 M ea eas ur urin g po in ints of Tran sT sTig 25 00 00

(1) Fig. 25 Meas ur uri ng ng p oi oint s of Tran sT sTig 30 00 00  

Measuring points (continued)

(1)

(1)

(1) (2)

(2)

(2)

(2)

(2)

(2)

(1)

(1)

Fig. 26 Measuri Measuring ng points of MagicWave MagicWave 2500  2500 

(1) (3)

(3)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(2)

(1)

(1)

(1)

(1)

(1)

(1) Fig. 27 Measuri Measuring ng points of MagicWave MagicWave 3000  3000 

Shunt General remarks

The shunt (item number 43,0001,1139) is a current sensor which permits the electrically isolated capture of the welding current.

Overview

Fig. Fi g. 28 Shu Shunt  nt 

Technical data

Supply voltage Nominal current

Function overview

+15 V /- 15 V 500 A

Output current at nominal current

250 mA  

Transformation ratio

1 : 2000

The shunt operates according to the compensatio compensation n principle, where a magnetically soft probe functions as a magnetic field detector. The shunt is characterised by the following features: -

Compact design Low offset current Low hysteresis Hig igh h te tempe pera ratu ture re st sta abi bili litty Integrated ele electronics

The shunt is supplied by a bipolar working voltage of +/- 15 V and provides an output signal which is proportional to the measured welding current. The output signal to welding current transmission ratio is 1:2000.

   

Function overview (continued)

Other functions: Electr Ele ctric ic isola isolatio tion n betwe between en pow power er circu circuit it and and elec electro tronic nic cir circui cuitt Nulll bala Nul balance nce and amp amplif lifica icatio tion n proce procedur dures es do not app apply ly Based Base d on the princ principle iple of compe compensat nsation ion of magne magnetic tic fields fields,, the curre current nt trans transduce ducers rs provide a measured current proportional to the primary current

Pin assignment

Plug

Function

X1 Pin 1 Pin 2

Molex plug from adapter cable +15 V   -15 V  

Pin 3 Pin 4

I Real GND

LED checklist

There are no LED indicators on the shunt.

Measuring points

The welding current can be captured indirectly by measuring the voltage. At a welding current of 100 A for instance, a voltage of 0.33 V must be measured on the UST PC board, plug X4, pins 5 and 17. Measuring points

Plug/pin

Measuring result set value

Welding current

X4/5 - X4/17

0.33 V at a welding current of 100 A  

NOTE! To prevent malfunctions, and to exclude the possibility of damage to NOTE! To other parts in the power source, use only the adapter cable supplied.

TP 592S temperature sensor  The TP 592S temperature sensor (item number 43,0001,0600) 43,0001,0600) is an electronic temperature sensor. It has an integrated temperature/current temperature /current converter chip. The chip is integrated into the plastic housing and has a plug-in Molex connection.

General remarks

Fig.29 Fig .29 TP 592S 592S temperat temperature ure sensor  sensor 

Technical data

Function overview

Supply voltage

4 - 30 V DC

Output current

1 µ A /K

-

The tempe temperatu rature re sensor sensor is fitted fitted to the the coolin cooling g element element and meas measures ures the elem element’ ent’s s temperature. The tempe temperatur rature e sensor sensor outp outputs uts a current current of exactly exactly 1 µA per K (Kelvin) (Kelvin),, provided provided that a voltage of 4 - 30 V DC is present. 0 K corresponds to a temperature of -273.15°C 0 °C corresponds to 273.15 K  273.15 K corresponds to 273.15 µA 

Pin assignment

Measuring points

Plug

Function

X1 Pin 1

2-pin Molex plug Temp. 1+

Pin 2

Temp. 1-

Measure the current flowing through the temperature sensor as follows: Remove Rem ove lea lead d at pin 1 from from Mole Molex x plug plug usin using g Molex Molex ext extrac ractor tor too tool. l. Connect Conn ect mult multimet imeter er betwe between en remo removed ved lead and now free Mole Molex x plug plug pin pin in in series series The temperature can now be calculated using the measured current, as described in “Functional description”.

