Totalarc3-4-5000.pdf Servis PDF

TransSynergic 4000/5000
TransPuls Synergic 2700

Service manual
TransPuls Synergic 3200/4000/5000 GB
Spare parts list
MIG/MAG Power source
42,0410,1237 012007
Table of contents
Foreword and safety instructions .................................................................................................................. 5
Safety ....................................................................................................................................................... 5
Fronius Technical Support Center (TSC) ................................................................................................. 5
General remarks ...................................................................................................................................... 5
Tools and measuring instruments ............................................................................................................ 6
Function overview .................................................................................................................................... 6
Fault location aid ...................................................................................................................................... 6
Detailed description .................................................................................................................................. 6
Changing components ............................................................................................................................. 6
Terms and abbreviations used ................................................................................................................. 6
Spare parts list and entire circuit diagram ................................................................................................ 6
Tools and measuring instruments ................................................................................................................. 7
General remarks ...................................................................................................................................... 7
Tools required .......................................................................................................................................... 7
Measuring and inspection equipment ...................................................................................................... 7
Ancillary materials .................................................................................................................................... 7
Function overview ......................................................................................................................................... 8
Principle of the digital family of machines ................................................................................................ 8
Useful information .................................................................................................................................... 8
Block diagram .......................................................................................................................................... 9
Block diagram legend............................................................................................................................... 9
Fault location aid .......................................................................................................................................... 11
General remarks ..................................................................................................................................... 11
Fault flowcharts ........................................................................................................................................... 12
Overview ................................................................................................................................................ 12
Poor ignition and welding properties with MIG/MAG welding .............................................................. 13
Poor ignition and welding properties with TIG welding ........................................................................ 14
Poor weld properties with rod electrode (MMA) welding ...................................................................... 15
Nothing happens on control panel (TPS 2700) ...................................................................................... 16
Nothing happens on control panel (TPS 3200/4000/5000) .................................................................... 18
No or incorrect welding current .............................................................................................................. 20
No or incorrect wirefeed speed .............................................................................................................. 21
Insufficient torch cooling (FK 4000/FK 4000 R) ..................................................................................... 22
Service code Err 50 ................................................................................................................................ 24
UST service codes ...................................................................................................................................... 26
Safety ..................................................................................................................................................... 26
Table of service codes ........................................................................................................................... 26
Special displays used with service codes ............................................................................................... 32
Service codes SR 4xA ................................................................................................................................ 33
Safety ..................................................................................................................................................... 33
Table of service codes ........................................................................................................................... 33
Service codes for push-pull calibration ....................................................................................................... 34
Safety ..................................................................................................................................................... 34
Checking actual-value pick-up ............................................................................................................... 34
Error codes shown when the drive units are engaged (engaged calibration) ...................................... 34
Error codes shown when the drive units are engaged (engaged calibration) ...................................... 35
Detailed description ..................................................................................................................................... 37
General remarks .................................................................................................................................... 37
Position of electronic components ......................................................................................................... 37
Overview ................................................................................................................................................ 37
1
ASU 27 - additional PC board ..................................................................................................................... 38
General remarks .................................................................................................................................... 38
Component position in the machine ....................................................................................................... 38
Overview ................................................................................................................................................ 38
Technical Data ........................................................................................................................................ 38
Function overview .................................................................................................................................. 39
Plug layout ............................................................................................................................................. 39
LED checklist ......................................................................................................................................... 40
Measuring points .................................................................................................................................... 40
ASU 40 - additional PC board ..................................................................................................................... 41
General remarks .................................................................................................................................... 41
Overview ................................................................................................................................................ 41
Technical Data ........................................................................................................................................ 42
Plug layout ............................................................................................................................................. 42
LED checklist ......................................................................................................................................... 43
BPS 25/BPT 27 - power module PC board ................................................................................................. 45
General remarks .................................................................................................................................... 45
Overview ................................................................................................................................................ 45
Technical Data ........................................................................................................................................ 46
Plug layout BPS 25/BPT 27 ................................................................................................................... 46
LED checklist ......................................................................................................................................... 48
BPS 32/40/42/43/50/53 - power module PC board ..................................................................................... 50
General remarks .................................................................................................................................... 50
Overview ................................................................................................................................................ 50
Technical Data ........................................................................................................................................ 51
Plugs on the power module PC boards .................................................................................................. 52
Plug layout ............................................................................................................................................. 52
LED checklist of power module PC boards ............................................................................................ 54
NT 24 - switched mode power supply 24 V ................................................................................................. 57
General remarks .................................................................................................................................... 57
Overview ................................................................................................................................................ 57
Technical Data ........................................................................................................................................ 58
Plug layout ............................................................................................................................................. 58
LED checklist ......................................................................................................................................... 59
NT 60 - switched mode power supply 60 V ................................................................................................. 61
General remarks .................................................................................................................................... 61
Overview ................................................................................................................................................ 61
Technical Data ........................................................................................................................................ 62
Plug layout ............................................................................................................................................. 62
LED checklist ......................................................................................................................................... 63
2
UST - Control and regulation unit ................................................................................................................ 65
General remarks .................................................................................................................................... 65
Overview ................................................................................................................................................ 65
Technical Data ........................................................................................................................................ 66
Plug layout ............................................................................................................................................. 66
LED checklist ......................................................................................................................................... 68
Changing UST PC board ....................................................................................................................... 68
NF 3160 - Line filter ..................................................................................................................................... 69
General remarks .................................................................................................................................... 69
Overview ................................................................................................................................................ 69
Technical Data ........................................................................................................................................ 69
Plug layout ............................................................................................................................................. 70
LED checklist ......................................................................................................................................... 70
NF 3400 - Line filter/line filter 40 A/80 A ...................................................................................................... 71
General remarks .................................................................................................................................... 71
Overview ................................................................................................................................................ 71
Technical Data ........................................................................................................................................ 72
Plug layout NF 3400 ............................................................................................................................... 72
Plug layout line filter 40 A/80 A ............................................................................................................... 73
LED checklist ......................................................................................................................................... 73
Shunt ........................................................................................................................................................... 74
General remarks .................................................................................................................................... 74
Overview ................................................................................................................................................ 74
Technical Data ........................................................................................................................................ 75
Plug layout ............................................................................................................................................. 75
LED checklist ......................................................................................................................................... 75
SR 41 - Wire-feed unit regulation unit ......................................................................................................... 76
General remarks .................................................................................................................................... 76
Overview ................................................................................................................................................ 76
Technical Data ........................................................................................................................................ 77
Plug layout ............................................................................................................................................. 77
LED checklist ......................................................................................................................................... 79
Temperature sensor TP 592S ..................................................................................................................... 81
General remarks .................................................................................................................................... 81
Technical Data ........................................................................................................................................ 82
Plug layout ............................................................................................................................................. 82
Secondary power module TPS 2700 ........................................................................................................... 83
General remarks .................................................................................................................................... 83
Overview ................................................................................................................................................ 83
3
Secondary power module TS 4000/5000, TPS 3200/4000/5000 ................................................................ 85
General remarks .................................................................................................................................... 85
Assembly position in the machine .......................................................................................................... 85
Overview ................................................................................................................................................ 85
Primary rectifier ........................................................................................................................................... 87
General remarks .................................................................................................................................... 87
Assembly position in the machine .......................................................................................................... 87
Overview ................................................................................................................................................ 87
Plug layout ............................................................................................................................................. 88
Changing components ................................................................................................................................ 89
Safety ..................................................................................................................................................... 89
General remarks .................................................................................................................................... 89
Overview ................................................................................................................................................ 89
Changing throttle (TS 4000/5000, TPS 3200/4000/5000) ........................................................................... 90
Removing throttle ................................................................................................................................... 90
Fitting throttle ......................................................................................................................................... 91
Changing throttle (TPS 2700) ...................................................................................................................... 93
Removing throttle ................................................................................................................................... 93
Fitting throttle ......................................................................................................................................... 94
Changing earth current watchdog ............................................................................................................... 97
Removing earth current watchdog ......................................................................................................... 97
Fitting earth current watchdog ................................................................................................................ 98
Changing PC board ASU 27 (TPS 2700 MV) ............................................................................................ 100
Removing ASU 27 ................................................................................................................................ 100
Fitting ASU 27 ...................................................................................................................................... 100
Changing shunt (TPS 2700) ...................................................................................................................... 101
Removing shunt ................................................................................................................................... 101
Fitting shunt .......................................................................................................................................... 102
Changing temperature sensor TP 592S .................................................................................................... 104
NOTEs ................................................................................................................................................. 104
Changing transformer (TS 4000/5000, TPS 3200/4000/5000) .................................................................. 105
Removing transformer ......................................................................................................................... 105
Fitting transformer ................................................................................................................................ 106
Changing transformer (TPS 2700) ............................................................................................................ 108
Removing transformer ......................................................................................................................... 108
Fitting transformer ................................................................................................................................ 109
Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000) ...................................... 111
Removing intermediate circuit capacitors ............................................................................................. 111
Fitting intermediate circuit capacitors .................................................................................................... 112
Safety inspection ........................................................................................................................................ 114
General remarks ................................................................................................................................... 114
Terms and abbreviations used ................................................................................................................... 115
General remarks ................................................................................................................................... 115
Terms and abbreviations ....................................................................................................................... 115
Entire circuit diagram ................................................................................................................................. 117
Storage location .................................................................................................................................... 117
Spare parts list/circuit diagram
Fronius Worldwide
4
Foreword and safety instructions
Safety The following safety instructions apply to all activities described in these service instruc-
tions:
WARNING! Work performed incorrectly can cause serious injury and damage.
All activities described in the service instructions must only be carried out by
Fronius-trained personnel. Take note of the Safety rules chapter in the power
source operating instructions.
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
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.
Fronius Techni- If you have any questions about fault isolation, there is a team of experts on hand.
cal Support E-mail: techsupport@fronius.com
Center (TSC)
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:
5
Tools and measu- This provides an overview and description of all equipment required for servicing the
ring instruments power source professionally. This equipment includes:
- Tools required
- Measuring and inspection equipment
- Ancillary materials
Function over- Contains a brief descriptive overview of the entire system:

view - in text form
- in block diagram form
Fault location aid 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
Detailed descrip- Contains detailed descriptions of the relevant components in the power source.
tion
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
Changing com- In the Changing components section there is a description of how to change compon-
ponents ents which
- have no instructions of their own regarding changing and
- require a complete description of how to change them
Terms and abbre- Contains a description of essential terms and abbreviations for a better understanding of
viations used the service instructions
Spare parts list The Spare parts list and Entire circuit diagram sections contain the complete spare
and entire circuit parts list and complete circuit diagram for the power source.
diagram
6
Tools and measuring instruments
General remarks 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
Tools required - 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)
- Oeteker pliers
- Molex extractor tool (42,0410,0290)
Measuring and - Digital multimeter

inspection equip- - PC with MS Windows operating system
ment (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)
Ancillary materi- - Contact spray (40,0009,0014) or alcoholic solvent

als - Heat-conductive paste (40,0009,0043)
- Application instrument for heat-conductive paste (42,0435,0020)
- Sandpaper (42,0410,0436), grit size 500 or finer
7
Function overview
Principle of the The machines are totally digitized, microprocessor-controlled inverter power sources. A
digital family of universal control regulates the entire welding process. The actual data are measured
machines 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.
Useful informati-
on
OS CFM
BSL-Tool UST
DB
Local Net
Fig. 1 Function outline
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.
8
Block diagram
Remote control
unit
Wire-feed unit
Control panel
Regulation unit
Local
Net
Gas Welding torches
Wire
Valve
(1) Iact Workpiece

Control and Local
regulation unit Net Welding current
55 V (10)
sensor
Uact
24 V Power Output choke
(2) (3) (9)
supply
24 V 55 V
Primary
rectifier
Control
Mains
Secondary
filter
(8)
lead
Rectifer
Transistors
Welding transformer
TPS 2700 only: PFC
(Power Factor Control)
Intermediate circuit
capacitors
3 x 400 V
Primary power module

(4) (5) (6) (7)
Fig. 2 Block diagram of Trans Synergic 4000/5000 and TransPuls Synergic 2700/3200/4000/5000 power
sources
Block diagram (1) Control and regulation unit:

legend 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.
9
Block diagram (6) Transistors:
legend The transistors carry the intermediate circuit voltage in intervals at high frequency to
(continued) 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.
10
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
11
Fault flowcharts
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).
Poor ignition and weld properties with

the selected MIG/MAG welding
process
Poor ignition and weld properties with

the selected TIG welding process
Poor weld properties with selected rod

electrode (MMA) welding process
Nothing happens on control panel (TPS

2700)
Mains switch in the
On position
Nothing happens on control panel (TPS
3200/4000/5000)
No welding current, or current does not

correspond to set value
No or incorrect wirefeed
Insufficient welding torch cooling (FK

4000/FK 4000 R)
Service codes displayed
12
Poor ignition and
welding proper- Start
ties with MIG/
MAG welding
Correct shielding gas connected, Connect correct shielding gas and

and l/min set correctly? check l/min
No
Yes
Gas-test button: Shielding gas Check shielding gas solenoid

flowing out? valve, including control
No
Yes
Welding torch and grounding Check welding torch and groun-

(earthing) cable OK? ding (earthing) cable
No
Yes
Parameters set correctly? - Check settings on control panel

- Check set-up parameters
No
- Possibly reset to factory set-
Yes tings (FAC) (see operating instruc-
tions)
Check whether power source OK,

and check application
End
13
Poor ignition and
welding proper- Start
ties with TIG
welding
Correct shielding gas connected, Connect correct shielding gas and

and l/min set correctly? check l/min
No
Yes
Gas-test button: Shielding gas Check shielding gas solenoid

flowing out? valve, including control
No
Yes

(earthing) cable OK? ding (earthing) cable
No
Yes

No - Check set-up parameters
tions)

End
14
Poor weld pro-
perties with rod Start
electrode (MMA)
welding
Electrodes/grounding (earthing) Connect cable correctly

cable connected/functioning
No
correctly?
Yes

No - Check set-up parameters
tions)

End
15
Nothing happens
Start
on control panel
(TPS 2700)
Voltage OK on prima- Check mains cable,

ry rectifier V1=320V/ mains switch, line
560V DC? filter, rectifier and
No supply voltage
Yes
Voltage on intermedia-
te circuits 1 and 2 >
250V DC? Change BPS
No
Yes On MV power sources

Are LEDs +5V, +12V
flashing on the ASU 27,
as well as LED for mains
400V at 400V Unom, Change ASU 27
No
and LED for mains 230V
at 230V Unom?
Yes
Change BPS
Switch power source

+24V int/ext LEDs off, unplug plug X3
flashing on UST? from UST, switch
No power source on
Yes
Steady +24V int/ext

LEDs on NT 24? Change NT 24
No
Yes
Switch power source

off, plug X3 plug into
UST and unplug X7,
switch power source
on
Steady +24V int/ext

