FRO­NIUS TransSynergic 4000 User manual

TransSynergic 4000/5000
TransPuls Synergic 2700
TransPuls Synergic 3200/4000/5000
Service manual
Spare parts list
MIG/MAG Power source
/ Battery Charging Systems / Welding Technology / Solar Electronics
EN
42,0410,1237 011-28062017

1
EN
Table of contents
Foreword and safety instructions .................................................................................................................. 6
Safety ....................................................................................................................................................... 6
Fronius Technical Support Center (TSC) ................................................................................................. 6
General remarks ...................................................................................................................................... 6
Function overview .................................................................................................................................... 7
Fault location aid ...................................................................................................................................... 7
Detailed description ................................................................................................................................. 7
Changing components ............................................................................................................................. 7
Terms and abbreviations used................................................................................................................. 7
Spare parts list and entire circuit diagram ............................................................................................... 7
Tools and measuring instruments ............................................................................................................ 7
Tools and measuring instruments ................................................................................................................. 8
General remarks ...................................................................................................................................... 8
Tools required .......................................................................................................................................... 8
Measuring and inspection equipment ...................................................................................................... 8
Ancillary materials .................................................................................................................................... 8
Function overview ......................................................................................................................................... 9
Principle of the digital family of machines ................................................................................................ 9
Useful information .................................................................................................................................... 9
Block diagram ........................................................................................................................................ 10
Block diagram legend ............................................................................................................................ 10
Fault location aid ......................................................................................................................................... 12
General remarks .................................................................................................................................... 12
Fault flowcharts ........................................................................................................................................... 13
Overview ................................................................................................................................................ 13
Poor ignition and welding properties with „MIG/MAG welding“ ............................................................. 14
Poor ignition and welding properties with „TIG welding“ ....................................................................... 15
Poor weld properties with „rod electrode (MMA) welding“ ..................................................................... 16
Nothing happens on control panel (TPS 2700) .....................................................................................17
Nothing happens on control panel (TPS 3200/4000/5000) ................................................................... 19
No or incorrect welding current.............................................................................................................. 21
No or incorrect wirefeed speed.............................................................................................................. 22
Insufficient torch cooling (FK 4000/FK 4000 R) ..................................................................................... 23
Service code Err 50 ............................................................................................................................... 25
UST service codes ...................................................................................................................................... 27
Safety ..................................................................................................................................................... 27
Table of service codes ........................................................................................................................... 27
Special displays used with service codes .............................................................................................. 33
Service codes SR 4xA ................................................................................................................................ 34
Safety ..................................................................................................................................................... 34
Table of service codes ........................................................................................................................... 34
Service codes for push-pull calibration ....................................................................................................... 35
Safety ..................................................................................................................................................... 35
Checking actual-value pick-up............................................................................................................... 35
Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 35
Error codes shown when the drive units are engaged („engaged“ calibration) ..................................... 36
Detailed description .................................................................................................................................... 38
General remarks .................................................................................................................................... 38
Position of electronic components ......................................................................................................... 38
Overview ................................................................................................................................................ 38
ASU 27 - additional PC board..................................................................................................................... 39
General remarks .................................................................................................................................... 39
Component position in the machine ...................................................................................................... 39
Overview ................................................................................................................................................ 39

