Professional Documents
Culture Documents
42,0410,1121 012008
Contents
Foreword and safety instructions .................................................................................................................. 4
Safety ....................................................................................................................................................... 4
TechSupport National (TSN) .................................................................................................................... 4
General remarks ...................................................................................................................................... 4
Tools and measuring devices ................................................................................................................... 5
Function overview .................................................................................................................................... 5
Error location aid ...................................................................................................................................... 5
Detailed description .................................................................................................................................. 5
Replacing components ............................................................................................................................. 5
Terms and abbreviations used ................................................................................................................. 5
Spare parts list and entire circuit diagram ................................................................................................ 5
Tools and measuring devices ........................................................................................................................ 6
General remarks ...................................................................................................................................... 6
Tools required .......................................................................................................................................... 6
Measuring equipment, inspection equipment ........................................................................................... 7
Ancillary materials .................................................................................................................................... 7
Function overview of MW 1700 / 2200, TT 800 / 2200, PlasmaModule 10 ................................................... 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 welding properties with TIG welding ........................................................................... 12
Poor ignition and welding properties with MMA welding ......................................................................... 13
No or incorrect welding current .............................................................................................................. 14
No lights on control panel ....................................................................................................................... 15
Inadequate welding torch cooling (FK 2200) .......................................................................................... 19
Open circuit voltage +50 V faulty ............................................................................................................ 21
UST service codes ...................................................................................................................................... 22
Safety ..................................................................................................................................................... 22
Table of service codes ........................................................................................................................... 22
Special indications used with service codes ........................................................................................... 28
Detailed description ..................................................................................................................................... 29
General remarks .................................................................................................................................... 29
Overview ................................................................................................................................................ 29
BPS 17 - Power module PC board .............................................................................................................. 30
General remarks .................................................................................................................................... 30
Overview ................................................................................................................................................ 30
Function overview .................................................................................................................................. 30
Pin assignment ...................................................................................................................................... 31
Measuring points .................................................................................................................................... 32
LED checklist ......................................................................................................................................... 33
BPS 22 - Power module PC board .............................................................................................................. 34
General remarks .................................................................................................................................... 34
Overview ................................................................................................................................................ 34
Technical data ........................................................................................................................................ 34
Function overview .................................................................................................................................. 34
Pin assignment ...................................................................................................................................... 36
Measuring points .................................................................................................................................... 36
LED checklist ......................................................................................................................................... 37
1
HFF 22 - High frequency ignition unit, input filter ........................................................................................ 38
General remarks .................................................................................................................................... 38
Overview ................................................................................................................................................ 38
Function overview .................................................................................................................................. 39
Pin assignment ...................................................................................................................................... 40
NTFK 24 - Switched mode power supply for cooling unit ............................................................................ 42
General remarks .................................................................................................................................... 42
Function overview .................................................................................................................................. 42
Pin assignment ...................................................................................................................................... 43
Measuring points .................................................................................................................................... 44
LED checklist ......................................................................................................................................... 44
Secondary power module TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ......................................... 45
General remarks .................................................................................................................................... 45
Function overview .................................................................................................................................. 45
Pin assignment ...................................................................................................................................... 45
Measuring points .................................................................................................................................... 45
LED checklist ......................................................................................................................................... 46
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10 ........................................................................ 47
General remarks .................................................................................................................................... 47
Function overview .................................................................................................................................. 47
Pin assignment ...................................................................................................................................... 47
Measuring points .................................................................................................................................... 47
Important ................................................................................................................................................ 48
Technical data ........................................................................................................................................ 48
Function overview .................................................................................................................................. 48
Pin assignment ...................................................................................................................................... 48
LED checklist ......................................................................................................................................... 48
Measuring points .................................................................................................................................... 48
TP 592S temperature sensor ...................................................................................................................... 49
General remarks .................................................................................................................................... 49
Technical data ........................................................................................................................................ 49
Function overview .................................................................................................................................. 49
Pin assignment ...................................................................................................................................... 49
Measuring points .................................................................................................................................... 49
TTS 22 - IGBT driver and auxiliary power source ....................................................................................... 50
General remarks .................................................................................................................................... 50
Overview ................................................................................................................................................ 50
Technical data ........................................................................................................................................ 50
Function overview .................................................................................................................................. 50
Pin assignment ...................................................................................................................................... 51
Measuring points .................................................................................................................................... 51
LED checklist ......................................................................................................................................... 51
UST - Control and regulation unit ................................................................................................................ 52
General remarks .................................................................................................................................... 52
Function overview .................................................................................................................................. 52
Pin assignment ...................................................................................................................................... 53
Measuring points .................................................................................................................................... 54
LED checklist ......................................................................................................................................... 54
Change UST PC board .......................................................................................................................... 54
Changing modules ...................................................................................................................................... 55
General remarks .................................................................................................................................... 55
Overview ................................................................................................................................................ 55
Housing unit ................................................................................................................................................ 56
General remarks .................................................................................................................................... 56
Opening the housing .............................................................................................................................. 56
Closing the housing ................................................................................................................................ 57
2
Changing BPS 17 PC board ........................................................................................................................ 59
Instructions ............................................................................................................................................. 59
Changing BPS 22 PC board ........................................................................................................................ 59
Instructions ............................................................................................................................................. 59
Changing inverter module ........................................................................................................................... 59
Instructions ............................................................................................................................................. 59
Changing the TP 592S temperature sensor ................................................................................................ 59
Instructions ............................................................................................................................................. 59
Changing the TTS 22 PC board .................................................................................................................. 60
ESD measures ....................................................................................................................................... 60
Changing the TTS 22 PC board ............................................................................................................. 60
Installing the TTS 22 PC board .............................................................................................................. 62
Changing the BSV 22 PC board .................................................................................................................. 64
ESD measures ....................................................................................................................................... 64
Removing the BSV 22 PC board ............................................................................................................ 64
Installing the BSV 22 PC board .............................................................................................................. 66
Installing UST PC board ......................................................................................................................... 67
Changing the transformer ........................................................................................................................... 68
Removing the transformer ..................................................................................................................... 68
Installing the transformer ....................................................................................................................... 72
Safety Inspection ......................................................................................................................................... 78
Requirement .......................................................................................................................................... 78
Work instruction ..................................................................................................................................... 78
Terms and abbreviations used .................................................................................................................... 79
General remarks .................................................................................................................................... 79
Terms and abbreviations ........................................................................................................................ 79
Entire circuit diagram
Spare parts lists
Fronius Worldwide
3
Foreword and safety instructions
Safety The following safety instructions apply to all activities described in these service instruc-
tions:
WARNING! Work performed incorrectly can cause serious injury and damage.
