FRO­NIUS THP 120 - 300 SH User manual

Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
/ Perfect Charging / Perfect Welding / Solar Energy
THP 120 - 300 SH
THP 160 - 500d
THP 160 - 500i
HPT 220 - 400i
EN-US
Service manual
TIG manual welding torch
42,0426,0295,EA 007-13082020

Table of contents
Foreword and safety instructions 5
Safety 5
National Fronius Technical Support team (TSN) 5
General 6
Tools and Measurement Devices 6
Function Overview 6
Troubleshooting 6
Replacing Components 6
Testing Following Repairs 6
Tools and measurement devices 7
General 7
Required tools 7
Tool adapters 7
Measuring and inspection equipment 7
Auxiliary materials 8
Function Overview 9
Torch Body 9
Hosepack 9
F++ connection 9
Troubleshooting 10
General 10
Troubleshooting Table 10
Replacing components 12
Safety 12
ESD Guidelines 12
Tightening torques 12
THP 160 - 500i 13
Changing the torch body 13
Replacing the user interface 14
Replacing the slide 14
Opening the hand grip 15
Replacing the socket housing 15
Retrofitting TIGi LED insulation(i version only) 17
Replacing the LED (i version only) 17
Replacing the coupling housing 18
Opening the F++ connection 20
Replacing hose components 20
Closing the F++ connection 23
Closing the hand grip 23
THP 160 - 500d 25
Changing the torch body 25
Replacing the user interface 26
Replacing the slide 26
Opening the hand grip 27
Replacing the socket housing 27
Replacing the coupling housing 29
Opening the F++ connection 30
Replacing hose components 31
Closing the F++ connection 34
Closing the hand grip 34
THP 120 - 300 SH, without 150 SH 36
Changing the torch body 36
Opening the hand grip 37
Replacing the user interface 37
Replacing the slide 38
Replacing the socket housing 39
Replacing the coupling housing 41
Opening the F++ connection 42
Replacing hose components 43
Closing the F++ connection 45
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Closing the hand grip 46
HPT 220i and HPT 400i 48
Preparing components for replacement 48
Removing, replacing, and fitting the hosepack 50
Replacing the protective hose 52
Fitting components after replacement 53
Testing Following Repairs 56
Test process 56
Mechanical inspection/PP-SER-2010 56
Insulation test/PP-SER-2010 56
Gas flow rate and leak test/PP-SER-2001 57
Water flow rate and leak test/PP-SER-2001 58
Electrical testing of operating elements and displays 59
Current load test/voltage drop measurement 61
4

Foreword and safety instructions
Safety The safety instructions listed below apply for all activities described in these Service
Instructions:
WARNING!
Work performed incorrectly can cause serious injury and damage to property.
▶All activities described in the Service Instructions must only be carried out by a
trained Fronius service technician.
▶Please note the information in the “Safety Rules” chapter in the Operating Instruc-
tions for the power source.
WARNING!
An electric shock can be fatal.
Before removing the manual welding torch:
▶set the device power switch to "O"
▶unplug the device from the mains
▶secure against accidental switching on
CAUTION!
Risk of burns due to welding torch components and coolant heated during opera-
tion.
Allow all welding torch components and the coolant to cool down to room temperature
(+25 °C or +77 °F) before starting any of the work described in these Service Instruc-
tions.
CAUTION!
Improper connections can cause personal injury and/or damage to equipment.
All cables, leads, and hosepacks must always be securely connected, undamaged, cor-
rectly insulated, and adequately sized.
NOTE!
Never use water-cooled welding torches without coolant.
The manufacturer is not responsible for any damage resulting from improper use. All
warranty claims are considered void in such cases.
NOTE!
When disconnecting a water-cooled welding torch from the cooling unit or in spe-
cial cases from the wirefeeder, always seal the coolant hoses using the plastic
seal attached to the torch.
National Fronius
Technical Sup-
port team (TSN)
If you have any questions about the failure analysis, your national Fronius Technical
Support team is at your disposal (TSN).
mailto: [email protected]
5
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General The service manual can be found in the DownloadCenter under "downloadcen-
ter.fronius.com."
Each chapter of the service manual covers a different topic. Use each chapter as an
independent source of information. The following provides a brief description of each
chapter:
Tools and Meas-
urement Devices
Here you will find an overview and description of all the tools necessary to properly ser-
vice the device or the component. This includes the following tools:
- Required tools
- Measuring and inspection equipment
- Auxiliary materials
Function Over-
view
Contains an overview of functions of the welding torch components with information on
the following points:
- torch body
- hosepack
- F++ connection
Troubleshooting Used to systematically find causes of errors and correct these errors.
Replacing Com-
ponents
The “Replacing Components” chapter describes the steps that need to be carried out
during service in order to replace individual components.
Testing Following
Repairs
This chapter clarifies the safety-relevant test guidelines following repairs
6

