Transtig 2200 Magicwave 1700 / 2200 FK 2200: Service Manual Spare Parts List GB

TransTig 2200
Service Manual
MagicWave 1700 / 2200 GB
Spare Parts List
FK 2200 TIG power source
42,0410,1121 022003
Contents
Foreword and safety warnings ...................................................................................................................... 4
Safety ....................................................................................................................................................... 4
General remarks ...................................................................................................................................... 4
Tools and measuring instruments ............................................................................................................ 4
Functional description .............................................................................................................................. 4
Troubleshooting guide .............................................................................................................................. 5
Detailed explanation ................................................................................................................................. 5
Exchanging assemblies ........................................................................................................................... 5
Terms and abbreviations used ................................................................................................................. 5
Spare parts list and overall circuit diagram ............................................................................................... 5
Tools and measuring instruments ................................................................................................................. 6
General remarks ...................................................................................................................................... 6
Tools needed ............................................................................................................................................ 6
Measuring and testing equipment ............................................................................................................ 7
Auxiliary materials .................................................................................................................................... 7
Functional description ................................................................................................................................... 8
General remarks ...................................................................................................................................... 8
Block diagram .......................................................................................................................................... 8
Legend for block diagram ........................................................................................................................ 9
Troubleshooting guide ................................................................................................................................. 10
General remarks .................................................................................................................................... 10
Diagnostic search tree ................................................................................................................................. 11
Overview ................................................................................................................................................. 11
Poor ignition and welding properties in TIG welding ............................................................................ 12
Poor welding properties in Rod-electrode (MMA) welding ................................................................... 13
No welding current, or incorrect welding amperage ............................................................................... 14
Torch not being cooled adequately ......................................................................................................... 15
Control panel remains dark .................................................................................................................... 17
Open-circuit voltage is faulty .................................................................................................................. 21
Table of service codes ........................................................................................................................... 22
Special indications in connection with service codes ............................................................................. 27
Detailed explanation .................................................................................................................................... 28
General remarks .................................................................................................................................... 28
Overview ................................................................................................................................................ 28
BPS 17 - power-module board .................................................................................................................... 29
General remarks .................................................................................................................................... 29
Functional description ............................................................................................................................ 29
Connector pin assignment ..................................................................................................................... 30
Measuring points .................................................................................................................................... 31
LED checklist ......................................................................................................................................... 32
BPS 22 - power-module board .................................................................................................................... 33
General remarks .................................................................................................................................... 33
LED checklist ......................................................................................................................................... 36
HFF22 - high-frequency ignition unit, input filter .......................................................................................... 37
General remarks .................................................................................................................................... 37
LED checklist ......................................................................................................................................... 39
1
NTFK 24 - switched-mode power supply for the cooling unit ...................................................................... 40
General remarks .................................................................................................................................... 40
LED checklist ......................................................................................................................................... 42
Secondary power module ............................................................................................................................ 43
General remarks .................................................................................................................................... 43
LED checklist ......................................................................................................................................... 43
Shunt ........................................................................................................................................................... 44
General remarks .................................................................................................................................... 44
Special features ..................................................................................................................................... 44
TP 592S temperature sensor ...................................................................................................................... 45
General remarks .................................................................................................................................... 45
TTS 22 - IGBT driver and auxiliary voltage source ...................................................................................... 46
General remarks .................................................................................................................................... 46
LED checklist ......................................................................................................................................... 47
UST2B - control and regulation unit ............................................................................................................ 48
General remarks .................................................................................................................................... 48
LED checklist ......................................................................................................................................... 50
Exchanging the UST2B p.-c. board ........................................................................................................ 50
Exchanging assemblies .............................................................................................................................. 51
General remarks .................................................................................................................................... 51
Overview ................................................................................................................................................ 51
Housing ....................................................................................................................................................... 52
General remarks .................................................................................................................................... 52
Opening the housing .............................................................................................................................. 52
Closing the housing ................................................................................................................................ 53
Exchanging the BPS 17 board .................................................................................................................... 55
Note ....................................................................................................................................................... 55
Exchanging the BPS 22 board .................................................................................................................... 55
Note ....................................................................................................................................................... 55
Exchanging the inverter module .................................................................................................................. 55
Note ....................................................................................................................................................... 55
Exchanging the TP 592S temperature sensor ............................................................................................ 55
Note ....................................................................................................................................................... 55
Exchanging the power-section fan .............................................................................................................. 56
Removing the old fan ............................................................................................................................. 56
Fitting the new fan .................................................................................................................................. 57
2
Exchanging the control-system fan ............................................................................................................. 59
Removing the old fan ............................................................................................................................. 59
Fitting the new fan .................................................................................................................................. 61
Exchanging the TTS 22 board ..................................................................................................................... 63
ESD precautions .................................................................................................................................... 63
Removing the old TTS 22 board ............................................................................................................ 63
Fitting the new TTS 22 board ................................................................................................................. 65
Exchanging the BSV 22 board .................................................................................................................... 67
ESD precautions .................................................................................................................................... 67
Removing the UST2B board .................................................................................................................. 67
Removing the old BSV 22 board ............................................................................................................ 68
Fitting the new BSV 22 board ................................................................................................................. 69
Fitting the UST2B board ......................................................................................................................... 70
Exchanging the earth fault-current watchdog .............................................................................................. 71
Removing the old earth fault-current watchdog...................................................................................... 71
Fitting the new earth fault-current watchdog .......................................................................................... 72
Exchanging the transformer ........................................................................................................................ 73
Removing the old transformer ................................................................................................................ 73
Fitting the new transformer .................................................................................................................... 77
Terms and abbreviations used .................................................................................................................... 83
General remarks .................................................................................................................................... 83
Terms and abbreviations ........................................................................................................................ 83
Overall circuit diagram
Spare-parts lists
Fronius worldwide
3
Foreword and safety warnings
Safety The following safety warnings apply to all the actions described in this Service Manual:
Warning! Work that is not carried out correctly can cause serious injury and
damage. All the actions described in the Service Manual may ONLY be carried
out by skilled, Fronius-trained service technicians. Observe and follow the
section headed Safety rules in the Operating Instructions manual for the
power source.
Warning! An electric shock can be fatal. Before opening up the machine

- Shift the mains switch into the O position
- Unplug the machine from the mains
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, check to make sure that
electrically charged components (e.g. capacitors) have been discharged
Warning! An electric shock can be fatal. If the unit has to be briefly switched on
for testing while its housing is still open:
- Do not touch any parts inside the housing
- except with suitable measuring probes or test-prods
Caution! Inadequate PE conductor connections can cause serious injury and

damage. The housing screws provide a suitable PE conductor connection for
earthing (grounding) the housing and must NOT be replaced by any other
screws which do not provide a reliable PE conductor connection.
General remarks The latest version of the Service Manual is always available as an Adobe Acrobat PDF
file which can be downloaded free of charge from the TechGuide site:
www.fronius.com\techguide.
Each section of the Service Manual deals with a separate topic that is complete in itself.
Use each of these sections as a self-contained information source. There follows a brief
description of the various sections:
Tools and Here you will find an overview and description of all the resources that you will need in
measuring order to service the power source properly. These include:
instruments - Tools
- Measuring and testing equipment
- Auxiliary materials
Functional Contains a brief description of the system as a whole, giving you an overview:
description - in words
- with the aid of a block diagram
4
Troubleshooting Helps you to systematically track down and remedy the causes of faults. Contains the
guide following elements:
- The actual diagnostic search tree, for dealing with general faults
- Table of service codes for dealing with errors in connection with service codes
appearing on the display
Detailed Contains in-depth explanations on the relevant assemblies in the power source.
explanation
For each assembly, the following topics are discussed:
- General points (designation and article number of the assemblies)
- Functional description
- Measuring points (connector pin assignment)
- LED checklists
- Possible settings and adjustments
Exchanging Exchanging assemblies describes how to exchange components which

assemblies - do not come with any attached instructions explaining how to exchange them, and
which
- require a complete description of the exchange procedure
Terms and Contains explanations of key technical terms and abbreviations to help you understand
abbreviations the Service Manual better
used
Spare parts list The sections headed Spare parts list and Overall circuit diagram contain the entire
and overall spare-parts lists and the complete circuit diagram of the power source.
circuit diagram
5
Tools and measuring instruments
General remarks Tools and measuring instruments gives you an overview and description of all the
resources that you will need in order to service the machine properly. These include:
- Tools
- Measuring and testing equipment
- Auxiliary materials
Tools needed
(11) (18)
(3)
(9) (5) (12)
(10)
(6) (17) (2)
(9)
(10)
(1) (7) (8) (16) (15) (14) (13) (4)

Fig. 1 Tools needed
1. Socket spanner (8 mm)

2. Pointed pliers, large (approx. 160 mm)
3. Side-cutting pliers, small
4. Manual torque screwdriver (1-6 Nm, 42,0411,0013)
5. Screwdriver (small) for slot-type screws
6. Screwdriver (medium) for slot-type screws
7. Phillips-type screwdriver (PH1)
8. Phillips-type screwdriver (PH2)
9. Torx screwdriver (TX20)
or bit-insert for manual torque screwdriver (4)
10. Torx screwdriver (TX 25)
or bit-insert for manual torque screwdriver (4)
11. Spanner for hexagon socket head screw (5 mm)
12. Spanner for hexagon socket head screw (6 mm)
13. Fork spanner (13 mm)
16. Oeteker pliers
17. Molex remover tool (42,0410,0290)
18. Applicator for heat-transfer compound (42,0435,0020)
6
Measuring and 1. Digital multi-meter
testing 2. PC with MS Windows operating system
equipment (the system requirements can be found in the software manual for BSL-Tool)
3. BSL-Tool (4,050,082)
4. LocalNet RS 232 converter (4,100,262)
Auxiliary
materials
(1)
(2)
(3)
Fig. 2 Tools and resources
1. Contact spray (40,0009,0014) or alcohol-based solvent