All activities described in the service instructions must only be carried out by
Fronius-trained service technicians. Read the Safety rules chapter in the
power source operating instructions.
TechSupport If you have any questions about error analysis, your TechSupport National (TSN) sales
National (TSN) team is on hand.
mailto: welding.techsupport@fronius.com
General remarks The service instructions 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:
4
Tools and measu- This provides an overview and description of all equipment required for servicing the
ring devices power source professionally. This equipment includes:
- Tools required
- Measuring equipment, inspection equipment
- Ancillary material
Error location aid Serves to systematically locate and rectify the source of errors, and contains the follo-
wing elements:
- The actual error flowchart for dealing with general errors
- Service codes table for dealing with errors whose service codes appear on the
display
Detailed descrip- Contains detailed descriptions of the relevant modules in the power source.
tion
For every module, the following topics are dealt with:
- General remarks (designation, item number of the module)
- Position of the module in the device
- Overview
- Technical data
- Function overview
- Pin assignment
- LED checklists
- Measuring points
Replacing com- The Replacing components chapter describes how to replace components that
ponents - have no instructions of their own for replacement and
- require detailed replacement instructions
Terms and abbre- Contains a description of essential specialist terms and abbreviations for a better under-
viations used standing of the service manual
Spare parts list The Spare parts list and Entire circuit diagram chapters contain the complete spare
and entire circuit parts list and complete circuit diagram for the power source.
diagram
5
Tools and measuring devices
General remarks Tools and measuring devices provides an overview and description of all the equip-
ment required to service the device professionally. This equipment includes:
- Tools required
- Measuring equipment, inspection equipment
- Ancillary materials
6
Measuring equip- - Digital multimeter
ment, inspection - PC with MS Windows operating system
equipment (System requirements can be found in the operating instructions for the BSL tool)
- BSL tool (4,050,082)
- LocalNet RS 232 Converter (4,100,262)
- DVD TechGuide (40,0006,2910)
7
Function overview of MW 1700 / 2200, TT 800 / 2200,
PlasmaModule 10
General remarks The Function overview section explains the underlying functional principle of the
MagicWave 1700/2200 and TransTig 800/2200 power sources as well as PlasmaModule
10 with the help of a block diagram.
Block diagram
Welding torch
Workpiece
Remote control
Welding torch
control line
protective gas
shield
LocalNet
(12)
prot. gas shield solenoid valve HF transformer
Iact
(11)
HF
Welding current
Control and regulation unit
sensor
(10)
HF generator
Uact
Control panel
(9)
Inverter
Control line
*
Secondary power
module
(1)
(8)
Secondary rectifier
Control line
(7)
Welding transformer
24 V power supply
* only for MagicWave 1700 and MagicWave 2200 power sources
Power supply
** only for MagicWave 2200 and TransTig 2200 power sources
(6)
Switching
transistors
(5)
24 V
Intermediate circuit
capacitors
(4)
Control)
Primary power
module
(3)
Primary rectifier
230 V
(2)
Line filter
Fig. 1 Block diagram of the MagicWave 1700/2200, TransTig 1700/2200 and PlasmaModule 10 power sources
8
Block diagram (1) Control and regulation unit:
legend Controls, regulates and monitors the welding process and all power source func-
tions.
(4) PFC (Power Factor Control, MagicWave 2200 and TransTig 2200 only):
Ensures sinusoidal current input, for
- Supporting an optimum degree of efficiency
- Preventing perturbations in the mains supply
(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 transformer can be constructed to a very light, compact design
- Thermal losses due to the low inductance required of the transformer windings
can be kept to an absolute minimum
(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).