 

Changing modules

General remarks

The „Changing modules“ chapter describes how to replace components that: Have Hav e no no inst instruc ructio tions ns of the their ir own for rep replac lacem ement ent and Requ Re quir ire e deta detail iled ed rep repla lace ceme ment nt ins instr truc ucti tion ons s NOTE! Danger of damage to threads, especially when fastening screws with NOTE! Danger power tools (e.g. power screwdrivers). In order to avoid damage to threads, proceed as follows: - Turn screw screws s slightl slightlyy to to the the left left to guara guarantee ntee opti optimum mum cent centring ring.. - Scre Screw w in at at least least two two full full turns turns by by hand. hand. This preve prevents nts the screw from forming a new thread: - Ca Care refu full llyy tig tight hten en th the e scr screw  ew 

Overview

The „Replacing components“ section contains the following subsections: Cha han ngin ing g the tr tra ansf sfo orm rmer  er  Changing the fan

Changing the transformer  Removing the control panel

(1)

(2) X2 Fig. 1

1. 2.

Removing the control panel

Fig. 2

Control panel removed  

Remove Remo ve th the e sid side e pan panel el Unplug Unpl ug the the ribbon ribbon cable cable (1) (1) on UST UST PC boar board d of contr control ol panel panel (2) (2) at X2 NOTE! When removing the control panel, take care not to bend, trap or strain NOTE! When the ribbon cable.

3.

Carefully Care fully remo remove ve the the control control pan panel el (2) (2) with with ribbon ribbon cable

1. 2.

Removing the UST PC board

3.

Rem emo ove the co cove ver  r  Unpl Un plug ug all all plu plugs gs fro from m the the UST UST PC board (3) Undo Un do sp spac acer ers s and and remo remove ve UST UST PC PC board (3)

(3) Fig.. 3 Rem Fig Removin oving g the the UST UST PC boa board  rd 

Removing the retaining plate

(4)

(4)

(6)

1.

Undo the Undo the scr screws ews (4) for the ret retain aining ing plate (5) using a TX25 screwdriver  and remove retaining plate (5) NOTE! When loosening the front NOTE! When of the housing (6), do not trap, bend or strain the cables.

2. (4)

(4)

(5)

(4)

Fig.. 4 Rem Fig Removin oving g the ret retaini aining ng plate plate

Loosen the fro Loosen front nt of the hou housin sing g (6) (6) by by removing the remaining screws and swiveling to one side

Undoing leads on earthing socket

1.

Unscrew Unscre w hexa hexagon gon bol boltt (6) (6) fro from m the the earthing socket using 19 mm flat spanner 

1.

Unscrew Unscre w hexa hexagon gon bol boltt (7) (7) fro from m the the transformer centre-tap using 13 mm flat spanner  Cutt thr Cu throu ough gh ca cabl ble e tie tie (8 (8)) Remove Rem ove lus luster ter ter termin minal al (9) and and,, if  if  present, auxiliary voltage source leads from the choke holder  Remo Re move ve the the pri prima mary ry tra trans nsfo form rmer  er  leads (10) from the BPS PC board on the luster terminal (9)

(6)

Fig.. 5 Fig

Undoing transformer centre-tap and auxiliary power source leads

Removi Rem oving ng hexago hexagon n bolt bolt with with leads leads

(9)

(12)

2. 3.

(8) (11) (10)

Fig.. 6 Fig

(8)

4.

(7)

Removi Rem oving ng transfor transformer mer centre centre-tap -tap leads leads

(13)

(13) (13)

X4

X5

Only applies to TransTig 2500/3000: 5. Unplug blue lead (11) from HF transformer at the plug connection (12)

Only applies to MagicWave 2500/3000: 5. Cu Cutt thr throu ough gh ca cabl ble e ti tie e (13 (13)) 6. Unp Unplug lug and unt unthre hread ad auxi auxilia liary ry volt voltage age source leads (14) from FMW 3000 PC board at X4 and X5

(14) (13)

Fig.. 7 Fig

Removin Rem oving g auxilia auxiliary ry voltage voltage sourc source e leads leads

1.

Removing the HF transformer 

(15)

(16)

(16)

(18) (17)

Fig.. 8 Rem Fig Removin oving g the the HF tran transfor sformer  mer 

Remove two bla Remove blade de ter termin minals als (15 (15)) on on HFF22 PC board 2. Uns Unscre crew w the the thr three ee scr screw ews s (16) (16) on the copper brackets using a TX25 scre wdriver  3. Un Unsc scre rew w the the two two scre screws ws (17 (17)) on th the e HF transformer (18) using a TX25 screwdriver  4. Re Remo move ve HF tr tran ansf sfor orme merr (18 (18))

1.