Tools and measurement devices
General The "Tools and measurement devices" chapter contains an overview and description of
all the tools needed to properly service the device. This includes the following tools:
- Required tools
- Tool adapters
- Measuring and inspection equipment
- Auxiliary materials
All the required special tools, measuring and inspection equipment can be found in the
equipment lists at "downloadcenter.fronius.com".
Required tools - TX 6 screwdriver
- TX 8 screwdriver
- Torque screwdriver 1–6 Nm (42,0411,0013)
- Torque screwdriver 0.4–1.2 Nm (42,0435,0210)
- Torque screwdriver for socket (42,0411,0168)
- Socket 1/4" contact element (42,0001,6754)
- Size 7 mm wrench
- Size 8 mm wrench
- Size 10 mm wrench
- Size 11 mm wrench
- Needle-nosed pliers
- Side cutters
- Vise-grip wrench
- Oetiker pliers
- Knife
- Extractor tool
Tool adapters Small-handle manual torch version
- Threaded adapter hose retraction (42,1000,0364)
d and i manual torch version
- Threaded adapter hose retraction (44,0001,0017)
Measuring and
inspection equip-
ment
Equipment for inspection according to PP-SER-2010 test schedule
-Insulation test:
- Insulation meter (Metriso 5000)
Equipment for inspection according to PP-SER-2001 test schedule
-Gas flow rate test:
- Test box torch flow rate (4,078,016)
-Water flow rate test:
- Flow rate and leak test device (torch test bench)
- Short circuit adapter TTB ML W (42,1600,0015)
- Short circuit adapter lock TTB (44,0001,0016)
Equipment for inspection according to PP-SER-2002 test schedule
-Voltage drop measurement
- Digital multimeter
- Current load test adapter (44,0001,0018)
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Equipment for testing electrical function
-Electrical testing of operating elements and displays
- Service software for test box manual torch - current version (Downloadcenter)
- Basic Load driver software (Downloadcenter)
- Test box manual torch (4,045,998)
- Test box FSC (4,100,673)
- Adapter FSC - TMC (4,078,000)
- Adapter cable for SH welding torch (43,0004,5991)
Auxiliary materi-
als
- Contact spray cleaning agent (40,0009,0014)
- O-ring grease (40,0009,0044)
- Loctite 424 (40,0009,0002)
- Loctite 542 (40,0009,0021)
- Adhesive tape
- 1-ear clamp 7 mm
- 1-ear clamp 8 mm
- 1-ear clamp 9 mm
- 1-ear clamp 10 mm
8