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Technical Data ....................................................................................................................................... 39
Function overview .................................................................................................................................. 40
Plug layout ............................................................................................................................................. 40
LED checklist ......................................................................................................................................... 41
Measuring points ................................................................................................................................... 41
ASU 40 - additional PC board..................................................................................................................... 42
General remarks .................................................................................................................................... 42
Component position in the machine ...................................................................................................... 42
Overview ................................................................................................................................................ 42
Technical Data ....................................................................................................................................... 43
Function overview .................................................................................................................................. 43
Plug layout ............................................................................................................................................. 43
LED checklist ......................................................................................................................................... 44
Measuring points ................................................................................................................................... 45
BPS 25/BPT 27 - power module PC board ................................................................................................. 46
General remarks .................................................................................................................................... 46
Component position in the machine ...................................................................................................... 46
Overview ................................................................................................................................................ 46
Technical Data ....................................................................................................................................... 47
Function overview .................................................................................................................................. 47
Plug layout BPS 25/BPT 27 ................................................................................................................... 47
LED checklist ......................................................................................................................................... 49
Measuring points ................................................................................................................................... 49
BPS 32/40/42/43/50/53 - power module PC board .................................................................................... 51
General remarks .................................................................................................................................... 51
Component position in the machine ...................................................................................................... 51
Overview ................................................................................................................................................ 51
Technical Data ....................................................................................................................................... 52
Function overview .................................................................................................................................. 52
Plugs on the power module PC boards ................................................................................................. 53
Plug layout ............................................................................................................................................. 53
LED checklist of power module PC boards ........................................................................................... 55
Measuring points ................................................................................................................................... 55
NT 24 - switched mode power supply 24 V ................................................................................................ 58
General remarks .................................................................................................................................... 58
Component position in the machine ...................................................................................................... 58
Overview ................................................................................................................................................ 58
Technical Data ....................................................................................................................................... 59
Function overview .................................................................................................................................. 59
Plug layout ............................................................................................................................................. 59
LED checklist ......................................................................................................................................... 60
Measuring points ................................................................................................................................... 60
NT 60 - switched mode power supply 60 V ................................................................................................ 62
General remarks .................................................................................................................................... 62
Component position in the machine ...................................................................................................... 62
Overview ................................................................................................................................................ 62
Technical Data ....................................................................................................................................... 63
Function overview .................................................................................................................................. 63
Plug layout ............................................................................................................................................. 63
LED checklist ......................................................................................................................................... 64
Measuring points ................................................................................................................................... 64
UST - Control and regulation unit ............................................................................................................... 66
General remarks .................................................................................................................................... 66
Component position in the machine ...................................................................................................... 66
Overview ................................................................................................................................................ 66
Technical Data ....................................................................................................................................... 67
Plug layout ............................................................................................................................................. 67
Function overview .................................................................................................................................. 67
LED checklist ......................................................................................................................................... 69

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EN
Measuring points ................................................................................................................................... 69
Changing UST PC board ....................................................................................................................... 69
NF 3160 - Line filter .................................................................................................................................... 70
General remarks .................................................................................................................................... 70
Component position in the machine ...................................................................................................... 70
Overview ................................................................................................................................................ 70
Technical Data ....................................................................................................................................... 70
Function overview .................................................................................................................................. 71
Plug layout ............................................................................................................................................. 71
LED checklist ......................................................................................................................................... 71
Measuring points ................................................................................................................................... 71
NF 3400 - Line filter/line filter 40 A/80 A ..................................................................................................... 72
General remarks .................................................................................................................................... 72
Component position in the machine ...................................................................................................... 72
Overview ................................................................................................................................................ 72
Technical Data ....................................................................................................................................... 73
Function overview .................................................................................................................................. 73
Plug layout NF 3400 .............................................................................................................................. 73
Plug layout line filter 40 A/80 A .............................................................................................................. 74
LED checklist ......................................................................................................................................... 74
Measuring points ................................................................................................................................... 74
Shunt........................................................................................................................................................... 75
General remarks .................................................................................................................................... 75
Component position in the machine ...................................................................................................... 75
Overview ................................................................................................................................................ 75
Technical Data ....................................................................................................................................... 76
Function overview .................................................................................................................................. 76
Plug layout ............................................................................................................................................. 76
LED checklist ......................................................................................................................................... 76
Measuring points ................................................................................................................................... 76
SR 41 - Wire-feed unit regulation unit......................................................................................................... 77
General remarks .................................................................................................................................... 77
Component position in the machine ...................................................................................................... 77
Overview ................................................................................................................................................ 77
Technical Data ....................................................................................................................................... 78
Function overview .................................................................................................................................. 78
Plug layout ............................................................................................................................................. 78
LED checklist ......................................................................................................................................... 80
Measuring points ................................................................................................................................... 81
Temperature sensor TP 592S ..................................................................................................................... 82
General remarks .................................................................................................................................... 82
Component position in the machine ...................................................................................................... 82
Technical Data ....................................................................................................................................... 83
Function overview .................................................................................................................................. 83
Plug layout ............................................................................................................................................. 83
Measuring points ................................................................................................................................... 83
Secondary power module TPS 2700 .......................................................................................................... 84
General remarks .................................................................................................................................... 84
Component position in the machine ...................................................................................................... 84
Overview ................................................................................................................................................ 84
Function overview .................................................................................................................................. 85
Measuring points ................................................................................................................................... 85
Secondary power module TS 4000/5000, TPS 3200/4000/5000 ............................................................... 86
General remarks .................................................................................................................................... 86
Component position in the machine ...................................................................................................... 86
Overview ................................................................................................................................................ 86
Function overview .................................................................................................................................. 87
Measuring points ................................................................................................................................... 87