(12) HF transformer:
For non-contact HF ignition, the HF transformer (high-frequency transformer)
transmits high-voltage pulses to the welding circuit.
9
Error location aid
General remarks The chapter Error location aid consists of the following parts
- Error flowchart
- Table of service codes
The error flowchart is for the systematic locating 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 understand how the power source is constructed and
how it operates.
Important: The following applies to those who do not yet have much experience of
troubleshooting and fault diagnosis on the MagicWave 1700 / 2200, TransTig 800 / 2200
and PlasmaModule 10 power sources.
Before using the error location aid, read the following chapters:
- Function overview
- Entire circuit diagram
10
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).
11
Poor ignition and
welding proper- Start
ties with TIG
welding
yes
Gas test button: Protective gas Check protective gas shield sole-
shield flowing out? noid valve, including control
no
yes
Open circuit voltage with selected See Incorrect open circuit voltage
rod electrode (MMA) welding section
process = 50 V (+/- 1 V) ? no
yes
End
12
Poor ignition and
welding proper- Start
ties with MMA
welding
Open circuit voltage with selected See Incorrect open circuit voltage
MMA welding process = 50 V (+/- section
1 V) ? no
yes
End
13
No or incorrect
welding current Start
yes
Open circuit voltage with selected See Incorrect open circuit voltage
MMA welding process = 50 V (+/- section
1 V) ? no
yes
no
End
14
No lights on
control panel Start
Is the UZWK LED on the A2 BPS Check mains cable, mains switch
17 / BPS 22 power module PC and supply voltage
no
board on constantly?
yes
no
Are the LEDs for supply voltage on Change power module PC board
the A2 BPS 17 / BPS 22 on the A2 BPS 17 / BPS 22
no
power module PC board on con-
stantly?
yes
15
No lights on
A
control panel
(continued)
no
LEDs for supply voltage on A5 UST Change the A5 UST control board
control board constantly illumina- no
ted?
yes
yes
16
No lights on
B
control panel
(continued)
yes
yes
yes
17
No lights on
C
control panel
(continued)
yes
End
18
Inadequate
welding torch Start
cooling (FK 2200)
Fuse for coolant pump OK? Change fuse (check rating is same
as original)
no
yes
19
Inadequate
A
welding torch
cooling (FK 2200)
(continued)
Power LED on the A1 NTFK24 Check fuse F1 and 230 VAC power
power module illuminated con- supply on the A1 NTFK24 X2
no power module. Change A1
stantly ?
yes NTFK24 power module
yes no yes
yes
End
20
Open circuit
voltage +50 V Start
faulty
yes
End
21
UST service codes
Safety
WARNING! An electric shock can be fatal. Before opening the device
- Turn the mains switch to the O position
- Unplug the device from the mains
- Ensure that electrically charged components (e.g. capacitors) have been
discharged
22
Table of service
EcF | xxx (code no.32)
codes
(continued) Cause: BPS configuration error, x stands for:
1 TPS 2700 with incorrect power module
2 TS/TPS/TP 4000 with incorrect power module
3 TS/TPS/TP 5000 with incorrect power module
4 TT 2200, MW 2200 with incorrect primary power module
5 MW 1700 with incorrect primary power module
253 This configuration functions only from UST2A V1.3 A onwards
254 This configuration functions only from UST PC board, version
UST2A
255 Unknown primary power module
Remedy: Fit correct primary power module
23
Table of service
Err | PE (code no.53)
codes
(continued) Cause: Earth-fault error
Remedy: Remove earth fault. Configure device in insulated state. Check 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: Temperature sensor error (short circuit or break) - examples: tF1 - tempe-
rature sensor error on secondary rectifier, tF2 - temperature sensor error on
primary power module
Remedy: Check cable harness and change the relevant temperature sensor
24
Table of service
Err | 056 (code no.56)
codes
(continued) Cause: In conjunction with wire-feed unit and wire-end check option: no wire
available
Remedy: Insert new wirespool
25
Table of service
Err | 26.x (code no.26)
codes
(continued) Cause: Config memory (CFM) machine error, x stands for:
1 config memory not found
2 checksum error
3 CFM empty
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: Check cable harness. Change config memory on power source cable
harness.
26
Table of service
no | H2O (code no.39)
codes
(continued) Cause: Flow watchdog reporting water deficiency
Remedy: Check cooling system hose lines. Check pump pressure and flow rate.
Check flow watchdog.
tp1 | xxx (code no.5), tp2 | xxx (code no.6), tp3 | xxx (code no.7), tp4 | xxx (code
no.8), tp5 | xxx (code no.9)
Cause: Overtemperature in power source primary circuit (XXX stands for tempera-
ture indicator) - Example: tp1 - overtemperature at primary power module
Remedy: Allow the power source to cool down. Check that fan is running.
tp7 | Hot
Cause: Duty cycle exceeded
Remedy: Allow the power source to cool down. Check that fan is running.
ts1 | xxx (code no.2), tS2 | xxx (code no.3), tS3 | xxx (code no.4)
Cause: Overtemperature in power source secondary circuit (XXX stands for tempe-
rature indicator) - Examples: ts1 - overtemperature at secondary rectifier,
ts2 - overtemperature at the auxiliary voltage source, tst - overtemperature
at UST PC board
Remedy: Allow the power source to cool down. Check that fan is running.