2. Heat-transfer compound (40,0009,0043)
3. Grinding paper (42,0410,0436) with grain P 500 or finer
7
Functional description
General remarks Functional description explains the fundamental functional principle of the MagicWave
1700/2200 and TransTig 2200 power sources with the aid of a block diagram.
Block diagram
Welding torch
Workpiece
Remote-control unit
Torch control lead
LocalNet
(12)
Iact
HF transformer
(11)
HF
Welding current
sensor
(10)
HF generator
Uact
Control panel
regulation unit
Control and
(9)
Inverter
Control lead
*
module
Secondary power
(1)
(8)
Secondary rectifier
Control lead
(7)
Welding transformer
24 V supply
Power pack
** only on MagicWave 2200 and TransTig 2200 power sources
Switching (6)
transistors
only on MagicWave 1700 and MagicWave 2200 power
(5)
24 V
Indirect capacitors
(4)
PFC (Power Factor

**
Control)
Primary power
module
(3)
Primary rectifier
sources
230 V
(2)
Mains filter
*
Fig. 3 Block diagram of the MagicWave 1700, MagicWave 2200 and TransTig 1700/2200 power sources
8
Legend for block (1) Control and regulation unit:
diagram This not only controls but also regulates and monitors the welding process and all
power-source functions.
(2) Mains filter (EMC):

This is for attenuating any undesirable high-frequency ripple.
(3) Primary rectifier:

Converts the input voltage (mains voltage) into a rectified indirect voltage.
(4) PFC (Power Factor Control, only on MagicWave 2200 and TransTig 2200):
ensures sine-wave current input, for
- helping to achieve optimum efficiency
- preventing disturbances to the mains network
(5) Indirect capacitors:

These help to store and smooth the indirect voltage.
(6) Switching transistors:

The switching transistors transmit the indirect voltage in intervals, and at high
frequency, to the primary winding of the transformer. The high frequency means that
- the transformer can be built to be very lightweight and compact
- the thermal losses due to the low required inductivity of the transformer windings
can be kept extremely small
(7) Welding transformer:

- transforms the high primary voltage into a low secondary voltage
- ensures that the primary power module and secondary power module are
galvanically separated
(8) Secondary rectifier:

Converts the secondary voltage into a direct voltage
(9) Inverter (only on MagicWave 1700 and MagicWave 2200):

Converts the DC current into AC current for the TIG-AC welding operating mode
(10) HF generator:
For non-contacting HF (high-frequency) ignition, the HF generator produces the
high-frequency primary voltage of the HF-transformer (12).
(11) Welding current sensor:

This detects the instantaneous actual amperage value for the welding process
(12) HF transformer:
For non-contacting HF (high-frequency) ignition, the HF transformer transmits high-
voltage pulses to the welding circuit.
9
Troubleshooting guide
General remarks The Troubleshooting guide consists of the following parts:

- Diagnostic search tree
- Table of service codes
The diagnostic search tree helps you to systematically track down and remedy the
causes of faults. The Table of service codes lists the service codes shown on the
display, telling you what caused the fault and how to remedy it.
Before starting to use the Troubleshooting guide, first read the Functional description
and study the overall circuit diagram in order to gain an understanding of the structure
and mode of functioning of the power source.
Important! If you do not yet have a great deal of experience with error diagnostics and
troubleshooting on the MagicWave 1700 / 2200 and TransTig 2200 power sources:
Before you start work with the Troubleshooting guide, read the following sections of this
manual:
- Overall circuit diagram
10
Diagnostic search tree
Overview The overview below will help you find which branch of the diagnostic search tree to
start looking in.
The positions and meanings of the LEDs for the assemblies and p.-c. boards can be
found in the section headed Detailed explanation. This section (Detailed explanation)
contains an LED checklist for each of the various assemblies and p.-c. boards (with
LEDs).
Poor ignition and welding properties

where the TIG welding process has
been selected
Poor welding properties where the

Rod-electrode (MMA) welding
process has been selected
Mains switch in the No welding current, or the welding

On position current does not correspond to the
value set for Ides
Insufficient cooling of the welding torch
Control panel remains dark
No open-circuit voltage
Service codes in the display
11
Poor ignition and
welding Start
properties in
TIG welding
Is the right shielding gas Connect up the right shielding gas

connected up, and the right l/min and check l/min
set? No
Yes
Gas-test button: Is shielding gas Check the shielding-gas solenoid

flowing out? valve, including the addressing
No
Yes
Are the welding torch and Check the welding torch and
grounding (earthing) cable OK? grounding (earthing) cable
No
Yes
Parameters set correctly? - Check the settings on the

No control panel
- Check the set-up parameters
- If necessary, restore the factory
settings (FAC) (see instruction
manual)
Yes
When the Rod-electrode (MMA) See Open-circuit voltage is faulty

welding process is selected, does
the open-circuit voltage = 50 V No
(+/- 1 V) ?
Yes
Power source is OK; check the

application
End
12
Poor welding
properties in Start
Rod-electrode
(MMA) welding
Are the electrodes and grounding Connect up the cables correctly

(earthing) cable connected No
correctly and in good working order
?
Yes
Has the right process been set? Select the correct process
No
Yes
Parameters set correctly? - Check the settings on the

No control panel
- Check the set-up parameters
- If necessary, restore the factory
settings (FAC) (see instruction
manual)
Yes

(+/- 1 V ?
Yes

application
End
13
No welding
current, or Start
incorrect welding
amperage
Are the welding torch and Check the welding torch and
grounding (earthing) cable grounding (earthing) cable
No
connected correctly and in good
working order ?
Yes
Control panel remains dark ? See Control panel remains dark

Yes
No

(+/- 1 V ?
Yes
- Welding amperage Ides can no Change current sensor A1 VAC

longer be adjusted, or Yes
- Welding amperage is always
Imax ?
No

application
End
14
Torch not being
cooled Start
adequately
In set-up, is the cooling unit set to In set-up, change the setting to

Off ? Auto or On
Yes
No
Switch off the power source
Enough coolant ? Top up with coolant, then vent the

No cooling unit
Yes
Coolant-pump fuse OK? Change the fuse (for one of the

same rating)
No
Yes
Coolant pump blocked ? Using a screwdriver, slightly turn

Yes the shaft of the coolant pump.
If the pump is difficult to turn,
replace it with a new pump so as
not to overload the power pack.
No
Unplug X4 on the power pack A1

NTFK24, switch on the power
source; in set-up, change the
cooling-unit setting to On
15
Torch not being
A
cooled
adequately
(continued)
Is the Power LED on power pack Check fuse F1 and the 230 V AC
A1 NTFK24 always lit up? voltage supply on power pack A1
No NTFK24 X2. Change power pack
A1 NTFK24
Yes
Is the On LED on power pack A1 Voltage on power pack A1 NTFK24

NTFK24 lit up ? X3/2, X3/8 < 1 V DC
No
No
Check the cable harness, change

controller A5 UST2B in the power
source
Yes Yes
Are LEDs +15V, +24V, + 24V OK Change power pack A1 NTFK24

on power pack A1 NTFK24 always
lit up ? No
Yes
Change the coolant pump and/or

fan
End
16
Control panel
remains dark Start
Is LED UZWK on power-module Check mains cable, mains switch,

board A2 BPS 17 / BPS 22 always supply voltage
No
lit up?
Yes
Are the LEDs for supply voltage on Change control panel A6 FP 22

power-module board A2 BPS 17 /
Yes
BPS 22 and on control board A5
UST2B always lit up ?
No
- Shift the mains switch to the

Off position
- Disconnect the plugs from
control board A5 UST2B:X3, X6
On position
Are the LEDs for supply voltage on Change power-module board A2

power-module board A2 BPS 17 / BPS 17 / BPS 22
No
BPS 22 always lit up ?
Yes

Off position
- Connect the plug to control
board A5 UST2B:X3
On position
17
Control panel
A
remains dark
(continued)
Are the LEDs for supply voltage on Change power-module board A2

control board A5 UST2B always lit BPS 17 / BPS 22
Yes
up ?
No

"Off" position
- Connect plug X6 to control
board A5 UST2B
- Disconnect plugs X1, X2, X4,
X7, X9, X10 from control board
UST2B
"On" position
Are the LEDs for supply voltage on Change control board A5 UST2B
control board A5 UST2B always lit No
up ?
Yes
Connect plug X1 to control board

A5 UST2B
Are the LEDs for supply voltage on Change p.-c. board A4 TTS22
control board A5 UST2B always lit (driver for inverter)
No
up ?
Yes
18
Control panel
B
remains dark
(continued)

A5 UST2B
Are the LEDs for supply voltage on Change control panel A6 FP22
control board A5 UST2B always lit
No
up ?
Yes

A5 UST2B
Are the LEDs for supply voltage on Change current sensor A1 VAC
control board A5 UST2B always lit No
up ?
Yes

A5 UST2B
Are the LEDs for supply voltage on Check FK 2200 cooling unit
control board UST2B always lit up No
?
Yes
19
Control panel
C
remains dark
(continued)
Connect plugs X9, X10 to control

board A5 UST2B
Are the LEDs for supply voltage on Change p.-c. board A7 HFF22 (HF
control board A5 UST2B always lit generator / filter)
up ? No
Yes

application
End
20
Open-circuit
voltage is faulty Start
Is there any open-circuit voltage - Change p.-c. board A4 TTS22

when the Rod-electrode (MMA) (driver for inverter)
welding process is selected ? - Change p.-c. board A3 BSV22
Yes
(for voltage doubling)
No
From this point on, the error diagnostics apply only to the MW
1700/2200:
- Check p.-c. board A4 TTS22 Change p.-c. board A4 TTS22

(driver for inverter) (see Detailed (driver for inverter)
explanation) No
- Are LEDs +5 V, +18V, +24 V
always lit up ?
- If the polarity is changed with
the Process button: Does the
LED Neg./pos. ignition light up ?
Yes
Exchange inverter module A3
End
21
Table of service For every service code, this table tells you
codes - how the service code is indicated (e.g. Err | Arc)
- the code n(e.g. where the service code is outputted via a robot interface)
- what has caused the service code to be displayed
- appropriate ways of remedying the problem
dsP | Axx (Code n 20)

Cause: DSP outputs a general error, xx stands for additional data that are not
necessary for external service
Remedy: Update software. Change p.-c. board UST2.
dsP | A21 (Code n 20)

Cause: The power source is configured for either parallel operation (set-up
parameter P-C is set to ON) or for TimeTwin Digital (set-up parameter T-
C is set to ON). However, the LHSB link has been disconnected, or has
become faulty, while the power source was switched on.
Remedy: Dismiss the service code: Switch the power source off and back on again.
If necessary, restore or repair the LHSB link.
dsP | Cxx (Code n 29)