LEDs on UST? Check cooling unit
No
Yes
A Change BPS
16
Nothing happens
A
on control panel
(TPS 2700)
(continued)
Steady +5V, +15V, - Check/change control
15V on UST? panel/ribbon cable
Yes
No
Unplug X4 from UST
Steady +5V, +15V, -

15V on UST? Change VAC shunt
Yes
No
Unplug X2 from UST

Yes
No
Unplug X6 from UST
Steady +5V, +15V, -

15V on UST? Change BPS
Yes
No
Change UST
End
17
Nothing happens Start
on control panel
(TPS 3200/4000/
5000)
3x230V/3x400V on Check mains cable,
the terminal strip X7/5 line filter and supply
- X7/7 OK? voltage
No
Yes
MV power sources
with Unom 230V LED 230V flashing on
ASU 40 at Unom Change ASU 40
No 230V? No
Yes
Voltage on intermedia-
te circuits 1 and 2 > Voltage present on 2 Change primary
200V DC? No phases of rectifier V1? Yes rectifier
Yes
No
Mains switch/cabling Check/change mains

OK? No switch and cabling
Yes
Change BPS
Steady +24V int/ext Switch power source

LEDs on UST? off, unplug plug X3
No from UST, switch
Yes power source on
Steady +24V int/ext

LEDs on NT 24? Change NT 24
No
Yes
Switch power source

off, plug X3 plug into
UST and unplug X7,
switch power source
on
A B
18
Nothing happens
A B
on control panel
(TPS 3200/4000/
5000)
(continued)
Yes
No
Steady +24V int/ext

Check cooling unit LEDs on UST?
No
Unplug X4 from UST Yes
Change BPS
Steady +5V, +15V, -

15V on UST? Change VAC shunt
Yes
No
Unplug X2 from UST

Yes
No
Unplug X6 from UST
Steady +5V, +15V, -

15V on UST? Change BPS
Yes
No
Change UST
End
19
No or incorrect
welding current Start

(earthing) cable connected/functio- ding (earthing) cable
ning correctly? No
Yes
Nothing happening on control See subsection Nothing happens

panel? Yes on control panel
No
- Welding current Icomm no longer Change current sensor A1 VAC

adjustable, or Yes
- Welding current is constantly
Imax ?
No

End
20
No or incorrect
Start
wirefeed speed
Service code displayed? see service codes See Nothing happens

Yes table on control panel
flowchart
No
No
Wire-feed unit entered
+24V LED flashing on Steady +24Vext LED
in the service module?
SR 41? No on UST?
No
Yes Yes
Yes
Check cable harness/

VSP
BUS OK LED Connect service

flashing on the SR 41 module to the power
Yes when service module No source
unplugged?
Check VSP Power source entered

Change SR 41 in the service module?
Yes
No
Change UST
Does motor move +55V LED flashing on Check VSP, NT 60

when Feeder inching SR 41? overloaded or faulty
button is pressed? No No
Yes Yes
FWD LED flashing on

Change SR 41
SR 41? No
Yes
Change wire-feed unit

motor
Wrong motor speed? Calibrate push-pull

Yes unit
No
21
No or incorrect
A
wirefeed speed
(continued)
BRT LED flashes Check torch trigger/

when torch trigger No cabling
pressed?
Yes
Change SR 41
End
Insufficient torch
Start
cooling (FK 4000/
FK 4000 R)
Cooling unit set-up Switch set-up settings

settings switched to to AUTO or ON
OFF? Yes
No
Sufficient coolant? Top up coolant; vent

No cooling unit
Yes
Use a screwdriver to
turn the pump shaft;
if coolant pump is stiff,
Coolant pump blocked?
change it;
Yes Check securing
No device F1
+24V available from

Check cable harness;
X1/4 - X1/3?
No Change UST
Yes
Fan turning? Change fan

No
Yes
Relay K1 can be
Change relay K1
accessed? No
Yes
22
Insufficient torch
B
cooling (FK 4000/
FK 4000 R)
(continued)
400V AC available
Check cable harness
from plug X10/6 -
No to power source
X10/8?
Yes
Securing device F1 in Switch off unit;

the cooling unit OK? Disconnect pump;
No Replace fuse;
Switch on unit;
Yes
Check relay contact, Securing device F1

Change auto-transfor-
cable harness in OK? No mer
cooling circuit, auto-
transformer (if avai- Yes
lable) and voltage on
the pump Change pump
End
23
Service code Err
Start
50
Does service code Err

50 appear directly
after switching on, Select Rod electrode
although the primary mode
power module is not
operating? Change UST Yes
Yes
No
Imbalance in interme- +5V available on UST
diate circuit > 35V? from X6/26 - X7/8?
No
Yes Yes
Change BPS
Does Err 50 disappear Change intermediate

after a short while? Yes circuit electrolytic
capacitors
No
On the BPS, the
brightness of the
Switch off power Change UST control LEDs remains
source; unplug X2 No unchanged when the
from NT 60; switch on BPS is accessed
power source
Yes
Err 50? Change NT 60

No
Yes
Switch off power

source; discharge
intermediate circuit
electrolytic capacitors;
unplug X1 from NT 24;
switch on power source
Imbalance in interme-
Change NT 24
diate circuit > 35V? No
24
Service code Err
A
50
(continued)
Switch off power

source; discharge
intermediate circuit
electrolytic capacitors;
unplug X7/1 - X7/4
switch on power source
Imbalance in interme-
Change BPS
diate circuit > 35V? No
Yes
Change intermediate
circuit electrolytic
End
25
UST service codes
Safety
- Ensure that electrically charged components (e.g. capacitors) have been
discharged
Table of service For every service code there is information on

codes - Service code indicator (e.g. Err | Arc)
- Code no. (e.g. when service code is displayed by a robot interface)
- Reason for the service code being displayed
- Corresponding troubleshooting measures
dsP | Axx (code no.20)

Cause: DSP displays general faults, xx stands for additional entries not required for
external service
Remedy: update software. Change UST2 PC board.
dsP | A21 (code no.20)

Cause: The power source is configured for either parallel operation (set-up parame-
ter P-C is set to ON) or for TimeTwin Digital (set-up parameter T-C is set
to ON). However, the LHSB link has been disconnected, or has become
faulty, while the power source was switched on.
Remedy: Dismiss the service code: Switch the power source off and back on again.
If necessary, restore or repair the LHSB link.
dsP | Cxx (code no.29)

Cause: DSP SoftCom fault, xx stands for additional entries not relevant for external
service
dsP | E05 (code no.17)

Cause: DSP displays internal fault
dsP | Exx (code no.21)

Cause: DSP displays general fault, xx stands for
1 timeout during charging
2 EOF during charging
3 fault on data channel (LT selection)
4 fault on com channel (LT selection)
5 timeout at EM stop command
dsP | Sy (code no.35)

Cause: internal fault (version conflict)
dsP | nSy (code no.36)

Cause: internal fault (version conflict)
26
Table of service
EcF | xxx (code no.32)
codes
(continued) Cause: BPS configuration fault, x stands for:
1 TPS 2700 with incorrect power module
2 TS/TPS/TP 4000 with incorrect power module
3 TS/TPS/TP 5000 with incorrect power module
4 TT 2200, MW 2200 with incorrect primary power module
5 MW 1700 with incorrect primary power module
253 This configuration functions only from UST2A V1.3 A onwards
254 This configuration functions only from UST PC board, version
UST2A onwards
255 Unknown primary power module
Remedy: Fit correct primary power module
EFD | xx.y (code no.30)

Cause: Fault in wirefeed system, xx and y emanate from the list of service codes
for the wirefeed system.
Remedy: check wirefeed system
EIF | xx.y (code no.63)

Cause: fault connected with a robot interface, xx and y emanate from the list of
service codes of your robot interface.
Remedy: check robot interface, update software, change robot interface
Err | Arc (code no.61)

Cause: DPS 5000 only: DPS detected arc formation
Remedy: check application
Err | bPS (code no.18)

Cause: DSP displays internal fault
Remedy: update software. Change UST2 PC board. Change BPS PC board.
Err | Cfg (code no.72)

Cause: Power source configuration changed (e.g. connected in parallel with a
second power source)
Remedy: dismiss service code by pressing set-up button
Err | EPF (code no.22)

Cause: Fault during charging of flex
Err | IP (code no.19)

Cause: DSP displays primary overcurrent
Remedy: check secondary power module. Change primary power module.
Err | Jo (code no.67)

Cause: JobMaster temperature sensor faulty
Remedy: change JobMaster welding torch
Err | Lic (code no.40)

Cause: faulty/incorrect licence key
Remedy: check licence key. Check and update enable codes. Check/change earth
current watchdog
27
Table of service
Err | PE (code no.53)
codes
(continued) Cause: Ground (earth) fault
Remedy: remove earth fault. Configure machine in insulated state. Check earth
current watchdog and change if necessary.
Err | tF1 (code no.11), Err | tF2 (code no.12), Err | tF3 (code no.13), Err | tF4 (code
no.14), Err | tF5 (code no.15)
Cause: temperature sensor fault (short circuit or interruption)
Remedy: check cable harness and change temperature sensor
Err | tF6 (code no.16)

Cause: fault on BPS PC board or on the connection to BPS PC board
Remedy: check ribbon cable. Change BPS PC board.

Cause: temperature sensor fault on UST
Remedy: Changing UST PC board

Cause: in conjunction with thermostat option: cooling unit temperature sensor fault
Remedy: check cable harness. Change temperature sensor.
Err | 027 (code no.27)

Cause: one of the supply voltages is outside the tolerance range
Remedy: Change UST

Cause: Phase failure
Remedy: Check the mains fuse, the mains supply lead and the mains plug

Cause: voltage intermediate circuit balance error
Remedy: see fault flowchart Err 50 if available.
If there is a voltage of +5 V on the UST from X6/26 - X7/8, change BPS.
If there is a voltage of 0 V on the UST from X6/26 - X7/8 0V, change UST.

Cause: mains undervoltage: The mains voltage has dropped below the tolerance
range
Remedy: check mains voltage

Cause: mains overvoltage: The mains voltage has exceeded the upper limit of the
tolerance range
Remedy: check mains voltage

Cause: Wire stick control has tripped
Remedy: remove short circuit on filler wire

Cause: In conjunction with wire-feed unit and wire-end check option: no wire
available
Remedy: insert new wire spool
28
Table of service
codes
(continued) Cause: overvoltage in the secondary circuit: safety cut-out has tripped
Remedy: check secondary circuit, including TP4CEL40

Cause: DPS5000 only: Due to an opened door contact, SITRE1A has triggered
safety disconnection
Remedy: safety cut-out: close door contact

Cause: Remote control TP08 overtemperature
Remedy: allow TP08 to cool down. Change TP08.

Cause: secondary circuit safety cut-out has tripped
Remedy: change TTS PC board

Cause: illegal change of mode or process during welding
Remedy: reignite arc

Cause: no communication between power source and remote control RCU 5000i
Remedy: check LocalNet leads. Check software version (UST 3.21.4). Wait for
software update to finish.
Err | 23.x (code no.23)

Cause: config memory (CFM) fault on UST2B PC board, x stands for:
1 config memory not found
2 checksum error
3 CFM undescribed
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)
Remedy: update software. Change UST2B PC board.

Cause: config memory (CFM) fault on BPS PC board, x stands for:
2 checksum error
3 CFM undescribed
Remedy: check ribbon cable. Change BPS PC board.

Cause: config memory (CFM) alternator fault, x stands for:
2 checksum error
3 never tested
4 test was not OK
Remedy: change TTS
29
Table of service
codes
(continued) Cause: config memory (CFM) machine fault, x stands for:
2 checksum error
3 CFM undescribed
Remedy: check cable harness. change config memory on power source cable
harness.

Cause: EEProm save error

Cause: fault with the digital gas control option, x stands for:
1 no sensor found
2 no shielding gas
3 calibration fault
4 shielding gas solenoid valve interruption or short circuit
5 no shielding gas solenoid valve found
Remedy: for cause x
1 check cable harness, change shielding gas sensor
2 check shielding gas supply (min. 2 bar)
3 no or insufficient shielding gas, change shielding gas solenoid valve
4 change shielding gas solenoid valve, change shielding gas sensor
5 check cable harness, change shielding gas solenoid valve

Cause: Limit failure, x stands for:
1 upper current limit exceed
2 exceed of lower current limit
3 voltage limit exceeded
4 exceed of lower voltage limit
Remedy: check application. check parameters.
hot | H2O (code no.65)

Cause: in conjunction with thermostat option: Overtemperature in cooling system
Remedy: allow cooling unit to cool down. Open cooling unit and clean heat exchan-
ger. Check whether ventilator is functioning properly.
no | Arc (code no.58)

Cause: arc is broken, arc-break monitor has tripped
Remedy: check welding parameters. Reignite arc Check grounding (earthing)
connection.
no | GAS (code no.57)

Cause: in conjunction with the digital gas control option: no shielding gas available
Remedy: check shielding gas supply
30
Table of service
no | H2O (code no.39)
codes
(continued) Cause: flow watchdog reporting water deficiency
Remedy: check cooling system hosepipes. Check pump pressure and flow rate.
Check flow watchdog.
no | Ign (code no.55)

Cause: Ignition time-out fault: no ignition within the value set in the set-up menu.
The safety cut-out has tripped.
Remedy: clean workpiece surface. Check parameters in set-up menu. Check
grounding (earthing) connection.
no | Prg (code no.1)

Cause: no saved program selected
Remedy: select saved program
off (code no.150)

Cause: no communication between the LocalNet participants (e.g. power source,
wire-feed unit, remote control or welding torch)
Remedy: check LocalNet leads. Change remote control/welding torch. Wait for
software update to finish.
-Stop- (code no.38)

Cause: Robot not ready
Remedy: when using a robot interface or field bus coupler, initialise the Robot
ready and Source error reset signals.
tJo | xxx (code no.66)

Cause: JobMaster overtemperature
Remedy: allow machine to cool down. Check cooling system.
tp1 | xxx (code no.5), tp2 | xxx (code no.6), tp3 | xxx (code no.7), tp4 | xxx (code
no.8), tp5 | xxx (code no.9)
Cause: overtemperature in power source primary circuit (XXX stands for tempera-
ture indicator)
Remedy: allow the power source to cool down. Check that ventilator is running.
tp6 | xxx (code no.10)

Cause: overtemperature in power source primary circuit, temperature sensor on
BPS PC board has tripped (XXX stands for temperature indicator)
ts1 | xxx (code no.2), tS2 | xxx (code no.3), tS3 | xxx (code no.4)
Cause: overtemperature in power source secondary circuit (XXX stands for tempe-
rature indicator)
tSt | xxx (code no.33)

Cause: overtemperature in control circuit, xxx stands for the temperature indicator
Remedy: allow the power source to cool down. Check ventilator.
US | POL (code no.37)

