FRO­NIUS TransSteel 2200 User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
TransSteel 2200
MTG 2100S
EN
Service manual
MIG/MAG power source
42,0426,0273,EN 007-01042021

Contents
General information 5
Foreword and safety instructions 7
Safety 7
Fronius Technical Support National (TSN) 7
General 7
Tools and measuring devices 8
Tools required 8
Measuring and testing equipment 8
Ancillary materials 8
Error location aid 9
LED checklists 11
LSTMAG20 LED checklist 11
Measuring points 13
TSt 2200c measuring points 13
Temperature sensor 13
Service codes 15
General 15
Service codes table 15
Replacing modules 23
Replacing modules 25
Safety 25
General 25
Opening the housing 26
Opening the housing 26
Replacing the LSTMAG20 PC board 27
Removing the LSTMAG20 PC board 27
Installing the LSTMAG20 PC board 28
Replacing secondary diodes 30
Replacing the secondary diode 30
Replacing the fan 32
Replacing the fan 32
Replacing the transformer 33
Removing the transformer 33
Fitting the transformer 33
Replacing the solenoid valve 35
Replacing the solenoid valve 35
Replacing the drive 37
Removing the drive 37
Installing the drive 38
Calibrating the motor 38
Replacing the motor plate 40
Removing the motor plate 40
Installing the motor plate 41
Closing the housing 43
Closing the housing 43
MTG 2100 S 44
MTG2100S welding torch/trigger/coaxial cable 44
MTG2100S FSC 45
MTG2100S inspection following repairs 46
Software 49
Software update 51
Software update 51
Service menu 52
3
EN

General 52
Opening/closing the service menu 52
Description of the menu contents 52
Safety Inspections 55
Safety Inspections 57
Safety inspection 57
Responsibility 57
Test record 57
Visual inspections 58
General 58
Mains supply and connecting lines 58
Housing and covers 58
Adjustment and display devices 58
Rating plate and warning stickers 58
Electrical tests 59
Ground conductor resistance 59
Insulation resistance 59
Open circuit voltage 60
Documentation 61
Documentation 61
Function tests 62
Mains on/off devices 62
Indicators and control elements 62
Gas solenoid valve 62
Test weld 62
4

General information
5

6

Foreword and safety instructions
Safety The following safety instructions apply to all activities described in this service manual:
WARNING!
Work that is carried out incorrectly can cause serious injury and damage.
All activities described in the service manual must only be carried out by Fronius-trained
service technicians. Read the "Safety rules" chapter in the power source operating
instructions.
WARNING!
An electric shock can be fatal.
Before opening the device
▶Turn the mains switch to the "O" position
▶Unplug the machine from the mains
▶Prevent it from being switched on again
▶Using a suitable measuring instrument, check to make sure that electrically charged
components (e.g. capacitors) have discharged
WARNING!
An electric shock can be fatal.
If the device needs to be switched on briefly for testing while the housing is open:
▶Do not touch any parts inside the housing
▶Only touch using suitable measuring or test probes
WARNING!
An inadequate ground conductor connection can cause serious injury or damage.
The housing screws provide a suitable ground conductor connection for earthing the
housing and must NOT be replaced by any other screws that do not provide a reliable
ground conductor connection.
Fronius Technical
Support National
(TSN)
If you have any questions about error analysis, your Fronius Technical Support National
(TSN) sales team will be able to help.
mailto: [email protected]
General The service manual can be obtained from the DownloadCenter at "downloadcen-
ter.fronius.com".
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.
7
EN

Tools and measuring devices
Tools required - Torx screwdriver (TX8)
- Torx screwdriver (TX10)
- Torx screwdriver (TX20)
- Torx screwdriver (TX25)
- Torx screwdriver (TX40)
- Box spanner, 8 mm
- Flat spanner, 17 mm
- 2 x flat spanner, 15 mm
- Flat spanner, 19 mm
- Slotted screwdriver, 3 mm
- Phillips screwdriver (PZ2)
- Phillips screwdriver (PH2)
- Torque wrench, 1 - 5 Nm
- BT1 fitting tool (item number 42,0411,0039)
- Torque wrench (item number 42,0411,9040)
- Adjustable spanner insertion tool (item number 42,0435,0229)
Measuring and
testing equip-
ment
- Digital multimeter
- Insulation tester (Metriso 5000)
- Torch flow rate testbox (4,078,016)
- Flow and leak tester
- Manual welding torch testbox (4,045,998)
- Apparatus tester e.g. Fluke 6200
Ancillary materi-
als
- Contact spray or alcohol-based solvent
- Cleaning paper
8