Cause: DSP SoftCom error; xx stands for additional data that are not relevant for
external service
dsP | E05 (Code n 17)

Cause: DSP outputs internal error
dsP | Exx (Code n 21)

Cause: DSP outputs a general error, xx stands for
1 Timeout during booting
2 EOF error during booting
3 Data-channel error (selection of power module)
4 Com-channel error (selection of power module)
5 Timeout during EM Stop command
dsP | Sy (Code n 35)

Cause: Internal error (version conflict)
dsP | nSy (Code n 36)

Cause: Internal error (version conflict)
EcF | xxx (Code n 32)

Cause: BPS configuration error, x stands for:
1 TPS 2700 has wrong power module
2 TS/TPS/TP 4000 has wrong power module
3 TS/TPS/TP 5000 has wrong power module
4 TT 2200 or MW 2200 has wrong primary power module
5 MW 1700 has wrong primary power module
253 This configuration only functions from UST2A V1.3 A upward
254 This configuration only functions with a UST p.-c. board of version
UST2A and upward
255 Unknown primary power module
Remedy: Install the right primary power module
22
Table of service
EFD | xx.y (Code n 30)
codes
(continued) Cause: Fault in the wirefeed system; xx and y can be seen from the list of service
codes for the wirefeed system.
Remedy: Check the wirefeed system
EIF | xx.y (Code n 63)

Cause: Error in connection with a robot interface; xx and y can be seen from the list
of service codes for your robot interface.
Remedy: Check robot interface, update software, change robot interface
Err | Arc (Code n 61)

Cause: Only with DPS 5000: DPS has detected arc formation
Remedy: Check the application
Err | bPS (Code n 18)

Cause: DSP outputs internal error
Remedy: Update software. Change p.-c. board UST2. Change p.-c. board BPS.
Err | Cfg (Code n 72)

Cause: Power source is configured for parallel operation (set-up parameter P-C is
set to ON) or TimeTwin Digital (set-up parameter T-C is set to ON.
However, after being switched on, the power source was unable to estab-
lish an LHSB link (LHSB link was previously detached or became faulty).
Remedy: Dismiss the service code: Switch the power source off and back on again.
If necessary, restore or repair the LHSB link.
Err | EPF (Code n 22)

Cause: Error during Flex booting
Err | IP (Code n 19)

Cause: DSP reports primary overcurrent
Remedy: Check secondary power module. Change primary power module.
Err | Jo (Code n 67)

Cause: JobMaster temperature sensor faulty
Remedy: Change JobMaster welding torch
Err | Lic (Code n 40)

Cause: Faulty licence key
Remedy: Check the licence key. Check and update the enabling codes.
Err | PE (Code n 53)

Cause: Earth-fault error
Remedy: Eliminate the earth fault. Mount the installation in such a way that it is
insulated from earth.
Err | tF1 (Code n 11), Err | tF2 (Code n 12), Err | tF3 (Code n 13), Err | tF4 (Code n
14), Err | tF5 (Code n 15)
Cause: Temperature-sensor defect (short circuit or break in circuit)
Remedy: Check the cable harness and change the relevant temperature sensor
Err | tF6 (Code n 16)

Cause: Error on p.-c. board BPS or in the link to p.-c. board BPS
Remedy: Check the ribbon cable. Change p.-c. board BPS.
23
Table of service
codes
(continued) Cause: Temperature-sensor error on UST
Remedy: Change p.-c. board UST

Cause: in conjunction with the optional thermostat: Fault in cooling-unit
temperature sensor
Remedy: Check cable harness. Change temperature sensor.
Err | 027 (Code n 27)

Cause: One of the supply voltages is outside the tolerance range
Remedy: Change UST
Err | 049 (Code n 49)

Cause: Phase failure
Remedy: Check mains fuse protection, mains supply lead and mains plug
Err | 050 (Code n 50)

Cause: Intermediate voltage-circuit balance error
Remedy: Check the indirect capacitors. Change p.-c. board BPS.
Err | 051 (Code n 51)

Cause: Mains undervoltage: The mains voltage has dropped below the tolerance
range
Remedy: Check the mains voltage
Err | 052 (Code n 52)

Cause: Mains overvoltage: The mains voltage has risen above the tolerance range
Remedy: Check the mains voltage
Err | 054 (Code n 54)

Cause: Wire stick check has been triggered
Remedy: Eliminate the short circuit on the welding wire
Err | 056 (Code n 56)

Cause: In conjunction with wirefeeder and optional wire-end check: No more wire
available
Remedy: Insert a new wire-spool
Err | 059 (Code n 59)

Cause: Overvoltage in the secondary circuit: Safety cut-out has been triggered
Remedy: Check the secondary circuit incl. p.-c. board TP4CEL40
Err | 060 (Code n 60)

Cause: Only DPS5000: SITRE1A has triggered the safety switch due to an open
door contact
Remedy: Safety cut-out: Close the door contact
Err | 062 (Code n 62)

Cause: Overtemperature in TP08 remote-control unit
Remedy: Allow the TP08 to cool down. Change the TP08.
24
Table of service
Err | 068 (Code n 68)
codes
(continued) Cause: Secondary-circuit safety cut-out has been triggered
Remedy: Change the TTS board
Err | 069 (Code n 69)

Cause: Illegal change of operating mode or process during welding
Remedy: Re-ignite the arc
Err | 23.x (Code n 23)

Cause: Config memory (CFM) error on p.-c. board UST2B; x stands for:
1 Config memory not found
2 Checksum error
3 CFM not described
5 Unknown type of board
8 Invalid identifier (UST1 instead of UST2)
Remedy: Update software. Change the UST2B p.-c. board.
2 Err | 24.x (Code n 24)

Cause: Config memory (CFM) error on p.-c. board BPS; x stands for:
2 Checksum error
3 CFM not described
Remedy: Check the ribbon cable. Change p.-c. board BPS.
2 Err | 25.x (Code n 25)

Cause: Config memory (CFM) error on alternator; x stands for:
2 Checksum error
3 Never been tested
4 Test was not OK
Remedy: Change TTS

Cause: Config memory (CFM) error on machine; x stands for:
2 Checksum error
3 CFM not described
Remedy: Check cable harness. Change config memory on the cable harness of the
power source.

Cause: EEProm memory error
25
Table of service
codes
(continued) Cause: Error in connection with optional Digital Gas Control; x stands for:
1 No sensor found
2 No shielding gas
3 Calibration error
4 Shielding-gas solenoid valve: interruption or short circuit
5 No shielding-gas solenoid valve found
Remedy: for cause x
1 Check cable harness, change shielding-gas sensor
2 Check shielding-gas supply (min. 2 bar)
3 If no shielding gas, or too little, change the shielding-gas solenoid valve
4 Change the shielding-gas solenoid valve and shielding-gas sensor
5 Check the cable harness, change the shielding-gas solenoid valve
hot | H2O (Code n 65)

Cause: in conjunction with the optional thermostat: Overtemperature in the cooling
system
Remedy: Allow the cooling unit to cool down. Open the cooling unit and clean the
heat exchanger.
no | Arc (Code n 58)

Cause: Arc has broken, arc-break watchdog has been triggered
Remedy: Check welding parameters. Re-ignite the arc. Check the earth (ground
connection).
no | GAS (Code n 57)

Cause: In conjunction with the optional Digital Gas Control: No shielding gas
available
Remedy: Check the shielding-gas supply
no | H2O (Code n 39)

Cause: Rate-of-flow watchdog reports insufficient coolant
Remedy: Check the cooling unit
no | Ign (Code n 55)

Cause: Ignition time-out error: No ignition has taken place within the value (length
of wire) specified in the Set-up menu. The safety cut-out has been
triggered.
Remedy: Clean the surface of the workpiece. Check the parameters in the Set-up
menu. Check the earth (ground connection).
no | Prg (Code n 1)
Cause: No stored program selected
Remedy: Select a stored program
Stop (Code n 38)

Cause: Robot not ready
Remedy: When using a robot interface or a field-bus coupler, set the signals Robot
ready and Source error reset.
tJo | xxx (Code n 66)

Cause: Overtemperature in JobMaster
Remedy: Allow the installation to cool down. Check the cooling system.
26
Table of service
tp1 | xxx (Code n 5), tp2 | xxx (Code n 6), tp3 | xxx (Code n 7), tp4 | xxx (Code n
codes
8), tp5 | xxx (Code n 9)
(continued)
Cause: Overtemperature in the primary circuit of the power source (XXX stands for
temperature display)
Remedy: Allow the power source to cool down. Check whether the fan is running.
tp6 | xxx (Code n 10)

Cause: Overtemperature in the primary circuit of the power source, temperature
sensor on p.-c. board BPS has been triggered (XXX stands for temperature
display)
ts1 | xxx (Code n 2), tS2 | xxx (Code n 3), tS3 | xxx (Code n 4)
Cause: Overtemperature in the secondary circuit of the power source (XXX stands
for temperature display)
tSt | xxx (Code n 33)

Cause: Overtemperature in the control circuit, xxx stands for temperature display
Remedy: Allow the power source to cool down. Check the fan.
US | POL (Code n 37)

Cause: Measuring system for secondary voltage (Usec) either has reversed polarity
or is faulty
Remedy: Check cable harness. Change p.-c. board UST2.
Special The following service codes are special indications in the event of software problems:
indications in
connection with - And | Opc - STK | OVL
service codes - Prt | Flt - STK | UVL
- Ill | Opa - Err | Dog
- Ill | Ina - ASS | Ert
- Ill | Bus - Edg | 1
- Err | 105
If any of these service codes appear, you can access more detailed information on the
control panel of the power source. By pressing the parameter selection buttons (arrow
left / arrow right), you can change between the following display levels:
- Level 1 (e.g. Und | Opc): Display of service codes
(appears automatically)
- Level 2 (e.g. CS 01): Display of segments
(by pressing the parameter selection button once)
- Level 3 (e.g. IP 3456): Instruction-Pointer
(by pressing the parameter selection button several times)
Important! Please make a note of the data displayed in Level 1, Level 2 and Level 3,
and give this information to Fronius. These data will enable Fronius able to localise the
exact cause of the fault.
27
Detailed explanation
General remarks Detailed explanation contains an in-depth description of the electronic assemblies,
taking in the following points:
- General remarks (designation, article number)
- Measuring points (connector pin assignment if required)
- LED checklists
- Possible settings and adjustments
Overview The following assemblies will be described on the following pages:

- BPS 17 - power-module board
- BPS 22 - power-module board
- HFF 22 - high-frequency ignition unit, input filter
- NTFK 24 - switched-mode power supply for the cooling unit
- Secondary power module
- Shunt + adapter
- TP 592 S
- TTS 22 - IGBT driver and auxiliary voltage source
- UST2B - control and regulation unit
28
BPS 17 - power-module board
General remarks BPS 17 (article number 4,070,798) is the power-module board for the MW 1700 power
source.
Functional
Input voltage 230 VAC (+15 % / -20 %)
description
Supply voltage from power pack 24 Vint (+/-20 %), 2.5 A
24 Vext (+/-20 %), 1.5 A
15 Vp (+10 %), 0.2 A
Components on board BPS 17
(5) (1)
(3)
(4)
(6)
(2)
Fig. 4 Components on the BPS 17 power-module board
The following components are to be found on the BPS 17 p.-c. board:

(1) Mains filter
(2) Rectifier
(3) Capacitor charging circuit
(4) Indirect capacitors
(5) Switched-mode power supply (+24 V internal, +24 V external)
(6) Power full bridge
The BPS 17 p.-c. board also features a safety-relevant primary/secondary isolating point.
29
Functional (1) Mains filter
description The mains filter is located in the AC branch and is configured in two stages. The mains
(continued) filter is for attenuating the disturbance produced in the unit vis--vis the mains supply
lead.
(2) Rectifier
The rectifier produces a direct voltage for the intermediate voltage circuit from the input
voltage (mains voltage).
(3) Switched-mode power supply

The switched-mode power supply is a flyback converter which is supplied by the indirect
capacitors. The switched-mode power supply is clocked to 65 kHz and supplies output
voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); The 15 Vp-
winding is not insulated from the primary (mains) voltage and is only used for supplying
power internally to the PWM-ICs of the switched-mode power supply. The output
voltages are galvanically separated from one another and are each protected by PTC
resistors.

PTC resistors provide a limitation of the inrush current. The control system (p.-c. board
UST2B) specifies the capacitor-charging time. In order for the charging resistors to be
shunted out by means of relays, a permanently pre-set length of time has to have
elapsed, and a pre-set indirect-voltage value has to have been reached. The charging
resistors are shunted out - by means of relays - once
- the capacitor-charging time has elapsed
- a pre-set value for the indirect voltage has been reached

The indirect capacitors are for smoothing and stabilising the rectified input voltage.

The power full-bridge chops the rectified indirect voltage into a 100 kHz signal. The
bridge converter (with 4 power MOSFETs) is addressed by way of driver stages.
Connector pin X1 ...... (secondary), ribbon cable from UST2B (X6)

assignment
X3 ...... TRAFO2 (primary), connecting lead to the welding transformer
X9 ...... (L1 - phase - primary), connecting lead to the mains switch

X10 .... (N - PEN conductor - primary), connecting lead to the mains switch
30
Connector pin X28 .... (secondary), internal / external voltage supply
assignment
(continued) Pin Designation Pin Designation
1 +24 V-EXT, +24 V remote- 5 GND-EXT, remote-control
control unit connection GND
2 NC 6 NC
3 UZW, measuring of 7 GND-UZW, measuring of
indirect voltage indirect voltage
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply
Measuring points The measurements carried out on the diode paths illustrated below must each give a
result of approx. 0.4 V.
The illustration also shows the MSS (main-switch signal) LED and the CCS (capacitor
charging signal) LED (see the following section: Control LEDs).
MSS LED
CCS LED
Fig. 5 Diode paths on the BPS 17 power-module board
31
LED checklist Control LEDs on p.-c. board BPS 17
Uzwk
+15 Vp
CCS LED
+24 Vext +24 Vint MSS

Fig. 6 Control LEDs on power-module board BPS 17
LED
Uzwk .............. glows when supply is forthcoming from the intermediate circuit
LEDs for supply voltage:

+15 Vp ............. glows when the switched-mode power supply is working correctly
+24 Vext ........... glows when the switched-mode power supply is working correctly
+24 Vint ............ glows when the switched-mode power supply is working correctly
MSS LED ....... glows when the power source cuts out
CCS LED ........ glows when the capacitor-charging relay is closed
32
BPS 22 - power-module board
General remarks BPS 22 (article number 4,070,799) is the power-module board for the MW 2200 and TT
2200 power sources.
Functional
Input voltage 230 VAC (+15 % / -30 %)
description
Supply voltage from power pack 24 Vint (+/-20 %), 2.5 A
24 Vext (+/-20 %), 1.5 A
15 Vp (+10 %), 0.2 A
Components on board BPS 22
(1)
(2)
(8)
(3)
(4)
(7)
(5)
(6)
Fig. 7 Components on the BPS 22 power-module board
The following components are to be found on the BPS 17 p.-c. board:

(1) Mains filter
(4) Rectifier
(5) PFC (Power Factor Controller)
(6) Shunt
(8) Switched-mode power supply (+24 V internal, +24 V external)
33
Functional (1) Mains filter
description The mains filter is located in the AC branch and is configured in two stages. The mains
(continued) filter is for attenuating the disturbance produced in the unit vis--vis the mains supply
lead.

PTC resistors provide a limitation of the inrush current. The control system (p.-c. board
UST2B) specifies the capacitor-charging time. In order for the charging resistors to be
shunted out by means of relays, a permanently pre-set length of time has to have
elapsed, and a pre-set indirect-voltage value has to have been reached.

The indirect capacitors are for smoothing and stabilising the rectified input voltage.
(4) Rectifier
The rectifier produces a direct voltage for the intermediate voltage circuit from the input
voltage (mains voltage).
(5) PFC (Power Factor Controller)

The Power Factor Controller helps to achieve sine-wave mains-current input. Due to the
fact that practically no reactive current occurs, a very high degree of current input from
the single-phase network is possible.
(6) Shunt
This is for measuring mains current for the PFC.

The power full bridge produces a 100 kHz signal from the rectified indirect voltage. The
bridge converter (with 4 power MOSFETs) is addressed by way of driver stages.
(8) Switched-mode power supply

The switched-mode power supply is a flyback converter which is supplied by the indirect
capacitors. The switched-mode power supply is clocked to 65 kHz and supplies output
voltages of 24 Vint (max. 2.5 A), 24 Vext (max. 1.5 A) and 15 Vp (max. 0.2 A); The 15 Vp-
winding is not insulated from the primary (mains) voltage and is only used for supplying
power internally to the PWM-ICs of the switched-mode power supply. The output
voltages are galvanically separated from one another and are each protected by
PTC resistors.
34
Connector pin X1 ...... (secondary), ribbon cable from UST2B (X6)
assignment
X9 ...... (L1 - phase - primary), connecting lead to the mains switch

X10 .... (N - PEN conductor - primary), connecting lead to the mains switch
X28 .... (secondary), internal / external voltage supply
Pin Designation Pin Designation

1 +24 V-EXT, +24 V- 5 GND-EXT, remote-control
remote-control unit GND connection
connection
6 NC
2 NC
7 GND-UZW, measuring of
3 UZW, measuring of indirect voltage
indirect voltage
8 GND-INT, internal voltage
4 +24 V-INT, internal voltage supply
supply
Measuring points The measurements carried out on the diode paths illustrated below must each give a
result of approx. 0.4 V.
Fig. 8 Diode paths on the BPS 22 power-module board
35
LED checklist Control LEDs on p.-c. board BPS 22
PFC
LED
Uzwk
CCS
+15 Vp LED
MSS
LED
+24 Vext +24 Vint

Fig. 9 Control LEDs on power-module board BPS 22
Uzwk .............. glows when supply is forthcoming from the intermediate circuit
LEDs for supply voltage:

+15 Vp ............. glows when the switched-mode power supply is working correctly
+24 Vext ........... glows when the switched-mode power supply is working correctly
+24 Vint ............ glows when the switched-mode power supply is working correctly
MSS LED ....... glows when mains switch is in O position
CCS LED ........ glows when the power source cuts out
PFC LED ........ glows when Power Factor Controller (PFC) is working
36
HFF22 - high-frequency ignition unit, input filter
General remarks HFF 22 (article number 4,070,812) takes care of high-frequency ignition on the MW
1700 and MW 2200 power sources, at the same time as being a filter arrangement for
remote control units and torch triggers.
Functional
Supply voltage + 24 VDC (+/- 20 %)
description
Output voltage 1000 VDC
The following components are to be found on the HFF 22 p.-c. board:
(1) HF unit
Starting from the +24 V supply (green 24 V LED), the HF unit produces a +15V supply
(green + 15V LED) for the internal control section. A flyback-converter charging circuit
charges the pulsing capacitor from + 24 V to 1000 V. Immediately after this charging
operation, the ignition thyristor is addressed and the pulsing capacitor discharges via the
primary winding of the HF coupling coil. The HF coupling coil transforms the charging
voltage of the pulsing capacitor from 1000 V to approx. 10 kV. Every time the pulsing
capacitor is charged, this is indicated by the (red) SIG LED lighting up.
(2) Filter section

The filter section consists of two 6-pole current-compensated filter inductances (one for
the torch trigger and one for the remote-control unit). The filter inductances eliminate HF
pulses - caused by parasitic capacitances - in the data lines. A circuit arrangement with
capacitors and Transil arrays (protector diodes) ensures that overvoltages are
transferred out of the data lines.
Connector pin X1 ...... Plus-pole for HF pulse (tab connection to the primary side of the HF coupling
assignment coil)
X2 ...... Minus-pole for HF pulse (tab connection to the primary side of the HF coupling
coil)
X3 ...... HF-addressing leads (link to UST2B)

1 NC 3 SIGNAL
2 + 24 V 4 GND
37
Connector pin X4 ...... Torch-trigger leads (link to UST2B)
assignment
(continued)
1 NC 6 NC
2 DOWN 7 NC
3 CRATERFILL 8 IDENTIF
4 UP 9 GND
5 MAIN CURR 10 NC
X5 ...... Torch-trigger leads (link 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 unit leads (link to remote-control unit)