Remedy: Check cable harness. Change UST2 PC board.
27
Table of service
tSt | xxx (code no.33)
codes
(continued) Cause: Overtemperature in control circuit, xxx stands for the temperature indicator
Remedy: Allow the power source to cool down. Check fan.
Special indicati- The following service codes are special indications for software problems:
ons used with
service codes - And | Opc - STK | OVL
- Prt | Flt - STK | UVL
- Ill | Opa - Err | Dog
- Ill | Ina - ASS | Ert
- Ill | Bus - Edg | 1
- Err | 105
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:
- Level 1 (e.g. And | Opc): service code display
(appears automatically)
- Level 2 (e.g. CS 01): segment display
(press parameter selection button once)
- Level 3 (e.g. IP 3456): instruction pointer
(press parameter selection button again)
Important: Please make a note of the indications in levels 1, 2, and 3, and pass them on
to Fronius. Using this data, Fronius can locate the precise cause of the error.
28
Detailed description
General remarks This section contains a detailed description of the electronic modules with regard to the
following points:
- General (designation, item number)
- Position of the module in the device
- Overview
- Technical data
- Function overview
- Pin assignment
- LED checklist
- Measuring points
29
BPS 17 - Power module PC board
General remarks BPS 17 (item no. 4,070,798,Z) is the power module PC board for power sources TT 800,
MW 1700 and PlasmaModule 10.
Function over-
Input voltage 230 VAC (+15 % / -20 %)
view
Supply voltage from the power module 24 Vint (+/-20 %), 2.5 A
24 Vext (+/-20 %), 1.5 A
15 Vp (+10 %), 0.2 A
(5) (1)
(3)
(4)
(6)
(2)
30
Function over- The BPS 17 PC board includes the following components:
view (1) Line filter
(continued) (2) Rectifier
(3) High-charging circuit
(4) Intermediate circuit capacitors
(5) Switched mode power supply (+24 V internal, +24 V external)
(6) Power full bridge
(2) Rectifier
The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the
intermediate circuit.
Details on the pin assignment can be found in the chapter entitled Detailed description
- UST in the section Pin assignment X6.
31
Pin assignment X28 .... (secondary voltage), voltage supply internal/external
(continued)
Pin Designation Pin Designation
1 +24 V-EXT, +24 V remote 5 GND-EXT, remote control
control connection connection GND
2 NC 6 NC
3 UZW, intermediate circuit 7 GND-UZW, intermediate
voltage measuring circuit voltage measuring
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply
Measuring points Measurement on each of the diode regions depicted below must produce a result of
0.4 V.
The picture also shows the HS LED and the HLS LED (see following section Control
LEDs).
HS LED
HLS LED
Further measuring points can be found in the chapter entitled Detailed description -
UST in the section Pin assignment.
32
LED checklist Control LEDs on BPS 17 PC board
Uzwk
+15 Vp
HLS LED
Uzwk ................. lights up when there is supply from the intermediate circuit
HLS LED ........ lights up when the high charging relay is activated
33
BPS 22 - Power module PC board
General remarks BPS 22 (item no. 4,070,799,Z) is the power module PC board for TT 2200 and MW 2200
power sources.
Technical data
Input voltage 230 VAC (+15 % / -30 %)
Supply voltage from the power module 24 Vint (+/-20 %), 2.5 A
24 Vext (+/-20 %), 1.5 A
15 Vp (+10 %), 0.2 A
(1)
(2)
(8)
(3)
(4)
(7)
(5)
(6)
34
Function over- The BPS 22 PC board includes the following components:
view (1) Line filter
(continued) (2) High-charging circuit
(3) Intermediate circuit capacitors
(4) Rectifier
(5) PFC (Power Factor Control)
(6) Shunt
(7) Power full bridge
(8) Switched mode power supply (+24 V internal, +24 V external)
(4) Rectifier
The rectifier takes the input voltage (mains voltage) and generates a DC voltage for the
intermediate circuit.
(6) Shunt
Measures the mains current for the PFC.
35
Pin assignment X1 ...... (secondary), ribbon cable from UST (X6)
Details on the pin assignment can be found in the chapter entitled Detailed description
- UST in the section Pin assignment X6.
Measuring points Measurement on each of the diode regions depicted below must produce a result of
0.4 V.
Further measuring points can be found in the chapter entitled Detailed description -
UST in the section Pin assignment.
36
LED checklist Control LEDs on BPS 22 PC board
PFC
LED
Uzwk
+15 Vp HLS
LED
HS
LED
Uzwk ................. lights up when there is supply from the intermediate circuit
HLS LED ........ lights up when the high charging relay is activated
PFC LED ........ lights up or flashes with varying degrees of brightness depending on
power drawn. High brightness equals high power.
37
HFF 22 - High frequency ignition unit, input filter
General remarks HFF 22 (item number 4,070,812,Z) is used for high frequency ignition in the MW 1700
and MW 2200 power sources and is also a filter assignment for remote controls and
torch triggers.