Error location aid
9

10

LED checklists
LSTMAG20 LED
checklist
RXD-A
TXD-A
+15V
+5V
+24Vint
TXD-B RXD-B
+14Vprim
+24VMotor
LT-ON
-15V TXsec
PFC Error TXprim
ntc-1 ntc-2
ntc-3 ntc-4
LED Description
+5V Lights up when there is a supply voltage of + 5 V DC
+14Vprim Lights up when there is a primary supply voltage of + 14 V DC
+15V Lights up when there is a supply voltage of + 15 V
-15V Lights up when there is a supply voltage of - 15 V
+24Vint Lights up when there is an internal primary supply voltage of + 24 V
+24VMotor Lights up when there is a supply voltage of +24 V for the motor
TXD-A Lights up when data is being transferred to the control panel
RXD-A Lights up when data is being transferred to the control panel
TXD-B Flashes in normal operation; lights up when data is being sent to
the LocalNet update interface
RXD-B Lights up when data is being received by the LocalNet update inter-
face
TXsec Flashes in normal operation when data is being transferred from
the secondary circuit to the primary circuit
11
EN

LED Description
TXprim Lights up when data is being transferred from the primary circuit to
the secondary circuit
LT-On Lights up when the power module is switched on
PFC Flashes when there are no errors on the PFC
Error Lights up when the PFC is faulty or is not configured
Temperature
sensor
Description
ntc-1 PC board wirefeeder
ntc-2 Temperature sensor of the motor controller voltage doubler
ntc-3 Temperature sensor of the motor controller secondary circuit
ntc-4 Temperature sensor of the motor controller PFC
12

Measuring points
TSt 2200c
measuring points
The image below shows the measuring points on the secondary diodes.
The secondary diodes can be measured in the de-energised state with a multimeter in
diode test mode.
A voltage of approx. 0.15 V must be measured in the conducting direction of the diode
(1). Other measuring results indicate a defect in the diode, meaning it needs to be
replaced.
Temperature
sensor
X2
Cooling element /
transformer connection
X2 2-pin Microfit connector
Pin 1 Temperature signal Pin 2 + 5 V
A temperature-dependent resistance as per the table below must be measured between
pins 1 and 2 of the X2 connector.
Temp. [°C] R Nom [W] Temp. [°C] R Nom [W] Temp. [°C] R Nom [W]
0 32,650 35 6531 70 1752
5 25,388 40 5327 75 1481
10 19,900 45 4369 80 1258
15 15,708 50 3603 85 1072
13
EN

20 12,490 55 2986 90 917.7
25 10,000 60 2488 95 788.5
30 8057 65 2083 100 680
Maximum tolerance +/- 4.7%
An example for the approximation of the target resistance for temperatures not specified
in the table is shown below.
Example: Ambient temperature = Tamb = 23°C
Rdiff = (Rlow - Rhigh) / 5 = (12,490 ohm - 10,000 ohm) / 5 = 498 ohm
Rtarget = Rhigh + Rdiff *(Thigh - Tamb) = 10,000 ohm + 498 ohm * (25-23) = 10,996 ohm
The individual symbols stand for the following variables:
- Tamb = ambient temperature of the temperature sensor in °C
- Rlow = resistance in ohm according to the table for the next temperature down from
the ambient temperature
- Rhigh = resistance in ohm according to the table for the next temperature up from the
ambient temperature
- Thigh = temperature in °C for resistance Rhigh
- Rdiff = difference per °C in ohm between Rlow and Rhigh
- Rtarget = target resistance for the specified ambient temperature in °C
14

Service codes
General If an error message that is not described here appears on the displays, proceed as fol-
lows to resolve the problem:
1Turn the power source mains switch to the "O" position
2Wait 10 seconds
3Move the mains switch to the I position
If the error occurs again despite several attempts to eliminate it, or if the troubleshooting
measures listed here are unsuccessful.
1Make a note of the error message displayed
2Note down the configuration of the power source
3Contact our After-Sales Service team with a detailed description of the error
Service codes
table
The following service codes may be displayed if there is a software problem:
- EdA 0
- EdP 1
- EFd 0 - 3
- EdP 1
- EGA 0 - 1
- ELn 0, 1, 3
- EPG 1 - 6, 18 - 28, 30 - 34, 36
- EPR 0 - 6, 10 - 12
- ESr 0 - 14
- Et 0 - 3
- Etb 0 - 1
If the service codes shown above appear on the display, it may be possible to resolve the
problem by updating the database software and the firmware (for details see "Software
update").
If the problem is not resolved by a software update, please contact Fronius Technical
Support (TSN, TSI). When contacting them, please provide the following information:
- Service code displayed
- Configuration of the welding system
- Software version numbers (for details see Service menu)
- Environmental conditions.
ESr 15 <PA>
One of the connected device IDs has an invalid CRC (checksum error)
<PA> 0 = Motherboard CFM (on power module PC board)
<PA> 4 = device ID on wirefeeder motor
If the Device ID is present on the motor, replace motor, otherwise replace
PC board (The motor ID from the TT 2200 is located as standard on the PC
board)
0 = replace power module PC board
4 = replace wirefeeder motor, replace device ID on wirefeeder motor
Cause:
Remedy:
15
EN