Function Overview
Torch Body The torch body is used to hold the TIG electrode.
Hosepack Flexible connection between torch body and power source. which contains all lines
required for welding operation.
F++ connection The F++ is a compact interface between the hosepack and power source.
- Tool-free, simple, and quick hosepack replacement without operating errors
- Process safety due to defined current transfer
- Central connector for all TIG welding applications
9
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Troubleshooting
General The error search tree is used to systematically find and correct errors.
Troubleshooting
Table Welding torch cannot be connected
Bayonet lock bent
Replace bayonet lock
No welding current
Power source switched on, power source indication illuminates, shielding gas present
Incorrect ground connection
Establish proper ground connection
Power cable in hosepack damaged or broken.
Replace faulty components in the hosepack
Tungsten electrode loose
Tighten tungsten electrode using torch cap
Wearing parts loose
Tighten wearing parts
No function after pressing torch trigger
Power source switched on, power source indication illuminates, shielding gas present
Power plug not plugged in
Plug in power plug
Hosepack or hosepack control line faulty
Open hosepack, measure control line for continuity and replace faulty com-
ponent
Plug connections “torch trigger/control line/power source” faulty
Check plug connections and replace faulty component
PCB in hosepack faulty
Replace PCB
HF arc-flash at hosepack connection
Hosepack connection not tight
Replace O-ring on the bayonet lock
HF arc-flash at the ergonomic handle
Shielding gas hose connection to torch body not sealed
Adjust and seal hose
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
10

No shielding gas
All other functions present
Gas cylinder empty
Change gas cylinder
Gas pressure regulator faulty
Replace gas pressure regulator
Gas hose kinked, damaged, or not attached
Attach and straighten gas hose. Replace faulty gas hose
Gas solenoid valve faulty
Replace gas solenoid valve
Poor ignition properties
Unsuitable tungsten electrode (e.g., WP electrode for DC welding)
Use suitable tungsten electrode
Wearing parts loose
Screw on wearing parts tightly
Gas nozzle is cracked
Tungsten electrode not protruding far enough out of the gas nozzle
Have tungsten electrode protrude more out of the gas nozzle
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
Cause:
Remedy:
11
EN-US

Replacing components
Safety WARNING!
Work performed incorrectly can cause serious injury and damage to property.
All activities described in the Service Instructions must only be carried out by a trained
Fronius service technician. Please note the information in the “Safety Rules” chapter of
the Operating Instructions for your device.
WARNING!
An electric shock can be fatal.
Before removing the welding torch:
▶set device power switch to “O”
▶unplug the device from mains power
▶secure against anyone turning on power again.
ESD Guidelines NOTE!
Observe ESD guidelines when handling electronic components and PC boards.
This applies primarily to ESD-compatible
- Packaging
- Work surfaces
- Floors
- Seating
- Grounding options
- Handling
No guarantee or warranty claims can be made in respect of any improperly handled elec-
tronic component or PC board.
Tightening
torques
NOTE!
When replacing spare parts, observe the tightening torques according to the User
Information or the information in the Service Instructions.
12

THP 160 - 500i
Changing the
torch body
3
(1)
(2)
WARNING!
Before removing the torch body,
observe all safety-relevant notes and
procedural steps according to the
Operating Instructions.
Removing the torch body
1Press the slide (1) and turn the torch
body (2) 180°
(2)
2Note the arrows and carefully remove
the torch body (2)
Attaching the torch body
1Put the torch body back on (2) and
attach in the reverse order
NOTE!
The torch body must snap into place.
13
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Replacing the
user interface
(1)
(2)
Removal
1Unscrew one TX 8 screw (1)
2Disconnect the user interface (2)
Installation
1Connect the user interface (2)
2Secure one TX 8 screw (1)
Tightening torque: 0.6 Nm
Replacing the
slide
(1)
(2)
1Remove the user interface as per the
"Replacing the user interface" chapter
2Position a suitable tool on the plastic
guide on the slide (1) and carefully
push it in the direction of the arrow
using slight pressure
3Remove the slide (2) from the guide
(2)
(2)
4Insert the new slide (2) into the guide
until it engages
5Install the user interface as per the
"Replacing the user interface" chapter
14