Overview
HF module
Filter module
Fig. 25 HFF 22
38
Function over-
Supply voltage + 24 VDC (+/- 20 %)
view
Output voltage 1000 VDC
(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 control module. A flyback converter charging circuit char-
ges 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 charge voltage of the impulse capacitor
from 1000 V to approx. 10 kV. Each charging process of the impulse capacitor is indica-
ted by the SIG LED (red) lighting up.
39
Pin assignment
(X3)
(X1)
(X2)
(X5)
(X4)
(X6)
(X7)
40
Pin assignment X1 ...... HF pulse positive pole (blade terminal connection to primary voltage of the HF
(continued) launch coil
X2 ...... HF pulse negative pole (blade terminal connection to primary voltage of the HF
launch coil)
41
NTFK 24 - Switched mode power supply for cooling
unit
General remarks NTFK 24 (item number 4,070,819,Z) is the switched mode power supply for the FK 2200
cooling unit.
Function over-
Range of input voltage 140 VAC... 280 VAC
view
200 VDC... 400 VDC
Output voltage 24 V (+/- 1 V), 5.5 A
(max. 30 V in idle)
Max. current 5.5 A (fused with PTCs)
(2) Control
If the pin X3:2 (=/cooler on) is set to signal ground, the cooling unit starts.
42
Function over- (4) Flow controller and undervoltage control
view
(continued) If no flow monitor is present, pin X1/2 (/water ctrl.sig.) is switched to signal ground
(GND) via a short circuit jumper.
The undervoltage detector of the coolant pump is also coupled to the flow controller. If
the supply voltage of the coolant pump is lower than 20 V, (e.g the pump is blocked), a
message to the UST controller board is sent (service code).
The flow monitor is powered from the power source. The signal voltages at pins X3 and
X1, as well as the supply voltage of the coolant pump are electrically isolated from one
another.
X2 ...... Mains voltage (fused with external glass-tube F1, 4 A - slow blow)
43
Pin assignment X4 ...... Connection for fan and coolant pump of the cooling unit
(continued)
Pin Designation Pin Designation
1 + 24 V coolant pump 4 GND coolant pump
2 +24 V Fan 5 GND fan
3 LED+, external control LED 6 GND LED
LED checklist
+15 VP
Power
+24 VOK
+24 V
ON
Fig. 31 Control LEDs on NTFK 24 PC board
44
Secondary power module TT 800 / 2200, MW 1700 /
2200, PlasmaModule 10
General remarks The secondary power module for the TransTig 800 / 2200, MagicWave 1700 / 2200 and
PlasmaModule 10 power sources contains the following number(s) of diode modules
(item number 41,0003,0203):
Secondary rectifier
- 1 diode module (PlasmaModule 10)
- 2 diode modules (TT 800 / 2200)
- 4 diode modules (MW 1700 / 2200)
Inverter
- previous version consisting of MW 2200 inverter checked (item number
41,0003,0282,Z)
- new version from serial number 17352516 comprising 4 IGBT transistor modules
(item number 41,0003,0279) and PC board FMW22IS (item number 4,070,949,Z)
Function over- The rectifier generates DC from the AC from the welding transformer.
view
Important: The following description only applies to MagicWave 1700 / 2200 power
sources.
The transistor modules on the inverter module convert the DC to AC, which is then sent
to the welding sockets. The transistor modules are controlled by the TTS 22 PC board.
On the FMW 22 IS PC board the integrated suppressor diodes protect the inverter
transistors from excessive voltages from the welding circuit.
Pin assignment Important: The following description only applies to MagicWave 1700 / 2200 power
sources.
Measuring points Measurements taken on the diode regions depicted below must produce approximately
the following results:
- approx. 0.4 V at the suppressor diodes on the inverter module (A) (measuring points
can be found in the following picture).
- approx. 0.15 V at the rectifier diodes (B) (measuring points can be found in Pin
assignment section).
Torques:
- Copper clips and PC board on power semiconductors: 1.5 Nm
- Power semiconductors on heat sink: 2.1 Nm
45
Measuring points
(continued) (B) (B) (A)
0.4 V
0.15 V 0.15 V
Important: TransTig 800 / 2200 power sources only offer two diode modules and the
PlasmaModule 10 only offers one.
On the TransTig 800 and PM 10 power sources the single diode is fitted on the top left.
On the TransTig 2200 the two diodes are fitted on the left.
On the MagicWave 1700 / 2200 power sources all 4 diodes are fitted.
The temperature sensor can be found between the diode modules, where the connec-
ting leads of the temperature sensor run off to the left.
(B)
(B)
0.15 V 0.15
(B) (B) V33 0.15 V
0.15 V
0.15 V 0.15 V
(B) 0.15 V
46
Shunt TT 800 / 2200, MW 1700 / 2200, PlasmaModule 10
Function over- The shunt operates according to the compensation principle, where a magnetically soft
view probe functions as a magnetic field detector. The shunt is characterised by the following
features:
- Compact design
- Low offset current
- Low hysteresis
- High temperature stability
- Integrated electronics
The shunt is supplied by a bipolar operating voltage of +/- 15 V and provides an output
signal which is proportional to the measured welding current. The output signal to wel-
ding current transmission ratio is 1:2000.
