Repair Manual TT MW 2500 3000 PDF

TransTig 2500 / 3000
Service manual
MagicWave 2500 / 3000 GB
Spare parts list
TIG Power Source
42,0410,1557 012008
Contents
Foreword and safety instructions .................................................................................................................. 5
Safety ....................................................................................................................................................... 5
TechSupport National (TSN) .................................................................................................................... 5
General remarks ...................................................................................................................................... 5
Tools and measuring devices ................................................................................................................... 6
Function overview .................................................................................................................................... 6
Error location aid ...................................................................................................................................... 6
Detailed description .................................................................................................................................. 6
Replacing components ............................................................................................................................. 6
Terms and abbreviations used ................................................................................................................. 6
Spare parts list and entire circuit diagram ................................................................................................ 6
Tools and measuring devices ........................................................................................................................ 7
General remarks ...................................................................................................................................... 7
Tools required .......................................................................................................................................... 7
Measuring equipment, inspection equipment ........................................................................................... 7
Ancillary materials .................................................................................................................................... 7
Functional description MW/TT 2500/3000 .................................................................................................... 8
General remarks ...................................................................................................................................... 8
Block diagram .......................................................................................................................................... 8
Block diagram legend............................................................................................................................... 9
Error location aid ......................................................................................................................................... 10
General remarks .................................................................................................................................... 10
Error flowchart .............................................................................................................................................. 11
Overview ................................................................................................................................................. 11
Poor ignition and weld properties with TIG welding ................................................................................ 12
Poor ignition and weld properties with MMA welding ............................................................................. 13
No or incorrect welding current .............................................................................................................. 14
Insufficient welding torch cooling (FK 2500/FK 2500 FC/FK 2500 Rob) ................................................ 15
No lights on control panel ....................................................................................................................... 17
Open circuit voltage +50 V faulty ............................................................................................................ 19
Err 50 service code on the display ....................................................................................................... 20
UST service codes ...................................................................................................................................... 22
Safety ..................................................................................................................................................... 22
Table of service codes ........................................................................................................................... 22
Special indications used with service codes ........................................................................................... 28
Detailed description ..................................................................................................................................... 29
General remarks .................................................................................................................................... 29
Overview ................................................................................................................................................ 29
ASU 2500 PC board .................................................................................................................................... 30
General remarks .................................................................................................................................... 30
Overview ................................................................................................................................................ 30
Function overview .................................................................................................................................. 30
Pin assignment ...................................................................................................................................... 31
LED checklist ......................................................................................................................................... 31
BPS 3000/MV PC board .............................................................................................................................. 32
General remarks .................................................................................................................................... 32
Overview ................................................................................................................................................ 32
Technical data ........................................................................................................................................ 33
Pin assignment ...................................................................................................................................... 33
LED checklist ......................................................................................................................................... 34
Measuring points .................................................................................................................................... 34
1
BSV 3000 PC board voltage doubler ........................................................................................................... 35
General remarks .................................................................................................................................... 35
Overview ................................................................................................................................................ 35
Pin assignment ...................................................................................................................................... 35
FKC 2500 PC board .................................................................................................................................... 36
General remarks .................................................................................................................................... 36
Overview ................................................................................................................................................ 36
Pin assignment ...................................................................................................................................... 37
LED checklist ......................................................................................................................................... 37
FKR 2500 PC board .................................................................................................................................... 38
General remarks .................................................................................................................................... 38
Overview ................................................................................................................................................ 38
Pin assignment ...................................................................................................................................... 39
FMW 2500/3000 PC board ......................................................................................................................... 40
General remarks .................................................................................................................................... 40
Overview ................................................................................................................................................ 40
Pin assignment ...................................................................................................................................... 41
LED checklist ......................................................................................................................................... 42
HFF 22 PC board ........................................................................................................................................ 43
General remarks .................................................................................................................................... 43
Overview ................................................................................................................................................ 43
Technical data ........................................................................................................................................ 44
Pin assignment ...................................................................................................................................... 45
NT 2500 PC board ...................................................................................................................................... 47
General remarks .................................................................................................................................... 47
Technical data ........................................................................................................................................ 47
Overview ................................................................................................................................................ 48
Pin assignment ...................................................................................................................................... 48
LED checklist ......................................................................................................................................... 48
NT 60 .......................................................................................................................................................... 49
General remarks .................................................................................................................................... 49
Overview ................................................................................................................................................ 49
Technical data ........................................................................................................................................ 49
Pin assignment ...................................................................................................................................... 50
LED checklist ......................................................................................................................................... 51
RP 3000 PC board ...................................................................................................................................... 53
General remarks .................................................................................................................................... 53
Overview ................................................................................................................................................ 53
Pin assignment ...................................................................................................................................... 54
SNT 3 PC board .......................................................................................................................................... 55
General remarks .................................................................................................................................... 55
Overview ................................................................................................................................................ 55
Pin assignment ...................................................................................................................................... 55
LED checklist ......................................................................................................................................... 56
2
UST PC board ............................................................................................................................................. 57
General remarks .................................................................................................................................... 57
Pin assignment ...................................................................................................................................... 58
LED checklist ......................................................................................................................................... 59
Changing UST PC board ....................................................................................................................... 59
Line filter ...................................................................................................................................................... 60
General remarks .................................................................................................................................... 60
Overview ................................................................................................................................................ 60
Technical data ........................................................................................................................................ 60
Pin assignment ...................................................................................................................................... 60
Primary rectifier ........................................................................................................................................... 61
General remarks .................................................................................................................................... 61
Overview ................................................................................................................................................ 61
Pin assignment ...................................................................................................................................... 61
Secondary power module ............................................................................................................................ 63
General remarks .................................................................................................................................... 63
Overview ................................................................................................................................................ 63
LED checklist ......................................................................................................................................... 64
Shunt ........................................................................................................................................................... 66
General remarks .................................................................................................................................... 66
Overview ................................................................................................................................................ 66
Technical data ........................................................................................................................................ 66
Pin assignment ...................................................................................................................................... 67
LED checklist ......................................................................................................................................... 67
TP 592S temperature sensor ...................................................................................................................... 68
General remarks .................................................................................................................................... 68
Technical data ........................................................................................................................................ 68
Pin assignment ...................................................................................................................................... 68
Changing modules ...................................................................................................................................... 69
General remarks .................................................................................................................................... 69
Overview ................................................................................................................................................ 69
Changing the transformer ........................................................................................................................... 70
Removing the control panel ................................................................................................................... 70
Removing the UST PC board ................................................................................................................. 70
Removing the retaining plate .................................................................................................................. 70
Undoing leads on earthing socket .......................................................................................................... 71
Undoing transformer centre-tap and auxiliary power source leads ........................................................ 71
Removing the HF transformer ................................................................................................................ 71
Removing the toroidal tape cores .......................................................................................................... 72
Removing the transformer ..................................................................................................................... 72
Installing the transformer ....................................................................................................................... 73
Securing the toroidal tape cores and transformer .................................................................................. 73
Fitting the secondary transformer leads ................................................................................................. 74
Fitting the HF transformer ...................................................................................................................... 74
Fitting transformer centre-tap and auxiliary power source leads ............................................................ 74
3
Fitting leads to earthing socket .............................................................................................................. 75
Fitting the retaining plate ........................................................................................................................ 76
Fitting the UST PC board ....................................................................................................................... 76
Fitting the control panel .......................................................................................................................... 76
Changing the fan ......................................................................................................................................... 77
Removing the solenoid valve and fan lead ............................................................................................. 77
Removing the air baffle .......................................................................................................................... 78
Removing the fan ................................................................................................................................... 78
Installing the fan ..................................................................................................................................... 78
Fitting the air baffle ................................................................................................................................. 79
Carrying out a safety inspection .................................................................................................................. 81
When is it required? ............................................................................................................................... 81
Work instructions ................................................................................................................................... 81
Terms and abbreviations used .................................................................................................................... 82
General remarks .................................................................................................................................... 82
Terms and abbreviations ........................................................................................................................ 82
Entire circuit diagram
Spare parts lists
Fronius Worldwide
4
Foreword and safety instructions
Safety The following safety instructions apply to all activities described in these service manual:
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. All activities described in the service manual must only be carried out
by Fronius-trained service technicians. Read the Safety rules chapter in the
power source operating instructions.
WARNING! An electric shock can be fatal. Before opening the device