1 +24 V-EXT 4 GND 485
2 RXDL 485 5 TXDL 485
3 RXDH 485 6 TXDH 485
X7 ...... Remote-control leads (link to UST2B)

1 +24 V-EXT 4 GND 485
2 TXDL 485 5 RXDL 485
3 TXDH 485 6 RXDH 485
Measuring points See Connector pin assignment.
38
LED checklist Control LEDs on the HFF 22 p.-c. board
SIG
+24 V .............. glows when the supply is
present
+15 V
+15 V .............. glows when the internally
produced supply for the
control section is present +24 V
SIG ................. flashes while the pulsing

capacitor is being charged
(the frequency of flashing
will depend upon the pre-
set HF repetition time)
Possible causes of faults if the (red) SIG-

LED is dark or is glowing only very weakly:
- The control signal from the power
source is faulty (X3-Pin3)
- The charging circuit is faulty
- Secondary-side short circuiting of the
charging circuit (e.g. due to a
defective thyristor or free-wheeling
diode)
Fig. 10 Control LEDs on the HFF 22 p.-c. board
39
NTFK 24 - switched-mode power supply for the
cooling unit
General remarks NTFK 24 (article number 4,070,819) is the switched-mode power supply for the FK 2200
cooling-unit.
Functional Input voltage range 140 VAC ... 280 VAC

description 200 VDC ... 400 VDC
Output voltage 24 V (+/- 1 V), 5.5 A
(max. 30 V in open circuit)
Maximum current 5.5 A (protected by PTC resistors)
The following components are to be found on the NTFK 22 p.-c. board:
(1) Charging circuit

NTC resistors limit the charging current at the instant of closing. The resistors R58 and
R59 are NTCs, which become highly resistive (high-ohmic) in operation. For this reason,
an external glass-tube fuse with 4 A (slow-blow) is required, as NTCs do not limit any
fault currents which may occur.
(2) Addressing
If Pin X3:2 (=/Cooler On) is applied to signal earth, the cooling unit will start up.
(3) Controller for fan and coolant pump

The +24 V supply is protected by PTC resistors. If an overcurrent occurs, the PTCs
become high-ohmic. This function depends upon the extent of the overload and on the
ambient temperature (5.5 A at 60 C).
40
Functional (4) Coolant watchdog and undervoltage monitor
description
(continued) If no coolant watchdog has been installed, switch Pin X1:2 (/Watercontr.-Sig.) to signal
earth (GND) by using a shorting jumper.
The undervoltage-detection feature of the coolant-pump is also coupled to the coolant

watchdog. If the supply voltage to the coolant-pump is lower than 20 V (e.g. pump is
blocked), a message is sent to the UST2B controller board (service code).
The coolant watchdog itself is kept supplied by the power source. The signal voltages on
Pins X3 and X1, and the supply voltage to the coolant pump, are galvanically separated
from one another.
Connector pin X1 ...... Connection for coolant watchdog

assignment
1 +24V supply to coolant 3 GND
watchdog
2 Coolant watchdog signal 4 GND
(low-active)
X2 ...... Mains voltage (protected by external glass-tube fuse F1, 4 A - slow-blow)

1 Phase 2 PEN conductor
X3 ...... Link to power source

1 NC 6 NC
2 /Cooler On 0V = cooling 7 + 24 V - control supply
unit ON voltage from the power
source
3 /Watercontrol 0 V = 8 GND Watercontrol - GND
coolant-flow and supply for the control supply
voltage to coolant-pump voltage from the power
are OK source
4 NC
9 NC
5 NC
10 GND (+ 24 V) - GND for the
control supply voltage from
the power source
41
Connector pin X4 ...... Connection for the cooling-unit fan and coolant-pump
assignment
(continued) Pin Designation Pin Designation
1 +24 V coolant pump 4 GND coolant pump
2 +24 V fan 5 GND fan
3 LED+, external control 6 GND LED
LED
Measuring points See Connector pin assignment
LED checklist
+15 Vp
Power
+24 VOK
+24 V
ON
Fig. 11 Control LEDs on the NTFK 24 board
Power ............. Mains voltage available

+15 Vp ............. Supply for PWM-IC available
+24 VOK ......... The supply voltage to the coolant-pump is greater than 20 V
+24 V .............. Pump and fan voltage is available
ON .................. External signal for switching-on the coolant-pump is available
42
Secondary power module
General remarks The secondary power module contains the following components:
- 4 rectifier diodes of type DIOSIL 300 400 100 ISOTO SF (article number
41,0003,0203)
- MW 2200 inverter, tested (article number 41,0003,0282,Z)
Functional The rectifier produces a direct voltage from the current delivered by the welding
description transformer.
Important! The following description only applies to MagicWave 1700/2200.
The transistor modules on the inverter module transform the direct voltage into an AC
current which is then fed to the welding sockets. The transistor modules are addressed
by way of p.-c. board TTS 22.
Connector pin Important! The following description only applies to MagicWave 1700/2200.
assignment
X8 ...... Link from the inverter module to the TTS 22.
Measuring points The measurements carried out on the diode paths illustrated below must give approx.
the following results:
- 0.4 V on the inverter module (A)
- 0.1 V on the rectifier diodes (B)
Tightening torques:
- Copper bracket to diodes: 1.5 Nm
- Diode to heat-sink: 2 Nm
(B) (B) (A)
LED for welding current

LED for welding current
(B) (B)
Fig. 12 Diode paths on the secondary power module
Important! TransTig 2200 power sources only have two diode-modules.
LED checklist See Fig.12 Diode paths on the secondary power module
43
Shunt
General remarks The shunt (article number 43,0001,1191)

is a current sensor that is used for
galvanically separated acquisition of the
welding current.
Fig. 13 Shunt for acquiring the welding current
Functional The shunt works on the compensation principle, with a magnetically-soft probe serving
description as the magnetic-field detector. This shunt stands out for the following main features:
- compact design
- low offset current
- low hysteresis
- high temperature-stability
- integrated electronics
The shunt is supplied with a bipolar operating voltage of +/- 15 V and delivers an output
signal which is proportional to the measured welding current. The transmission ratio
between output signal and welding amperage is 1:2000.
Connector pin X1 ...... Molex connector on adapter cable

assignment
1 NC 5 NC
2 NC 6 NC
3 Iact 100 A corresponds to 7 GND
0.33 V
8 + 15 V
4 - 15 V
Measuring points The welding amperage can be ascertained indirectly, by measuring the voltage. For a
welding current of 100 A, for example, a voltage of 0.33 V should be measured:
- either on the Molex connector of the adapter cable, Pin 3 and Pin 7;
- or on the UST2B board, Molex connector X4, Pin 5 and Pin 17
Special features Various different versions of the shunt are in use.
Note! To prevent malfunctions and to rule out damage to other parts of the
power source, please only use the adapter cable supplied with the shunt.
44
TP 592S temperature sensor
General remarks TP 592S (article number 43,0001,0600) is

an electronic temperature sensor. The TP
592S has an integral temperature/current
converter chip.
Fig. 14 Temperature sensor
Functional The converter chip is integrated in the plastic housing and has a pluggable Molex
description connection.
When a voltage of 4 - 30 VDC is applied, the temperature sensor allows a current of

exactly 1 micro-A per K (Kelvin) to pass.
The value given in K is the temperature above absolute zero (-273.15 C). 0 C equals
273.15 K.
This means that:

Temperature in K = temperature in C + 273.15
Example:
- Temperature = 54 C
- 54 C corresponds to a temperature of 273.15 K+ 54 K = 327.15 K
Measuring points Use the temperature sensor to measure the current as follows:
- Using a Molex remover tool, remove the lead from the Molex connector at Pin 1.
- Connect a multimeter in series between the lead that you have just removed and the
(now vacant) pin of the Molex connector
Calculate the temperature from the measured voltage, as described in the example
given in Functional description above.
45
TTS 22 - IGBT driver and auxiliary voltage source
General remarks P.-c. board TTS 22 (article number 4,070,804) fulfils the function of an IGBT-driver and
an auxiliary voltage source.
Functional TTS 22 controls the polarity of the welding current and the auxiliary voltage source. The
description auxiliary voltage source makes it possible to re-ignite the arc. Essentially, the TTS 22
board and the adapter board FMW22 work together.
TTS 22 produces two independent voltages - + 5 V and + 18 V - from the + 24 V supply

voltage, for the board controller.
This control unit pre-processes the control signals (welding-current polarity and re-
ignition) and ensures that these are galvanically separated and relayed to the respective
transistor modules (IGBT). This operation is indicated:
- by the LEDs Neg. ignition and Pos. ignition (for the auxiliary voltage source)
- by LED - and LED + on the FMW 22 board (for the polarity of the welding current)
Also, the welding voltage is measured. If the welding voltage goes outside the permitted
range in the event of a fault, the following measures are taken:
- Inverter addressing signals are set to Stop
- 18 V board supply stopped: LED + 18 V goes out
- Error LED (red) lights up
- Error signal X7:4 to p.-c. board UST2B is active (low-signal)
Connector pin X1 ...... Common

assignment
X2 ...... AC, alternating voltage for positive half-wave
X3 ...... AC, alternating voltage for positive half-wave
X4 ...... AC, alternating voltage for negative half-wave

X5 ...... AC, alternating voltage for negative half-wave
X6 ...... Link to p.-c. board FMW22

X7 ...... Link to p.-c. board UST2B
X8 ...... Measuring of welding voltage

1 Uact- 2 Uact+
X9 ...... Link to controller (p.-c. board UST2B)

1 Uact- 2 Uact+
46
LED checklist
Negative ignition Positive ignition
Error
+ 24 V
+ 18 V
+6V
Fig. 15 Control LEDs on the TTS 22 p.-c. board
47
UST2B - control and regulation unit
General remarks The p.-c. board UST2B (article number 4,070,860,Z) is a universal control, regulation
and monitoring unit for fully digitised Fronius power sources.
Functional The UST2B board performs the following functions:

description
(1) Power-module addressing
The power module is addressed from the UST2B via the plug-in connector X6 (the driver
circuits are located on the UST2B).
(2) Addressing the control panel