Cause: measuring device for secondary voltage (USek) incorrectly connected, or
defective for some other reason
Remedy: check cable harness. Change UST2 PC board.
31
Special displays The following service codes are special displays for software problems:
used with service
codes - And | Opc - STK | OVL
- Prt | Flt - STK | UVL
- Ill | Opa - Err | Dog
- Ill | Ina - ASS | Ert
- Ill | Bus - Edg | 1
- Err | 105
If the service codes shown above appear, more detailed information can be requested at
the power source control panel. Using the parameter selection buttons (left/right arrows),
you can switch between the following display levels:
- Level 1 (e.g. And | Opc): service codes display
(appears automatically)
- Level 2 (e.g. CS 01): segment display
(press parameter selection button once)
- Level 3 (e.g. IP 3456): instruction pointer
(press parameter selection button again)
Important! Please make a note of the displays in levels 1, 2, and 3, and pass them on to
Fronius. Using this data, Fronius can locate the precise cause of the fault.
32
Service codes SR 4xA
Safety
discharged
Table of service
EFD 1.x
codes
Cause: flex communication error
Remedy: change SR 4x
EFD2.1
Cause: oscillator watchdog fault
EFD 3.1
Cause: watchdog timer fault
EFD 5.x
Cause: SR 4x config memory (CFM) not legible
EFD 7.x
Cause: wire-feed unit config memory (CFM) not legible
Remedy: check cable harness. Change config memory (CFM) in cable harness.
EFD 8.x
Cause: motor overcurrent, x stands for:
1 motor overcurrent SR 4x (main motor)
2 motor overcurrent PM 4x (PM motor)
Remedy: check wirefeed system. For permitted nominal currents, see operating
instructions for the relevant wire-feed unit.
EFD 9.x
Cause: supply to motor, x stands for:
1 exceed of lower motor supply voltage limit
2 motor supply upper voltage limit exceed
Remedy: check VSP. check/change mains adapter NTxx
EFD 10.x
Cause: PMxxA config memory (CFM) not legible
Remedy: check PM xx connection to SR 4x. Change PM xx
EFD 12.x
Cause: VD actual speed value check outside of range, x stands for:
1 actual-value pick-up fault 1
2 actual-value pick-up fault 2
Remedy: check cable harness and actual value pick-up.
33
Service codes for push-pull calibration
Safety
discharged
Checking actual- The actual-value pick-up is checked by measuring the direct voltage on the actual-value
value pick-up pick-up leads.
Motor not activated:

- the voltage on the actual-value pick-up cable connections is approx. 13 V.
Motor activated:
- The motor speed is conveyed in the form of impulses on the actual-value pick-up
cable connections.
- The voltage sinks to approx. 11 V.
Error codes
Err | Eto
shown when the
drive units are Cause: Incorrect measurement during push-pull calibration
engaged (enga- Remedy: Repeat push-pull calibration
ged calibration)
St1 | E 1
Cause: At minimum wire feed speed, the wire-feed unit motor does not deliver any
actual rotational speed value.
Remedy: Repeat the push-pull calibration. If the error message re-appears: check
the actual-value pick-up and the cable connections to and from it
St1 | E 2
Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any
St1 | E 3
St1 | E 4
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver
any actual rotational speed value.
34
Error codes
St1 | E 5
shown when the
drive units are Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any
engaged (enga- actual rotational speed value.
ged calibration) Remedy: Repeat the push-pull calibration. If the error message re-appears: check
St1 | E 6
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
St1 | E 16
Cause: push-pull calibration has been interrupted: Quick-stop was activated by
pressing the torch trigger.
Remedy: Repeat push-pull calibration
St2 | E 7
Cause: Push-pull calibration - open-circuit has not been carried out
Remedy: Carry out push-pull calibration - open-circuit
St2 | E 8
St2 | E 9
Cause: At minimum wirefeed speed, the motor of the push-pull unit does not deliver
any actual rotational speed value.
St2 | E 10
Cause: At minimum wirefeed speed, the motor current of the wire-feed unit motor is
outside the permitted range. Possible causes of this include the wire-feed
unit motors not being engaged, and other wirefeed problems.
Remedy: Engage the drive units of both wire-feed unit motors, arrange the hose-
pack in as straight a line as possible; check the inner liner for kinks or
soiling; check the contact pressure on the 2-roller or 4-roller drive of the
push-pull unit;
Repeat the push-pull calibration
St2 | E 11
Cause: At minimum wirefeed speed, the motor current of the push-pull unit is
push-pull unit;
Repeat the push-pull alignment. If the error message re-appears: check
PPU settings
35
Error codes
St2 | E 12
shown when the
drive units are Cause: At maximum wirefeed speed, the wire-feed unit motor does not deliver any
engaged (enga- actual rotational speed value.
ged calibration) Remedy: Repeat the push-pull calibration. If the error message re-appears: check
(continued) the actual-value pick-up and the cable connections to and from it
St2 | E 13
Cause: At maximum wirefeed speed, the motor of the push-pull unit does not
deliver any actual rotational speed value.
the actual-value pick-up and the cable connections to and from it, and
change if necessary.
St2 | E 14
Cause: At maximum wirefeed speed, the motor current of the wire-feed unit motor
is outside the permitted range. Possible causes of this include the wire-feed
push-pull unit.
Repeat the push-pull calibration. If the error message re-appears: check
PPU settings
St2 | E 15
Cause: At maximum wirefeed speed, the motor current of the push-pull unit is
push-pull unit.
Repeat the push-pull calibration. If the error message re-appears: check
PPU settings
St2 | E 16
Cause: push-pull calibration has been interrupted: quick-stop was activated by
pressing the torch trigger.
Remedy: Repeat push-pull calibration
36
Detailed description
General remarks This section contains a detailed description of the electronic components with regard to
the following points:
- General (designation, item number)
- Component position in the machine
- Overview
- Technical Data
- Function overview
- Plug layout
- LED checklist
- Measuring points
Position of
electronic com-
ponents
Fig. 3 TPS 2700: Position of electronic components Fig. 4 TS 4000/5000, TPS 3200/4000/5000:
Position of electronic components
Overview Detailed description is composed of the following sections:

- ASU 27 - additional PC board
- ASU 40 - additional PC board
- BPS 25/BPT 27 - power module PC board
- BPS 32/40/42/50 - power module PC board
- NT 24 - 24 V switched mode power supply for control and regulation unit
- NT 60 - 60 V switched mode power supply for wire-feed unit
- UST - Control and regulation unit
- NF 3160 - Line filter
- NF 3400 - Line filter/black box
- Shunt
- SR 41 - Wire-feed regulation unit
- Temperature sensor TP 592S
- Secondary power module TPS 2700
- Secondary power module TS 4000/5000, TPS 3200/4000/5000
- Primary rectifier
37
ASU 27 - additional PC board
General remarks The ASU 27 PC board (item number 4,070,691,Z) is an additional PC board for the TPS
2700 MV power sources and is for switching between 230 V and 400 V.
Component
position in the
machine
Fig.5 TPS 2700 MV: Position of ASU 27 PC board
Overview
LED +5 V
LED +12 V
LED 230 V AC X1
LED 400 V AC
X2
Fig.6 ASU 27 PC board
Technical Data Input voltage 230/400 V AC

Input voltage tolerance +/- 15 %
38
Function over- - For switching between 230 V AC and 400 V AC
view - For generating control voltage +12 V and +5 V from the input voltage
- When switching on, the switching mechanism on the PC board detects the input
voltage:
a) With an input voltage of 400 V AC, the ASU 27 PC board switches both power
modules on BPS 25/BPT 27 in series
b) With an input voltage of 230 V AC, the ASU 27 PC board switches both power
modules on BPS 25/BPT 27 in parallel.
Plug layout
(X6) (X4)
(X1)
(X2)
(X5)
(X3)
Fig.7 Plug and connections on ASU 27 PC board
Pin Function
X1 Connection to cooling unit
Pin 1 NC Pin 9 NC
Pin 2 230/400 V from Pin 10 NC
primary rectifier
Pin 3 NC Pin 11 NC
Pin 4 Cooler 400 V Pin 12 NC
Pin 5 NC Pin 13 NC
Pin 6 Cooler 230 V Pin 14 NC
Pin 7 NC Pin 15 NC
Pin 8 NC Pin 16 NC
X2 not connected
X3 Connection to BPS 25/BPT 27 PC board (intermediate circuit 1+)
X4 Connection to BPS 25/BPT 27 PC board (intermediate circuit 1-)
X5 Connection to BPS 25/BPT 27 PC board (intermediate circuit 2+)
X6 Connection to BPS 25/BPT 27 PC board (intermediate circuit 2-)
39
LED checklist
LED +5 V
LED +12 V
LED 230 V AC
LED 400 V AC
Fig. 8 LED indicators on ASU 27 PC board
Measuring points There are no measuring points available on the ASU 27 PC board.
40
ASU 40 - additional PC board
General remarks The ASU 40 PC board (item number 4,070,685) is an additional PC board for TPS 3200 MV,
TS/TPS 4000/5000 MV, and is for switching the input voltage between 230 V AC and 400
V AC.
Component
position in the
machine
Fig. 9 TPS 3200 MV, TS/TPS 4000/5000:

Position of ASU 40 PC board
Overview
LED charge unit
(X12)
LED + 5 V
LED 230 V
LED + 12 V
(X1)
(X8)
Fig. 10 ASU 40 PC board
41
Technical Data Input voltage 230/400 V AC
Input voltage tolerance +/- 15 %
Function over- - For switching between 230 V AC and 400 V AC

view - For generating control voltage +12 V and +5 V from the input voltage
- When switching on, the switching mechanism on the PC board detects the input
voltage:
a) With an input voltage of 400 V AC, the ASU 40 PC board switches both power
modules on BPS 32/40/42/43/50/53 in series
b) With an input voltage of 230 V AC, the ASU 40 PC board switches both power
modules on BPS 32/40/42/43/50/53 in parallel.
- High charging connection by means of resistance; the relays for bridging the resis-
tances are controlled by the BPS PC board. The high charging connection is only
active at an input voltage of 230 V AC.
Plug layout
(X3)
(X9)
(X4)
(X10)
(X7)
(X11)
(X6)
(X2) (X12)
(X5)
(X8)
(X1)
Fig. 11 Plug and connections on ASU 40 PC board
Pin Function
X1 Connection to BPS 40/42/50 PC board
Pin 1 NC Pin 9 Intermediate circuit voltage 1+

Pin 2 NC Pin 10 NC
Pin 3 NC Pin 11 Intermediate circuit voltage 2-
Pin 4 NC Pin 12 NC
Pin 5 NC Pin 13 NC
Pin 6 NC Pin 14 NC
Pin 7 NC Pin 15 GND primary
Pin 8 +15 V primary Pin 16 High charging connection signal
42
Plug layout Pin Function
(continued)
X2 Connection to 2nd line filter L1 out
X3 Connection to 2nd line filter L2 out
X4 Connection to 3rd line filter L3 out
X5 Connection to 2nd rectifer L1
X8 not connected
X9 Connection to cooling unit 230 V
X10 Connection to cooling unit L2
X11 Connection to cooling unit L1
X12 Connection to 1st primary rectifer
Pin 1 Rectifer L1 Pin 9 NC

Pin 2 NC Pin 10 NC
Pin 3 Rectifer L2 Pin 11 Rectifer L2
Pin 4 NC Pin 12 NC
Pin 5 Rectifer L3 Pin 13 NC
Pin 6 NC Pin 14 NC
Pin 7 NC Pin 15 NC
Pin 8 NC Pin 16 NC
LED checklist
LED charge unit
LED 230 V LED + 5 V
LED + 12 V
Fig. 12 LED indicators on ASU 40 PC board
43
LED checklist LED charge unit ............. flashes once the intermediate circuit has been charged
(continued) LED 230 V ...................... flashes at an input voltage of 230 V
Measuring points There are no measuring points available on the ASU 40 PC board.
44
BPS 25/BPT 27 - power module PC board
General remarks BPS 25 (item number 4,070,631,Z) and BPT 27 (item number 4,070,739,Z) are power
module PC boards for the TPS 2700 power source.
The BPT 27 has serial numbers of 14481582 and upwards and replaces the BPS 25.
Important! On PC boards BPS 25/BPT 27, primary voltage is on!
BPS 25/BPT 27 consist of 2 PC boards:

- Power module PC board BPS 25/BPT 27
- PC board BPZ 25 for primary/secondary isolation
PC board BPZ 25 and BPS 25/BPT 27 form one unit. BPZ 25 and BPS 25/BPT 27
cannot be ordered separately.
Component
position in the
machine
Fig. 13 TPS 2700, position of PC board BPS 25/

BPT 27
Overview
Transistor module control LEDs
Control LED
Boost converter
X2
PC board BPZ 25 LED 15 V primary

with X1
Fig. 14 PC board BPS 25/BPT 27
45
Technical Data Input voltage 3 x 230/400 V AC
Input voltage tolerance (+/-15%)
Supply voltage (from NT 24A) 15 V DC primary
Boost converter work frequency 47 kHz
Transistor module switching frequency 100 kHz
Function over- - Basic composition: two individual power modules (advantage: power modules can
view be switched in series as well as parallel)
- Suitable for a 3 x 400 V AC and 3 x 230 V AC mains supply
- Inputs and outputs are electrically isolated by means of isolating transformers and
optical couplers
- 3 temperature sensors, each one in the transistor module housing
- Temperature analysed by a PWM signal electrically isolated by an optical coupler:
the temperature of the warmest transistor module is transmitted to the UST PC
board
- Monitoring of both intermediate circuits for imbalance: a signal is transmitted to the
UST PC board if there is any deviation from a permitted range
- Switching with boost converter for increasing the intermediate circuit voltage from
approx. 282 V DC to 320 Volt DC per circuit (at 400 V AC input voltage).
- Controlling the transistor module via driver stages from the UST PC board
- High charging connection via PTC resistors, time for bridging the PTC by means of
relay is given by UST PC board
- Activation of boost converter only once the high charging time is completed
- Quick switch-off of power module in the case of a module fault due to permanent
primary current measurement
Plug layout BPS

(X13) (X1) (X14) (X10) (X4)
25/BPT 27
(X7)
(X3)
(X9)
(X11)
(X6)
(X8)
(X16) (X15) (X2) (X12) (X5)
Fig. 15 Plugs and connections on PC board BPS 25/BPT 27
46
Plug layout BPS Pin Function
25/BPT 27
X1 Ribbon cable connection to UST PC board (on BPZ 25 PC board)
(continued)
Pin 1 Primary current measurement Pin 2 Primary current measurement
+T1 GND T1
+T2 GND T2
Pin 5 Transistor control Pin 6 Transistor control
Pin 13 GNDD Pin 14 GNDD
Pin 15 +5V Pin 16 + 15 V
Pin 17 + 24 V Pin 18 Main switch detection
(0 V = off/5 V = on)
Pin 19 Temperature value PWM signal Pin 20 Signal for high charging
connection
(0 V = relay on/15 V = relay off)
Pin 21 CFM data line Pin 22 CFM data line
Pin 23 NC Pin 24 NC
Pin 25 NC Pin 26 Intermediate circuit imbalance
detection
(0 = fault/5 V = OK)
X2 Intermediate circuits 1 and 2 primary connection
Pin 1 Intermediate circuit 1 + Pin 9 Intermediate circuit 1 +