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Primary rectifier ........................................................................................................................................... 88
General remarks .................................................................................................................................... 88
Component position in the machine ...................................................................................................... 88
Overview ................................................................................................................................................ 88
Function overview .................................................................................................................................. 88
Plug layout ............................................................................................................................................. 89
Measuring points ................................................................................................................................... 89
Changing components ................................................................................................................................ 90
Safety ..................................................................................................................................................... 90
General remarks .................................................................................................................................... 90
Overview ................................................................................................................................................ 90
Changing throttle (TS 4000/5000, TPS 3200/4000/5000) .......................................................................... 91
Removing throttle ................................................................................................................................... 91
Fitting throttle ......................................................................................................................................... 92
Changing throttle (TPS 2700) ..................................................................................................................... 94
Removing throttle ................................................................................................................................... 94
Fitting throttle ......................................................................................................................................... 95
Changing earth current watchdog .............................................................................................................. 98
Removing earth current watchdog ......................................................................................................... 98
Fitting earth current watchdog ............................................................................................................... 99
Changing PC board ASU 27 (TPS 2700 MV) ........................................................................................... 101
Removing ASU 27 ............................................................................................................................... 101
Fitting ASU 27 ...................................................................................................................................... 101
Changing shunt (TPS 2700) ..................................................................................................................... 102
Removing shunt ................................................................................................................................... 102
Fitting shunt ......................................................................................................................................... 103
Changing temperature sensor TP 592S ................................................................................................... 105
Notes.................................................................................................................................................... 105
Changing transformer (TS 4000/5000, TPS 3200/4000/5000) ................................................................. 106
Removing transformer ......................................................................................................................... 106
Fitting transformer ................................................................................................................................ 107
Changing transformer (TPS 2700)............................................................................................................ 109
Removing transformer ......................................................................................................................... 109
Fitting transformer .................................................................................................................................110
Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000) ....................................112
Removing intermediate circuit capacitors .............................................................................................112
Fitting intermediate circuit capacitors ...................................................................................................113
Safety inspection........................................................................................................................................115
General .................................................................................................................................................115
Responsibility ........................................................................................................................................115
Visual inspections ......................................................................................................................................116
General .................................................................................................................................................116
General conditions ................................................................................................................................116
Welding torch/electrode holder/welding current return terminal ...........................................................116
Mains supply and connecting lines .......................................................................................................116
Welding circuit.......................................................................................................................................116
Housing and covers ..............................................................................................................................117
Adjustment and display devices ...........................................................................................................117
Electrical tests ............................................................................................................................................118
Ground conductor resistance ...............................................................................................................118
Insulation resistance .............................................................................................................................119
Open circuit voltage U0 ........................................................................................................................119