The UST2B board addresses the control panel via a 10-pole ribbon cable (X2).
Addressing takes place by way of a database link (LocalNet).
(3) Evaluating the mains-switch signal

The UST2B board evaluates the mains-switch signal coming from the BPS board. When
the indirect voltage reaches a certain value, the relays will close after a defined period of
time. If the power source is switched off or cuts out, UST2B detects this from the mains-
switch signal. UST2B stores the latest settings and activates the fans for discharging the
intermediate circuit.
(3) Evaluating the temperature

UST2B evaluates the signals from the temperature sensors and addresses the fans. If
the temperature climbs any further and the cooling provided by the fan is no longer
sufficient (e.g. because the duty cycle has been exceeded), the power source cuts out
and outputs an appropriate service code.
(4) Addressing the fan

UST2B carries out control of the fan (X5), as dictated by the temperature and the
firmware.
(5) LocalNet interface

The LocalNet interface is used for data transmission, from the plug-in connector (X9) to
the peripherals, by way of the filter board (e.g. HFF22).
(6) Regulating welding amperage and voltage

Welding amperage and voltage are regulated by the DSP (digital signal processor)
integrated in the UST2B, and by the firmware.
(7) Addressing the inverter

The UST2B board addresses the inverter module via the plug (X1).
48
Connector pin X1 ...... Addressing the inverter (link to TTS 22)
assignment X2 ...... Connecting lead to the control panel (10-pole ribbon cable)
X3 ...... Supply
1 +24 V-EXT, +24 V remote- 5 GND-EXT, remote-control
control unit connection GND connection
2 NC 6 NC
3 UZW, measuring of indirect 7 GND-UZW, measuring of
voltage indirect voltage
4 +24 V-INT, internal voltage 8 GND-INT, internal voltage
supply supply
X4 ...... Temperature; Uact, Iact

1 Uact - 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 - link to power module (BPS), 26-pole 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)
49
Connector pin X8 ...... Programming interface, for updating the firmware using BSL-Tool
assignment
(continued) Note! Risk of damage to electronic components. Before connecting or
disconnecting BSL-Tool, switch off the power source.
X9 ...... RS485 connecting lead to the remote-control unit, via a filter board
LED checklist
+24 Vext
+24 Vint
+ 5V
+15 V
- 15 V
STAT + 5V
Fig. 16 Control LEDs on p.-c. board UST2B
+24 Vext ..................... glows when the switched-mode power supply is working correctly
+24 Vint
+ 5V ................ RS 485
+15 V
- 15 V
+ 5V
STAT .............. Status LED
Glows if no firmware is available
If dark: Process is OK
Exchanging the Note! Options which have been enabled with the Service module software are
UST2B p.-c. stored on the UST2B and must be re-enabled after the UST2B has been
board changed. Before exchanging the UST2B, check with the customer which
options have been enabled, and obtain the enabling codes for these from the
customer.
50
Exchanging assemblies
General remarks Exchanging assemblies describes how to exchange components which

- do not come with any attached instructions explaining how to exchange them, and
which
- require a complete description of the exchange procedure
Note! Risk of damage to threads, especially when screws are tightened with
machine tools (e.g. battery-powered screwdrivers). To avoid damaging the
threads, proceed as follows:
- Turn the screw a short way to the left (i.e. anti-clockwise), to ensure that it is
properly centred.
- Turn the screw at least two turns of the thread by hand. By doing this, you
can prevent the screw cutting a new thread:
- Carefully tighten the screw
Overview Exchanging assemblies contains the following sections:

- Housing
- Exchanging the BPS 17 board
(see the installation instructions supplied with the p.-c. board BPS 17 )
- Exchanging the BPS 22 board
(see the installation instructions supplied with the p.-c. board BPS 22)
- Exchanging the inverter module
(see the installation instructions supplied with the inverter module)
- Exchanging the TP 592S temperature sensor
- Exchanging the power-section fan
- Exchanging the control-system fan
- Exchanging the TTS22 board
- Exchanging the BSV22 board
- Exchanging the earth fault-current watchdog
- Exchanging the transformer
51
Housing
General remarks The section headed Housing describes how to open and close the housing in order to
carry out the part-changing jobs described below.
Opening the - Undo the screws (1) for the side

housing panels, on both sides of the power
source
- Take off the side panels
(1) (1) (1)

Fig. 1 Detaching the side panels of the housing
Note! After undoing the screws

(2) (2) (2), make sure that the control
panel does not fall out of the
rack.
- Undo the screws (2) at the front
Fig. 2 Undoing the screws at the front
- Undo the screws (3) at the rear

(3) (3)
Fig. 3 Undoing the screws at the rear
52
Opening the If the machine is fitted with a carrying
housing (7) (4) (4) handle, detach the mount at one end of
(continued) the handle, as follows:
- Undo the screws (4) on the mount for
the carrying handle
Fig. 4 Undoing the screws for the carrying-handle

mount
Take off the cover, as follows:

- Slightly lift the carrying handle (5) and
(5)
the mount (6)
(6) - Take off the cover (7) (Fig.4)
Fig. 5 Detaching the carrying-handle mount
Closing the - Replace the cover (7)

(7) (4) (6) (4)
housing - Where fitted, replace the carrying
handle (6) and the mount (5), and fix
them in place with the two screws (4).
Fig. 6 Replacing the cover and fastening the

handle back on
- Tighten the screws (2) at the front

(2) (2)
Fig. 7 Tightening the screws at the front
53
Closing the - Tighten the screws (3) at the rear
housing (3) (3)
(continued)
Fig. 8 Tightening the screws at the rear
Warning! Risk of electric shock if the housing is not properly insulated. All
electric shocks are hazardous to life. Before mounting the side panels, insert
the board-insulation film behind the side panel on the same side as the BPS 17
/ 22 boards.
- On both sides of the power source,

replace the side panels and fasten
them with the screws (1)
(1) (1) (1)

Fig. 9 Fixing the side panels of the housing back on
54
Exchanging the BPS 17 board
Note When changing the p.-c. board BPS 17, you must follow the installation instructions
supplied with the new BPS 17 board.
Exchanging the BPS 22 board
Note When changing the p.-c. board BPS 22, you must follow the installation instructions
supplied with the new BPS 22 board.
Exchanging the inverter module
Note When changing the inverter module, you must follow the installation instructions supplied
with the new inverter module.
Exchanging the TP 592S temperature sensor
Note The temperature sensor is plugged (rather than screwed) in place, so you can prise it
out carefully with a simple screwdriver, and/or pull it out using a pair of flat pliers.
Before inserting the new temperature sensor, fill the hole for the sensor with heat-
transfer compound, so as to ensure proper thermal transfer.
If the temperature sensor is obstructed by other components which need to be removed

first, please follow the instructions for dismounting any such part in the section headed
Exchanging assemblies.
55
Exchanging the power-module fan
Removing the old - Undo the two screws (1) for the rack
fan at the rear
(1) (1)
Fig. 1 Undoing the screws on the rack at rear
- Unplug the 4-pole Molex connector

(2) from X5 on the UST2B board
(2)
Fig. 2 Unplugging the 4-pole Molex connector
- 4-pole Molex connector (2):

Using a Molex remover tool, remove
the red fan-cable lead from Pin 1 and
the black fan-cable lead from Pin 2
(2)
Fig. 3 Removing leads from the Molex connector
56
Removing the old - Slightly tilt up the rack at the rear
fan - Undo the two screws (3) on the fan
(continued) holder
(3)
Fig. 4 Undoing the screws on the fan
(4) (5)
(5)
Fig. 5 Dismounting the fan from the fan holder
- Take out the fan (4), complete with the fan holder
- Dismount the fan (4) by undoing the screws (5) on the fan holder
Fitting the new Note! When mounting the fan, make sure that the arrow symbol on the fan
fan housing points towards the inside of the unit.
- Mount the fan (4) to the fan holder, using the screws (5)
- Insert the fan assembly
- Tighten the two screws (3) on the fan

holder
(3)
Fig. 6 Fixing the fan in place
57
Fitting the new
fan
(continued)
(A) (2)
Fig. 7 Arranging the fan-lead and plugging-on the 4-pole Molex connector
- Take the fan lead across to the opposite side of the power source, as shown in Fig.7
(Item A)
- 4-pole Molex connector (2) at X5 on UST2B board:
Attach the red fan-cable lead to Pin 1 and the black fan-cable lead to Pin 2
- Plug on the Molex connector
- Fix the fan-leads using cable-ties
- Press the rack (Fig.6) at the rear

inwards
- Tighten the two screws (1) for the
rack at the rear
(1) (1)
Fig. 8 Tightening the screws on the rack at rear
58
Exchanging the control-system fan
Removing the old - Unplug the 4-pole Molex connector

fan (2) from X5 on the UST2B board
(2)
Fig. 7 Unplugging the 4-pole Molex connector
- Using the Molex remover tool, remove

the following single leads (without
silicone hose) from the 4-pole Molex
connector (2):
- red lead from Pin 3
- black lead from Pin 4
(2)
- Unplug the tab connector (4) from the

(4) gas-solenoid valve
Fig. 9 Unplugging the tab connector
59
Removing the old - Undo the screw (3) from the fan
fan holding plate
(continued)
(3)
Fig. 10 Undoing the screw (3) from the fan holding
plate
(5)
(6) (7)
(8)
(9)
(10)
Fig. 11 Undoing the screws for the holding plate
- Undo the six screws - (5) to (10) - on the opposite side
(12)
(11)
(13)
(11)
(12)
Fig. 12 Detaching the fan, complete with fan holding plate
- Detach the fan (11), complete with the fan holding plate (12)
- Undo the four screws from the fan holding plate (12) at the locations shown here as
Item (13), and take off the fan (11)
60
Fitting the new Note! When mounting the fan, make sure that the arrow symbol on the black
fan fan-housing points towards the inside of the housing after the fan has been
inserted.
- Mount the fan (11) on the fan holding plate (12), with four screws at the locations
shown as Item (13)
- Insert the entire assembly
(5)
(6) (7)
(8)
(9)
(10)
Fig. 13 Tightening the screws for the holding plate
- Tighten the six screws - (5) to (10) - for the fan holding plate
- Tighten the screw (3) on the fan

holding plate
(3)
Fig. 14 Tightening the screw on the fan holding
plate
61
Fitting the new - Plug the tab connector (4) onto the
fan (4) gas-solenoid valve
(continued)
Fig. 15 Plugging-on the tab connector
- 4-pole Molex connector (2) at X5 on