Opening the hand
grip
(1)(2)
(2)
(2)
1Open and push back the union nut (1)
2Unscrew three TX 8 screws (2), dis-
connect the user interface and open
the hand grip
Replacing the
socket housing
NOTE!
Socket housing: 43,0003,0800
(2)
(1)
1Open the hand grip as per the “Open-
ing the hand grip” chapter
2Remove the coupling housing (1) and
Minitek plug (2) from the guide
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(2)
(3)
3Carefully open the Minitek plug (2)
lock
4Remove the socket housing (3) by
pushing forwards
(2)
ABCDEF
Pink Grey Yellow White Brown Green
-i
(4)
(3)
(5)
(2)
U/D
NOTE!
Observe the pin assignment* (color-
coded arrangement of the wires) for
each interface version and note it down
in advance.
5Release the wires (4) using tweezers
and pull them out
6Replace the socket housing (3)
7Insert the wires (4) into the socket
housing (3) according to the color-
coded arrangement* per interface ver-
sion and check the lock
8Push the socket housing (3) into the
Minitek plug (2) and lock it (5)
(2)
(1)
(6)(7)
9Position the Minitek plug (2) in the
handle
NOTE!
Observe the following when positioning
the Minitek plug:
▶Press the cable sheathing (6) right
down to the bottom of the strain-relief
device guide
▶Lay the control line (7) in a loop
underneath the handle screw connec-
tion
10 Insert the coupling housing (1) and
close the hand grip as per the “Closing
the hand grip” chapter
16

Retrofitting TIGi
LED insulation
(i version only)
(1)
NOTE!
If the LED insulation film is not present,
it can be retrofitted.
LED insulation film: 42,1600,0055
1Open the hand grip as per the "Open-
ing the hand grip" chapter
2If necessary, insert LED insulation film
(1)
3Close the hand grip as per the "Clos-
ing the hand grip" chapter
Replacing the
LED
(i version only)
(1) (2)
NOTE!
When replacing the LED, the socket
housing must also be replaced.
Socket housing: 43,0003,0800
1Open the hand grip as per the "Open-
ing the hand grip" chapter
2Remove the coupling housing with
LED (1) from the guide
3If necessary, insert LED insulation film
(2)
(2)
(3)
4Carefully open the Minitek plug (2)
lock
5Remove the socket housing (3) by
pushing forwards
17
EN-US

(1)
(3)
(5)
(4)
(2)
-i
(3)
U/D
NOTE!
Observe the pin assignment* (color-
coded arrangement of the wires) for
each interface version and note it down
in advance.
6Release the wires (4) using tweezers
and pull them out
7Pull out and replace the LED (1)
8Insert the wires (4) into the socket
housing (3) according to the color
arrangement* per interface version
and check the lock
9Push the socket housing (3) into the
Minitek plug (2) and lock it (5)
(2)
(6)
(7)(8)
10 Position the Minitek plug (2) in the
handle
NOTE!
Observe the following when positioning
the Minitek plug:
▶Press the cable sheathing (7) right
down to the bottom of the strain-relief
device guide
▶Lay the control line (8) in a loop
underneath the handle screw connec-
tion
11 Insert the coupling housing (6) and
close the hand grip as per the "Closing
the hand grip" chapter
Replacing the
coupling housing
(1)
Removal
1Open the hand grip as per the “Open-
ing the hand grip” chapter
NOTE!
Carefully place the socket onto the con-
tact element to prevent damage.
2Open the contact element (1) with the
8 mm socket
18

(2)(1)
NOTE!
The coupling housing must be replaced
as a closed unit.
3Remove the contact element (1)
4Carefully remove the coupling housing
(2)
(2)(1)
Installation
1Fit the coupling housing (2)
2Insert the contact element (1)
(1)
3Pre-mount the contact element (1)
with 8 mm socket
4Secure the contact element (1) with a
torque screwdriver and socket as per
the “Required tools” chapter
Tightening torque: 5 Nm
5Close the hand grip as per the “Clos-
ing the hand grip” chapter
19
EN-US

Opening the F++
connection
(1)
(1)
(1)
(1)
1Unscrew four TX 8 screws (1)
2Remove upper and lower base shell
on the F++ connection
Replacing hose
components
(1) (2)
Hand grip disassembly
1Open the hand grip as per the “Open-
ing the hand grip” chapter
2Remove the coupling housing as per
the “Replacing the coupling housing”
chapter
3Pull the power cable (1) out of the
insulating plate (2) and unclip the
existing connections
NOTE!
Before removal, align sharp-edged
hose clamps accordingly to protect the
hose fabric.
20