- Turn the mains switch to the O position
- Unplug the device 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 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 any parts inside the housing
- Only touch using suitable measuring or test probes
CAUTION! Failure to connect a correctly-dimensioned earth lead may result in

serious injury or damage. The housing screws provide a suitable PE conductor
connection for earthing (grounding) the housing and must NOT be replaced by
any other screws that do not provide a reliable PE conductor connection.
TechSupport If you have any questions about error analysis, your TechSupport National (TSN) sales
National (TSN) team will be able to help.
mailto: welding.techsupport@fronius.com
General remarks The service manual can be found in the DownloadCenter TechGuide at
www.fronius.com\downloadcenter.
Each chapter in the service manual deals with one complete topic. Use each chapter as
a self-contained source of information. A short description of each chapter follows:
5
Tools and measu- This provides an overview and description of all equipment required for servicing the
ring devices power source professionally. This equipment includes:
- Tools required
- Measuring equipment, inspection equipment
- Ancillary material
Function over- Contains a brief descriptive overview of the entire system:

view - In text form
- In block diagram form
Error location aid Serves to systematically locate and rectify the source of errors, and contains the follo-
wing elements:
- The actual error flowchart for dealing with general errors
- Service codes table for dealing with errors whose service codes appear on the
display
Detailed descrip- Contains detailed descriptions of the relevant modules in the power source.
tion
For every module, the following topics are dealt with:
- General remarks (designation, item number of the module)
- Position of the module in the device
- Overview
- Technical data
- Function overview
- Pin assignment
- LED checklists
- Measuring points
Replacing com- The Replacing components chapter describes how to replace components that
ponents - Have no instructions of their own for replacement and
- Require detailed replacement instructions
Terms and abbre- Contains a description of essential specialist terms and abbreviations for a better under-
viations used standing of the service manual
Spare parts list The Spare parts list and Entire circuit diagram chapters contain the complete spare
and entire circuit parts list and complete circuit diagram for the power source.
diagram
6
Tools and measuring devices
General remarks Tools and measuring devices provides an overview and description of all the equip-
ment required to service the device professionally. This equipment includes:
- Tools required
- Measuring equipment, 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 (medium)
- Phillips screwdriver (PH1)
- Phillips screwdriver (PH2)
- Torx screwdriver (TX 15) or insert bit for manual torque wrench
- Torx screwdriver (TX 25) or insert bit for manual torque wrench
- Flat spanner (10 mm)
- Oeteker pliers
- Molex extractor tool (42,0410,0290)
- Application instrument for heat-conductive paste (42,0435,0020)
Measuring equip- - Digital multimeter

ment, inspection - PC with Microsoft Windows operating system
equipment (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)
- DVD TechGuide (40,0006,2910)
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), grade 500 or finer
7
Functional description MW/TT 2500/3000
General remarks The Functional description explains the underlying functional principle of the Magic-
Wave 2500/3000 and TransTig 2500/3000 power sources with the help of a block dia-
gram.
Block diagram
Welding torch
Remote control
Workpiece
Welding torch
control line
Protective gas shield
Output choke
LocalNet
only for MagicWave 2500 and MagicWave 3000 power sources
Protective gas shield

Iact solenoid valve
HF transformer
(12)
HF
Welding current
(10) (11)
sensor
HF generator
Uact
Control line
(9)
Inverter
*
module
Secondary power
(8)
Secondary
rectifier
(7)
Welding
transformer
*
Control line
(6)
Transistors
Control panel
Control and regulation
55 V
(5)
Intermediate circuit
capacitors
Power
supply
24 V
(4)
24 V power supply
PFC (Power
Primary power module
Factor Control)
unit
Power
supply
(1)
(3)
Primary rectifier
3 x 400 V
(2)
Line filter
Fig. 1 Block diagram of the MagicWave 2500/3000 and TransTig 2500/3000 power sources
8
Block diagram (1) Control and regulation unit:
legend Controls, regulates and monitors the welding process and all power source func-
tions.
(2) Line filter (EMC):

Reduces unwanted high-frequency noise.
(3) Primary rectifier:

Converts the input voltage (mains voltage) to a rectified intermediate circuit voltage.
(4) PFC:
Ensures sinusoidal current input, for
- Supporting an optimum degree of efficiency
- Preventing reactions in the mains supply
(5) Intermediate circuit capacitors:

Store and smooth the intermediate circuit voltage.
(6) Transistors:
the transistors carry the intermediate circuit voltage in intervals at high frequency to
the primary coil on the transformer. The high frequency means that:
- The transformer can be constructed to a very light, compact design
- Thermal losses due to the low inductance required of the transformer windings
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 DC voltage
(9) Inverter (only MagicWave 2500 and MagicWave 3000):

Converts direct current to alternating current for TIG AC welding operating mode
(10) HF generator:
For non-contact HF ignition, the HF generator (high-frequency generator) generates
the high-frequency primary voltage of the HF transformer (12).
(11) Welding current sensor:

Captures the actual current value for the welding process
(12) HF transformer:
For non-contact HF ignition, the HF transformer (high-frequency transformer)
transmits high-voltage pulses to the welding circuit.
9
Error location aid
General remarks The chapter Error location aid consists of the following parts
- Error flowchart
- Table of service codes
The error flowchart is for the systematic location and rectifying of errors. In the Table of
service codes chapter, there is also a table which deals with the service codes shown
on the display, as well as the causes of errors and how to rectify them.
Before using the error location aid, read the Function overview chapter and study the
entire circuit diagram in order to understand how the power source is constructed and
how it operates.
Important! The following applies to those with even less experience of troubleshooting
and fault diagnosis on the MagicWave 2500/3000 and TransTig 2500/3000 power
sources.
Before using the error location aid, read the following chapters:
- Function overview
- Entire circuit diagram
10
Error flowchart
Overview The overview will help you to find the relevant sections of the flowchart from among
those listed below.
The positions and meanings of the measuring points and LEDs for the modules/PC
boards can be found in the Detailed description chapter. which contains an LED
checklist or a Measuring points sub-section for each of the modules/PC boards (with
LEDs).
Poor ignition and weld properties with

TIG welding
Poor ignition and weld properties with

MMA welding
No or incorrect welding current
Move the mains Insufficient welding torch cooling (FK

switch to the I 2500/FK 2500 FC/FK 2500 Rob)
position
No lights on control panel
Open circuit voltage + 50 V faulty
Err 50 service code on the display
Table of service codes
11
Poor ignition and
weld properties Start
with TIG welding
Correct protective gas shield Connect correct protective gas

connected, and l/min set correctly? shield and check l/min
no
yes
Gas test button: Protective gas Check protective gas shield sole-
shield flowing out? noid 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,

no check set-up parameters,
possibly reset to factory settings
yes
(FAC) (see operating instructions)
Open circuit voltage with selected See Incorrect open circuit voltage
rod electrode (MMA) welding section
process = 50 V (+/- 1 V) ? no
yes
Check whether power source OK,

and check application
End
12
Poor ignition and
weld properties Start
with MMA wel-
ding
Electrodes/grounding (earthing) Connect cable correctly

cable connected/functioning no
correctly?
yes
Welding process set correctly? Select correct welding process

no
yes
Parameters set correctly? - Check settings on control panel

no - Check set-up parameters
- Possibly reset to factory set-
yes
tings (FAC) (see operating instruc-
tions)
MMA welding process = 50 V (+/- section
1 V) ? no
yes

End
13
No or incorrect
welding current Start
Welding torch and grounding Check welding torch and groun-

(earthing) cable connected/functio- ding (earthing) cable
no
ning correctly?
yes
No lights on control panel? See section entitled No lights on

yes control panel
no
MMA welding process = 50 V (+/- section
1 V) ? no
yes
- Welding current Iset no longer Change current sensor A1 VAC

adjustable, or yes
- Welding current is always Imax ?
no

End
14
Insufficient
welding torch Start
cooling (FK 2500/
FK 2500 FC/FK
2500 Rob)
Cooling unit set-up parameters Switch C-C set-up parameter to

switched to OFF? yes On
no
Sufficient coolant? Top up coolant; vent cooling unit

no
yes
Change pump
no
Pump rotating? Pump pressure OK?

yes
no yes
Check cooling system (flow rate)

and change defective components
Coolant pump jammed? Turn pump using a screwdriver, if it

yes will not turn change the pump,
check fuse F1
no
FKC/FKR 2500 PC board: Cooler Check cable harness, if OK

ON signal 24V X2/4 - X2/3 and change UST PC board
24V X2/8 - X2/3 present? no
yes
FKC/FKR 2500 PC board: Mains Check cable harness and fuse F1

voltage present on plug X1/1 - X1/
2? no
yes
15
Insufficient
A
welding torch
cooling (FK 2500/
FK 2500 FC/FK
2500 Rob)
(continued)
Fans rotating? Replace fans
no
yes
400 VAC present on FKR 2500 PC Change water pump

board X5 - X6? yes
no
FK 2500 Standard FK 2500 MV

Check/change fuse on FK 2500 Check/change fuse on FK 2500
PC board PC board, check/change auto-
Change FKR 2500 PC board transformer, change FKC 2500 PC
board
End
16
No lights on
Start
control panel
Steady HS LED on the Check mains cable,

A2 BPS 3000/MV mains switch, line
power module board? filter and supply
no
voltage
yes
Steady +24V int/ext Switch power source

LEDs on UST? off, unplug X3 plug
no from the UST PC
board, switch power
yes source on
Steady +24V int/ext Change the A3 NT

LEDs on A3 NT 2500 no 2500 power module
power module board? board
yes
Switch power source

off, plug X3 plug into
the UST PC board
and unplug X7, switch
power source on
Steady +24V int/ext Change A2 BPS 3000/

LEDs on UST PC MV power module
board? yes board
no
Check cooling unit
Steady +5V, +15V, - Check/change control