UST2B board:
Attach the red lead for the fan to Pin
3, and the black lead for the fan to Pin
4
- Plug on the Molex connector
- Fix the red and black fan-leads using
cable-ties
(2)
Fig. 16 Plugging-on the Molex 4-pole connector
62
Exchanging the TTS 22 board
ESD precautions Note! There is a risk of the TTS 22 board being damaged by electrical
discharge. Suitable ESD precautions must be taken before the p.-c. board TTS
22 is exchanged. These include:
- The workplace where it is intended to remove this p.-c. board must be fitted out with
the following ESD-compatible equipment:
- Worktops
- Floors
- Discharging wrist-bands
- Seating
- Outside the ESD-compatible workplace, use suitable transport containers
Removing the old (2)

TTS 22 board
(1)
(2)
(1)
(11)
(1)
Fig. 1 UST2B: Separating the plug-in connectors and unscrewing the spacers
UST2B board:
- Unplug the plug-in connectors (1)
- Unscrew the 5 spacers (2) and the metal spacer (11)
- Take out p.-c. board UST2B
63
Removing the - Unscrew 2 spacers (4) on the
old TTS 22 board insulation film
(continued)
(4) (4)
Fig. 2 Undoing the spacers
- Unplug the Molex connector (5) and

tab connectors (6) from p.-c. board
TTS 22
(5) (6)
Fig. 3 Undoing the plug-in connectors
- Undo 2 spacers (3) and 4 screws (9)
(9)
(3) (9) (9) (3) (9)
Fig. 4 Undoing the screws and spacers
- Take out p.-c. board TTS 22 (7),

complete with its holding plate (10)
- Undo 5 spacers (8) on the TTS 22
board
- Take out the TTS 22 board (7) from its
(8) (10) holding plate (10)
(7)
Fig. 5 Taking out p.-c. board TTS 22 and spacers
64
Fitting the new - Place p.-c. board TTS 22 (7) onto the spacers (8) on the holding plate
TTS 22 board
- Tighten the 5 spacers (8) on the TTS
22 board
- Place down the new TTS 22 board
(7), complete with its holding plate
(8)
(7)
Fig. 6 Fastening the new TTS 22 board, using
spacers
- Using 2 spacers (3) and 4 screws (9),

screw down the TTS 22 p.-c. board,
complete with its holding plate
(9)
(3) (9) (9) (3) (9)
Fig. 7 Tightening the screws and spacers
- Plug the Molex connector (5) to the

TTS 22 board
Important! When plugging-on the five tab

connectors (6), proceed as follows:
- Plug the single tab connector onto the
Common X1 slot
- The other tab connectors - joined into
pairs using silicone hoses - can be
plugged onto any of the remaining
slots. The only condition is that the tab
connectors have to be plugged onto
X2/X3, and X4/X5, in pairs.
(5) (6)
Fig. 8 Making the plug-in connections
- Tighten the spacers (4) on the

insulation film
(4) (4)
Fig. 9 Tightening the spacers
65
Fitting the new - Fit the p.-c. board UST2B in place
TTS 22 board
(continued)
Fig. 10 Fitting the UST2B board in place
(2)
(1) (2)
(1)
(11)
(1)
Fig. 11 UST2B: Making the plug-in connections and tightening the spacers
UST2B board:
- Restore the plug-in connections (1)
Note! When fastening the spacers (2), screw the metal spacer to the location
shown as Item (11).
- Tighten the 5 spacers (2) and the metal spacer (11)
66
Exchanging the BSV 22 board
ESD precautions Note! There is a risk of the BSV 22 board being damaged by electrical
discharge. Suitable ESD precautions must be taken before the p.-c. board
BSV 22 is exchanged. These include:
- The workplace where it is intended to remove this p.-c. board must be fitted out with
the following ESD-compatible equipment:
- Worktops
- Floors
- Discharging wrist-bands
- Seating
- Outside the ESD-compatible workplace, use suitable transport containers
Removing the (2)

UST2B board
(1)
(2)
(1)
(11)
(1)
Fig. 1 UST2B: Separating the plug-in connectors and unscrewing the spacers
UST2B board:
- Unplug the plug-in connectors (1)
- Unscrew the 5 spacers (2) and the metal spacer (11)
- Take out p.-c. board UST2B
67
Removing the - Unscrew 2 spacers (4) on the
old BSV 22 board insulation film
(4) (4)
(5) (6) - Unplug the Molex connector (5) and

tab connectors (6) from p.-c. board
BSV 22
Fig. 3 Undoing the plug-in connectors
- Undo 2 spacers (3) and 4 screws (9)
(9)
(3) (9) (9) (3) (9)
Fig. 4 Undoing the screws and spacers
- Take out p.-c. board BSV 22 (7),

(8) (7) (8) (10)
complete with its holding plate (10)
- Undo 4 spacers (8) on p.-c. board
BSV 22
- Take out the BSV 22 board (7) from
its holding plate (10)
(8) (8)
Fig. 5 Taking out p.-c. board BSV 22 and spacers
68
Fitting the new - Place p.-c. board BSV 22 (7) onto the spacers (8) on the holding plate
BSV 22 board
- Tighten the 4 spacers (8) on the BSV
(8) (7) (8) (10)
22 board (7)
- Place down the new BSV 22 board
(7), complete with its holding plate
(8) (8)
Fig. 6 Fastening the new BSV 22 board, using
spacers
- Using 2 spacers (3) and 4 screws (9),

screw down the BSV 22 board,
complete with its holding plate
(9)
(3) (9) (9) (3) (9)
Fig. 7 Tightening the screws and spacers
(5) (6) - Plug the Molex connector (5) to X9 on

the BSV 22 board
- Plug on tab connectors X1 to X4 (6) in
accordance with the labelling on the
cables and on the BSV22 board.
Fig. 8 Making the plug-in connections
- Tighten the spacers (4) on the

insulation film
(4) (4)
69
Fitting the UST2B - Fit the p.-c. board UST2B back in
board place
Fig. 10 Fitting UST2B in place
(2)
(1) (2)
(1)
(11)
(1)
Fig. 11 UST2B: Making the plug-in connections and tightening the spacers
UST2B board:
- Restore the plug-in connections (1)
Note! When fastening the spacers (2), screw the metal spacer to the location
shown as Item (11).
- Tighten the 5 spacers (2) and the metal spacer (11)
70
Exchanging the earth fault-current watchdog
Removing the old - Unplug the 24-pole Molex connector

earth fault- (1) X4 from p.-c. board UST2B
current watchdog (1) - Using a Molex remover tool, remove
lead (2) from Pin 10 and lead (3) from
(2) Pin 22 on the 24-pole Molex
connector
(3)
- Cut through the cable tie that fastens

the cables (4) for the earth fault-
current watchdog, and unthread the
cables (4)
(4)
Fig. 2 Uncovering the cable of the earth fault-
current watchdog
(6) (9) (10)
(7)
(5)
(8)
Fig. 3 Dismounting the earth fault-current watchdog
- Undo the screw (5) on the lamp-wire connector (6) and remove the yellow-green
earthing (grounding) lead (7)
- Undo the two screws (8) on the earth fault-current watchdog (9) and detach the
earth fault-current watchdog (9)
71
Fitting the new - Place the earth fault-current watchdog in position (10) and mount it using two
earth fault- screws (8)
current watchdog - Insert the yellow-green earthing (grounding) lead (7) in the lamp-wire connector (6)
and fasten it by tightening the screw (5)
Insert the following leads to the 24-pole

Molex connector (1) X4:
(1) - Lead (2) to Pin 10
- Lead (3) to Pin 22
(2)
- Plug the 24-pole Molex connector (1)
X4 to p.-c. board UST2B
(3)
Fig. 4 Inserting the leads into the Molex connector
Arrange the cables for the earth fault-current watchdog, and fix them using cable ties.
72
Exchanging the transformer
Removing the old - Undo the two screws (1) for the rack
transformer at the front
(1) (1)
Fig. 1 Undoing screws on rack at front
- Unplug the ribbon cable (2) for the

control panel from X2 on the UST2B
board
- Detach the control panel
(2)
Fig. 2 UST2B: Unplugging the ribbon cable
- Unplug the ribbon cable (3) from p.-c.

board BPS
(3)
Fig. 3 BPS: Unplugging the ribbon cable
73
Removing the old - Undo 2 screws (4) on the HF
transformer transformer (5)
(continued)
(5)
(4)
Fig. 4 HF transformer: Undoing the screws
(5) - Lift the HF transformer (5) and undo

the 2 screws (6) behind the HF
transformer
(6)
Fig. 5 Undoing the screws behind the HF

transformer
- Dismount the secondary transformer

leads (7): Unscrew the 2 screws with
serrated lock washers (not illustrated)
(7)
Fig. 6 Detaching the secondary transformer leads
- Cut through the cable tie on the

secondary transformer leads (7)
(cable tie not illustrated here)
- Take off the strip-wound cores (8) of
the secondary transformer leads
(8) (7)
Fig. 7 Taking off the strip-wound cores
74
Removing the old - Undo the hexagonal bolt (9) - width-
transformer across 19
(continued) - Take off the hexagonal bolt (9),
(12) together with the serrated lock washer
and plain washer
(10)
(11) The following leads will now have been
(9) detached:
- Centre-tap transformer lead (10)
- Measuring lead (11) - white cable
labelled Massebuchse (meaning
earthing socket)
- Secondary protective-circuit lead (12)
Fig. 8 Dismounting the centre-tap transformer lead - unlabelled white cable
- Undo the spacers (13)
(13) (13)
- Unplug tab connectors (15) X2 to X5

(15) (16)
- Unplug tab connector X1 Common
(16) of the welding-voltage measuring
lead
- Cut the cable tie for the measuring
lead (16) - Fig.11
Fig. 10 Detaching the tab connectors for the

measuring leads
75
Removing the old - Remove the welding-voltage
transformer measuring lead (16)
(continued) (18) - Unthread the centre-tap transformer
lead (17) from the current sensor (18)
(16) (17)
Fig. 11 Unthreading the centre-tap transformer lead
- Loosen the 2 screws (19) on the