Pin 2 NC Pin 10 NC
Pin 3 Intermediate circuit 1 - Pin 11 Intermediate circuit 1 -
Pin 4 NC Pin 12 NC
Pin 6 NC Pin 14 NC
Pin 7 Intermediate circuit 2 - GNDP Pin 15 Intermediate circuit 2 - GNDP
Pin 8 + 15 V primary Pin 16 + 15 V primary
X3 Intermediate circuit 1+ (for MV only)

X4 Intermediate circuit ZWK 1-, bridge for operation in series
X5 Intermediate circuit ZWK 2+, bridge for operation in series
X6 Intermediate circuit 2- (for MV only)
X7 Cable with blade terminal, rectifer +
X8 Cable with blade terminal, rectifer -
X9 PFC throttle connection L2
X13 Primary transformer connection (e.g. blue)
X14 Primary transformer connection (e.g. blue)
X15 Primary transformer connection (e.g. orange)
X16 Primary transformer connection (e.g. orange)
47
LED checklist
1 x 15 V primary supply LED

2 control LEDs
8 transistor module control LEDs
Boost converter
Fig. 16 LED indicators on PC board BPS 25/BPT 27
Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor field effect
transistors) with diode. This diode provides information about the state of the transistor:
using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltage
cannot be measured, the module is faulty.
4 x diode
(module M1)
Charging resistor (PTC)

120 R at 25C
4 x diode
module M2
4 x diode (module M3)

Fig. 17 Measuring points on the BPS 25/BPT 27 PC board
48
Measuring points Measuring points Plug/pin Measuring result command
(continued) value
Intermediate circuit voltage 1 M1/TP1-TP3 320 V DC
Intermediate circuit voltage 2 M2/TP5-TP7 320 V DC
Diode check module M1 M1/TP1-TP2 (+) 0.46 V
M1/TP1-TP4 (+) 0.46 V
M1/TP3 (+) - TP2 0.46 V
M1/TP3 (+) - TP4 0.46 V
Diode check module M2 M2/TP5-TP6 (+) 0.46 V
M2/TP5-TP8 (+) 0.46 V
M2/TP7 (+) - TP6 0.46 V
M2/TP7 (+) - TP8 0.46 V
Diode check module M3 M3/TP9 (+) - TP11 0.46 V
M3/TP11 (+) - TP10 0.38 V
M3/TP13 (+) - TP14 0.46 V
M3/TP14 (+) - TP12 0.38 V
NOTE!
The resulting measurement command values change according to the temperature.
49
BPS 32/40/42/43/50/53 - power module PC board
General remarks BPS 32/40/42/43/50/53 are power module PC boards:

TPS 3200 .................. BPS 32 (item number 4,070,681,Z)
BPS 42 >/= V1.4A (item number 4,070,738,Z)
BPS 43 (item number 4,070,771,Z)
TS/TPS 4000 ............. BPS 40 (item number 4,070,617,Z)
TS/TPS 5000 ............. BPS 50 (item number 4,070,658,Z)
Important! On the power module PC boards, primary voltage is on!
Component
position in the
machine
Fig. 18 TS 4000/5000, TPS 3200/4000/5000:

Position of PC board BPS xx
Overview
X1 X2
*)
**)
*) X3
Fig. 19 PC board BPS 50 < V1.4A (BPS 42 < V1.4A / BPS 32)
*) ... not on PC board BPS 42 < V1.4A **) ... not on PC board BPS 32
50
Overview
Main switch LED LED +15 V primary
(continued)
imbalance LED
X1 X2
*)
X3
High charging relay LED
Fig. 20 PC board BPS 53 / 50 >/= V1.4A / 43 / 42 >/= V1.4A
*) ... not on PC board BPS 42 >/= V1.4A and BPS 43
Technical Data Input voltage 3 x 230/400 V AC

Input voltage tolerance (+/-15%)
Supply voltage (from NT 24A) 15 V DC primary
Transistor module switching frequency 70 kHz
Intermediate circuit voltage at 400 V AC 2 x 280 V DC
Function over- - Basic composition: two individual power modules (advantage: power modules can
view be switched in series as well as parallel)
- Suitable for a 3 x 400 V AC and 3 x 230 V AC mains supply
- Inputs are electrically isolated by means of isolating transformers and optical coup-
lers
- Outputs are electrically isolated by means of optical couplers
- 4 parallel transistor modules for BPS 32, BPS 42 >/= V1.4A and BPS 43
6 parallel transistor modules for BPS 42 < V1.4A, BPS 50 and BPS 53
- Each transistor module has a temperature sensor
- Temperature analysed by a PWM signal electrically isolated: the temperature of the
warmest transistor module is transmitted to the UST PC board
- Monitoring of both intermediate circuits for imbalance: a signal is transmitted if there
is any deviation from a permitted range
- Controlling the transistor module via driver stages from the UST PC board
- High charging connection via resistors, time for bridging the resistors by means of
relay is given by UST PC board
- Quick switch-off of power module in the case of a module fault due to permanent
primary current measurement
51
Plugs on the
power module PC (X18)(X7)
(X19) (X1) (X20) (X21)(X4) (X12) (X11) (X2) (X10)
boards
(X6) (X15) (X14) (X17) (X16) (X5) (X13) (X9) (X8) (X3)
Fig. 21 Plugs and connections on power module PC board, e.g. BPS 50 < V1.4A
The position of the plug and connections is identical for all power module PC boards.

X1 Ribbon cable connection to PC board UST (secondary voltage)

+T1 GND T1
+T2 GND T2
Pin 13 GNDD Pin 14 GNDD
Pin 15 +5V Pin 16 + 15 V
Pin 17 + 24 V Pin 18 Main switch detection
(0 V = off/5 V = on)
Pin 19 Temperature value PWM signal Pin 20 Signal for high charging
connection
(0 V = relay on/15 V = relay off)
Pin 21 CFM data line Pin 22 CFM data line
Pin 23 NC Pin 24 15 V supply
Pin 25 NC Pin 26 Intermediate circuit balance
detection (0/5 V)
52
(continued)
X2 Intermediate circuits 1 and 2 primary connection

Pin 2 NC Pin 10 NC
Pin 4 NC Pin 12 NC
Pin 6 NC Pin 14 NC
Pin 8 + 15 V primary Pin 16 + 15 V primary
X3 Main switch connection (primary voltage)
Pin 1 L1 Pin 9 NC
Pin 2 NC Pin 10 High charging resistor L1
Pin 3 L2 Pin 11 NC
Pin 4 NC Pin 12 High charging resistor L2
Pin 5 NC Pin 13 NC
Pin 6 Main switch detection Pin 14 NC
Pin 7 NC Pin 15 NC
Pin 8 +15 V primary Pin 16 High charging connection
X4 N1- transformer connection

X5 N2- transformer connection
X6 N2+ transformer connection
X7 N1+ transformer connection
X8 Primary rectifier L1
X9 Line filter L1
X10 Line filter L3
X12 Line filter L2
X14 Intermediate circuit 2-, blue cable
X16 Intermediate circuit 2+, red cable
53
LED checklist of
power module PC
boards
Fig. 22 LED indicators on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32
Main switch LED LED +15 V primary
imbalance LED
High charging relay LED
Fig. 22a LED indicators on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A
Measuring points In every transistor module there are 4 MOS-FETs (metal oxide semiconductor field effect
transistors) with diode. This diode provides information about the state of the transistor:
using a diode tester, a diffusion potential of 0.4 - 0.5 V must be measured. If this voltage
cannot be measured, the module is faulty.
54
Measuring points
(continued)
Fig. 23 Measuring points on PC board BPS 50 < V1.4A, BPS 42 < V1.4A, BPS 40, BPS 32
4 x diode
4 x diode
Fig. 23a Measuring points on PC board BPS 53, BPS 50 >/= V1.4A, BPS 43, BPS 42 >/= V1.4A
55
Measuring points Measuring points Plug/pin Measuring result command value
(continued)
Intermediate circuit voltage 1 TP1-TP3 320 V DC
Intermediate circuit voltage 2 TP5-TP7 320 V DC
Diode check module M1 TP1-TP2 (+) 0.46 V
TP1-TP4 (+) 0.46 V
TP3 (+) - TP2 0.46 V
TP3 (+) - TP4 0.46 V
TP5 - TP6 (+) 0.46 V
TP5 - TP8 (+) 0.46 V
TP7 (+) - TP6 0.46 V
TP7 (+) - TP8 0.46 V
Important! No continuity during diode check of module M1 with reverse polarity.
NOTE!
The resulting measurement command values change according to the temperature.
56
NT 24 - switched mode power supply 24 V
General remarks NT 24 switched mode power supply (item number 4,070,626,Z) for internal and external
components.
Important! On NT 24 switched mode power supply, the primary voltage is on!
Component
position in the
machine
Fig. 24 TPS 2700, position of NT 24 Fig. 25 TPS 3200, TS/TPS 4000/5000:

Position of NT 24
Overview Secondary voltage Primary voltage
X1
X2
LED 24 V internal LED 15 V primary

LED 24 V external
Fig. 26 NT 24
57
Technical Data Input voltages 2 x 230 - 380 V DC from intermediate circuit
Output voltages 15 V DC primary
24 V DC internal
24 V DC external
Fuse protection from PTC 15 V primary 2A
24 V internal 5A
24 V external 2A
Function over- - Internal and external components supplied with +24 V DC

view - Power module supplied with +15 V DC primary
NOTE! +15 V DC is for primary. Do not use for supplying other components.
- Supply voltages are electrically isolated and protected by PTC

- Electrically isolated measurement of intermediate circuit voltage, evaluation on UST
PC board
Plug layout
8 16
7 15
6 14
5 1 5 13
6 2 4 12
(X1)
(X2) 7 3 3 11
8 4 2 10
1 9
Fig. 27 Plug on NT 24 A
Pin Function
X1 Primary connection intermediate circuit 1 and 2

Pin 2 NC Pin 10 NC
Pin 4 NC Pin 12 NC
Pin 6 NC Pin 14 NC
Pin 8 +15 V primary Pin 16 +15 V primary
58
Plug layout Pin function
(continued)
X2 Secondary connection +24 V
Pin 1 +24 V external Pin 5 GND EXT

Pin 2 NC Pin 6 NC
Pin 3 Intermediate circuit voltage UZW Pin 7 GND UZW
Pin 4 +24 V internal Pin 8 GND INT
LED checklist
LED 24 V internal LED 15 V primary

LED 24 V external
Fig. 28 LED indicators on mains adapter NT 24 A
Measuring points
8 16
7 15
6 14
5 1
X2 5 13
6 2 4 12
7 3 3 11
8 4 2 10
1 9
X1
Fig. 29 Plug X1 and X2 on mains adapter NT 24 A
59
(continued)
Intermediate circuit voltage 1 X1/1 - X1/3 approx. 280 V DC at a nominal voltage of
400 V AC
approx. 320 V DC at a nominal voltage of
230 V AC
400 V AC
230 V AC
+15 V primary X1/8 - X1/7 approx. 15 V DC
+24 V internal X2/4 - X2/8 approx. 24 V DC
+24 V external X2/1 - X2/5 approx. 24 V DC
60
NT 60 - switched mode power supply 60 V
General remarks The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feed
unit motor.
Important! On NT 60 switched mode power supply, the primary voltage is on!
Component
position in the
machine
Fig.30 TPS 2700, position of NT 60 Fig.31 TPS 3200, TS/TPS 4000/5000:

Position of NT 60
Overview Primary voltage Secondary voltage
Intermediate
circuit 2 supply
LED
X2 X1
Intermediate circuit 1 supply LED Error LED (PTC active) Supply LED
55 V
Fig.32 NT 60
61
Technical Data Supply voltage from intermediate circuit 2 x 230 - 380 V DC
Output voltage Idle 59 (+/- 2) V
at a load of 4 A 55 (+/- 2) V
Function over- - Output voltage is electrically isolated and protected by 2 parallel switched PTC
view resistors.
- The 1 V/A falling output characteristic of the NT 60 circuit enables several NT 60
adapters to be connected in parallel.
- If there is a short circuit, the NT 60 restricts to max. 15 A, using the internal current
limit, until the PTC resistors have reached the switch-off temperature. In the case of
a short circuit, the 55 V supply LED does not flash. As soon as the PTC resistors
trip, the Error LED flashes.
Plug layout
(X2) (X1)
Fig. 33 Plug on NT 60 mains adapter
Pin Function
X1 Connection to wire-feed unit (secondary voltage)
Pin 1 + 55 V Pin 3 GND

Pin 2 + 55 V Pin 4 GND
X2 Primary connection intermediate circuit 1 and 2
Pin 1 Intermediate circuit 1+ Pin 9 Intermediate circuit 1+

Pin 2 NC Pin 10 NC
Pin 4 NC Pin 12 NC
Pin 5 Intermediate circuit 2+ Pin 13 Intermediate circuit 2+
Pin 6 NC Pin 14 NC
62
Plug layout Pin 7 Intermediate circuit 2- GND P Pin 15 Intermediate circuit 2- GND P
(continued) Pin 8 + 15 V primary Pin 16 + 15 V primary
LED checklist
Intermediate circuit 2 supply LED

Error LED (PTC highly resistive)
55 V supply LED
Intermediate circuit 1 supply LED
Fig. 34 LED indicators on mains adapter NT 60
Measuring points
X2 X1
Fig. 35 Plug X1 and X2 on mains adapter NT 60
63
(continued)
X2/9 - X2/11 400 V AC
230 V AC
X2/13 - X2/15 400 V AC
230 V AC
+55 V X1/1 - X1/3 approx. 57-61 V DC in idle
X1/2 - X1/4
64
UST - Control and regulation unit
General remarks The UST PC board is a universal control, regulation and monitoring unit for fully digitised
Fronius power sources. The UST PC board comes in the following variants:
- UST2A
- UST2B, item number 4,070,860,Z (replaces UST2A)
Component
position in the
machine
Fig.36 TPS 2700: position of UST PC board Fig.37 TPS 3200, TS/TPS 4000/5000:
position of UST PC board
Overview
X4
X3
X9
X1
X10
X7 X5
X6 X2 X8
LED STAT LED +5 V LED +24 V external