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EN
Function tests............................................................................................................................................ 120
General ................................................................................................................................................ 120
Mains power on/off equipment............................................................................................................. 120
Indicators and controls......................................................................................................................... 120
Gas solenoid valve .............................................................................................................................. 120
Earth current watchdog........................................................................................................................ 120
Test weld .............................................................................................................................................. 120
Documentation .......................................................................................................................................... 121
Test record ........................................................................................................................................... 121
Test label .............................................................................................................................................. 121
Terms and abbreviations used.................................................................................................................. 122
General remarks .................................................................................................................................. 122
Terms and abbreviations...................................................................................................................... 122
Entire circuit diagram ................................................................................................................................ 124
Storage location ................................................................................................................................... 124
Spare parts list / Circuit diagram
Fronius Worldwide

6

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EN
Foreword and safety instructions
General remarks The service instructions can be found in the TechGuide at www.fronius.com\techguide
Each chapter in the service instructions deals with one complete topic. Use each
chapter as a self-contained information source. A short description of each chapter
follows:
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 personnel. Take note of the „Safety rules“ chapter in the power
source operating instructions.
WARNING! An electric shock can be fatal. If the machine needs to be switched
on briefly for testing while the housing is open,
- Do not touch the parts inside the housing
- Only touch using suitable measuring or test probes
CAUTION! Inadequate PE conductor connections can cause serious injury
and damage. The housing screws provide a suitable PE conductor connection
for earthing (grounding) the housing and must NOT be replaced by any other
screws which do not provide a reliable PE conductor connection.
WARNING! An electric shock can be fatal. Before opening up the machine
- Move the mains switch to the “O” position
- Unplug machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that electrical-
ly charged components (e.g. capacitors) have been discharged
Fronius Techni-
cal Support
Center (TSC)
If you have any questions about fault isolation, there is a team of experts on hand.
E-mail: [email protected]

8
Contains a description of essential terms and abbreviations for a better understanding
of the service instructions
The „Spare parts list“ and „Entire circuit diagram“ sections contain the complete spare
parts list and complete circuit diagram for the power source.
In the „Changing components“ section there is a description of how to change compon-
ents which
- have no instructions of their own regarding changing and
- require a complete description of how to change them
Serves to systematically locate and rectify the source of faults, and contains the follo-
wing elements:
- The actual fault flowchart for dealing with general faults
- Service codes table for dealing with faults whose service codes appear on the
display
Contains detailed descriptions of the relevant components in the power source.
For every component, the following topics are dealt with:
- General remarks (designation, item number of the component)
- Component position in the machine
- Overview
- Technical Data
- Function overview
- Plug layout
- LED checklists
- Measuring points
Fault location aid
Detailed descrip-
tion
Changing com-
ponents
Terms and abbre-
viations used
Spare parts list
and entire circuit
diagram
Tools and
measuring
instruments
This provides an overview and description of all equipment required for servicing the
power source professionally. This equipment includes:
- Tools required
- Measuring and inspection equipment
- Ancillary materials
Function over-
view
Contains a brief descriptive overview of the entire system:
- in text form
- in block diagram form

9
EN
„Tools and measuring instruments“ offers an overview and description of all equipment
needed to service the machine professionally. This equipment includes:
- Tools required
- Measuring and inspection equipment
- Ancillary materials
- Box spanner (8 mm)
- Large needle nosed pliers (approx. 160 mm)
- Small wire cutting pliers
- Manual torque wrench (1-6 Nm, 42,0411,0013)
- Slotted screwdriver (small)
- Slotted screwdriver (medium)
- Phillips screwdriver (PH1)
- Phillips screwdriver (PH2)
- Torx screwdriver (TX 20) or insert bit for manual torque wrench
- Torx screwdriver (TX 25) or insert bit for manual torque wrench
- Allen key (3 mm)
- Allen key (4 mm)
- Allen key (5 mm)
- Flat spanner (13 mm)
- Flat spanner (17 mm)
- Flat spanner (19 mm)
- Oeteker pliers
- Molex extractor tool (42,0410,0290)
- Digital multimeter
- PC with MS Windows operating system
(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)
- CD ROM TechGuide (40,0006,2365)
- Contact spray (40,0009,0014) or alcoholic solvent
- Heat-conductive paste (40,0009,0043)
- Application instrument for heat-conductive paste (42,0435,0020)
- Sandpaper (42,0410,0436), grit size 500 or finer
Tools and measuring instruments
General remarks
Tools required
Measuring and
inspection equip-
ment
Ancillary materi-
als