Measuring points The welding current can be captured indirectly using by measuring the voltage. With a
welding current of 100 A for example, there should be a voltage of 0.33 V measured:
- Either on the Molex plug of the adapter cable, pin 3 and pin 7
- On UST PC board, Molex plug X4, pin 5 and pin 17
47
Important Various versions of the shunt are in use.
Function over- The shunt operates according to the compensation principle, where a magnetically soft
view probe functions as a magnetic field detector.
The shunt is characterised by the following features:
- Compact design
- Low offset current
- Low hysteresis
- High temperature stability
- Integrated electronics
The shunt is supplied by a bipolar operating 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.
Other functions:
- Electric isolation between power circuit and electronic circuit
- Null balance and amplification procedures do not apply
- Based on the principle of compensation of magnetic fields, the current transducers
provide a measured current proportional to the primary current
Measuring points The welding current can be captured indirectly using 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.
48
TP 592S temperature sensor
Function over- - The temperature sensor is fitted to the cooling element and measures the elements
view temperature.
- The temperature sensor emits a current of exactly 1 A per K (Kelvin), provided that
there is a voltage of 4 - 30 V DC.
Measuring points Measure the current flowing through the temperature sensor as follows:
- Remove lead at pin 1 from Molex plug using Molex extractor tool.
- Connect multimeter between removed lead and now free Molex plug pin in series
The temperature can now be calculated using the measured current, as described in
Functional description.
49
TTS 22 - IGBT driver and auxiliary power source
General remarks The TTS 22 PC board (item number 4,070,804) fulfills the function of an IGBT driver and
an auxiliary power source.
Overview
Negative ignition Positive ignition
Error
+ 24 V
+ 18 V
+6V
Fig. 46 TTS 22
Function over- The TTS 22 controls the polarity of the welding current and the auxiliary power source.
view The auxiliary power source allows the arc to be reignited. The TTS 22 and FMW PC
boards work in tandem.
The TTS 22 generates two independent voltages (+5V and +18V) for PC board control
from the +24V supply voltage.
The control unit conditions the control signals (polarity of welding current and reignition)
and is used to electrically isolate and forward the signals to the relevant transistor
module (IGBT). The process is displayed:
- On the neg ignition and pos. ignition LEDs for the auxiliary power source
- On the FMW PC board LED + and LED - for the polarity of the welding current
The welding voltage is also measured. If the welding voltage should fall outside the
permitted range, the following occurs:
- Inverter control signal goes to Stop
- 18V PC board supply stopped: +18 V LED goes out
- Error LED (red) lights up
- Error signal X7:4 to UST PC board active (low signal)
50
Pin assignment X1 ...... Common
51
UST - Control and regulation unit
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.
52
Pin assignment X1 ...... Inverter control (connection to TTS 22)
X2 ...... Connection to control panel (10-pin ribbon cable)
X3 ...... Supply
X5 ...... Fan
Pin Designation Pin Designation
1 + 24 V 3 + 24 V
2 FAN, fan power module 4 FAN, fan control unit
53
Pin assignment X8 ...... Programming interface for updating firmware via BSL tool
(continued)
NOTE! Risk of damage to electronic components. Switch off the power supply
before connecting or removing BSL tools.
LED checklist
+24 Vext
+24 Vint
+ 5V
+15 V
- 15 V
STAT + 5V
+24 Vext ........... lights up when switched mode power supply is working correctly
+24 Vint
+ 5V ................ RS 485
+15 V
- 15 V
+ 5V
STAT .............. Status LED
lights up if no firmware is present
if it does not light up: process OK
Change UST PC NOTE! Options enabled via service module software are stored on the UST,
board 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.
54
Changing modules
General remarks The Changing modules chapter describes how to replace components that
- have no instructions of their own for replacement and
- require detailed replacement instructions
55
Housing unit
General remarks The section headed Housing covers the opening and closing of the housing for the
replacement operations described below.
56
Opening the If handle is present, remove holder on one
housing (7) (4) (4) side as follows:
(continued) - Undo screws (4) on the holder for the
handle
57
Closing the - Tighten rear screws (3)
housing (3) (3)
(continued)
58
Changing BPS 17 PC board
Instructions When changing the BPS 17 PC board, always follow the installation instructions supplied
with the board.
Instructions When changing the BPS 22 PC board, always follow the installation instructions supplied
with the board.
Instructions When changing the inverter module, always follow the installation instructions supplied
with the module.
Instructions The temperature sensor is plugged in but can be lifted out by carefully using an ordinary
screwdriver or pulled out with flat pliers.
Before inserting the new temperature sensor, fill the hole for the sensor with heat con-
ductive paste to ensure perfect heat transfer.
If the temperature sensor is covered by other parts, please refer to instructions for
removing the part concerned, and see the special instructions in the Changing compon-
ents section, if available.