15V LEDs on UST PC panel/ribbon cable
board? yes
no
Unplug X4 from UST

PC board
17
No lights on
A
control panel
(continued)
Steady +5V, +15V, -

Change VAC shunt
15V LEDs on UST PC
board? yes
no
Unplug X2 from UST

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

15V LEDs on UST PC panel/ribbon cable
board? yes
no
Unplug X6 from UST

PC board
Steady +5V, +15V, -

Change BPS
15V LEDs on UST PC
board? yes
no
Change UST PC
board
End
18
Open circuit
voltage +50 V Start
faulty
Open circuit voltage for selected

MMA welding process not equal Change FMW 2500/3000 PC board,
to 50 V? yes Change BSVXX PC board
no
From here onwards, troubleshooting only applies to MagicWave 2500/3000
Steady +5 V, +18V, +24V LEDs on

FMW 2500/3000 PC board?
If the polarity changes using the
Change FMW 2500/3000 PC
Process button: neg./pos. no
ignition LED lit ?
yes
Check secondary power module

(see detailed explanation - se-
condary power module)
End
19
Err 50 service
Start
code on the
display
Does service code Err

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

pear after a short 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 activated
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
yes
20
Err 50 service
A
code on the
display
(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
capacitors
End
21
UST service codes
Safety
WARNING! An electric shock can be fatal. Before opening the device
- Turn the mains switch to the O position
- Unplug the device from the mains
- 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
- The corresponding troubleshooting measure
dsP | Axx (code no.20)

Cause: DSP displays a general error, xx stands for additional entries not required
for external service
Remedy: Update software. Change UST 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: Reset 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 error, xx stands for additional entries not relevant for external
service
dsP | E05 (code no.17)

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

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

Cause: Internal error (version conflict)
dsP | nSy (code no.36)

Cause: Internal error (version conflict)
22
Table of service
EcF | xxx (code no.32)
codes
(continued) Cause: BPS configuration error, 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
255 Unknown primary power module
Remedy: Fit correct primary power module
EFD | xx.y (code no.30)

Cause: Error in wirefeed system, xx and y can be found in the list of service codes
for the wirefeed system.
Remedy: Check wirefeed system
EIF | xx.y (code no.63)

Cause: Error in conjunction with a robot interface, xx and y can be found in the list
of service codes for 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 error
Remedy: Update software. Change UST 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: Reset service code by pressing set-up button
Err | EPF (code no.22)

Cause: Error 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.
23
Table of service
Err | PE (code no.53)
codes
(continued) Cause: Earth-fault error
Remedy: Remove earth fault. Configure device 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 error (short circuit or break) - examples: tF1 - tempe-
rature sensor error on secondary rectifier, tF2 - temperature sensor error on
primary power module, tF4 - temperature sensor error on primary power
module PFC (power factor control)
Remedy: Check cable harness and change the relevant temperature sensor
Err | tF6 (code no.16)

Cause: Error on BPS PC board or on the connection to the BPS PC board
Remedy: Check ribbon cable. Change BPS PC board.

Cause: Temperature sensor error on UST
Remedy: Change UST PC board

Cause: In conjunction with thermostat option: cooling unit temperature sensor error
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 lead and the mains plug

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

Cause: Mains undervoltage: The mains voltage has fallen below the tolerance
range
Remedy: Check mains voltage

Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check mains voltage

Cause: Wire stick control has tripped
Remedy: Remove short circuit on welding wire
24
Table of service
codes
(continued) Cause: In conjunction with wire-feed unit and wire-end check option: no wire
available
Remedy: Insert new wirespool

Cause: Overvoltage in the secondary circuit: safety cut-out has tripped
Remedy: Check secondary circuit, including TPCEL40 PC board

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
Err | 23.x (code no.23)

Cause: Config memory (CFM) error on UST PC board, x stands for:
1 config memory not found
2 checksum error
3 CFM empty
5 unknown PC board type
8 invalid identifier (identifier UST1 to UST2)

Cause: Config memory (CFM) error on BPS PC board, x stands for:
2 checksum error
3 CFM empty
Remedy: Check ribbon cable. Change BPS PC board.

Cause: Config memory (CFM) alternator error, x stands for:
2 checksum error
3 never tested
4 test not OK
5 unknown board type
Remedy: Change TTS
25
Table of service
codes
(continued) Cause: Config memory (CFM) machine error, x stands for:
2 checksum error
3 CFM empty
Remedy: Check cable harness. Change config memory on power source cable
harness.

Cause: EEProm save error
Remedy: Update software. Change UST2 PC board.

Cause: Error with the digital gas control option, x stands for:
1 no sensor found
2 no protective gas shield
3 alignment error
4 protective gas shield solenoid valve break or short circuit
5 no protective gas shield solenoid valve found
Remedy: For cause x
1 check cable harness, change protective gas shield sensor
2 check shielding gas supply (min. 2 bar)
3 no or insufficient protective gas shield, change protective gas shield
solenoid valve
4 change protective gas shield solenoid valve, change protective gas
shield sensor
5 check cable harness, change protective gas shield solenoid valve

Cause: Limit error, x stands for:
1 exceed of upper current limit
2 exceed of lower current limit
3 exceed of upper voltage limit
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 fan 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 protective gas shield
available
Remedy: Check shielding gas supply
26
Table of service
no | H2O (code no.39)
codes
(continued) Cause: Flow watchdog reporting water deficiency
Remedy: Check cooling system hose lines. Check pump pressure and flow rate.
Check flow watchdog.
no | Ign (code no.55)

Cause: Ignition time-out error: 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 cables. 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 device 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) - Example: tp1 - overtemperature on primary power module,
tp2 - overtemperature on primary power module PFC (power factor control)
Remedy: Allow the power source to cool down. Check that fan 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)
tp7 | Hot
Cause: Duty cycle exceeded
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) - Examples: ts1 - overtemperature at secondary rectifier,
ts2 - overtemperature at the auxiliary voltage source, tst - overtemperature
at UST PC board
27
Table of service
tSt | xxx (code no.33)
codes
(continued) Cause: Overtemperature in control circuit, xxx stands for the temperature indicator
Remedy: Allow the power source to cool down. Check fan.
US | POL (code no.37)

Cause: Measuring device for secondary voltage (Usec) incorrectly connected, or
defective for some other reason
Remedy: Check cable harness. Change UST2 PC board.
Special indicati- The following service codes are special indications for software problems:
ons 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 code 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 indications in levels 1, 2, and 3, and pass them on
to Fronius. Using this data, Fronius can locate the precise cause of the error.
28
Detailed description
General remarks This section contains a detailed description of the electronic modules with regard to the
following points:
- General (designation, item number)
- Position of the module in the device
- Overview
- Technical data
- Function overview
- Pin assignment
- LED checklist
- Measuring points
Overview Detailed description is composed of the following sections:

- ASU 2500 PC board
- BPS 3000/MV PC board
- BSV 3000 PC board
- FKC 2500 PC board
- FKR 2500 PC board
- FMW 2500/3000 PC board
- HFF 22 PC board
- NT 2500 PC board
- NT 60 PC board
- RP 3000 PC board
- SNT 3 PC board
- UST PC board - control and regulation unit
- Line filter
- Primary rectifier
- Secondary power module
- Shunt
- Temperature sensor AD592
29
ASU 2500 PC board
General remarks The ASU 2500 PC board (item number 4,071,075,Z) supplies the KD Supply 2500
Overview
LED +5V OK LED +12V OK
LED 230V OK LED 400V OK
LED high
charging relay active
(X3) (X2) (X1)
Fig. 2 ASU 2500 PC board
Function over- The ASU 2500 PC board supplies the NT60 power supply in the KD Supply 2500 and
view performs the following tasks:
- 5 V and 12 V power supply for the board
- Generation of intermediate circuit voltage from the power source supply voltage for
supplying the NT 60 power supply
- Glass tube fuse on input side 10 A/500 V
- Automatic voltage switching using relay enables operation in all voltage ranges (200
- 560V)
30
Pin assignment Plug Function
X1 ......... Mains voltage supply to FK 2500
Pin 1 PE Pin 2 NC
Pin 3 0 V AC/L1 Pin 4 NC
Pin 5 PE Pin 6 NC
Pin 7 NC Pin 8 400V AC/L2
X2 ......... Mains voltage supply to power supply
Pin 1 PE Pin 2 NC
Pin 3 0 V AC/L1 Pin 4 NC
Pin 5 PE Pin 6 NC
Pin 7 NC Pin 8 400V AC/L2
X3 ......... Supply to NT 60
Pin 1 ZWK1+ Pin 2 NC
Pin 3 ZWK1- Pin 4 NC
LED checklist LED +12V ....... Control voltage 12 V OK (must always be lit)
LED +5V ......... Control voltage 5 V OK (must always be lit)
LED 230V ....... Supply voltage is 230 V
LED 400V ....... Supply voltage is 400 V
LED Hochl ...... High charging connection active
31
BPS 3000/MV PC board
General remarks BPS 3000/MV (item no. 4,071,63/64,Z) is the power module board for the power source.
Important! The primary voltage is on the power module board.
Overview
LED +17V Power supply plug
(X9)
(X4)
(X8)
(X6)
(X1)
LED PFC
(X10)
LED HLSX
LED HS
(X3)
(X2)
(X5) (X7) LED +5V
Plug to RP 3000 PC board Power module