10
Fig. 1 Function outline
Function overview
Principle of the
digital family of
machines
Useful informati-
on
The machines are totally digitized, microprocessor-controlled inverter power sources. A
universal control regulates the entire welding process. The actual data are measured
continuously, and the machine responds immediately to any changes. Special control
algorithms ensure that the target status is maintained at all times. A decisive factor for
the power source welding properties is the software system, instead of a rigid, barely
alterable hardware system. This gives the weld process an unrivalled degree of precisi-
on, with exact reproducibility of welding results and excellent operating properties.
BSL-Tool
OS
DB
UST
Local Net
CFM
In the universal control (UST), there is information on subsequently enabled options.
Information on power source functions and parameters as well as data related to the
process are called up from the operating system (OS) by the universal control. The
welding program database (DB) contains welding-engineering know-how. Welding
characteristics for different materials and their parameter settings are called up from
this database.
Important! The operating system and the welding process database are constantly
being enhanced. Use „Update“ to bring the software up to date. The BSL tool is used for
this purpose. Enabled options need only be reactivated after the UST PC board has
been changed.
Communication with system components takes place via a serial databus (LocalNet).
The LocalNet connection socket is the interface for system components, e.g. wire-feed
unit or remote control. Establishing a connection and disconnecting takes place accor-
ding to the „plug and play“ principle.

11
EN
Block diagram
Control and
regulation unit
(1)
(2)
Mains filter
(3)
Primary rectifier
(4)
TPS 2700 only: PFC
(Power Factor Control)
(5)
Intermediate circuit
capacitors
(6)
Transistors
(7)
Welding transformer
(8)
Secondary
Rectifer
(9)
Output choke
(10)
Welding current
sensor
Workpiece
Welding torches
Control panel
Remote control
unit
Wire-feed unit
24 V 55 V
Power
supply
55 V
24 V
Primary power module
Local
Net
Local
Net
Uact
Iact
Control lead
Fig. 2 Block diagram of Trans Synergic 4000/5000 and TransPuls Synergic 2700/3200/4000/5000 power
sources
3 x 400 V
Block diagram
legend
(1) Control and regulation unit:
Controls, regulates and monitors the welding process and all power source func-
tions.
(2) Line filter (EMV):
For attenuation of
- high frequency parts of the mains supply
- reactions on the mains supply
(3) Primary rectifier:
Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage.
(4) PFC (Power Factor Control, TPS 2700 only):
Ensures a sinusoidal current input.
(5) Intermediate circuit capacitors:
Store and smooth the intermediate circuit voltage.
Regulation unit
Valve
Gas
Wire

12
Block diagram
legend
(continued)
(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 built very easily and compactly.
- Thermal losses due to the low inductivity required of the transformer coils can
be kept to an absolute minimum.
(7) Welding transformer:
- Transforms the high primary voltage into a low secondary voltage.
- Ensures electrical isolation of primary and secondary power modules.
(8) Secondary rectifier:
Converts the secondary voltage into a direct voltage.
(9) Output choke:
smooths the output current.
(10) Welding current sensor:
Registers the present actual current for the welding process.