LED -15 V LED +5 V (RS 485)
LED +15 V
LED +24 V internal
Fig.38 UST PC board
65
Technical Data Supply voltage (from NT 24A) 24 V DC
Function over- - Power module control (driver switches on UST PC board)

view - Operating panel control in the form of a databus connection (LocalNet)
- Evaluation of the mains switch signal coming from the BPS PC board:
a) Mains switch ON: Once the intermediate circuit voltage reaches a certain value,
the relays on the BPS PC board are controlled by the UST PC board
b) Mains switch OFF: UST stores present settings and activates the ventilators for
discharging the intermediate circuit capacitors
- Evaluation of signals from the temperature sensors; if there is a rise in temperature
and the ventilators do not cool sufficiently, (e.g. because the duty cycle was excee-
ded), the power source switches off and displays an appropriate service code.
- Ventilator control subject to temperature and firmware
- Data transmission to peripheral devices via LocalNet interface
- Regulation of welding current and welding voltage via the integral digital signal
processor (DSP) in the UST PC board
- Converter module control
Plug layout
(X4)
(X3)
(X9)
(X1)
(X10)
(X6) (X2) (X8) (X7) (X5)
Fig.39 Plug on UST PC board
Pin Function
X1 not assigned
X2 Connection to control panel
X3 Supply
Pin 1 +24 V external Pin 5 GND external

Pin 2 NC Pin 6 NC
Pin 3 Intermediate circuit voltage Pin 7 GND Intermediate circuit voltage
Pin 4 +24 V internal Pin 8 GND internal
66
(continued)
X4 Temperature transmission; voltage command value, current command value
Pin 1 Voltage actual value Pin 13 Voltage actual value +

Pin 2 NC Pin 14 NC
Pin 3 Shunt C 4000, Pin 15 Shunt D 5000,
Pin 4 Shunt A 3000, Pin 16 NC
Pin 5 Shunt B 2000, Pin 17 GND Shunt
Pin 6 -15 V Shunt Pin 18 +15 V Shunt
Pin 7 TH error 1 Pin 19 TH error 2
Pin 8 GND A (UP 400) Pin 20 UP 400
Pin 9 CFM- Pin 21 CFM+
Pin 10 ESC 1 Pin 22 ESC 2
Pin 11 Temperature 2- Pin 23 Temperature 2+
Pin 12 Temperature 1- Pin 24 Temperature 1+
X5 Ventilator control
Pin 1 +24 V Pin 3 +24 V

Pin 2 FAN Pin 4 FAN
X6 Power module PC board control
Pin 1 Primary current T1+ Pin 2 Primary current GND T1

Pin 3 Primary current T2+ Pin 4 Primary current GND T2
Pin 5 OUT A1 Pin 6 OUT A3
Pin 7 OUT A2 Pin 8 OUT A4
Pin 9 OUT B1 Pin 10 OUT B3
Pin 11 OUT B2 Pin 12 OUT B4
Pin 13 GND D Pin 14 GND D
Pin 15 +5 V Pin 16 +15 V
Pin 17 +24 V Pin 18 Main switch
Pin 19 PWM temperature Pin 20 High charging connection
Pin 21 SCL (CLOCK) Pin 22 SDA (DATA)
Pin 23 FAST OUT 1 Pin 24 +15 V
Pin 25 SYNC Pin 26 OV/UV
X7 Cooling unit control
Pin 1 Temperature + Pin 6 Temperature -

Pin 2 Cooling unit ON Pin 7 + 24 V
Pin 3 Water control Pin 8 GND (Water control)
Pin 4 CFM + Pin 9 CFM-
Pin 5 NC Pin 10 GND (SUPPLY)
X8 Programming interface, for updating firmware via BSL tool

X9 Connection to wire-feed unit
Pin 1 +24 V external Pin 4 GND external (+24 V)

Pin 2 RXDL-485 Pin 5 TXDL-485
Pin 3 RXDH-485 Pin 6 TXDH-485
67
(continued)
X10 Control for gas solenoid valve and TIG welding torch (optional)
Pin 1 High frequency on/off HF Pin 7 GND (HF)

Pin 2 Gas 1 Pin 8 +24 V (Gas 1)
Pin 3 Gas 2 Pin 9 +24 V (Gas 2)
Pin 4 Crater fill BRT Pin 10 Main current BRT
Pin 5 BRT UP Pin 11 BRT DOWN
Pin 6 GND (gun trigger) Pin 12 Detection
LED checklist
LED +24 V external

LED +24 V internal
LED +5 V (RS 485)
LED +15 V
LED -15 V
LED STAT LED +5 V
Fig.40 LED indicators on UST PC board
- LED STAT flashes when there is no firmware available
Measuring points See plug layout.
Measuring points Plug/pin Measuring result command value

Intermediate circuit imbalance X6/26 - X7/8 5 V = OK, 0 V = fault
Changing UST NOTE! Options enabled via service module software are stored on the UST,
PC board and must be re-enabled after changing the UST. Before changing the UST, the
enabled options must be clarified with the customer - the enable codes must be
supplied by the customer.
68
NF 3160 - Line filter
General remarks The NF 3160 PC board (item number 4,070,662) is used with the TPS 2700 power
source and is for filtering out parasitic frequencies:
- generated by the power source and which can affect other consumer loads
- that come from the mains supply and which can affect the power source
Important! On the NF 3160 PC board, the mains voltage is on!
Component
position in the
machine
Fig.41 TPS 2700, position of NF 3160 PC board
Overview
X1
X3
X5
X2 X4 X6
Fig.42 NF 3160 PC board
Technical Data Attenuation of parasitic frequencies > 60 Hz
69
Function over- - Varistors provide protection against momentary overvoltage of the mains
view - Capacitors and coils form an LC low-pass filter that moderates the parasitic fre-
quencies over 60 Hz
- Capacitors divert disturbances to earth and also between the phases
- Resistors discharge the line filter capacitors
Plug layout
X1
X3
X6
X4 X5
X2
Fig. 43 Connections on NF 3160 PC board
Pin Function
X1 L1 in, cable
X2 L1 out, cable
X3 L2 in, cable
X4 L2 out, cable
X5 L3 in, cable
X6 L3 out, cable
LED checklist There are no LED indicators on NF 3160 PC board.
Measuring points There are no measuring points on NF 3160 PC board.
70
NF 3400 - Line filter/line filter 40 A/80 A
General remarks The NF 3400 PC board (item number 4,070,664) is used with the TPS 3200, TS/TPS
4000/5000 power sources and is for filtering out parasitic frequencies:
- generated by the power source and which can affect other consumer loads
- that come from the mains supply and which can affect the power source
PC board NF 3400 (serial number 14280747 upwards) has been replaced by line filter
40 A (item number 43,0001,1199).
The line filter 40 A is used with TS 4000/5000, TPS 3200/3200 MV/4000/5000.
The line filter 80 A (serial number 15191632 upwards) is used with TS 4000/5000 MV,
TPS 4000/5000 MV.
Important! On the NF 3400 PC board, the mains voltage is on!
Component
position in the
machine
Fig.44 TPS 3200, TS/TPS 4000/5000 position of Fig.45 TPS 3200, TS/TPS 4000/5000 position of
NF 3400 PC board line filter 40 A/80 A
Overview
X1
X3
X5
X2 X4 X6
Fig.46 NF 3400 PC board
71
Overview
(continued) Line filter 40 A Line filter 80 A
X4
X1 X1
X2 X2
X3 X3
Fig. 47 Line filter 40 A and 80 A
Technical Data Attenuation of parasitic frequencies > 60 Hz
Function over- - Varistors provide protection against momentary overvoltage of the mains
view - Capacitors and coils form an LC low-pass filter that moderates the parasitic fre-
quencies over 60 Hz
- Capacitors divert disturbances to earth and also between the phases
- Resistors discharge the line filter capacitors
- The earth current watchdog is integrated on line filter 40 A/80 A
Plug layout NF
3400 X1
X3
X5
X6
X4
X2
Fig.48 Connections on NF 3400 PC board
Pin Function
X1 L1 in, cable
X2 L1 out, cable
X3 L2 in, cable
X4 L2 out, cable
X5 L3 in, cable
X6 L3 out, cable
72
Plug layout line
filter 40 A/80 A X1 Line filter 40 A X2 X1 Line filter 80 A X2 X4
X3 X3
Fig. 49 Connections on line filter 40 A and 80 A
Pin Function
X1 Mains supply
U1 L1 in
V1 L2 in
W1 L3 in
PE PE conductor
X2 Connection to BPS 42/50/53
U2 L1 out
V2 L2 out
W2 L3 out
X3 Earth current watchdog

X4 Connection to ASU 40 (on line filter 80 A only)
U2 L1 out
V2 L2 out
W2 L3 out
LED checklist There are no LED indicators on PC board NF 3400 or line filters 40 A/80 A.
Measuring points There are no measuring points on PC board NF 3400 or line filters 40 A/80 A.
73
Shunt
General remarks The shunt (item number 43,0001,1138) is a current sensor which permits the isolated
capture of the welding current.
Component
Shunt
position in the (behind the motor plate)
machine
Shunt
Fig. 50 TPS 2700, position of shunt Fig. 51 TPS 3200, TS/TPS 4000/5000:
position of shunt
Overview
Fig. 52 Shunt
74
Technical Data Supply voltage +15 V /- 15 V
Nominal current 500 A
Output current at nominal current 250 mA
Transformation ratio 1 : 2000
Function over- The shunt operates according to the compensation principle, where a magnetically soft,
view probe functions as a magnetic field detector. The shunt is characterised by the following
features:
- Compact design
- Low offset current
- Low hysteresis
- High temperature stability
- Integrated electronics
The shunt is supplied by a bipolar operating voltage of +/- 15 V and provides an output
signal which is proportional to the measured welding current. The output signal to wel
ding current transfer ratio is 1:2000.
Other functions:
- Electric isolation between high-voltage circuit and electronic circuit
- Null balance and amplification procedures do not apply
- Based on the principle of compensation of magnetic fields, the current transducers
provide a measured current proportional to the primary current

X1 Molex plug from adapter cable
Pin 1 +15 V Pin 3 I Real -

Pin 2 -15 V Pin 4 GND
LED checklist There are no LED indicators on the shunt.
Measuring points The welding current can be captured indirectly using a tension gauge. At a welding
current of 100 A for instance, a voltage of 0.33 V must be measured on the UST PC
board, plug X4, pins 5 and 17.
Measuring points Plug/pin Measuring result command value

Welding current X4/5 - X4/17 0.33 V at a welding current of 100 A
NOTE! To prevent malfunction, and to exclude the possibility of damage to

other parts in the power source, use only the adapter cable supplied.
75
SR 41 - Wire-feed unit regulation unit
General remarks On the TPS 2700 power source, the SR 41 PC board (item number 4,070,677,Z) is the
regulation unit for powering and controlling the wire-feed unit.
Component
position in the
machine
Fig. 53 TPS 2700, position of SR 41 PC board
Overview
LED BUS OK LED +15 V LED +55 V
LED FLEX OK LED +5 V
X9
X2 X11
X10
X1
X8
X3 X4 X5 X6 X7
LED -15 V
LED backwards
LED BRT LED -24 V LED gas
LED P OK LED forwards
Fig. 54 SR 41 PC board
76
Technical Data Supply voltage (from NT 24) + 24 V DC
Supply voltage (from NT 60) + 55 V DC
Function over- - Digital adjuster with power module (flow converter) for the wire-feed unit motor
view - two-stage adjustment for permanent stabilisation of the motor:
a) Stabilisation of fast, dynamic changes, using a voltage/current regulator
b) Stabilisation of slow, dynamic changes, using a speed controller via the actual-
value pick-up
- Controls the wire-feed unit via PWM signal
- Full bridge for controlling the motor, changing the motors direction of rotation and
for controlled accelerating and decelerating
- The switched mode supply on the SR 41 is supplied with 24 V from outside the
power source, and ensures an independent supply for the PC board, and supply for
any connected peripheral devices with voltages of +15 V, -15 V and + 5 V .
- Controls the gas magnet valve, blow-off signal
- Controls a push-pull system via the X12 plug
- Analyses the torch trigger signal
- Analyses the actual rotational speed value of the wire-feed unit motor,
- Analyses the robot sensor signals (e.g. wire end)
- 3 LocalNet interfaces for communicating between SR 41, power source, remote
control and options:
a) X2 for internal components (e.g.: control panel)
b) X6 for external components (e.g.: remote control)
c) X7 for the power source
Overvoltage protection (varistors) and overcurrent protection (PTC) on all LocalNet
interfaces, except X2
- Firmware update using BSL tool via programming connection X9
Plug layout
(X12)
(X9)
(X2) (X11)
(X10)
(X1)
(X8)
(X3) (X4) (X5) (X6) (X7)
Fig. 55 Plug on SR 41 PC board
77
(continued)
X1 Connection to control panel
Pin 1 GND for power potentiometer Pin 5 GND (arc correction)

Pin 2 +5 V for power potentiometer Pin 6 +5 V (arc correction
Pin 3 Power+ (actual value of power Pin 7 ARC-CORR + (arc correction
potentiometer) actual value)
Pin 4 Power - (clip on pin 1 with Pin 8 ARC-CORR - (clip on pin 5 with
potentiometer) potentiometer)
Pins 3/4 and 7/8 with differential amplifier
X2 LocalNet connection to control panel (ribbon cable)
Pin 1 -15 V Pin 2 +15 V

Pin 3 GND D Pin 4 +5 V
Pin 5 +5 V Pin 6 GND D
Pin 7 RXDL Pin 8 RXDH
Pin 9 TXDL Pin 10 TXDH
X3 Welding torch control
Pin 1 Gun Trigger Euro Pin 6 GND D Euro

Pin 2 +5 V PullMig potentiometer Pin 7 GND Pullmig potentiometer
Pin 3 PM LSP (PullMig potentiometer Pin 8 Torch detection
actual value)
Pin 4 UP / DOWN (+ 5 V = up, Pin 9 GND torch
0 V = down, 2.5 V = no buttons
pressed)
Pin 5 Gun Trigger - torch trigger Pin 10 +15 V
X4 Robot sensors/feeder inching and gas test
Pin 1 Torch blow out Pin 8 +24 V torch blow out

Pin 2 I on - current flow signal Pin 9 +24 V (res)
Pin 3 Wire retract Pin 10 Gas test
Pin 4 Wire in Pin 11 GND to pin 3/4/6/10/12
Pin 5 Wire end Pin 12 Real value - actual rotational
Pin 6 Gas pressure watchdog speed value
Pin 7 KAT - cut-out box Pin 13 GND wire end
Pin 14 GND cut-out box
X5 Actual rotational speed value, gas solenoid valve and configuration memory
Pin 1 GND actual rotational speed Pin 5 Actual rotational speed value in
value Pin 6 VD-ANA + (wire buffer sensor, 0-
Pin 2 VD-ANA - (wire buffer sensor) 5 V)
Pin 7 CFM +
Pin 3 CFM- Pin 8 Gas solenoid valve
Pin 4 +24 V gas solenoid valve
X6 LocalNet connection for remote control
Pin 1 +24 V Pin 4 GND

