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