Removing the toroidal tape cores

2.

(19)

(19)

(20)

Cut thr throug ough h cabl cable e ties ties (19 (19)) used used to hold the leads together  Remov Re move e toro toroida idall tape tape cor cores es (20 (20)) from from the leads

(19)

(19)

(19)

Fig.. 9 Rem Fig Removin oving g toroid toroidal al tape tape core cores s

Removing the transformer 

(21) (21) (22)

(24) (23)

(26)

(25) (21)

(25) (25)

(25) (21)

Fig. 10 10 Removin Removing g the transformer  transformer 

1.

Undo the Undo the screw screws s (21) (21) for for the the ret retain aining ing plate (22) using a TX25 screwdriver  2. Rem Remove ove ret retain aining ing pla plate te (22 (22)) alon along g  with choke (23) and shunt shu nt (24) 3. Un Unsc scre rew w the the four four scr screw ews s (25) (25) on on the the transformer (26) using a TX25 scre wdriver and remove transformer tra nsformer (26)

Installing the Installing transformer 

1.

(21) (21)

2. (22)

(24)

Tigh ighte ten n the the four four scre screws ws (25) (25) to fast fasten en the transformer (26) using a TX25 screwdriver  Tigh ighte ten n the the four four scre screws ws (21) (21) to fast fasten en the retaining plate (22), including choke (23) and shunt (24), using a TX25 screwdriver 

(23)

(26)

(25) (21)

(25) (25)

(25) (21)

Fig. 11 11 Fitting the transformer  transformer 

Securing the toroidal tape cores and transformer 

1.

(19)

2.

3.

(27) (20)

(28) (19)

(28)

(19)

(19)

(19)

Fig. 12 Securin Securing g the toroidal toroidal tape cores cores

Feed tran Feed transfo sforme rmerr cable cables s (27) (27) thr throug ough h the opening in the retaining plate Threa Thr ead d the the to toroi roida dall tape tape cor cores es (20 (20)) onto the leads (27) and, if present, (28) as shown Secure Sec ure the lea leads ds (27 (27)) and, and, if pre presen sent, t, (28) using cable ties (19) as shown

Fitting the secondary transformer leads

(16)

(29)

(16) (31) (28)

1x (30)

(16) (16)

(16) (28)

(27)

(31)

(29)

2x (30) (25) (TransTig)

(27)

(27)

Only applies to TransTig 2500/3000: 1. Fit the two sec second ondary ary tra transf nsform ormer  er  leads (27) together with TRAFO sek T1:2 leads (28), each using - TX25 sc screw (1 (16) - spacer (2 (29) - se serr rrat ated ed wa wash sher er (3 (30) 0) 2. Fi Fitt le lead (3 (31) 1) us usin ing g - TX25 sc screw (1 (16) - spacer (2 (29) - se serr rrat ated ed wa wash sher er (3 (30) 0)

Fig. 13 Fitting the secondary secondary transformer transformer leads

Only applies to MagicWave 2500/3000: 1. Fit two tra transf nsform ormer er lead leads s (27) (27) each each usi using ng - TX25 sc screw (1 (16) - spacer (2 (29) - se serr rrat ated ed wa wash sher er (3 (30) 0) 2. Fi Fitt le lead (3 (31) 1) us usin ing g - TX25 sc screw (1 (16) - spacer (2 (29) - se serr rrat ated ed wa wash sher er (3 (30) 0)

1.

Fitting the HF transformer 

2. (15) (18)

Tigh ighte ten n the the two two screw screws s (17) (17) to to faste fasten n the HF transformer (18) using a TX25 screwdriver  Insert Ins ert th the e two two blade blade ter termin minals als (15 (15)) of  the leads from the HF transformer  according to the inscription on the HFF22 board

(17)

Fig. 14 Fitting the the HF transformer  transformer 

Fitting transformer centre-tap and auxiliary power source leads

(13)

(13) (13)

X4

X5

(14) (13)

Fig. 15 Connecti Connecting ng auxiliary voltage voltage source leads

Only applies to MagicWave 2500/3000: 1. Rou Route te the aux auxili iliary ary vol volta tage ge sou source rce leads (14) to the FMW 3000 PC board and plug in to X4 and X5 2. Bin Bind d cabl cables es tog togeth ether er wit with h cabl cable e ties ties (13)

Fitting transformer centre-tap and auxiliary power source leads (continued)

Only applies to TransTig 2500/3000: 3. Plu Plug g in blu blue e lead lead (1 (11) from from HF tran transsformer to the plug connection (12)

(34)

(9)

(12) (7)

(8) (11)

(10)

(33)

(8)

Fig. 16 Fitting transformer transformer centre-tap centre-tap leads

(32) (31)

(7)

4.