Pin 2 RXDL-RC Pin 5 TXDL-RC
Pin 3 RXDH-RC Pin 6 TXDH-RC
78
(continued)
X7 LocalNet power source connection

Pin 2 RXDL-485 Pin 5 TXDL-485
Pin 3 RXDH-485 Pin 6 TXDH-485
X8 Wire-feed unit motor connection
Pin 1 Motor + (red) Pin 2 Motor - (blue)
X9 BSL tool (20 pin) connection

X10 + 55 V (NT 60) supply

X11 + 55 V remote control supply

X12 not connected (connection for PMR 4000 push-pull option and RobactaDrive)
LED checklist
LED Bus OK LED +15 V LED +55 V
LED Flex OK LED +5 V
LED -15 V
LED backwards
LED BRT LED -24 V LED gas
LED uP OK LED forwards
Fig.56 LED indicators on SR 41 PC board
79
LED checklist LED BUS OK .................. flashes when connection with Bus master (power source) is OK
(continued) LED FLEX OK ................ flashes when there is no fault
LED P OK ..................... flashes when the processor is working
LED BRT ........................ flashes when the torch trigger is pressed
LED + 55 V ..................... flashes when the supply voltage is OK
LED + 5 V ....................... flashes when the supply voltage is OK
LED forwards .................. flashes when the wire is moved forwards by the drive unit motor
LED backwards ............... flashes when the wire is moved backwards by the drive unit motor
LED Gas ......................... flashes when the gas solenoid valve is activated
Measuring points There are no measuring points for checking the SR 41 PC board. Checking can only be
done by referring to the LED indicators.
80
Temperature sensor TP 592S
General remarks The TP 592S temperature sensor (item

number 43,0001,0600) is an electronic
temperature sensor. It has an integrated
temperature/current converter chip.
The chip is integrated into the plastic
housing and provided with a pluggable
Molex connection.
Fig.57 Temperature sensor TP 592S
Component
position in the
machine
Temperature sensor
Fig.58 TPS 2700: position of temperature sensor

TP 592S
Temperature sensor Temperature sensor
Fig.59 TPS 3200, TS/TPS 4000/5000: position of Fig.60 TPS 3200, TS/TPS 4000/5000: position of
temperature sensor TP 592S (1) temperature sensor TP 592S (2)
81
Technical Data Check supply 4 - 30 V DC
Output current 1 A/K
Function over- - The temperature sensor is fitted to the cooling element and measures the elements
view temperature.
- The temperature sensor emits a current of exactly 1 A per K (Kelvin), provided that
there is a voltage of 4 - 30 V DC.
0 K corresponds to a temperature of -273.15C
0C corresponds to 273.15 K
273.15 K corresponds to 273.15 A

X1 2-pin Molex plug
Pin 1 Temp. 1+ Pin 2 Temp. 1-
Measuring points Measure the current flowing through the temperature sensor as follows:
- Remove lead at pin 1 from Molex plug using Molex extractor tool.
- Switch multimeter between removed lead and now free Molex plug pin in series
The temperature can now be calculated using the measured current, as described in
function overview.
82
Secondary power module TPS 2700
General remarks On the TPS 2700, the secondary power module consists of two diode modules (item
number 41,0003,0215 ), each of which has two integral diodes.
Component
position in the
machine
Secondary power module
Fig.61 TPS 2700, position of secondary power

module
Overview
PC board BPS 25/BPT 27
Diode module
Welding transformer
Cooling element
Diode module
Fig.62 Secondary power module
83
Function over- The diode modules go together to make up the secondary rectifier. The secondary
view rectifier transforms the welding transformers alternating current into a direct current,
which is fed to the welding sockets
Measuring points There are two diodes in every diode

module. Measurement on the diode
regions must produce a result of approx.
0.2 V.
Fig.63 Diode module
84
Secondary power module TS 4000/5000, TPS 3200/
4000/5000
General remarks On the TS 4000/5000 and TPS 3200/4000/5000, the secondary power module consists
of four diode modules (item number 41,0003,0203 ), each of which has two integral
diodes.
Component
position in the Secondary power module
(on cooling element)
machine
Fig.64 TPS 2700, position of secondary power

module
Overview
Copper busbar
Diode module
Copper busbar
Diode module
Temperature sensor
Diode module
Diode module
Cooling element
Copper busbar
Welding transformer
Fig.65 Secondary power module
85
Function over- The diode modules go together to make up the secondary rectifier. The secondary
view rectifier transforms the welding transformers alternating current into a direct current,
which is fed to the welding sockets
Measuring points There are two diodes in every diode

module. Measurement on the diode
regions must produce a result of approx.
0.2 V.
Fig.66 Diode module
86
Primary rectifier
General remarks The following primary rectifiers are used:

- TPS 2700: rectifier with item number 41,0002,0059
- TS 4000/5000, TPS 3200/4000/5000: rectifier with item number 42,0001,0060
Component
position in the Primary rectifier Primary rectifier
machine
Fig.67 TPS 2700: position of primary rectifier Fig.68 TS 4000/5000, TPS 3200/4000/5000:
position of primary rectifier
Overview
L1
L1
L2 (+) L2
L3
L3
(-)
(-)
(+)
Fig.69 Primary rectifier TPS 2700 Fig.70 Primary rectifier TS 4000/5000, TPS 3200/
4000/5000
Function over- The primary rectifier converts the input voltage (mains voltage) into a rectified voltage for
view the intermediate circuit.
87
Plug layout
L1
L1
L2 (+) L2
L3
L3
(-)
(-)
(+)
Fig.71 Connections on the primary rectifier Fig.72 Connections on the primary rectifier
TPS 2700 TS 4000/5000, TPS 3200/4000/5000
Pin function
L1 Mains voltage input L1
(+) Intermediate circuit voltage output +
(-) Intermediate circuit voltage output -
Measuring points
Fig.73 Measuring points on primary rectifier TPS Fig.74 Measuring points on primary rectifier TS
2700 4000/5000, TPS 3200/4000/5000
Measurement on each of the diode regions must produce a result of 0.4 V.
88
Changing components
Safety
- 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
General remarks 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
Overview Changing components contains the following subsections:

- Changing throttle (TS 4000/5000, TPS 3200/4000/5000)
- Changing throttle (TPS 2700)
- Changing earth current watchdog
- Changing PC board ASU 27 (TPS 2700 MV)
- Changing shunt (TPS 2700)
- Changing temperature sensor TP 592S
- Changing transformer (TS 4000/5000, TPS 3200/4000/5000)
- Changing transformer (TPS 2700)
- Changing intermediate circuit capacitors (TS 4000/5000, TPS 3200/4000/5000)
89
Changing throttle (TS 4000/5000, TPS 3200/4000/5000)
Removing throttle 1. Remove side panels

2. On the minus socket, loosen hexagon
bolt (1) using a size 19 spanner
- Feed out the throttle lead (2) from the
(1) shunt (3)
(3) (2)
Fig. 1 Preparing throttle lead for removal
(4) 1. On the transformer, loosen hexagon

nut (4) using a size 13 spanner
2. Remove protective element (5) and
throttle lead (2)
(5) (2)
Fig. 2 Removing throttle lead
1. Remove screw (6) from the front of

the housing:
(6)
NOTE! When removing the

control panel (7), take care not to
bend, stretch or strain the ribbon
(7) cable connected to it.
(6)
2. Carefully swivel out the control panel
(7) and unplug the ribbon cable
(6)
Fig. 3 Removing front of the housing
90
Removing throttle 1. Loosen 2 screws (8)
(continued) 2. Remove front of housing
(8) (8)
Fig.4 Removing front of housing
1. Unscrew 4 screws (10) and remove

sheet nuts (11) from throttle
(11) 2. Remove throttle (9)
(10)
(9)
(11)
Fig.5 Removing throttle
Fitting throttle 1. Put throttle (9) in place and fix in

place with 4 screws (10) and sheet
(11) nuts (11)
(10)
(9)
(11)
Fig.6 Fitting throttle
(4)
(12)
(5) (2)
(4) (13) (5) (2)

Fig.7 Fitting throttle lead Fig. 8 Fitting throttle lead
1. On the transformer, fit the following components in the order they are listed:
- Throttle lead cable lug (2)
- Protective element cable lug (5)
- Spacer (12)
- Spring washer (13)
2. Tighten hexagon nut (4) using a size 13 spanner
91
Fitting throttle 1. Place front of housing onto base plate
(continued) and press upwards and inwards
2. Tighten 2 screws (8)
(8) (8)
Fig.9 Putting front of housing in place
NOTE! When fitting the control

panel (7), take care not to bend,
(6) stretch or strain the ribbon cable.
1. Plug ribbon cable into control panel (7)

2. Carefully put control panel (7) in place
3. Tighten screw (6) on front of the
(7) housing
(6)
(6)
Fig. 10 Fitting front of the housing
(2)
(1)
(14) (17)
(3) (2) (1) (15) (16)

Fig. 11 Fitting throttle lead Fig. 12 Components on the minus socket
1. Feed the throttle lead (2) into the shunt (3)

2. Push the following components onto the hexagon bolt (size 13) in the order they are
given below:
- Spring washer (14)
- Spacer (15)
- Star with protective element (17)
3. Tighten hexagon bolt (1) onto minus socket using a size 13 spanner
4. Fitting the side panels
92
Changing throttle (TPS 2700)
Removing throttle 1. Open wire-feed unit cover

2. Remove side panel
3. Loosen two screws (1) on front
aperture
(1)
Fig.1 Screws on the front aperture
(2) 1. Loosen two screws (3) on the drive

unit (2)
NOTE! When lifting the drive unit

(2), do not pinch, bend or strain
(3) the cables.
2. Carefully raise the entire drive unit (2)
Fig.2 Loosening the drive unit
(4)
(2)
Fig.3 Removing the drive unit
1. Loosen 2-pin Molex plug connection (4)

2. Carefully place the entire drive unit (2) to one side
93
Removing throttle 1. Loosen hexagon bolt (5) on minus
(continued) (6) socket using size 19 spanner
2. Feed out the throttle lead (9) from the
shunt (8)
(9) (8) (5)

Fig.4 Loosening hexagon bolt
(11) 1. Remove both upper copper clips (10)

and (11) from the transformer
2. Loosen screw (12) on the middle tap
connection
(10) (12)
Fig.5 Exposing throttle
1. Loosen three screws (13) on throttle

(15) (14)
2. Carefully remove throttle (14) and
(13) throttle lead (15) together
(13)
(14)
Fig.6 Removing throttle
Fitting throttle 1. Feed throttle lead (9) through bushing

(16)
(9) (16)
Fig. 7 Feeding throttle lead
94
Fitting throttle 1. Fit throttle (14) using three screws
(continued) (13)
(13)
(13) (9)
(14)
Fig.8 Fitting throttle
(11) 1. Fasten throttle lead (9) - Fig.8 - onto

middle tap connection using screw
(12) - Fig.9.
2. Fit copper clips (11) and (10) as
shown in Fig.9
(10) (12)
Fig.9 Connecting throttle
(6)
(9)
(18) (21)
(5) (19) (20)

(9) (8) (5)
Fig.10 Fitting throttle lead Fig. 11 Components on the minus socket
1. Feed throttle lead (9) through shunt (8)

2. Push following components onto hexagon bolt (5):
- Lock washer (18)
- Spacer (19)
- Star (21)
3. Tighten hexagon bolt (5)
95
Fitting throttle
(continued)
(4)
Fig.12 Connecting drive unit
1. Reconnect two-pin Molex plug (4)
(2) NOTE! When putting the drive

unit (2) in place, do not pinch,
bend or strain the cables.
1. Fit the drive unit (2) using two screws

(3) (3)
Fig.13 Fitting drive unit
1. Fit two screws (1) on front aperture

2. Fit side panel
3. Close wire-feed unit cover
(1)
96
Changing earth current watchdog
Removing earth 1. Remove side panels

current watchdog 2. Loosen two screws (2) on earth
current watchdog (1)
(1)
(2)
Fig. 1 Removing earth current watchdog
1. Loosen screw (3) on luster terminal

2. Remove lead (4)
(4) (3)
Fig. 2 Loosening luster terminal on earth current

watchdog
(5) (6)
Fig. 3 Removing fan and exposing watchdog cable
1. Remove fan sheet (5) (including fan)

2. Cut through the cable ties on watchdog cable (6)
97
Removing earth 1. Unplug 24-pin Molex plug (7) from
current watchdog (7) UST:X4 PC board
(continued) 2. Remove leads (8) and (9) of the
watchdog cable (6) from the following
(9) (8) pins on the 24-pin Molex plug (7):
- X4:10
- X4:22
(6) - Use Molex extractor tool
Fig. 4 Detaching watchdog cable
Fitting earth 1. Insert leads (8) and (9) of the watch-

current watchdog (7) dog cable (6) into the following pins
on the 24-pin Molex plug (7):
- X4:10
(9) (8) - X4:22
2. Plug 24-pin Molex plug (7) into
UST:X4 PC board
(6)
Fig.5 Connecting watchdog cable
(5) (6)
Fig.6 Fixing watchdog cable in place and fitting fan
1. Fix watchdog cable (6) using cable ties

2. Fit fan sheet (5) (including fan)
98
Fitting earth 1. Insert lead (4) into earth current
current watchdog watchdog luster terminal
(continued) (4) 2. Tighten screw (3) on luster terminal
(3)
Fig. 7 Connecting earth current watchdog luster

terminal
1. Fix earth current watchdog (1) in

place using two screws (2)
2. Fitting the side panels
(1)
(2)
Fig. 8 Fitting earth current watchdog
99
Changing PC board ASU 27 (TPS 2700 MV)
Removing ASU 27 - Remove side panel

X4 - Unplug leads (for cable harness (1),
X3
Fig.2) from the following slots on the
BPT/BPS PC board:
X3
X4
X5
X6
X5 X6
Fig. 1 Detaching leads from BPT/BPS
- Cut open cable tie on cable harness (1)

(4) (4) - Feed cable harness (1) out through
bushing (2)
- Unplug 16-pin Molex plug ASU 27:X4
(3)
- Loosen four spacers (4) and remove
ASU 27 PC board
(1)
(4) (4)
(2) (3)
Fig. 2 Removing ASU 27 PC board
Fitting ASU 27 - Put ASU 27:X4 PC board in place and fit using four spacers (4) (Fig.2)
- Plug in 16-pin Molex plug ASU 27:X4 (3) (Fig.2)
- Feed cable harness (1) through bushing (2) (Fig.2)
- Plug leads (for cable harness (1),

X4 Fig.2) into the following slots on the
X3
BPT/BPS PC board:
X3
X4
X5
X6
- Bind cables together with cable tie
- Fit side panel
X5 X6
Fig. 3 Plugging leads into BPT/BPS
100
Changing shunt (TPS 2700)
Removing shunt 1. Open wire-feed unit cover