and cooling circuit supply Control plug to UST2C
PC board
Fig. 3 BPS 3000/MV PC board
32
Technical data Input voltage of BPS 3000 380 - 480 V AC (3-phase)
Input voltage tolerance of BPS 3000 (+/-15%)
Input voltage of BPS 3000 MV 200 - 480 V AC (1- and 3-phase)
Input voltage tolerance of BPS 3000 MV (+/-10%)
Supply voltage from NT 2500 15 V DC primary
Transistor module switching frequency 70 kHz
Intermediate circuit voltage 720 V DC
Function over- - Inputs and outputs are electrically isolated using optical couplers
view - Monitoring of both intermediate circuits for imbalance: a signal is transmitted to the
UST board if there is any deviation from a permitted range
- PFC boost converter for stepping up the intermediate circuit voltage to 720 VDC
- Controlling the transistor module via driver stages from the UST board
- Activation of boost converter only once the high charging time is completed
- Quick shutdown of power module in the event of a module fault due to permanent
primary current measurement
- Controlling the transistor module via driver stages from the UST PC board
- High charging connection via resistors, the time for bridging the resistors by means
of relays is specified by the UST board
- Quick shutdown of power module in the event of a module fault due to permanent
primary current measurement
- The power full bridge breaks down the rectified intermediate circuit voltage into a 40
kHz signal. The bridge circuit is controlled via driver stages from the UST board.

X1 ......... Ribbon cable from UST (power module control)
Further information on pin assignments can be found in the chapter entitled Detailed
description - UST.
X2/11 .... Primary rectifier +
X3 ......... Primary transformer
X4 ......... Primary transformer
X5/6 ...... PFC choke
X7 ......... Connection to RP 3000 PC board
Pin 1 L1 Pin 2 NC
Pin 3 L2 Pin 4 NC
Pin 5 L3 Pin 6 NC
Pin 7 Rel+ Pin 8 L1 cooling unit
Pin 9 NC Pin 10 L2 cooling unit
Pin 11 NC Pin 12 L3
Pin 13 NC Pin 14 Rel-
X8 ......... Earthing (screw connection on the PC board)
X9 ......... Connection to NT 2500
Pin 1 U ZWK Pin 2 NC
Pin 3 NC Pin 4 GND primary
Pin 5 GND primary Pin 6 U ZWK
Pin 7 NC Pin 8 NC
Pin 9 +17V Pin 10 GND primary
X10/12 .. Primary rectifier -
33
LED checklist LEDs for supply voltages (green)
LED +17V ....... light up when power supply is functioning correctly
LED +5V ......... light up when power supply on UST PC board is functioning correctly
Signal LEDs (red)

LED PFC ........ lights up or flashes with varying degrees of brightness depending on
power drawn from the power source (the brighter the LED the higher the
power)
HLSX LED ...... lights up when the high charging relays are activated
HS LED .......... lights up when mains switch is in - l - position
Measuring points Measurement on each of the diode regions depicted below must produce a result of
0.34 V.
Fig. 4 Measuring points on BPS 3000/MV PC board
Measuring points Plug/pin Measuring result set value

Intermediate circuit voltage X9/1 - X9/4 720 V DC
17 V primary X9/9 - X9/10 17 V DC
34
BSV 3000 PC board voltage doubler
General remarks The BSV 3000 (item number 4,071,071,Z) is an additional PC board for TransTig 2500/
3000 and is used for raising the output voltage
Overview
(X1) (X2) (X4) (X3)
(X9)
(X11)
Fig. 5 BSV 3000
Function over- The BSV 3000 PC board raises the open circuit voltage for optimised ignition properties
view during MMA and TIG welding.

X1 ......... AC from transformer
X3 ......... Welding voltage
X4 ......... GND
Pin 1 Welding voltage Pin 2 GND
X11 ....... PE (earthing screws)
35
FKC 2500 PC board
General remarks FKC 2500 (item number 4,071,073,Z) is the interface board for the MV variants of the FK
2500 cooling unit.
Overview
LED +10V
LED +5V
(X5)
(X6)
LED +5V_L1
(X9) LED PIC_OK
(X7)
(X2)
(X1) (X3) (X4)
Fig. 6 FKC 2500 PC board
Function over- The FKC 2500 PC board performs the following functions:
view - Electrically isolated control of the coolant pump
- Allows the combining of coolant pump, mains voltage, UST, flow sensor and two
fans
- Automatic switching of the mains voltage using power transistors, no manual swit-
ching required
36
X1 ......... 400 V AC supply
Pin 1 L1 (400 V) Pin 2 NC
Pin 3 NC Pin 4 L2 (400 V)
X2 ......... Control from UST
Pin 1 NC Pin 2 Water control
Pin 3 GND secondary Pin 4 Cooler on
Pin 5 NC Pin 6 NC
Pin 7 NC Pin 8 24 V
X3 ......... Fan
Pin 1 Cooler on Pin 2 24 V
X4 ......... Fan
X5 ......... L2 Pump motor
X7 ......... Flow sensor
Pin 1 GND secondary Pin 2 Water control
Pin 3 NC Pin 4 24 V
Pin 5 NC Pin 6 NC
X9 ......... Auto-transformer
Pin 1 230 V Pin 2 NC
Pin 3 L2 Pin 4 NC
Pin 9 440 V Pin 10 400 V
LED checklist LEDs for supply voltages (green)

LED +10V ....... for the switched mode power supply, must be on all the time
LED +5V ......... for the PIC (microcontroller) supply, must be on all the time
LED PIC_OK .. flashes when the PIC is working
LED +5V_L1 ... for the PIC supply, must be on all the time
37
FKR 2500 PC board
General remarks FKR 2500 (item number 4,071,074,Z) is the interface board for the standard variants of
the FK 2500 cooling unit.
Overview
(X2)
(X4)
(X3)
(X7)
(X1)
(X5)
Fig. 7 FKR 2500
38
Function over- The FKR 2500 PC board performs the following functions:
view Electrically isolated control of the coolant pump
- Electrically isolated control of the coolant pump
- Allows the combining of coolant pump, mains voltage, UST, flow sensor and two
fans

X1 ......... 400 V AC supply
Pin 1 L1 (400 V) Pin 2 NC
Pin 3 NC Pin 4 L2 (400 V)
X2 ......... Control from UST
Pin 1 NC Pin 2 Water control
Pin 3 GND secondary Pin 4 Cooler on
Pin 5 NC Pin 6 NC
Pin 7 NC Pin 8 24 V
X3 ......... Fan
X4 ......... Fan
X7 ......... Flow sensor
Pin 1 GND secondary Pin 2 Water control
Pin 3 NC Pin 4 24 V
Pin 5 NC Pin 6 NC
39
FMW 2500/3000 PC board
General remarks On the MagicWave 2500/3000 power sources, the FMW 2500/3000 PC board (item no.
4,071,065/66,Z) is used to control the inverter transistors and the auxiliary voltage
source, as well as to measure the open circuit voltage.
Overview
(X1) (X2) (X3) (X4) (X5) (X6)
(X10)
(X9)
(X7) (X8)
Fig. 8 FMW 2500
40
Function over- On the MagicWave 4000/5000 power sources, the FMW 2500/3000 PC board is used
view for the AC output voltage and performs the following tasks:
- Generating a DC voltage of 300V for charging the electrolyte capacitors in the
secondary intermediate circuit
- The electrolyte capacitors on the FMW 300 board are used to store excess energy
from the welding circuit during AC welding. In order to keep the electrolyte capaci-
tors free from AC voltage, which is connected shortly before zero-crossing during
AC welding, the electrolyte capacitors receive a charge of approx. 300 V.
- Limiting the secondary intermediate circuit to a maximum of 400 V
- Controlling the inverter transistors
- Power supply for generating the 5 V and 18 V voltages required by the PC board
- Generating an auxiliary voltage, in order to allow ignition after zero-crossing during
AC welding. The auxiliary voltage passes through an additional winding on the
welding transformer in the welding circuit.
- Measuring the open circuit voltage: If there is no voltage on pins X6/1 and X6/4, the
DC voltage is increased to 113 V. The device is then shut down and the Err | 068
service code appears.