ESr 18 <PA>
A configuration memory is not supported, <PA> represents the error number
<PA> = 0 replace LSTMAG20 PC board
<PA> = 4 replace wirefeeder motor, replace device ID on wirefeeder motor
Cause:
Remedy:
ESr 22
The bootloader must be updated
Contact TechSupport International (TSI)
Cause:
Remedy:
------
Empty flag selected
Select valid flag
Cause:
Remedy:
UPdAtE
Software is being installed
Wait for installation to finish
Cause:
Remedy:
ELn 6
Error when writing calibration data
Repeat calibration procedure, replace wire-feed unit motor
Cause:
Remedy:
ELn 7
The connected control panel is not supported
Perform software update, connect supported control panel
Cause:
Remedy:
ELn 13
Illegal welding process change during welding
Do not make illegal welding process changes, acknowledge service code
Cause:
Remedy:
Err 11
5 V power supply on power module faulty
Replace LSTMAG20 PC board
Cause:
Remedy:
Err 12
15 V power supply on power module faulty
Replace LSTMAG20 PC board
Cause:
Remedy:
Err 51
Mains undervoltage: mains voltage has fallen below the tolerance range
Check mains voltage, replace LSTMAG20 PC board
Cause:
Remedy:
Err 52
Mains overvoltage, mains voltage has exceeded the tolerance range
Check mains voltage, replace LSTMAG20 PC board
Cause:
Remedy:
PFC 56
LSTMAG20 power module PC board has detected an overcurrent on the
PFC
Replace LSTMAG20 PC board
Cause:
Remedy:
PFC 57
Power module PC board has detected an overvoltage in the primary inter-
mediate circuit
Operate power source within the permitted voltage range
Cause:
Remedy:
16

PFC 58
Power module PC board has detected a mains overvoltage
Operate power source within the permitted voltage range
Cause:
Remedy:
PFC 60
PFC driver supply on the LSTMAG20 PC board faulty
Replace LSTMAG20 PC board
Cause:
Remedy:
PFC 62
Communication error on LSTMAG20 PC board
Switch power source off and on again, replace LSTMAG20 PC board
Cause:
Remedy:
PFC 63
PFC on power module PC board not supported by the software
Update firmware
Cause:
Remedy:
Err IP
The controller has detected a primary overcurrent
Check/replace secondary rectifier, replace LSTMAG20 PC board
Cause:
Remedy:
EPS 7
Current sensor defective, current actual value offset too high
Replace LSTMAG20 PC board
Cause:
Remedy:
EPS 8
The voltage offset for welding voltage measurement is too high
Replace LSTMAG20 PC board
Cause:
Remedy:
EFd 4
Motor is not supported
Perform software update, replace motor
Cause:
Remedy:
EFd 7
Motor current sensor faulty
Replace LSTMAG20 PC board
Cause:
Remedy:
EFd 8
PC board LSTMAG20 overtemperature
Allow power source to cool down, check that fan is running
Causee:
Remedy:
EFd 9
Motor calibration data unavailable
Perform motor calibration
Cause:
Remedy:
EFd 11
The current for motor calibration is outside the permitted range
Repeat motor calibration (motor plate 2R pressure lever must be open);
check motor current, if motor current is too high replace motor, otherwise
replace LSTMAG20 PC board
Cause:
Remedy:
EFd 12
Motor calibration stopped prematurely
Restart motor calibration
Cause:
Remedy:
17
EN