2. Remove side panel
3. Loosen two screws (1) on front
aperture
(1)
(2) 1. Loosen two screws (3) on the drive

unit (2)
NOTE! When lifting the drive unit

(2), do not pinch, bend or strain
(3) the cables.
2. Carefully raise the entire drive unit (2)
Fig.2 Loosening the drive unit
(4)
(2)
Fig.3 Removing the drive unit
1. Loosen 2-pin Molex plug connection (4)

2. Carefully place the entire drive unit (2) to one side
101
Removing shunt 1. Loosen hexagon bolt (5) on minus
(continued) (6) socket using size 19 spanner
2. Unplug 8-pin Molex plug (6)
3. Loosen two screws (7) on shunt (8)
(7) 4. Remove shunt (8) and feed out
throttle lead (9)
(9) (8) (7) (5)

Fig.4 Removing shunt
Fitting shunt
(6)
(2)
(7)
(10) (13)
(5) (11) (12)

(9) (8) (7) (5)
Fig.5 Fitting shunt Fig.6 Components on the minus socket
1. Feed throttle lead (9) through shunt

2. Fit shunt (8) using two screws (7)
3. Plug in 8-pin Molex plug (6)
4. Push following components onto hexagon bolt (5):
Lock washer (10)
spacer (11)
throttle lead cable lug (12)
star (13) with protective element
5. Tighten hexagon bolt (5)
(4)
Fig. 7 Connecting drive unit
1. Reconnect two-pin Molex plug (4) for drive unit
102
Fitting shunt (2) NOTE! When putting the drive
(continued) unit (2) in place, do not pinch,
bend or strain the cables.
1. Put entire drive unit (2) in place

(3) 2. Fit the drive unit (2) using two screws
(3)
Fig.8 Fitting drive unit
1. Tighten two screws (1) on front

aperture
2. Fit side panel
3. Close wire-feed unit cover
(1)
103
Changing temperature sensor TP 592S
Notes The temperature sensor is fixed and can be lifted out by carefully using a simple scre-
wdriver or removed with flat pliers.
Before putting the new temperature sensor in place, fill the hole for the sensor with heat
conductive paste to ensure perfect heat transfer.
If the temperature sensor is covered by other parts, please refer to instructions for
removing the part concerned, and see the special NOTEs in the Changing components
section, if available.
104
Changing transformer (TS 4000/5000, TPS 3200/4000/
5000)
Removing trans- 1. Remove side panels

former (1) 2. On BPS 42/50 PC board, loosen 4
(2) screws (1) for primary transformer
leads
3. Remove protective elements (2)
(2)
(1)
Fig. 1 Removing transformer leads
1. Cut open cable tie on toroidal tape

cores (3) and (4)
Important! If necessary, cut open any

other cable ties near the toroidal tape
cores as well.
(3)
(4)
Fig. 2 Loosening toroidal tape cores
1. Feed primary transformer leads 1+

and 2+ out through toroidal tape
(6) cores (3) and (4)
2. Feed all primary transformer leads
(3) through bushing (6)
(4)
Fig. 3 Feeding transformer leads
105
Removing trans- (11) 1. Loosen 4 screws (7) for secondary
(7)
former transformer leads on copper sheet
(continued) 2. Loosen hexagon nut (8) using a size
13 spanner
(8) 3. Remove protective element (9) and
throttle lead (10)
(9) 4. Loosen 4 screws (11) on the transfor-
(10) mer holder (12)
5. Remove transformer holder (12)
6. Remove transformer with leads
(7)
(11) (12)
Fig. 4 Removing transformer
Fitting transfor- 1. Feed transformer leads through

mer (14) bushing (13)
1. Put transformer (14) in place
(13)
Fig.5 Putting transformer in place
(11) 1. Fit transformer holder (12) using 4

(7)
screws (11)
2. Using 4 screws (7), fix secondary
transformer leads to copper sheet
(8) 3. Using a size 13 spanner, fit protective
element (9) and throttle lead (10) by
(9) means of hexagon bolt (8)
(10)
(7)
(11) (12)
Fig.6 Fitting transformer
(6) 1. Feed primary transformer leads

through bushing (6)
2. Feed primary transformer lead 1+
through upper ferrite ring (3) from the
inside out
3. Feed primary transformer lead 2+
through second ferrite ring (4) from
(3) the inside out
1+
2+
(4)
Fig. 7 Feeding through transformer leads
106
Fitting transfor- NOTE! When fitting the primary
mer (1) transformer leads, ensure that
(continued) they are assigned to the correct
(2)
terminals:
- e.g. screw transformer lead
1+ to terminal N1+
(2)
1. Fit the following to the BPS 42/50 PC
(1) board using 4 screws (1):
- Primary transformer leads, as
described on labelling
- Protective elements (2)
Fig. 8 Fitting transformer leads
107
Changing transformer (TPS 2700)
Removing trans- (5) (2) 1. Remove side panel

former 2. Loosen terminal screws (2) and
remove primary transformer leads (3)
3. Cut open cable tie (4)
4. Remove copper clips (5) and (6)
(3)
(4) (2)
(6) (2)
Fig. 1 Exposing transformer 1
1. Remove copper clips (7) and (8)

2. Loosen screw (9) on middle tap
connection and remove throttle lead
(10)
(10) (8)
(9)
(7)
Fig. 2 Exposing transformer 2
1. Loosen four screws (11) on the

(13) (12)
transformer holder (12)
2. Remove transformer holder (12) and
transformer (13) together
(11)
Fig. 3 Removing transformer
1. Cut open cable tie (14) on ferrite core

(15)
and feed out cable
2. Remove insulators (15) from se-
condary connections
(15) (14)
Fig. 4 Removing insulators and ferrite core
108
Fitting transfor- 1. Push insulators (15) onto secondary
(15)
mer connections
2. Wind both of the middle primary leads
twice around the ferrite core and
fasten with cable tie (14)
(15) (14)
Fig.5 Fastening insulators and ferrite core
Before fitting the transformer, arrange the

primary leads as follows:
(16) 1. Feed the blue lead through the
upper sensor (16)
2. Feed the orange lead through the
(17) lower sensor (17)
Fig.6 Feeding primary leads through sensors
1. Fit transformer holder (12), including

(13) (12) transformer (13), using four screws (11)
(11)
Fig. 7 Fitting transformer
1. Fit throttle lead (10) to middle tap

connection using screw (9)
2. Fit copper clips (7) and (8)
(10) (8)
(9)
(7)
Fig. 8 Connecting transformer 1
109
Fitting transfor-
mer
(continued) (5) (19)
(18) (22)
(20) (23)
(6) (21)
Fig. 9 Connecting transformer 2
1. Fit copper clips (5) and (6)

2. Feed outer blue primary lead through cut-outs (18) on PC board and clamp in
place with terminal screw (19)
3. Feed outer orange primary lead through cut-outs (20) on PC board and clamp in
place with terminal screw (21)
4. Clamp inner blue primary lead using terminal screw (22)
5. Clamp inner orange primary lead using terminal screw (23)
6. Fit side panel
110
Changing intermediate circuit capacitors (TS 4000/
5000, TPS 3200/4000/5000)
Removing inter- 1. Remove side panels

mediate circuit 2. Loosen three screws (1) on rear of
capacitors (1) housing (2)
3. Remove rear of housing (2)
(1)
(2)
Fig. 1 Removing rear of housing
1. Loosen two screws (3) on cover sheet

(4)
2. Remove cover sheet (4)
(3) (3)
(4)
Fig. 2 Removing cover sheet
(5)
(7)
(6)
(5)
Fig. 3 Loosening capacitor screws Fig. 4 Loosening capacitor nuts
1. Loosen four capacitor screws (5)
NOTE! When loosening capacitor nuts (6) - Fig.4 - hold the capacitors (7) -
Fig.3 - in place.
2. Loosen two capacitor nuts (6)

3. Remove capacitors (7)
111
Fitting intermedi- Important! After removing a capacitor (7), its grommets (8) - Fig.5 - can either
ate circuit capaci- - adhere to the front of the capacitor (7)
tors - remain on the partition (9) inside the power source
- be disposed of
NOTE! When fitting the capaci-

(7) (8) (9) (6)
tors, ensure that the grommets
(8) are arranged correctly, as
shown in Fig.5.
Fig.5 Fitting capacitors
(7)
(6)
Fig.6 Putting capacitors in place Fig. 7 Fitting capacitors
1. Fit capacitors (7), including grommets (8), in place (Fig.5)

2. Hold capacitors in place and fit using capacitor nuts (6) (Fig.7)
(5)
(5) + - (5)
ELKO1+ ELKO1-
(7) (10)
- +
(5) (5)
ELKO2-
ELKO2+
(5)
Fig. 8 Connecting leads Fig 9 Installing capacitor
Fit the following elements using capacitor screws (5):

1. Capacitor leads ELKO1+ to ELKO2-
2. Connecting lead (10)
112
Fitting intermedi- 1. Fit cover sheet (4) using two screws (3)
ate circuit capaci-
tors
(continued) (3) (3)
(4)
Fig. 10 Fitting cover sheet
1. Fasten rear of housing (2) with three

screws (1)
(1) 2. Fit side panels
(1)
(2)
Fig. 11 Fitting rear of housing
113
Safety inspection
General remarks A safety inspection must be carried out according to the relevant national and local
regulations:
- after any changes are made
- after any additional parts are installed and after any conversions
- after repair, care and maintenance
- at least once every twelve months
You will find the following free Adobe Acrobat PDF file in the TechGuide at
www.fronius.com\techguide under General , Basics:
- The latest version of the Safety inspection of welding systems as part of repair and
maintenance work instructions.
114
Terms and abbreviations used
General remarks Terms and abbreviations is a glossary of specific technical terms essential for an
understanding of the service instructions.
Terms and abbre- BSL tool:

viations The BSL tool is a special tool for updating the power source with new firmware. A PC or
notebook is required for the update.
Config memory (CFM):

The CFM component supplements the UST2B PC board firmware (central control and
regulation unit) with individual, machine- specific data.
DSP:
Digital signal processor. Part of the UST2B PC board (central control and regulation
unit). The DSP captures digitised actual values on the part of the welding process, and
ensures constant regulation and optimisation of the welding current and voltage, on the
basis of
- the parameters set
- the saved firmware
- the actual values measured
EMI:
Electromagnetical interference. Electromagnetical interference is high-frequency over-
laps in the mains voltage. The line filter absorbs such overlaps and thereby ensures
optimum welding results and trouble-free operation of the power source.
FAC:
Factory resets settings in the setup menu. By pressing and holding the Store button for
two seconds, the original factory settings can be restored. When the display reads
PrG, the welding machine has been reset. Jobs and parameter settings in the second
level of the set-up menu are not deleted.
Hall shunt:
Ensures electrically isolated measuring of the welding current. The UST2B (central
control and regulation unit) analyses the signal.
IGBT:
Insulated gate bipolar transistor. Is a special bipolar transistor for switching to high
power settings. IGBTs are used in the power source as modules. On the TT/MW 1700/
2200 power sources, IGBT modules are used in a secondary role to prepare the welding
current for AC welding.
Instruction pointer:
When a software fault appears: Third display level displays more detailed information on
the cause of the fault (see fault location aid section)
LocalNet RS232 converter:

For connecting the power source to the serial interface on a PC, for:
- uploading software options
- communicating data from the power source using PC-based software (Fronius
Backup, Fronius Service Module, Job-Explorer, etc.)
115
Terms and abbre- NTC resistors:
viations NTC = negative temperature coefficient. These resistors have high resistance at low
(continued) temperatures. As long as the operating temperature has not been reached, the high
resistance ensures the limitation of the starting current. Shortly after switching on, the
current limit is raised as a result of the rapid heating of the NTC resistors.
PTC resistors:
PTC = positive temperature coefficient These resistors acquire a higher resistance as
the temperature rises. Since the resistor temperature rises as the current increases, the
current is automatically limited.
PFC:
Power factor control Ensures sinusoidal power consumption, for
- supporting an optimum degree of efficiency
- preventing reactions on the mains supply
Voltage doubling:
Ensures that the open circuit voltage and welding voltage are increased at greater arc
lengths. The voltage doubling contributes considerably to optimum ignition properties
and a stable arc.
Segment display:
When a software fault appears: Second display level displays more detailed information
on localising the fault (see fault location aid section)
Software service module:

The software service module helps determine the hardware and software configuration
for the power source and peripheral devices. The display of the following components is
especially useful:
- Design and version of the power sources and peripheral devices.
- The accompanying software modules and PC boards.
- Indication of serial numbers for some machines
In addition, the software service module allows you to call up the relevant order informa-
tion for the selected options.
Temperature/current converter chip:

is used in the temperature sensor. +A specially endowed semi-conductor ensures
conversion of the measured temperature into a corresponding voltage signal. The
voltage signal arrives at the UST2B PC board (central control and regulation unit), and
the computer uses it to calculate the actual temperature.
116
Entire circuit diagram
Storage location The circuit diagram is located inside the power source.
- attached to the inside of the right side panel
117
118
Ersatzteilliste
D
Schaltplan
Spare Parts List

GB
Circuit Diagram
Liste de pices de rechange

F
Schma de connexions
Lista parti di ricambio

I
Schema
Lista de repuestos
E
Esquema de cableado
Lista de peas sobresselentes

P
Esquema de conexes
Onderdelenlijst
NL
Bedradingsschema
Reservdelsliste
N
Koblingsplan
Seznam nhradnch dl
CZ
schma zapojen

RUS

ud_fr_st_tb_00149 012002
TransPulsSyn. 2700 4R/Z 4,075,095
TransPulsSyn. 2700 4R/E 4,075,095,001
TransPulsSyn. 2700 4R/D 4,075,095,002
MV
TransPulsSyn. 2700 MV/4R/Z 4,075,095,630
TransPulsSyn. 2700 MV/4R/E 4,075,095,631
ALU - Edition
TransPulsSyn. 2700 4R/Z/ALU 4,075,095,633
TransPulsSyn. 2700 4R/E/ALU 4,075,095,634
MV / ALU - Edition
TransPulsSyn. 2700 MV/4R/Z/ALU 4,075,095,635
TransPulsSyn. 2700 MV/4R/E/ALU 4,075,095,636
CrNi
TransPulsSynerg.2700 4R/Z CrNi 4,075,095,856
TransPulsSynerg.2700 4R/E CrNi 4,075,095,857
MV / CrNi
TransPulsSynerg.2700 MV/4R/Z CrNi 4,075,095,858
TransPulsSynerg.2700 MV/4R/E CrNi 4,075,095,859
DUO / TIG
TransPulsSyn. 2700 4R/Z TIG 4,075,095,850
TransPulsSyn. 2700 4R/Z DUO 4,075,095,851
TransPulsSyn. 2700 4R/Z DUO/TIG 4,075,095,852
TransPulsSyn. 2700 4R/E TIG 4,075,095,853
TransPulsSyn. 2700 4R/E DUO 4,075,095,854
TransPulsSyn. 2700 4R/E DUO/TIG 4,075,095,855
US
TransPulsSyn. 2700 MV/4R/Z US 4,075,095,800
TransPulsSyn. 2700 MV/4R/E US 4,075,095,801
AUS
TransPulsSyn. 2700 4R/E AUS 4,075,095,638
CMT
TransPulsSyn. 2700 4R/Z CMT 4,075,136
TransPulsSyn. 2700 MV/4R/Z CMT 4,075,136,630
TransPulsSyn. 2700 MV/4R/Z CMT US 4,075,136,800

Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/3
el_fr_st_mi_00154 022006
42,0407,0449
42,0406,0292
42,0200,8860 32,0405,0164
AM2,0200,9330
45,0200,0918
44,0001,1309 45,0200,1078 - ALU
45,0200,1186 - CrNi
45,0200,1030 45,0200,1201 - CMT
45,0200,1077 - ALU
45,0200,1187 - CrNi
45,0200,1235 - CMT
12,0405,0208
42,0405,0220
44,0550,0060
42,0001,3045,Z
42,0405,0219
44,0001,1195 - Z
44,0001,1196 - E
44,0001,1207 - D
43,0001,1139
12,0405,0206
33,0024,0032
43,0001,1092
43,0010,0164
43,0001,0600
40,0009,0043
41,0003,0215
43,0030,0045
33,0010,0227

el_fr_st_mi_00154 022006
42,0001,3541 - US
43,0013,0015
42,0407,0063
42,0407,0284 - E
43,0004,2382 - DUO
40,0001,0012 - *
43,0002,0371
42,0406,0297
32,0409,2640
42,0409,2914 - TIG
32,0409,2976
42,0409,2649 43,0004,0789
42,0409,2760 - ALU 43,0001,3234 43,0004,0507 - MV
42,0409,2930 - TIG 43,0001,3260 - US 43,0004,2323 - US
42,0409,2931 - DUO 43,0001,3268 - AUS
42,0409,2932 - DUO/TIG 43,0001,3270 - CrNi 42,0300,1511
42,0409,3012 - AUS 43,0001,3306 - CMT 42,0407,0532 - US
43,0004,2384 - DUO
43,0003,0031 - DUO
42,0409,2973 - DUO
42,0406,0073 - DUO
4,070,627,Z - NT60
4,070,662,Z - NF3160
42,0406,0315
42,0406,0093 60 4,070,691,Z - ASU27-MV
31
NF
32,0409,2639
7
42,0409,3148 - CMT U2
AS
43,0003,0485
60
32,0405,0229
4A NT 41
SR43 4,100,217 - PM41
T2
32,0405,0183 N SR T4 4,100,519 - PM43
SN
4,070,626,Z - NT24A T2
43,0004,2855 US 41
PM43
42,0405,0056 PM
43,0003,0485 4,070,960,Z - UST2C
43,0001,1095 4,070,776 - SNT4-DUO
42,0405,0154
4,070,677,Z - SR41
42,0404,0024 43,0004,2961 4,070,905,Z - SR43
43,0004,1819
43,0003,0031 41,0002,0059
4,100,423
T 27
42,0407,0284 BP 40,0009,0043
4,100,517
40,0001,0352 - *
4,070,739,Z - BPT27

el_fr_st_mi_00154 022006
TransPuls Synergic 3200 4,075,124 US
TransSynergic 4000 C 4,075,097 TransPuls Synergic 3200 MV 4,075,124,800
TransSynergic 5000 C 4,075,098 TransSynergic 4000 C MV 4,075,097,800
TransSynergic 4000 4,075,099 TransSynergic 5000 C MV 4,075,098,800
TransSynergic 5000 4,075,101 TransPuls Synergic 4000 MV 4,075,100,800
TransPuls Synergic 4000 4,075,100 TransPuls Synergic 5000 MV 4,075,102,800
TransPuls Synergic 5000 4,075,102 TransPuls Syn. 4000 MV Pipe 4,075,100,810
MV US/RC
TransPuls Synergic 3200 MV 4,075,124,630 TransPuls Synergic 3200 MV R 4,075,124,800,R
TransSynergic 4000 C MV 4,075,097,630 TransSynergic 4000 MV R 4,075,097,800,R
TransSynergic 5000 C MV 4,075,098,630 TransSynergic 5000 MV R 4,075,098,800,R
TransSynergic 4000 MV 4,075,099,630 TransPulsSynergic 4000 MV R 4,075,100,800,R
TransSynergic 5000 MV 4,075,101,630 TransPulsSynergic 5000 MV R 4,075,102,800,R
TransPuls Synergic 4000 MV 4,075,100,630
TransPuls Synergic 5000 MV 4,075,102,630 460V
TransPuls Synergic 3200 460V 4,075,124,801
RC TransPuls Syn. 3200 Pipe Single 4,075,124,808
TransPuls Synergic 3200 R 4,075,124,R TransPuls Syn. 3200 Pipe Tandem 4,075,124,809
TransSynergic 4000 R 4,075,097,R TransPuls Syn. 3200 Pipe HE 4,075,124,810
TransSynergic 5000 R 4,075,098,R TransPuls Syn. 3200 Pipe BA 4,075,124,811
TransPuls Synergic 4000 R 4,075,100,R TransSynergic 4000 C 460V 4,075,097,801
TransPuls Synergic 5000 R 4,075,102,R TransSynergic 4000 C 460V 4,075,097,930
TransSynergic 4000 460V 4,075,099,930
MV/RC TransSynergic 5000 C 460V 4,075,098,801
TransPuls Synergic 3200 MV R 4,075,124,630,R TransSynergic 5000 C 460V 4,075,098,930
TransSynergic 4000 MV R 4,075,097,630,R TransSynergic 5000 460V 4,075,101,930
TransSynergic 5000 MV R 4,075,098,630,R TransPuls Synergic 4000 460V 4,075,100,801
TransPulsSynergic 4000 MV R 4,075,100,630,R TransPuls Synergic 4000 460V 4,075,100,930
TransPulsSynergic 5000 MV R 4,075,102,630,R TransPuls Synergic 5000 460V 4,075,102,801
TransPuls Synergic 5000 460V 4,075,102,930
AUS
TransPuls Synergic 3200 4,075,124,638 460V/RC
TransPuls Synergic 4000 4,075,100,638 TransSynergic 4000 460V R 4,075,097,930,R
TransPuls Synergic 5000 4,075,102,638 TransSynergic 5000 460V R 4,075,098,930,R
TransPulsSynergic4000 460V R 4,075,100,930,R
CMT TransPulsSynergic5000 460V R 4,075,102,930,R
TransPuls Synergic 3200 CMT 4,075,137
TransPuls Synergic 4000 CMT 4,075,138 CrNi
TransPuls Synergic 5000 CMT 4,075,139 TransPuls Synergic 3200 CrNi 4,075,124,631
TransPuls Synergic 3200 CMT MV 4,075,137,630 TransPuls Synergic 3200 MV CrNi 4,075,124,632
TransPuls Synergic 4000 CMT MV 4,075,138,630 TransPuls Synergic 4000 CrNi 4,075,100,631
TransPuls Synergic 5000 CMT MV 4,075,139,630 TransPuls Synergic 4000 MV CrNi 4,075,100,632
TransPuls Synerg.3200 CMT MV US 4,075,137,800 TransPuls Synergic 5000 CrNi 4,075,102,631
TransPuls Synerg.4000 CMT MV US 4,075,138,800 TransPuls Synergic 5000 CrNi 460V 4,075,102,632
TransPuls Synerg.5000 CMT MV US 4,075,139,800
TransPuls Synerg.3200 CMT 460 V 4,075,137,801
TransPuls Synerg.4000 CMT 460 V 4,075,138,801 TIME 5000 Digital 4,075,140,930
TransPuls Synerg.5000 CMT 460 V 4,075,139,801
CMT/RC
TransPuls Synergic 3200 CMT R 4,075,137,R
TransPuls Synergic 3200 CMT MV R 4,075,137,630,R
TransPulsSynerg.3200 CMT MV US R 4,075,137,800,R
TS / TPS / 3200 / 4000 / 5000, TIME 5000 Digital

el_fr_st_mi_00153 032007
42,0200,8860
32,0405,0164
AM2,0200,8819
45,0200,0918 45,0200,0918
45,0200,1186 - CrNi 45,0200,1186 - CrNi
45,0200,1201 - CMT 45,0200,1201 - CMT
41,0003,0203 12,0405,0208
40,0009,0043
43,0001,1103
43,0001,0600
43,0001,1139 41,0003,0203
33,0005,4112
33,0005,4120 - MV
33,0005,4120 - 460V/US
33,0010,0335
43,0001,1186
43,0001,1187
43,0006,0152
43,0001,1092 - TPS3200
41,0009,0187
41,0002,0060
S
BP
40,0009,0043
43,0001,0600
33,0010,0345 - TIME 5000

43,0001,1104
4,070,738,Z - BPS42 TS/TPS 3200/4000

12,0405,0208 4,070,771,Z - BPS43 TS/TPS 3200/4000
4,070,658,Z - BPS50 TS/TPS 5000/TIME
4,100,413 4,070,772,Z - BPS53 TS/TPS 5000/TIME

el_fr_st_mi_00153 032007
43,0004,0664 - MV 43,0004,0987
43,0004,0586 - 460V 43,0004,2727 - TIME 5000
43,0004,2324 - US AWG 6
43,0004,2955 - US AWG 10
42,0407,0437 - MV
42,0407,0533 - US AWG 6
42,0407,0534 - US AWG 10
43,0001,1213 - MV/US 80A
43,0013,0015
BE2,0201,1934 - MV
BE2,0201,1355 - US
BE2,0201,1593 - US
42,0300,1511
43,0001,1199 - 40A 42,0300,1815 - TIME 5000
4,070,685,Z - ASU40
42,0409,5083 - TPS 3200 32,0405,0183
0
U4
42,0409,3055 - TPS 3200 AUS
32,0405,0229
AS
42,0409,2650 - TS 4000
42,0409,2651 - TPS 4000 43,0003,0485
42,0409,2652 - TS 5000
42,0409,2653 - TPS 5000 32,0409,2657
42,0409,3013 - TPS 4000 AUS
42,0409,3014 - TPS 5000 AUS
42,0409,3027 - TPS 4000 Pipe 42,0400,0132 43,0003,0031 black
42,0409,3097 - TPS 3200 Pipe 42,0300,1523 43,0003,0986 red
42,0409,3082 - TIME 5000 41,0005,0288
42,0409,3202 - TPS 3200 Pipe Single
42,0409,3203 - TPS 3200 Pipe Tandem 32,0409,2658
32,0409,2740 - MV/US
43,0001,3234 - COMF
43,0001,3235 - TS
43,0001,3253 - RC 4,070,627,Z - NT60
43,0001,3260 - US
43,0001,3268 - AUS 4,070,677,Z - SR41
43,0001,3270 - CrNi 4,070,905,Z - SR43
43,0001,3276 - CMT Rem.
43,0001,3277 - TIME 5000
43,0001,3306 - CMT COMF
60SR4413
42,0406,0315
NT SR
42,0406,0093
24
32,0409,2656
NT T2
43,0409,3223 - PIPE US
43,0003,0031 43,0006,0168
40,0001,0352 - *
4,100,423
4,070,960,Z - UST2C
42,0407,0284
* gewnschte Lnge angeben 4,070,626,Z - NT24
* Specify the length required 4,070,928 - NT24T Pipe
42,0406,0299 * Indiquer la longueur dsire
* Indicar la longitud deseada
43,0002,0358 * Indicare la lunghezza desiderat
43,0002,0423 - 5pol.,PIPE * indicar o comprimento desejado
XYHG
WHSRDGRYDQRXGpONX

el_fr_st_mi_00153 032007
TPS 2700
TPS 2700 MV
TS 4000 / 5000, TPS 3200 / 4000 / 5000
TPS 3200 MV (Teil 1)
TPS 3200 MV (Teil 2)
TS 4000 MV / 5000 MV, TPS 4000 MV / 5000 MV
FRONIUS INTERNATIONAL GMBH
Buxbaumstrae 2, A-4600 Wels, Austria
Tel: +43 (0)7242 241-0, Fax: +43 (0)7242 241-3940
E-Mail: sales@fronius.com
www.fronius.com
www.fronius.com/addresses
Under http://www.fronius.com/addresses you will find all addresses
of our Sales & service partners and Locations.
ud_fr_st_so_00082 012008

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TransSynergic 4000/5000

TransPuls Synergic 2700

WARNING! An electric shock can be fatal. Before opening up the machine

WARNING! An electric shock can be fatal. If the machine needs to be switched

CAUTION! Inadequate PE conductor connections can cause serious injury and

Function over- Contains a brief descriptive overview of the entire system:

Tools required - Box spanner (8 mm)

Measuring and - Digital multimeter

Ancillary materi- - Contact spray (40,0009,0014) or alcoholic solvent

In the universal control (UST), there is information on subsequently enabled options.

(1) Iact Workpiece

Primary power module

Block diagram (1) Control and regulation unit:

(2) Line filter (EMV):

(3) Primary rectifier:

(4) PFC (Power Factor Control, TPS 2700 only):

(5) Intermediate circuit capacitors:

(7) Welding transformer:

(8) Secondary rectifier:

(9) Output choke:

(10) Welding current sensor:

Poor ignition and weld properties with

Poor ignition and weld properties with

Poor weld properties with selected rod

Nothing happens on control panel (TPS

No welding current, or current does not

Insufficient welding torch cooling (FK

Service codes displayed

Correct shielding gas connected, Connect correct shielding gas and

Gas-test button: Shielding gas Check shielding gas solenoid

Welding torch and grounding Check welding torch and groun-

Parameters set correctly? - Check settings on control panel

Check whether power source OK,

Correct shielding gas connected, Connect correct shielding gas and

Gas-test button: Shielding gas Check shielding gas solenoid

Welding torch and grounding Check welding torch and groun-

Parameters set correctly? - Check settings on control panel

Check whether power source OK,

Electrodes/grounding (earthing) Connect cable correctly

Parameters set correctly? - Check settings on control panel

Check whether power source OK,

Voltage OK on prima- Check mains cable,

Yes On MV power sources

Switch power source

Steady +24V int/ext

Switch power source

Steady +24V int/ext

Unplug X4 from UST

Steady +5V, +15V, -

Unplug X2 from UST

Steady +5V, +15V, - Check/change control

Unplug X6 from UST

Steady +5V, +15V, -

Mains switch/cabling Check/change mains

Steady +24V int/ext Switch power source

Steady +24V int/ext

Switch power source

Steady +24V int/ext

Unplug X4 from UST Yes