X2 ......... Connection to UST
Pin 1 24 V Pin 2 Polarity
Pin 3 NC Pin 4 Error
Pin 5 SCL Pin 6 Temp5-
Pin 7 NC Pin 8 GND
Pin 9 HQ-ON Pin 10 NC
Pin 11 NC Pin 12 SDA
Pin 13 Temp5+ Pin 14 NC
X3 ......... Common (centre-tap) transformer
Pin 1 Common Pin 2 Common
X4 ......... Auxiliary voltage source transformer winding
Pin 1 IN1.1 Pin 2 IN1.2
X5 ......... Auxiliary voltage source transformer winding
X6... Voltage measurement
Pin 1 VOWI1.1 (U-act +) Pin 2 NC
Pin 3 NC Pin 4 VOWI2.1 (U-act -)
Pin 5 VOWI1.2 (U-act +) Pin 6 NC
Pin 7 NC Pin 8 VOWI2.2 (U-act -)
X7 ......... Cable to copper busbar (top left)
X8 ......... Cable to middle copper plate
X9 ......... Cable to copper plate (outside right)
X10 ....... Cable to middle copper plate
41
LED checklist
LED 24V
LED 18V
LED 5V
Err
LED Help
LED pos
LED neg LED PosHelp

LED NegHelp
Fig. 9 LED indicators on FMW 2500
LEDs for supply voltages (green)

LED 24V ......... control voltage, must be on all the time
LED 18V ......... IGBT voltage supply, electrically isolated, must be on all the time
LED 5V ........... for the processor voltage supply, must be on all the time
Error ............... lights up if overvoltage - 18 V supply for IGBTs and power module are
shut off immediately
LED pos ......... lights up if transistors for positive welding current are being actuated
LED neg ......... lights up if transistors for negative welding current are being actuated
LED pos and LED neg light up alternately if AC is present and with increasing brightness
as frequency increases.
LED PosHelp .. auxiliary voltage, must be on all the time - lights up at positive zero
crossing peak
LED NegHelp . auxiliary voltage, must be on all the time - lights up at negative zero
crossing peak
LED PosHelp and LED NegHelp light up alternately if AC is present and with increasing
brightness as frequency increases.
42
HFF 22 PC board
General remarks HFF 22 (item number 4,070,812,Z) is used for high frequency ignition in the MW 2500
and MW 3000 power sources and is also a filter assignment for remote controls and
torch triggers.
Overview
HF module
Filter module
Fig. 10 HFF 22
43
Technical data Supply voltage + 24 VDC (+/- 20 %)
Output voltage 1000 VDC
Function over- The HFF 22 PC board includes the following components:

view
(1) HF module
From the +24 V supply (24 V LED green), the HF module generates a +15 V supply (+15
V LED green) for the internal control module. A flyback converter charging circuit char-
ges the impulse capacitor from +24 V to 1000 V. Immediately after charging the ignition
thyristor is activated and the impulse capacitor discharges the HF launch coil via the
primary coil. The HF launch coil transforms the charging voltage of the impulse capacitor
from 1000 V to approx. 10 kV. Each charging process of the impulse capacitor is indica-
ted by the SIG LED (red) lighting up.
(2) Filter module

The filter module comprises two 6-pin, current-compensated filter chokes (one choke
each for remote control and torch trigger). The filter chokes eliminate high-frequency
impulses on the data lines caused by parasitic capacities. A circuit layout of capacitors
and Transil arrays (protective diodes) is used for discharging overvoltage of the data
lines.
44
Pin assignment
(X3)
(X1)
(X2)
(X5)
(X4)
(X6)
(X7)
Fig. 11 Pin assignment on HFF 22 PC board
45
Pin assignment X1 ...... HF pulse positive pole (blade terminal connection to primary voltage of the HF
(continued) launch coil)
X2 ...... HF pulse negative pole (blade terminal connection to primary voltage of the HF
launch coil)
X3 ...... High frequency control cables (connection to UST)

Pin Designation Pin Designation
1 NC 3 SIGNAL
2 + 24 V 4 GND
X4 ...... Torch trigger cables (connection to UST)

1 NC 6 NC
2 DOWN 7 NC
3 CRATERFILL 8 IDENTIF
4 UP 9 GND
5 MAIN CURR 10 NC
X5 ...... Torch trigger cables (connection to welding torch)

1 NC 6 NC
2 DOWN 7 NC
3 CRATERFILL 8 IDENTIF
4 UP 9 GND
5 MAIN CURR 10 NC
X6 ...... Remote control cables (connection to remote control)

1 +24 V-EXT 4 GND 485
2 RXDL 485 5 TXDL 485
3 RXDH 485 6 TXDH 485
X7 ...... Remote control cables (connection to UST)

1 +24 V-EXT 4 GND 485
2 TXDL 485 5 RXDL 485
3 TXDH 485 6 RXDH 485
46
NT 2500 PC board
General remarks The NT 2500 switched mode power supply is used to supply internal and external
components
Technical data Input voltage max. 800 V DC from the intermediate circuit
Output voltages 24 V internal
24 V external
17 V primary
Fuse protection by PTC
24 V internal 4.2 A
24 V external 2A
15 V primary 0.25 A
Function over- - Internal and external components supplied with 24 V

view - Power module supplied with 17 V primary
WARNING! An electric shock can be fatal. 17 V configured in 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
47
Overview
X1
LED 24 V
internal
LED 24 V
external
Supply
LED
X2 LED 17 V
Fig. 12 Pin assignment on HFF 22 PC board

X1
Pin 1 24 V external Pin 2 NC
Pin 3 UZW Pin 4 24 V internal
Pin 5 GND EXT Pin 6 NC
Pin 7 GND Pin 8 GND INT
X2
Pin 1 + UZWK Pin 2 NC
Pin 3 NC Pin 4 GNDP
Pin 5 GNDP Pin 6 UZWK
Pin 7 NC Pin 8 NC
Pin 9 17 V primary Pin 10 GNDP
LED checklist Supply LED ............... lights up if no error is present and the power supply is being fed by
the intermediate circuit
.................................. flashes or does not light up if the power supply is defective
LED 24V external ...... lights up if the 24 V external voltage is present
LED 24V internal ....... lights up if the 24 V internal voltage is present
LED 17V primary ....... lights up if the 17 V primary voltage is present
Important! The 24 V internal/external and 17 V primary LEDs go out or become dimmer

if there is a short circuit.
48
NT 60
General remarks The NT 60 switched mode power supply (item number 4,070,627,Z) for the wire-feed
unit motor.
Important! The primary voltage is on the NT 60 switched mode power supply.
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. 13 NT 60
Technical data Supply voltage from intermediate circuit 2 x 230 - 380 V DC

Output voltage Open circuit 59 (+/- 2) V
at a load of 4 A 55 (+/- 2) V
Function over- - Output voltage is electrically isolated and protected by 2 parallel connected PTC
view resistors.
- The 1 V/A falling output characteristic of the NT 60 circuit enables several NT 60
power supplies 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 light up. As soon as the PTC resistors
trip, the Error LED flashes.
49
Pin assignment
(X2) (X1)
Fig. 14 Plug on NT 60 power supply
Plug Function
X1 ......... Connection to wire-feed unit (secondary voltage)
Pin 1 + 55 V Pin 2 + 55 V
X2 ......... Primary connection intermediate circuits 1 and 2
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 5 Intermediate circuit 2+ Pin 13 Intermediate circuit 2+
Pin 6 NC Pin 14 NC
Pin 7 Intermediate circuit 2- GND P Pin 15 Intermediate circuit 2- GND P
Pin 8 +15 V primary Pin 16 +15 V primary
50
LED checklist
Intermediate circuit 2 supply LED

Error LED (PTC highly resistant)
55 V supply LED
Intermediate circuit 1 supply LED
Fig. 15 LED indicators on power supply NT 60
Measuring points
X2 X1
Fig. 16 Plug X1 and X2 on power supply NT 60
51
Measuring points Measuring points Plug/pin Measuring result set value
(continued)
Intermediate circuit voltage 1 X2/1 - X2/3 approx. 280 V DC at 400 V AC
X2/9 - X2/11 approx. 320 V DC at 230 V AC
Intermediate circuit voltage 2 X2/5 - X2/7 approx. 280 V DC at 400 V AC
X2/13 - X2/15 approx. 320 V DC at 230 V AC
55 V X1/1 - X1/3 approx. 57-61 V DC in open-
circuit
X1/2 - X1/4
52
RP 3000 PC board
General remarks The RP 3000 PC board (item no. 4,071,068) is used to charge the intermediate circuit
capacitors.
Overview
(X6)
(X5)
(X7)
(X4)
(X3)
(X2)
(X1)
Fig.17 RP 3000
Function over- - PTC resistors for limiting the starting current of the power source
view - PTC resistors are bridged by the relays after a predetermined period of time and
after having reached a predefined intermediate circuit voltage (controlled by the UST
via the BPS 3000)
- Limiting of the starting current occurs at and above an input voltage of approx. 240
VDC
- Undervoltage shut-off at approx. 165 V
53
X1 ......... L1 from line filter
X2 ......... L1 to rectifier
X7 ......... Connecting leads to BPS 3000
Pin1 L1 Pin2 NC
Pin3 L2 Pin4 NC
Pin5 L3 Pin6 NC
Pin7 Rel+ Pin8 NC
Pin9 NC Pin10 NC
Pin11 NC Pin12 L3
Pin13 NC Pin14 Rel-
Measuring points Measuring points Plug/pin Measuring result set value

PTC resistor X1 - X2 approx. 75 Ohm (2 PTCs in
parallel)
X3 - X4 at approx. 20 C
X5 - X6 Short circuit - relay sticks
Remedy: Change PC board
54
SNT 3 PC board
General remarks The SNT 3 PC board (item no. 4,070,730) is an active LocalNet distributor for digital
power sources and peripheral devices.
Overview
X11_1
X11_2
X11_3
X10
X7
X6_1
LED 1
X6_2
LED 2
X6_3
LED 3
Fig.18 SNT 3
Function over- SNT 3 is used to automatically connect and disconnect the LocalNet nodes in line with
view the Hot Plug and Play principle.