13
EN
Fault location aid
General remarks The „Fault location aid“ section consists of the following parts
- Fault flowcharts
- Table of service codes
The fault flowcharts are for the systematic locating and rectifying of fault sources. In the
„Table of service codes“ section, there is also a table which deals with the service
codes shown on the display, as well as causes and measures for rectifying them.
Before starting with the fault location aid, read the „Function overview“ section and
study the entire circuit diagram in order to understand the composition and functioning
of the power source.
Important! The following NOTE applies to those with even less experience of troubles-
hooting the power sources. Before working with the fault location aid, read the following
section:
- „Function overview“
- „Entire circuit diagram“

14
Overview The overview will help you to find the relevant (section of) flowchart.
The positions and meanings of the LEDs for the components/PC boards can be found
in the „Detailed description“ section. The „Detailed description“ section contains an
„LED checklist“ sub-section for each of the components/PC boards (with LEDs).
Fault flowcharts
Poor ignition and weld properties with
the selected „TIG welding“ process
Nothing happens on control panel
(TPS 2700)
No welding current, or current does not
correspond to set value
Service codes displayed
Mains switch in the
“On” position
Poor weld properties with selected „rod
electrode (MMA) welding“ process
Insufficient welding torch cooling (FK
4000/FK 4000 R)
Poor ignition and weld properties with
the selected „MIG/MAG welding“
process
Nothing happens on control panel
(TPS 3200/4000/5000)
No or incorrect wirefeed

15
EN
Poor ignition and
welding proper-
ties with „MIG/
MAG welding“
End
Correct shielding gas connected,
and l/min set correctly?
Start
Gas-test button: Shielding gas
flowing out?
Welding torch and grounding
(earthing) cable OK?
Parameters set correctly?
Check shielding gas solenoid
valve, including control
Check welding torch and groun-
ding (earthing) cable
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory set-
tings (FAC) (see operating instruc-
tions)
Check whether power source OK,
and check application
Connect correct shielding gas and
check l/min
Yes
No
No
No
Yes
Yes
Yes
No

16
Poor ignition and
welding proper-
ties with „TIG
welding“
End
Correct shielding gas connected,
and l/min set correctly?
Start
Gas-test button: Shielding gas
flowing out?
Welding torch and grounding
(earthing) cable OK?
Parameters set correctly?
Check shielding gas solenoid
valve, including control
Check welding torch and groun-
ding (earthing) cable
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory set-
tings (FAC) (see operating instruc-
tions)
Check whether power source OK,
and check application
Connect correct shielding gas and
check l/min
Yes
No
No
No
Yes
Yes
Yes
No

17
EN
Poor weld pro-
perties with „rod
electrode (MMA)
welding“
Connect cable correctly
Electrodes/grounding (earthing)
cable connected/functioning
correctly?
Start
Parameters set correctly?
Check whether power source OK,
and check application
End
No
No
Yes
Yes
- Check settings on control panel
- Check set-up parameters
- Possibly reset to factory set-
tings (FAC) (see operating instruc-
tions)

18
Start
Voltage OK on prima-
ry rectifier V1=320V/
560V DC?
Check mains cable,
mains switch, line
filter, rectifier and
supply voltage
No
Voltage on intermedi-
ate circuits 1 and 2 >
250V DC?
Change BPS
Are LEDs +5V, +12V
flashing on the ASU 27,
as well as LED for mains
400V at 400V Unom,
and LED for mains 230V
at 230V Unom?
Change ASU 27
On MV power sources
Change BPS
+24V int/ext LEDs
flashing on UST?
Switch power source
off, unplug plug X3
from UST, switch
power source on
Change NT 24
Yes
Yes
Steady +24V int/ext
LEDs on NT 24?
Switch power source
off, plug X3 plug into
UST and unplug X7,
switch power source
on
No
No
Check cooling unit
Steady +24V int/ext
LEDs on UST?
Yes
No
Yes
No
Change BPS
No
Yes
Yes
A
Nothing happens
on control panel
(TPS 2700)