59
Changing the TTS 22 PC board
ESD measures NOTE! There is danger of damage to the TTS 22 PC board from electrical
discharge. When changing the TTS 22, take appropriate ESD (electrostatic
discharge) measures. These include:
- The workspace used when removing the board must be equipped with the following
ESD-appropriate protective measures:
- Work surfaces
- Floors
- Conductive wristband
- Seating
- In addition to the ESD-appropriate workspace, use a suitable transport container
(1)
(2)
(1)
(11)
(1)
UST PC board:
- Remove plug connections (1)
- Unscrew the 5 spacers (2) and metal spacer (11)
- Remove UST PC board
60
Changing the - Unscrew the two spacers (4) on the
TTS 22 PC board insulating sheet
(continued)
(4) (4)
Fig. 2 Loosening the spacers
(5) (6)
Fig. 3 Removing plug connections from sockets
(9)
(7)
Fig. 5 Removing TTS 22 PC board and spacers
61
Installing the TTS - Place the TTS 22 (7) on the spacers (8) on the retaining plate
22 PC board
- Screw in the five spacers (8) on TTS
22 PC board
- Replace TTS 22 PC board (7) com-
plete with retaining plate
(8)
(7)
Fig. 6 Fasten TTS 22 PC board with spacers
(5) (6)
Fig. 8 Inserting plugs into sockets
(4) (4)
Fig. 9 Tightening spacers
62
Installing the TTS - Lay down UST PC board
22 PC board
(continued)
(2)
(1) (2)
(1)
(11)
(1)
UST PC board:
- reinsert plug connections (1)
NOTE! When tightening the spacers (2), screw metal spacer into position (11).
63
Changing the BSV 22 PC board
ESD measures NOTE! There is danger of damage to the BSV 22 PC board from electrical
discharge. When changing the BSV 22, take appropriate ESD (electrostatic
discharge) measures. This includes:
- The workspace used when removing the board must be equipped with the following
ESD-appropriate protective measures:
- Work surfaces
- Floors
- Conductive wristband
- Seating
- In addition to the ESD-appropriate workspace, use a suitable transport container
(1)
(2)
(1)
(11)
(1)
UST PC board:
- Remove plug connections (1)
- Unscrew the 5 spacers (2) and metal spacer (11)
- Remove UST PC board
64
Removing the - Unscrew the two spacers (4) on the
BSV 22 PC board insulating sheet
(continued)
(4) (4)
Fig. 2 Loosening the spacers
(9)
(8) (8)
Fig. 5 Removing BSV 22 PC board and spacers
65
Installing the - Place the BSV 22 (7) on the spacers (8) on the retaining plate
BSV 22 PC board
- Tighten the four spacers (8) on BSV
(8) (7) (8) (10)
22 PC board (7)
- Replace BSV 22 PC board (7) com-
plete with retaining plate
(8) (8)
Fig. 6 Fasten BSV 22 PC board with spacers
(4) (4)
Fig. 9 Tightening spacers
66
Installing the BSV - Lay down UST PC board
22 PC board
(continued)
(1) (2)
(1)
(11)
(1)
UST PC board:
- reinsert plug connections (1)
NOTE! When tightening the spacers (2), screw metal spacer into position (11).
67
Changing the transformer
(1) (1)
Fig. 1 Undoing screws on front of device frame
(2)
(3)
68
Removing the - Undo the two screws (4) on HF
transformer transformer (5)
(continued)
(5)
(4)
(6)
(7)
(8) (7)
Fig. 7 Removing toroidal tape cores
69
Removing the - Undo hexagon bolt (9) using a size 19
transformer spanner
(continued) - Remove hexagon bolt (9) with serra-
(12) ted washer and shim
(10)
The following leads are now disconnected:
(11) - Middle tap transformer lead (10)
(9) - Measuring line (11) - white cable with
Massebuchse written on it
- Secondary wiring lead (12) - white
cable with no writing
(13) (13)
Fig. 9 Loosening the spacers
70
Removing the - Remove measuring lead (16) for the
transformer welding voltage
(continued) (18) - Feed out the middle tap transformer
lead (17) on the current sensor (18)
(16) (17)
(19)
(23)
(25)
(22)
71
Removing the - Unthread the middle tap transformer
transformer lead (17) on the EP rings (25)
(continued) (see also Fig. 14)
(25)
(17)
(26)
(27)
Fig. 16 Removing the plates on the transformer
Installing the - Fasten side plates (27) to the transformer using the four screws (26)
transformer
- Thread EP rings (25) onto the middle
tap transformer lead (17) and make
(24) two winds
- Fasten EP rings (25) and middle tap
(23) transformer lead (17) with cable ties
(25)
(22)
72
Installing the - Installing the transformer (22) into the power source
transformer
(continued) - Tighten screws (22)
(16)
(17)
73
Installing the - Feed middle tap transformer lead (17)
transformer in direction of arrow through the
(continued) (18) current sensor (18)
- Route measuring line (16) for the
blade terminal X1 common
(see fig. 19)
(16) (17)
(13) (13)
Fig. 24 Tightening spacers
74
Installing the
transformer
(continued)
(12)
(10)
(11)
(9)
(9)
Align the following components on the hexagon bolt (9) in the numbered order:
- Serrated washer (29)
- Shim (30)
- Measuring line (11) - white cable with Massebuchse written on it
- Secondary wiring lead (12) - white cable with no writing
- Middle tap transformer lead (10)
- Tighten hexagon bolt (9) using a size 19 spanner
(8) (7)
Fig. 26 Fitting toroidal tape cores
(31)
(7)
NOTE!When tightening the screws with serrated washers for the secondary
voltage of the transformer, maintain the tightening torque given below.