X6_1 ..... LocalNet plug 1
X7 ......... LocalNet in
X10 ....... 55 V DC input
X11_1 ... 55 V DC
X11_2 ... 55 V DC
X11_3 ... 55 V DC
55
LED checklist LED 1 ........................ flashes when a node is connected to LocalNet plug 1 and the
connection is OK
LED 2 ........................ flashes when a node is connected to LocalNet plug 2 and the
connection is OK
LED 3 ........................ flashes when a node is connected to LocalNet plug 3 and the
connection is OK
56
UST PC board
General remarks The UST PC board (item number 4,070,860,Z) is a universal control, regulation and
monitoring unit for fully digitised Fronius power sources.
Function over- The UST PC board performs the following functions:

view
(1) Power module control
The control of the power module is performed by the UST via plug X6; the driver circuits
are on the UST.
(2) Control of control panel

The UST controls the control panel via a 10-pin ribbon cable (X2). The control is handled
via a databus connection (LocalNet).
(3) Mains switch evaluation

The UST evaluates the incoming mains switch signal from the BPS PC board. If the
intermediate circuit voltage reaches a certain level, the relays close after a specified
time. The UST uses the mains switch signal to detect when the power source is swit-
ched off. The UST stores the current settings and activates the fans to discharge the
intermediate circuit.
(4) Temperature evaluation

The UST evaluates the signals from the temperature sensors and controls the fans. If
the temperature continues to rises and the fans cannot cool sufficiently (e.g. because the
duty cycle is exceeded), the power source switches off and outputs an appropriate
service code.
(5) Control of fan

The UST controls the fan (X5) depending on temperature and firmware.
(6) LocalNet interface

The LocalNet interface is used to transmit data from the plug connection (X9) to the
peripheral devices via the filter PC board (e.g. HFF22).
(7) Regulation of welding current and voltage

The welding current and voltage is regulated by the DSP (digital signal processor) and
the firmware integrated in the UST.
(8) Control of inverter

The UST PC board controls the inverter module via the plug (X1).
57
Pin assignment X1 ...... Inverter control (connection to TTS 22)
X2 ...... Connecting lead to control panel (10-pin ribbon cable)
X3 ...... Supply

1 +24 V-EXT, +24 V remote 5 GND-EXT, remote control
control connection connection GND
2 NC 6 NC
3 UZW, intermediate circuit 7 GND-UZW, intermediate
voltage measuring circuit voltage measuring
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply
X4 ...... Temperature; Uact, Iact

1 Uist - 13 U IST +
2 NC 14 NC
3 LEM C 4000, Shunt 15 LEM D 5000
4 LEM A 3000, Shunt 16 NC
5 LEM B 2000, Shunt 17 GNDD LEM
6 - 15 V LEM 18 + 15 V LEM
7 TH - ERROR 1 19 TH - ERROR 2
8 GND A (UP 400) 20 UP 400
9 CFM - 21 CFM +
10 ESC 1 22 ESC 2
11 TEMP 2 - 23 TEMP 2 +
12 TEMP 1 - 24 TEMP 1 +
X5 ...... Fan
1 + 24 V 3 + 24 V
2 FAN, fan power module 4 FAN, fan control
X6 ...... Power source - connection to power module (BPS), 26-pin ribbon cable
X7 ...... Cooling unit

1 Temp 6 + 6 TEMP 6 -
2 COOLER ON 7 + 24 V
3 WAT. CONTR. 8 GND (WAT. CONTR.)
4 CFM + 9 CFM -
5 NC 10 GND (SUPPLY)
58
Pin assignment X8 ...... Programming interface for updating firmware via BSL tool
(continued)
NOTE! Risk of damage to electronic components. Switch off the power supply
before connecting or removing BSL tools.
X9 ...... RS485 connecting lead to remote control via a filter PC board
Measuring points See pin assignment
LED checklist
+24 Vext
+24 Vint
+5V
+15 V
- 15 V
STAT + 5V
Fig. 19 Control LEDs on UST PC board
+24 Vext ........... lights up when switched mode power supply is working correctly
+24 Vint
+ 5V ................ RS 485
+15 V
- 15 V
+ 5V
STAT .............. Status LED
lights up if no firmware is present
if it does not light up: process OK
Changing UST NOTE! Options enabled via the Service module software are stored on the
PC board UST 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.
59
Line filter
General remarks The 29 A line filter (item no. 43,0001,3320) is a part of the TransTig and MagicWave
2500/3000 power sources and is used to filter out parasitic frequencies that:
- are generated by the power source and could affect other consumer loads
- come from the grid and could affect the power source
Overview
X2 L1'
L3' X6
L2' X4
PECONTR2 PECONTR1
X1 L1
X3 L2
X5 L3
Fig. 20 Line filter
Technical data Attenuation of parasitic frequencies > 60 Hz
Function over- - Varistors provide protection against momentary mains overvoltages

view - Capacitors and coils form an LC low-pass filter that attenuates the parasitic frequen-
cies over 60 Hz
- Capacitors divert disturbances to earth and also between the phases
- Integrated earth current watchdog: used to protect the welding machine and the in-
house installation from vagabond currents that are conducted via the earthing

X1 ................... Mains voltage input L1
X2 ................... Mains voltage input L1'
PECONTR1 .... Earth current watchdog reed contact (normally closed)
PECONTR2 .... Earth current watchdog reed contact (normally closed)
60
Primary rectifier
General remarks Three-phase bridge rectifier with item number 42,0001,0060
Overview
L1
(+) L2
L3
(-)
Fig. 21 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.

L1 Mains voltage input L1
(+) Intermediate circuit voltage output +
(-) Intermediate circuit voltage output -
61
Measuring points Measurement on each of the diode regi-
ons must produce a result of 0.4 V.
Fig. 22 Measuring points on primary rectifier TS

4000/5000, TPS 3200/4000/5000
62
Secondary power module
General remarks The secondary power module for the TransTig 2500/3000 and MagicWave 2500/3000
power sources contains the following components:
- TransTig 2500: 2 diode modules (item number 41,0003,0203)
- TransTig 3000: 3 diode modules (item number 41,0003,0203)
- MagicWave 2500: 4 diode modules (item number 41,0003,0203)
6 transistor modules (item number 41,0003,0279)
- MagicWave 3000: 6 diode modules (item number 41,0003,0291)
10 transistor modules (item number 41,0003,0279)
- TransTig 2500/3000, MagicWave 2500: 4 toroidal tape cores
- MagicWave 3000: 10 toroidal tape cores (item number 41,0012,0030)
2 HXP 200 1kOhm resistors (item number 43,0001,1274)
- 1 thermoelement (item number 43,0001,0600)
Overview
Fig. 23 Secondary power module
63
Function over- The diode modules form the secondary rectifier, which is executed as a centre-tap
view connection. The secondary rectifier generates DC from the AC of the welding transfor-
mer. An output choke smoothes the direct current. The diodes are protected from over-
voltage by toroidal tape cores on the transformer leads. The transistors on the inverter
convert the DC of the secondary rectifier to AC, which is then sent to the welding so-
ckets. The transistor module is controlled by the UST PC board via the FMW PC board.
LED checklist This information is the same as the contents of the LED checklist section of the FMW
2500/3000 PC board section.
Measuring points
Measuring point Measuring result set value
Diode regions (1) 0.15 V
Resistance (3) 1.8 kOhm
(1) (1)
(1)
(1)
(1)
(1)
(1) (1)
Fig. 24 Measuring points of TransTig 2500 Fig. 25 Measuring points of TransTig 3000
64
Measuring points
(continued) (1)
(1)
(1)
(2) (2)
(1)
(2) (2)
(1)
(2) (2)
Fig. 26 Measuring points of MagicWave 2500
(1)
(3) (3)
(1)
(1)
(2) (2)
(1)
(2) (2)
(1)
(2) (2)
(1)
(2) (2)
(1)
Fig. 27 Measuring points of MagicWave 3000
65
Shunt
General remarks The shunt (item number 43,0001,1139) is a current sensor which permits the electrically
isolated capture of the welding current.
Overview
Fig. 28 Shunt
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 working voltage of +/- 15 V and provides an output
signal which is proportional to the measured welding current.
The output signal to welding current transmission ratio is 1:2000.
66
Function over- Other functions:
view - Electric isolation between power circuit and electronic circuit
(continued) - 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 by measuring the voltage. 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 set value

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

other parts in the power source, use only the adapter cable supplied.
67
TP 592S temperature sensor
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 has a plug-in Molex connec-
tion.
Fig.29 TP 592S temperature sensor
Technical data Supply voltage 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 outputs a current of exactly 1 A per K (Kelvin), provided
that a voltage of 4 - 30 V DC is present.
0 K corresponds to a temperature of -273.15C