EFd 13
The voltage for motor calibration is out of limits
Perform motor calibration (motor plate 2R pressure lever must be open),
replace motor, replace LSTMAG20 PC board
Cause:
Remedy:
EFd 14
Fault in the wirefeed system (overcurrent in wirefeeder drive, motor
blocked)
Arrange the hosepack in as straight a line as possible. Check inner liner and
contact tip; check contact pressure on 2-roller drive; possibly remove any
wire entanglements on the motor plate 2R; check motor current in open cir-
cuit (≤1,0A at 10m/min), if motor current is too high replace motor
Cause:
Remedy:
EFd 80
Fault in the wirefeed motor (break in circuit)
Check motor plug, replace motor
Cause:
Remedy:
EFd 81
Fault in the wirefeed system (overcurrent in wirefeeder drive)
Arrange the hosepack in as straight a line as possible. Check inner liner and
contact tip, check contact pressure on 2-roller drive; observe duty cycle of
the device; check motor current in open circuit (≤1,0A at 10m/min), if motor
current is too high replace motor
Cause:
Remedy:
EFd 83
Short circuit in wirefeeder motor or on LSTMAG20 PC board
Unplug motor; start function test; if there is no error EFd 83 replace motor,
otherwise replace LSTMAG20 PC board
Cause:
Remedy:
EFd 84
Fault on the PC board, no command is send to the motor
Check 24V motor power supply, replace PC board
Cause:
Remedy:
to0<TMP>
Overtemperature on the PC board LSTMAG20 (secondary circuit), <TMP>
is the temperature indicator
Allow power source to cool down, check air filter and clean if necessary,
check that fan is working
Cause:
Remedy:
to2<TMP>
Overtemperature on power source secondary circuit, <TMP> is the temper-
ature indicator
Allow power source to cool down, check air filter and clean if necessary,
check that fan is running
Cause:
Remedy:
to3<TMP>
Overtemperature on the PC board LSTMAG20 (motor controller), <TMP>
stands for temperature indicator
Allow power source to cool down, check air filter and clean if necessary,
check that fan is working
Cause:
Remedy:
to6<TMP>
Overtemperature on the PC board LSTMAG20 (voltage doubler), <TMP> is
the temperature indicator
Allow power source to cool down, check air filter and clean if necessary,
check that fan is working
Cause:
Remedy:
18

to7<TMP>
Overtemperature on the controller (Kernel), <TMP> is the temperature indic-
ator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
to8<TMP>
Power module overtemperature error, <TMP> is the temperature indicator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
to9<TMP>
PFC module overtemperature error, <TMP> is the temperature indicator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
toA<TMP>
Overtemperature on the PC board LSTMAG20 (PFC), <TMP> is the tem-
perature indicator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
tu0<TMP>
Undertemperature on the PC board LSTMAG20 (secondary circuit), <TMP>
is the temperature indicator
Operate power source within the permitted temperature range
Cause:
Remedy:
tu2<TMP>
Undertemperature in the power source secondary circuit
Operate power source within the permitted temperature range
Cause:
Remedy:
tu3<TMP>
Undertemperature on the PC board LSTMAG20 (motor controller), <TMP>
is the temperature indicator
Operate power source within the permitted temperature range
Cause:
Remedy:
tu6<TMP>
Undertemperature on the PC board LSTMAG20 (voltage doubler), <TMP>
is the temperature indicator
Operate power source within the permitted temperature range
Cause:
Remedy:
tu7<TMP>
Undertemperature on the controller (Kernel), <TMP> is the temperature
indicator
Operate power source within the permitted temperature range
Cause:
Remedy:
tu8<TMP>
Power module undertemperature error, <TMP> is the temperature indicator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
tu9<TMP>
PFC module undertemperature error, <TMP> is the temperature indicator
Allow power source to cool down, check that fan is running
Cause:
Remedy:
tuA<TMP>
Undertemperature error on the PC board LSTMAG20 (PFC), <TMP> is the
temperature indicator
Operate power source within the permitted temperature range
Cause:
Remedy:
19
EN

Err tf0
Temperature sensor on the PC board LSTMAG20 faulty (secondary circuit)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tf2
Temperature sensor fault in power source secondary circuit (short circuit or
interruption)
Check cable harness and replace temperature sensor on secondary rectifier
Cause:
Remedy:
Err tf3
Faulty temperature sensor on the PC board LSTMAG20 (motor controller)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tf6
Faulty temperature sensor on the PC board LSTMAG20 (voltage doubler)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tf7
Temperature sensor fault on LSTMAG20 PC board (Kernel)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tf8
Temperature sensor fault on LSTMAG20 PC board (power module)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tf9
Temperature sensor fault on LSTMAG20 PC board (PFC module)
Replace LSTMAG20 PC board
Cause:
Remedy:
Err tfA
Temperature sensor fault on PC board (PFC)
Replace LSTMAG20 PC board
Cause:
Remedy:
no Prg
No saved program selected
Select saved program
Cause:
Remedy:
No IGn
"Ignition time-out" function is active; current did not start flowing before the
length of wire specified in the set-up menu had been fed. The power source
safety cut-out has tripped.
Shorten the end of the wire; press the torch trigger again; clean the surface
of the workpiece; if necessary, increase the wire length until the safety cut-
out trips in "Set-up menu: Level 2".
Cause:
Remedy:
EPG 35
RL calibration has failed
Check grounding cable, current cable or hosepack and replace if necessary,
restart RL calibration
Cause:
Remedy:
toF xxx
The power source safety cut-out has tripped in order to prevent the mains
fuse from tripping.
After a pause in welding of around 90 s, the message disappears and the
power source is operational again.
Cause:
Remedy:
20