- Slide the serrated washers onto the fastening screws (not shown).
- Fasten the secondary transformer leads (7): Tighten the screws (31) including
serrated washers (not shown) with a torque of 4 Nm.
75
Installing the (5) - Lift high frequency (HF) transformer
transformer (5) and tighten two screws (6) behind
(continued) the HF transformer
(6)
(4)
(3)
- Connect the ribbon cable (2) for the control panel at X2 on the UST PC board
- Insert the operating panel
76
Installing the - Press front of frame on
transformer - Tighten two front screws (1) for the
(continued) device frame
(1) (1)
77
Safety Inspection
Work instruction The work instruction Safety Inspection of Arc Welding and Cutting Equipment is avai-
lable in the TechGuide DownloadCenter under Safety, Environment & Health.
78
Terms and abbreviations used
General remarks Terms and abbreviations is a glossary of specific technical terms essential for an
understanding of the service manual.
DSP:
Digital SignalProcessor. 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 ensu-
res constant regulation and optimisation of the welding current and voltage, on the basis
of
- the parameters set
- the saved firmware
- the actual values measured
EMI:
ElectroMagnetic Interference. Electromagnetic interference is high-frequency noise in
the mains voltage. The line filter absorbs this noise and thereby ensures optimum
welding results and trouble-free operation of the power source.
FAC:
Factory 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 parameters in the second level of the
set-up menu are not deleted.
Hall shunt:
Ensures electrically isolated measuring of the welding current. The UST (central control
and regulation unit) analyses the signal.
IGBT:
Insulated Gate Bipolar Transistor. This is a special bipolar transistor for switching to high
power settings. IGBTs are used in the power source as modules. On the TT/MW 1700/
2200 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)
79
80
TransTig 800
TransTig 2200
MagicWave 1700
MagicWave 2200
PlasmaModule 10
FK 2200
MagicWave 2200 Job G/F 4,075,119 MagicWave 2200 G/F 4,075,125
MagicWave 2200 Job G/F/US 4,075,119,800 MagicWave 2200 G/F/US 4,075,125,800
TransTig 800 Job G/F 4,075,159 TransTig 2200 G/F 4,075,126
TransTig 2200 Job G/F 4,075,120 TransTig 2200 G/F/US 4,075,126,800
TransTig 2200 Job G/F/US 4,075,120,800 MagicWave 1700 G/F 4,075,127
MagicWave 1700 Job G/F 4,075,121 MagicWave 1700 G/F/US 4,075,127,800
MagicWave 1700 Job G/F/US 4,075,121,800
12,0405,0369
42,0201,1328
42,0406,0320
43,0004,1993 - US
43,0004,0519
AM2,0201,1327
43,0002,0295
42,0300,0648
45,0200,1151
42,0409,2979 - US
42,0409,2911
42,0001,3541 - US
43,0013,0015
42,0407,0273 BE2,0201,1329
40,0001,0310 - *
12,0405,0365
33,0005,4146 - TT800
33,0005,4130 - MW1700
33,0005,4129 - MW/TT2200
43,0006,0152 - MW2200
43,0006,0134 - MW1700/TT800/2200
42,0405,0421
4,070,949 - FMW22IS
41,0003,0279
41,0003,0203
12,0405,0365 33,0010,0326
43,0001,1177 43,0001,0600
43,0001,1176 - TT
43,0001,1178
43,0001,3280 - TT 2200 42,0409,3211 - TT800 43,0001,1273 TT800
43,0001,3279 - MW1700/2200 42,0409,2935 - TT2200
43,0001,3258 - TT800/2200 Job 42,0409,2934 - MW1700
43,0001,3259 - MW1700/2200 Job 42,0409,2882 - MW2200
42,0406,0315 * gewnschte Lnge angeben
42,0405,0398 - MW1700/2200 * Specify the length required
42,0406,0093 42,0405,0399 - TT2200 * Indiquer la longueur dsire
* Indicar la longitud deseada
42,0001,1501 43,0004,2328 * Indicare la lunghezza desiderat
* indicar o comprimento desejado
42,0001,5477 43,0004,2330
XYHG
WHSRDGRYDQRXGpONX
32,0405,0183
42,0404,0024
el_fr_st_wi_00545 012007
4,070,813 - BSV22 TT2200
4,070,798,Z - BPS17 MW 1700/TT 800
4,070,804,Z - TTS22 MW1700/2200
4,070,799,Z - BPS22 TT/MW 2200
41,0001,0627
41,0009,0057
33,0024,0032
2
S2
TT 22 33,0010,0325 - MW/TT2200
V
BS
S
BP 43,0006,0168
43,0001,1191
42,0405,0420
4,070,960,Z - UST2C
T2
2 US
F2
HF
4,070,812 - HFF22
43,0004,1122 - 26pol.
el_fr_st_wi_00545 012007
FRONIUS INTERNATIONAL GMBH
Buxbaumstrae 2, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.
ud_fr_st_so_00082 012008