0 C 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.
- Connect 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
Functional description.
68
Changing modules
General remarks The Changing modules chapter describes how to replace components that:
- Have no instructions of their own for replacement and
- Require detailed replacement instructions
NOTE! Danger of damage to threads, especially when fastening screws with

power tools (e.g. power screwdrivers). In order to avoid damage to threads,
proceed as follows:
- Turn screws slightly to the left to guarantee optimum centring.
- Screw in at least two full turns by hand. This prevents the screw from
forming a new thread:
- Carefully tighten the screw
Overview The Replacing components section contains the following subsections:

- Changing the transformer
- Changing the fan
69
Changing the transformer
Removing the
control panel
(1)
(2)
X2
Fig. 1 Removing the control panel Fig. 2 Control panel removed
1. Remove the side panel

2. Unplug the ribbon cable (1) on UST PC board of control panel (2) at X2
NOTE! When removing the control panel, take care not to bend, trap or strain
the ribbon cable.
3. Carefully remove the control panel (2) with ribbon cable
Removing the 1. Remove the cover

UST PC board 2. Unplug all plugs from the UST PC
board (3)
3. Undo spacers and remove UST PC
board (3)
(3)
Fig. 3 Removing the UST PC board
Removing the (4) (4) (6) 1. Undo the screws (4) for the retaining
retaining plate plate (5) using a TX25 screwdriver
and remove retaining plate (5)
NOTE! When loosening the front

of the housing (6), do not trap,
bend or strain the cables.
2. Loosen the front of the housing (6) by

removing the remaining screws and
(4) (4) (5) (4) swiveling to one side
Fig. 4 Removing the retaining plate
70
Undoing leads on 1. Unscrew hexagon bolt (6) from the
earthing socket earthing socket using 19 mm flat
spanner
(6)
Fig. 5 Removing hexagon bolt with leads
Undoing transfor- (9) 1. Unscrew hexagon bolt (7) from the

mer centre-tap transformer centre-tap using 13 mm
and auxiliary flat spanner
power source 2. Cut through cable tie (8)
(12)
leads 3. Remove luster terminal (9) and, if
(8) present, auxiliary voltage source leads
from the choke holder
(11) 4. Remove the primary transformer
(10) (8) (7) leads (10) from the BPS PC board on
the luster terminal (9)
Only applies to TransTig 2500/3000:

Fig. 6 Removing transformer centre-tap leads 5. Unplug blue lead (11) from HF transfor-
mer at the plug connection (12)
Only applies to MagicWave 2500/3000:

5. Cut through cable tie (13)
6. Unplug and unthread auxiliary voltage
source leads (14) from FMW 3000 PC
(13) (13) (13) X4 X5 board at X4 and X5
(14)
(13)
Fig. 7 Removing auxiliary voltage source leads
Removing the HF 1. Remove two blade terminals (15) on

transformer HFF22 PC board
2. Unscrew the three screws (16) on the
copper brackets using a TX25 scre-
(15) (16) (16) wdriver
3. Unscrew the two screws (17) on the
(18) HF transformer (18) using a TX25
(17) screwdriver
4. Remove HF transformer (18)
Fig. 8 Removing the HF transformer
71
Removing the 1. Cut through cable ties (19) used to
toroidal tape hold the leads together
cores 2. Remove toroidal tape cores (20) from
the leads
(19) (20) (19)
(19) (19) (19)
Fig. 9 Removing toroidal tape cores
Removing the (21) 1. Undo the screws (21) for the retaining
transformer plate (22) using a TX25 screwdriver
(21) 2. Remove retaining plate (22) along
with choke (23) and shunt (24)
(22) 3. Unscrew the four screws (25) on the
(24) transformer (26) using a TX25 scre-
wdriver and remove transformer (26)
(23)
(26) (25)
(25) (21)
(25) (25)
(21)
Fig. 10 Removing the transformer
72
Installing the (21) 1. Tighten the four screws (25) to fasten
transformer the transformer (26) using a TX25
(21) screwdriver
2. Tighten the four screws (21) to fasten
(22) the retaining plate (22), including
(24) choke (23) and shunt (24), using a
TX25 screwdriver
(23)
(26) (25)
(25) (21)
(25) (25)
(21)
Fig. 11 Fitting the transformer
Securing the (19) 1. Feed transformer cables (27) through

toroidal tape the opening in the retaining plate
cores and trans- 2. Thread the toroidal tape cores (20)
former onto the leads (27) and, if present,
(28) as shown
3. Secure the leads (27) and, if present,
(28) using cable ties (19) as shown
(27) (20) (28) (19)
(28)
(19) (19) (19)
Fig. 12 Securing the toroidal tape cores
73
Fitting the se- (16) (29) Only applies to TransTig 2500/3000:
condary transfor- (16) 1. Fit the two secondary transformer
mer leads (31) leads (27) together with TRAFO sek
1x T1:2 leads (28), each using
(28) (30)
(16) - TX25 screw (16)
(31)
(16) (29) - spacer (29)
(16) - serrated washer (30)
2. Fit lead (31) using
(28) (27) - TX25 screw (16)
2x
(30) - spacer (29)
(27) (25) - serrated washer (30)
(TransTig) (27)
Fig. 13 Fitting the secondary transformer leads
Only applies to MagicWave 2500/3000:

1. Fit two transformer leads (27) each using
- TX25 screw (16)
- spacer (29)
- serrated washer (30)
2. Fit lead (31) using
- TX25 screw (16)
- spacer (29)
Fitting the HF 1. Tighten the two screws (17) to fasten

transformer the HF transformer (18) using a TX25
screwdriver
2. Insert the two blade terminals (15) of
(15) the leads from the HF transformer
according to the inscription on the
(18) HFF22 board
(17)
Fig. 14 Fitting the HF transformer
Fitting transfor- Only applies to MagicWave 2500/3000:

mer centre-tap 1. Route the auxiliary voltage source
and auxiliary leads (14) to the FMW 3000 PC board
power source and plug in to X4 and X5
leads (13) (13) (13) X4 X5 2. Bind cables together with cable ties
(13)
(14)
(13)
Fig. 15 Connecting auxiliary voltage source leads
74
Fitting transfor- (9) (34) Only applies to TransTig 2500/3000:
mer centre-tap 3. Plug in blue lead (11) from HF trans-
and auxiliary former to the plug connection (12)
power source
(12)
leads 4. Connect the primary transformer
(continued) (7) (8) leads (10) from the BPS PC board to
the luster terminal (9)
(11) 5. Insert luster terminal (9) and, if
present, auxiliary voltage source leads
into the choke holder
(10) (8) (33) 6. Bind cables together with cable ties
(8)
Fig. 16 Fitting transformer centre-tap leads 7. Fit the following to the transformer
centre-tap using the 13 mm hexagon
bolt (7):
- spring washer (31)
- spacer (32)
(32) (34) - centre-tap lead (33)
(31) - choke lead (34)
(7) (33)
Fig. 17 Layout of transformer centre-tap leads
Fitting leads to 1. Fit the following to the earthing socket

earthing socket using the 19 mm hexagon bolt (6):
- spacer (36)
- X57 protective circuit cable lug
(37)
- TransTig 2500/3000 only: varistor
cable lug (38)
- choke lead (39)
(6)
Fig. 18 Fitting earthing socket leads
(38)
(TransTig)
(37) (39)
(35)
(6) (36)
Fig. 19 Layout of earthing socket leads
75
Fitting the retai- (4) (4) 1. Fit retaining plate (5) using TX25
ning plate screws (4)
(4) (4) (5) (4)
Fig. 20 Fitting the retaining plate
Fitting the UST 1. Put UST PC board (3) into place,

(6)
PC board position using screw spacers and
remake plug connections
NOTE! When fitting the front of

the housing (6), do not trap, bend
or strain the cables.
2. Fit front of housing (6)
(3)
Fig. 21 Fitting the UST PC board
Fitting the cont- 1. Fit the control panel (2)

rol panel 2. Plug the ribbon cable (1) of the control
panel (2) into X2 on the UST PC
board
3. Fit the side panels
(1)
(2)
X2
Fig. 22 Fitting the control panel
76
Changing the fan
Removing the 1. Removing the side panels

solenoid valve 2. Remove the hexagon nut (1) for the
and fan lead solenoid valve (2) - Fig. 2 - using a 17
mm flat spanner
NOTE! When loosening the rear

of the housing (3), do not trap,
(1) (3) bend or strain the cables.
3. Remove the screws for the rear of the

housing (3), and swivel it carefully to
one side
Fig. 1 Removing the hexagon nut
(7) (6) (4) (5)
(4) (4) (2) (3)
Fig. 2 Removing the solenoid valve and fan cable
4. Cut through the cable ties (4) on the fan lead (5)
5. Disconnect Molex plug (6) from the Molex socket (7)
6. Undo fan lead contacts (5) from the plug housing (6) using a Molex extractor tool
(not shown)
77
Removing the air
baffle
(8)
(8) (8)
(10)
Fig. 4 Removing the screw for the air baffle
1. Unscrew the eight screws (8) using a