5.

6. 7.

(34)

Connec Conn ectt the the prima primary ry tra trans nsfo form rmer  er  leads (10) from the BPS PC board to the luster terminal (9) Insert Ins ert lus luster ter ter termin minal al (9) an and, d, if  present, auxiliary voltage source leads into the choke holder  Bind Bin d cabl cables es tog togeth ether er wit with h cabl cable e ties ties (8) Fit the fol follow lowing ing to th the e tran transfo sforme rmer  r  centre-tap using the 13 mm hexagon bolt (7): - spr prin ing g wa wash sher er (3 (31) 1) - spacer (3 (32) - ce cent ntre re-t -tap ap le lead ad (3 (33) 3) - choke le lead (3 (34)

(33)

Fig. 17 Layout of transformer transformer centre-tap centre-tap leads

1.

Fitting leads to earthing socket

(6)

Fig. 18 Fitting earthing earthing socket socket leads

(38) (TransTig) (37)

(39)

(35)

(6)

(36)

Fig. 19 Layout of earthing earthing socket socket leads

Fit th the e follo followin wing g to the ea earth rthing ing soc socket ket using the 19 mm hexagon bolt (6): - se serr rrat ated ed wa wash sher er (3 (35) 5) - spacer (3 (36) - X5 X57 7 prot protec ecti tive ve cir circu cuit it cab cable le lug lug (37) - Tran ransT sTig ig 2500 2500/30 /3000 00 only only:: varis varistor  tor  cable lug (38) - choke le lead (3 (39)

Fitting the retaining plate

(4)

(4)

(4)

(4)

(5)

1.

Fit reta Fit retain inin ing g plat plate e (5) (5) usin using g TX25 TX25 screws (4)

1.

Put UST Put UST PC bo boar ard d (3) (3) into into pla place ce,, position using screw spacers and remake plug connections

(4)

Fig. 20 Fitting the the retaining retaining plate

Fitting the UST PC board

(6)

NOTE! When fitting the front of  NOTE! When the housing (6), do not trap, bend or strain the cables. 2. Fi Fitt fron frontt of ho hous usin ing g (6) (6) (3) Fig. 21 Fitting the the UST PC board  board 

Fitting the control panel

1. 2.

3. (1)

(2) X2 Fig. 22 Fitting the the control panel  panel 

Fit th Fit the e co cont ntro roll pan panel el (2 (2)) Plug Plu g the the ribb ribbon on cabl cable e (1) (1) of the con contro troll panel (2) into X2 on the UST PC board Fitt th Fi the sid side e pa pane nels ls

Changing the fan 1. 2.

Removing the solenoid valve and fan lead

(1)

Removi Remo ving ng th the e si side de pa pane nels ls Remove Rem ove th the e hexa hexago gon n nut nut (1) for the solenoid valve (2) - Fig. 2 - using a 17 mm flat spanner  NOTE! When loosening the rear  NOTE! When of the housing (3), do not trap, bend or strain the cables.

(3) 3.

Remove th Remove the e screw screws s for for the the rea rearr of th the e housing (3), and swivel it carefully to one side

Fig.. 1 Rem Fig Removi oving ng the hex hexago agon n nut  nut 

(7)

(6) (4)

(5)

(4)

Fig.. 2 Fig

4. 5. 6.

(4)

(2)

(3)

Removin Rem oving g the solen solenoid oid valve valve and and fan cable cable

Cut thr throug ough h the cab cable le ties ties (4) (4) on the the fan fan lead lead (5) Disconne Disc onnect ct Molex Molex plug (6) from the Mole Molex x socket socket (7) Undo fan fan lead lead contacts contacts (5) (5) from the the plug housin housing g (6) using using a Molex Molex extractor extractor tool tool (not shown)

Removing the air  baffle (8)

(8)

(8) (10) Fig.. 4 Fig

1.

Unscrew Unscre w the the eig eight ht scr screws ews (8) usi using ng a TX25 screwdriver and remove air  baffle (9) 2. Un Undo do th the e scre screw w (10) (10) und under er the the RP 3000 PC board using a TX25 scre wdriver 

(8) (8) (9) Fig.. 3 Fig

Removi Rem oving ng the scre screws ws for the the air air baffle baffle

1.

Removing the fan

2.

(12) Fig.. 5 Fig

Remove fan (1 Remove (11) 1) and and ret retain aining ing pla plate te (12) from the side Detach Det ach fa fan n (11) (11) from from ret retain aining ing pla plate te (12)

(11)

Removin Rem oving g the fan fan and and retaini retaining ng plate plate

1.

Installing the fan

2.

(12) Fig.. 6 Fig

Removin Rem oving g the scre screw w for the the air baffl baffle e

(11)

Fitting Fit ting the fan fan and reta retaini ining ng plate plate

Attach fan (1 Attach (11) 1) to to reta retaini ining ng plat plate e with with four screws (12) Insert Ins ert fan (1 (11) 1) and and retain retaining ing pla plate te (12) (12) from the side

Fitting the air  baffle (8)

(8)

(8) (10) Fig.. 8 Fig

1.

Tigh ighten ten the eig eight ht scre screws ws (8) (8) to to secur secure e the air baffle (9) using a TX25 scre wdriver  2. Tigh ighten ten the scr screw ew (10 (10)) unde underr the the RP 3000 PC board using a TX25 scre wdriver 

(8) (8) (9) Fig.. 7 Fig

3. 4. 5.

Fitting Fit ting the screw screw for the the air air baffle baffle

Fittin Fit ting g the screw screws s for the the air baffl baffle e

Insert fan Insert fan lead lead contac contacts ts (5) (5) into the plug plug housin housing g (6) (not (not shown shown)) Connect Conn ect the the Molex Molex plug plug (6) of of the fan lead lead (5) (5) to the the Molex Molex socket socket (7) (7) Fix fan lea lead d (5) (5) usi using ng cab cable le tie ties s (4) (4)

(7)

(6) (4)

(5)

(4)

Fig.. 9 Fig

Fitting Fit ting the the solenoi solenoid d valve valve and fan fan cable cable

(4)

(2)

(3)

NOTE! When fitting the rear of  NOTE! When the housing (3), do not trap, bend or strain the cables.

Fitting the air  baffle (continued) 1. 2. (1)

Fig. 10 Fitting the the hexagon hexagon nut 

(3)

3.

Fit the Fit the ho hous usin ing g rea rearr pan panel el (3 (3)) Tigh ighte ten n the the hexag hexagon on nut (1) for fit fittin ting g the solenoid valve (2) - Fig. 9 - using a 17 mm flat spanner  Fitt th Fi the sid side e pa pane nels ls

Carrying out a safety inspection When is it required?

 A safety inspection is required: required : - Afte terr eve every ry re rep pair  - Whe Whene never ver som somet ethin hing g has has been been modi modifie fied d - At set set inte interva rvals ls (at (at leas leastt once once a yea year) r)

Work instructions

The work instruction „Safety Inspection of Arc Welding and Cutting Equipment“ is available in the TechGuide DownloadCenter under „Safety, Environment & Health“.

Terms and abbreviations used General remarks

„Terms and abbreviations“ is a glossary of specific technical terms essential for an understanding of the service manual.

Terms and abbreviations

BSL tool: The BSL tool is a special tool for updating the power source with new firmware. A PC or  notebook is required for the update. Config memory (CFM): The CFM module supplements the UST PC board firmware (central control and regulation unit) with individual, device-specific data. DSP: Digital Signal ignalP Processor rocessor.. Part of the UST PC board (central control and regulation unit). The DSP captures digitised actual values on the part of the welding process, and ensures constant regulation and optimisation of the welding current and voltage, on the basis of  the parameters set the saved firmware the act ctu ual va valu lues es measu sure red d FAC: Factory Fac tory resets the settings in the setup menu. The original factory settings are restored by pressing and holding the “Store” button for two seconds. The welding machine has been reset when the display reads “PrG”. Jobs and paramete parameterr settings in the second level of the set-up menu are not deleted. IGBT: Insulated Gate Bipolar Transistor. This is a special bipolar transistor used in highpower switching applications. IGBTs IGBTs are used in the power source as modules. On the TT/MW 1700/220 1700/2200 0 power sources, IGBT modules are used in a secondary role to prepare the welding current for AC welding. Instruction pointer: When a software error appears: the third level of the display contains more detailed information on the cause of the error (see “Error location aid” chapter) LocalNet RS232 converter: For connecting the power source to the serial interface on a PC, for: uplo up load adin ing g so softw twa are opt ptio ion ns transmit tran smitting ting dat data a from from the the powe powerr source source using using PC-b PC-based ased soft software ware (Fron (Fronius ius Backu Backup, p, Fronius Service Module, Job-Explorer Job-Explorer,, etc.)