(8)
TX25 screwdriver and remove air
baffle (9)
(8) 2. Undo the screw (10) under the RP
3000 PC board using a TX25 scre-
(9)
wdriver
Fig. 3 Removing the screws for the air baffle
Removing the fan 1. Remove fan (11) and retaining plate

(12) from the side
2. Detach fan (11) from retaining plate
(12)
(12) (11)
Fig. 5 Removing the fan and retaining plate
Installing the fan 1. Attach fan (11) to retaining plate with

four screws (12)
2. Insert fan (11) and retaining plate (12)
from the side
(12) (11)
Fig. 6 Fitting the fan and retaining plate
78
Fitting the air
baffle
(8)
(8) (8)
(10)
Fig. 8 Fitting the screw for the air baffle
1. Tighten the eight screws (8) to secure

(8)
the air baffle (9) using a TX25 scre-
wdriver
(8) 2. Tighten the screw (10) under the RP
3000 PC board using a TX25 scre-
(9)
wdriver
Fig. 7 Fitting the screws for the air baffle
3. Insert fan lead contacts (5) into the plug housing (6) (not shown)
4. Connect the Molex plug (6) of the fan lead (5) to the Molex socket (7)
5. Fix fan lead (5) using cable ties (4)
(7) (6) (4) (5)
(4) (4) (2) (3)
Fig. 9 Fitting the solenoid valve and fan cable
79
Fitting the air NOTE! When fitting the rear of
baffle the housing (3), do not trap, bend
(continued) or strain the cables.
1. Fit the housing rear panel (3)

2. Tighten the hexagon nut (1) for fitting
the solenoid valve (2) - Fig. 9 - using
(1) (3) a 17 mm flat spanner
3. Fit the side panels
Fig. 10 Fitting the hexagon nut
80
Carrying out a safety inspection
When is it re- A safety inspection is required:

quired? - After every repair
- Whenever something has been modified
- At set intervals (at least once a year)
Work instruc- The work instruction Safety Inspection of Arc Welding and Cutting Equipment is avai-
tions lable in the TechGuide DownloadCenter under Safety, Environment & Health.
81
Terms and abbreviations used
General remarks Terms and abbreviations is a glossary of specific technical terms essential for an
understanding of the service manual.
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 module supplements the UST PC board firmware (central control and regulati-
on unit) with individual, device-specific data.
DSP:
Digital SignalProcessor. Part of the UST 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
FAC:
Factory resets the settings in the setup menu. The original factory settings are
restored by pressing and holding the Store button for two seconds. The welding
machine has been reset when the display reads PrG. Jobs and parameter set-
tings in the second level of the set-up menu are not deleted.
IGBT:
Insulated Gate Bipolar Transistor. This is a special bipolar transistor used in high-
power switching applications. 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 error appears: the third level of the display contains more detailed
information on the cause of the error (see Error location aid chapter)
LocalNet RS232 converter:

For connecting the power source to the serial interface on a PC, for:
- uploading software options
- transmitting data from the power source using PC-based software (Fronius Backup,
Fronius Service Module, Job-Explorer, etc.)
82
TransTig 2500
TransTig 3000
MagicWave 2500
MagicWave 3000
MagicWave 2500 G/F 4,075,155 MagicWave 3000 G/F 4,075,157
MagicWave 2500 G/F US 4,075,155,800 MagicWave 3000 G/F US 4,075,157,800
TransTig 2500 G/F 4,075,151 TransTig 3000 G/F 4,075,153
TransTig 2500 G/F US 4,075,151,800 TransTig 3000 G/F US 4,075,153,800
MagicWave 2500 Job G/F 4,075,156 MagicWave 3000 Job G/F 14,075,158
MagicWave 2500 Job G/F US 4,075,156,800 MagicWave 3000 Job G/F US 4,075,158,800
TransTig 2500 Job G/F 4,075,152 TransTig 3000 Job G/F 4,075,154
TransTig 2500 Job G/F US 4,075,152,800 TransTig 3000 Job G/F US 4,075,154,800
MagicWave 2500 Comfort G/F 4,075,156,631 MagicWave 3000 Comfort G/F 4,075,158,631
MagicWave 2500 Comfort MV G/F 4,075,156,801 MagicWave 3000 Comfort MV G/F 4,075,158,801
TransTig 2500 Comfort G/F 4,075,152,631 TransTig 3000 Comfort G/F 4,075,154,631
TransTig 2500 Comfort G/F MV 4,075,152,801 TransTig 3000 Comfrt G/F MV 4,075,154,801
12,0405,0369
42,0201,2418
42,0406,0320
AM2,0201,2420
45,0200,1270
43,0004,0789
43,0004,2323 - MV
41,0003,0309
41,0003,0308
42,0406,0294
43,0001,0600 43,0002,0417 - MV
43,0002,0405
41,0003,0309 42,0001,3541
43,0013,0015
42,0300,1511
42,0407,0284
43,0001,1171 40,0001,0310 - *
42,0407,0532 - MV
43,0001,0600
42,0409,3197
41,0002,0059
41,0002,0060
41,0002,0060-MV 42,0409,3198 - MV
43,0001,1217
43,0001,1216 - TT2500 42,0405,0597
42,0405,0591
43,0001,1138
43,0006,0223
33,0005,4147 - TT2500
33,0005,4145
43,0001,1274 - MW 3000
42,0405,0591
41,0003,0279 - MW
43,0001,0600
41,0003,0203
41,0003,0291 - MW 3000
33,0005,0503
43,0001,1176 - TT
TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 1/2
el_fr_st_wi_01389 042008
43,0004,3830 - 26pol.
4,070,960,Z - UST2C
4,071,067,Z
T
N
4,071,068,Z
2
T
S
U
43,0001,3320
43,0006,0168
S
4,071,063,Z BP
4,071,064,Z - MV 33,0010,0366
RP
33,0010,0367
4,071,065,Z - MW2500
4,071,066,Z - MW3000
4,071,071 - TT3000
2 000
F2 V3
HF BS
42,0409,3196 - MW
42,0409,3195 - TT W
FM
43,0001,3318 - TT 2500/3000
43,0001,3319 - MW 2500/3000 4,070,812,Z - HFF22

33,0010,0377-TT2500
43,0001,3311 - MW
43,0001,3312 - MW JOB
43,0001,3313 - TT
43,0001,3314 - TT JOB
42,0406,0315 42,0405,0596 - MW
42,0405,0600 - TT
42,0406,0093
43,0004,2650
42,0001,1501
42,0001,5477 43,0004,2652
32,0405,0183 42,0404,0024
TT / MW 2500/3000 Job, TT / MW 2500/3000 Comfort

Ersatzteilliste / Spare parts list / Listes de pices de rechange / Lista de repuestos / Lista de pecas sobresselentes / Lista dei Ricambi 2/2
el_fr_st_wi_01389 042008
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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TransTig 2500 / 3000

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

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

CAUTION! Failure to connect a correctly-dimensioned earth lead may result in

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

Tools required - Box spanner (8 mm)

Measuring equip- - Digital multimeter

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

Protective gas shield

Protective gas shield

(2) Line filter (EMC):

(3) Primary rectifier:

(5) Intermediate circuit capacitors:

(7) Welding transformer:

(8) Secondary rectifier:

(9) Inverter (only MagicWave 2500 and MagicWave 3000):

(11) Welding current sensor:

Poor ignition and weld properties with

Poor ignition and weld properties with

No or incorrect welding current

Move the mains Insufficient welding torch cooling (FK

No lights on control panel

Open circuit voltage + 50 V faulty

Err 50 service code on the display

Table of service codes

Correct protective gas shield Connect correct protective gas

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

Welding process set correctly? Select correct welding process

Parameters set correctly? - Check settings on control panel

Check whether power source OK,

Welding torch and grounding Check welding torch and groun-

No lights on control panel? See section entitled No lights on

- Welding current Iset no longer Change current sensor A1 VAC

Check whether power source OK,

Cooling unit set-up parameters Switch C-C set-up parameter to

Sufficient coolant? Top up coolant; vent cooling unit

Pump rotating? Pump pressure OK?

Check cooling system (flow rate)

Coolant pump jammed? Turn pump using a screwdriver, if it

FKC/FKR 2500 PC board: Cooler Check cable harness, if OK

FKC/FKR 2500 PC board: Mains Check cable harness and fuse F1

400 VAC present on FKR 2500 PC Change water pump

FK 2500 Standard FK 2500 MV

Steady HS LED on the Check mains cable,

Steady +24V int/ext Switch power source

Steady +24V int/ext Change the A3 NT

Switch power source

Steady +24V int/ext Change A2 BPS 3000/

Check cooling unit

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

Unplug X4 from UST

Steady +5V, +15V, -

Unplug X2 from UST

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

Unplug X6 from UST

Steady +5V, +15V, -

Open circuit voltage for selected

From here onwards, troubleshooting only applies to MagicWave 2500/3000

Steady +5 V, +18V, +24V LEDs on

Check secondary power module