TransTig 2500

TransTig 3000

MagicWave 2500

MagicWave 3000

MagicWave 2500 G/F MagicWave 2500 G/F US TransTig 2500 G/F TransTig 2500 G/F US MagicWave 2500 Job G/F MagicWa MagicWave ve 2500 Job G/F US TransTig 2500 Job G/F Trans ransT Tig 2500 2500 Job Job G/F G/F US MagicWave 2500 Comfort G/F MagicWave 2500 Comfort MV G/F Trans ransTi Tig g 2500 2500 Comf Comfor ortt G/F G/F TransTig TransTig 2500 Comfort G/F MV

4,075,155 4,075,155,800 4,075,151 4,075,151,800 4,0 4,075,156 4,075,156,800 4,075,156,800 4,075,152 4,07 4,075, 5,15 152, 2,80 800 0 4,075,156,631 4,075,156,801 4,075 4,075,1 ,152, 52,63 631 1 4,075,152,801

MagicWave 3000 G/F MagicWave 3000 G/F US TransTig 3000 G/F TransTig 3000 G/F US Magi agicWave 3000 000 Job G/F MagicWav MagicWave e 3000 Job G/F US TransTig 3000 Job G/F Trans ransT Tig 3000 3000 Job Job G/F G/F US MagicWave 3000 Comfort G/F MagicW MagicWave ave 3000 Comfor Comfortt MV MV G/F G/F Trans ransTi Tig g 3000 3000 Comf Comfor ortt G/F G/F TransTig TransTig 3000 Comfrt G/F MV

4,075,157 4,075,157,800 4,075,153 4,075,153,800 14, 14,075,158 4,075,158,800 4,075,158,800 4,075,154 4,07 4,075, 5,15 154, 4,80 800 0 4,075,158,631 4,075,1 4,075,158,8 58,801 01 4,075 4,075,1 ,154, 54,63 631 1 4,075,154,801

12,0405,0369 42,0201,2418

42,0406,0320  AM2,0201,2420

45,0200,1270

43,0004,0789

43,0004,2323 - MV 41,0003,0309 41,0003,0308   42,0406,0294 43,0002,0417 - MV 43,0002,0405

43,0001,0600 41,0003,0309

42,0001,3541 43,0013,0015 42,0300,1511

42,0407,0284 43,0001,1171

40,0001,0310 - *

42,0407,0532 - MV

43,0001,0600 42,0409,3197 42,0409,3198 - MV

41,0002,0059 41,0002,0060-MV 41,0002,0060 43,0001,1217 43,0001,1216 - TT2500

42,0405,0597 42,0405,0591

43,0001,1138

43,0006,0223 33,0005,4147 - TT2500 33,0005,4145 43,0001,1274 - MW 3000 42,0405,0591 41,0003,0279 - MW

43,0001,0600 41,0003,0203 41,0003,0291 - MW 3000 33,0005,0503 43,0001,1176 43,0001,1176 - TT

TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

43,0004,3830 - 26pol.

4,070,960,Z - UST2C

4,071,067,Z      T      N

4,071,068,Z

    2      T     S      U

43,0001,3320 43,0006,0168

S BP

4,071,063,Z 4,071,064,Z - MV

33,0010,0366 33,0010,0367

RP

4,071,065,Z - MW2500 4,071,066,Z - MW3000

4,071,071 - TT3000

0 00 V3 BS

2 F2 HF

42,0409,3196 - MW 42,0409,3195 - TT

W FM

43,0001,3318 - TT 2500/3000

43,0001,3319 - MW 2500/3000

4,070,812,Z - HFF22 33,0010,0377-TT2500

43,0001,3311 - MW 43,0001,3312 - MW JOB 43,0001,3313 - TT 43,0001,3314 - TT JOB 42,0406,0315

42,0405,0596 - MW 42,0405,0600 - TT

42,0406,0093 42,0001,1501

43,0004,2650

42,0001,5477

43,0004,2652

32,0405,0183

42,0404,0024

TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

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