(20) lamp-wire connector
- Take out the primary leads(20)
(21) - Undo the screw (21)
(19)
Fig. 12 Disconnecting the primary transformer leads
- Undo the screws (22)
Important! If there is an earthing

(22) (grounding) lead, undo 3 screws (22).
Fig. 13 Undoing the screws on the transformer
- Take out the transformer (22)

- Cut through cable ties (23) and (24)
(24) on the transformer
(23)
(25)
(22)
Fig. 14 Removing the transformer
76
Removing the old - Unthread the centre-tap transformer
transformer lead (17) from the ferrite rings (25)
(continued) (see also Fig.14)
(25)
(17)
Fig. 15 Unthreading the centre-tap transformer lead
(27) - Undo the four screws (26) on the

transformer, and take off the side
plates (27)
(26)
(27)
Fig. 16 Dismounting the plates from the transformer
Fitting the new - Using the four screws (26), fasten the side plates (27) onto the transformer
transformer
- Thread ferrite rings (25) onto the
centre-tap transformer lead (17) and
(24) make 2 turns of the winding
- Fix the ferrite rings (25) and the
(23) centre-tap transformer lead (17) with
cable ties
(25)
(22)
Fig. 17 Arranging the centre-tap transformer lead
77
Fitting the new - Insert the transformer (22) into the power source
transformer
(continued) - Tighten the screws (22)
Important! If there is an earthing

(22) (grounding) lead, tighten the 3 screws (22)
and use the middle screw (22) to screw
down the earthing lead as well.
Fig. 18 Fastening the transformer
(16)
(17)
Fig. 19 Arranging the leads
Arrange the leads as follows, and fix them

with cable ties:
- Along Route 16 (Fig.19): Measuring
lead (16) for the X1 Common tab
connector
(17) (single lead)
- Along Route 17 (Fig.19 and Fig.20):
Auxiliary voltage-source leads for tab
connectors X2 to X5 (leads arranged
in pairs)
Fig. 20 Arranging the leads for the auxiliary voltage

source
Important! It does not matter which

(20) position the primary transformer leads (20)
have on the lamp-wire connector.
(21)
- Insert the transformer leads (20) into
(19) the lamp-wire connector and fix them
with the screws (19)
- Fix the lamp-wire connector and the
insulation with the screw (21)
Fig. 21 Connecting the primary transformer leads to - Tie the transformer leads together
the terminals with cable ties
78
Fitting the new - Pass the centre-tap transformer lead
transformer (17) through the current sensor (18) in
(continued) (18) the direction shown by the arrow
- Arrange the measuring lead (16) for
the X1 Common tab connector
(see Fig.19)
(16) (17)
Fig. 22 Arranging the transformer lead
When plugging-on the five tab connectors

(15) (16)
(15) and (16), proceed as follows:
- Plug the single tab connector (16)
onto the Common X1 slot
- The other tab connectors (15) - joined
into pairs using silicone hoses - can
be plugged onto any of the remaining
slots. The only condition is that the tab
connectors have to be plugged onto
X2/X3, and X4/X5, in pairs.
Fig. 23 Detaching the tab connectors for the

measuring leads
- Tighten the 2 spacers (2) on the

insulation film
(13) (13)
79
Fitting the new
transformer
(continued)
(12)
(10)
(11)
(9)
(9)
(29) (30) (11) (12) (10)

Fig. 25 Mounting the centre-tap transformer lead
Place the following components onto the hexagonal bolt (9), in the order in which they
are listed below:
- Serrated lock washer (29)
- Plain washer (30)
- Measuring lead (11) - white cable labelled Massebuchse (= earthing socket)
- Secondary protective-circuit lead (12) - unlabelled white cable
- Centre-tap transformer lead (10)
- Tighten the hexagonal bolt (9) - width-across 19
Note! When arranging the

secondary transformer leads (7),
make sure that the strip-wound
cores are located in the air-flow
(see Fig.28 for correct position in
air-flow), and that they are kept in
position by the cable ties.
(8) (7)
Fig. 26 Placing the strip-wound cores
(31)
(7)
Fig. 27 Fastening the secondary transformer leads
Note! When tightening the screws with serrated lock washers (for the
secondary transformer leads), tighten them to the torque given below.
- Push serrated lock washers onto the fixing-screws (not illustrated).

- Fasten the secondary transformer leads (7): Tighten the screws (31), including the
serrated lock washers (not illustrated), to a torque of 4 Nm
80
Fitting the new (5) - Lift the HF transformer (5) and tighten
transformer the screws (6) behind the HF
(continued) transformer
(6)
Fig. 28 Tightening the screws behind the HF

transformer
- Fit the HF transformer in place and

tighten the two screws (4)
(4)
Fig. 29 HF transformer: Tightening the screws
- Plug the ribbon cable (3) onto the

BPS board
(3)
Fig. 30 BPS: Plugging-on the ribbon cable
Note! Risk of malfunction in high-

(32) frequency (HF) ignition: When
arranging the ribbon cable (2),
make sure that this is routed
sufficiently far away from the HF
(2) lines (32).
Fig.31 shows the correct route for the

ribbon cable (2).
X2
Fig. 31 UST: Plugging-on the ribbon cable
- Plug the ribbon cable (2) for the control panel to X2 on the UST2B board
- Insert the control panel
81
Fitting the new - Press against the rack at front
transformer - Tighten the two screws (1) for the
(continued) rack at the front
(1) (1)
Fig. 32 Screws on rack at front
82
Terms and abbreviations used
General remarks Terms and abbreviations is a glossary of specific technical terms that are important for
understanding the Service Manual.
Terms and BSL-Tool:

abbreviations BSL-Tool is a special tool for updating the power source with new firmware. A PC or
notebook is needed for carrying out this update.
Config-Memory (CFM):
The CFM module supplements the firmware on the UST2B board (central control and
regulation unit) with individual, appliance-specific data.
DSP:
Digital Signal Processor. This is an integral part of the UST2B board (central control and
regulation unit). The DSP acquires digitised actual values from the welding process and
ensures that the welding amperage and voltage are constantly regulated and optimised
with reference to:
- the pre-set parameters
- the stored firmware
- the measured actual values
EMI:
Electro-Magnetical Interference. Electro-magnetical interference is high-frequency ripple
of the mains voltage. The mains filter absorbs this ripple, thereby ensuring an optimum
welding result and troublefree power-source operation.
FAC:
Factory is for resetting settings in the set-up menu. By pressing the Store button for
two seconds, the user can restore the factory settings (i.e. those with which the unit was
delivered). If the display reads PrG, this means that the welding installation has been
reset. Jobs and parameter settings in the second level of the set-up menu are not
deleted here.
Hall shunt:
This is used for galvanically separated measuring of the welding current. The UST2B
(central control and regulation unit) evaluates the signal.
IGBT:
Insulated Gate Bipolar Transistor. This is a special bipolar transistor for high-power
switching. In the power source, IGBTs are used as modules. In the TT/MW 1700/2200
power sources, IGBT modules are used on the secondary side to pre-process the
welding current for AC welding.
Instruction pointer:
When a software error is indicated: Third level of the display, for more detailed
information on the cause of a fault (see Troubleshooting guide)
LocalNet RS 232 converter:

For connecting the power source to the serial interface of a PC, for:
- uploading software options
- data communication between the power source and PC-based software (Fronius
Backup, Fronius Service Module, Job-Explorer, ...)
83
Terms and NTC resistors:
abbreviations NTC = Negative Temperature Coefficient. These resistors have high resistance at low
(continued) temperatures. As long as operating temperature has not been reached, the high
resistance results in a limitation of the inrush current. Shortly after the unit has been
switched on, the rapid rise in the temperature of the NTC resistors means that they no
longer limit the current.
PTC resistors:
PTC = Positive Temperature Coefficient. The higher the temperature of these resistors,
the greater their resistance. As the temperature of the resistor rises as the current
increases, limitation of the current takes place automatically.
PFC:
Power Factor Control. This ensures sine-wave power input, for
- helping to achieve optimum efficiency
- preventing disturbances to the mains network
Voltage doubling:
Provides an increase in the open-circuit voltage and the welding voltage when welding
with longer arcs. Voltage-doubling makes a significant contribution towards achieving
optimum ignition properties and a stable arc.
Display of segments:
When a software error is indicated: Second level of the display, for more detailed
information on localising an error (see Troubleshooting guide)
Software Service Module:

The Software Service Module is used for ascertaining the hardware and software
configuration of the power source and peripherals. A particularly helpful feature is that
the following components are indicated:
- the type and version of the power sources and peripherals
- the respective software modules and boards
- in the case of certain appliances, their serial numbers
Furthermore, the Software Service Module also enables you to call up the relevant
ordering information for the options that have been selected.
Temperature/current converter chip:

This is used in the temperature sensor. A specially doped semi-conductor ensures that
the measured temperature is converted into an appropriate voltage signal. The voltage
signal reaches the UST2B board (central control and regulation unit), and is used by the
computer to calculate the actual temperature.
84
TransTIG 2200
MagicWave 1700
MagicWave 2200
FK 2200
MagicWave 2200 Job G/F 4,075,119 MagicWave 2200 G/F 4,075,125
MagicWave 2200 Job G/F/US 4,075,119,800 MagicWave 2200 G/F/US 4,075,125,800
TransTig 2200 Job G/F 4,075,120 TransTig 2200 G/F 4,075,126
TransTig 2200 Job G/F/US 4,075,120,800 TransTig 2200 G/F/US 4,075,126,800
MagicWave 1700 Job G/F 4,075,121 MagicWave 1700 G/F 4,075,127
MagicWave 1700 Job G/F/US 4,075,121,800 MagicWave 1700 G/F/US 4,075,127,800
12,0405,0369
42,0201,1328
42,0406,0320
43,0004,1993 - US
43,0004,0519
AM2,0201,1327
43,0002,0295
42,0300,0648
45,0200,1151
42,0409,2979 - US
42,0409,2911
42,0001,3541 - US
43,0013,0015
42,0407,0273 BE2,0201,1329
40,0001,0310 - *
12,0405,0365
33,0005,4130 - MW1700
33,0005,4129 - MW/TT2200
43,0006,0152 - MW2200
43,0006,0134 - MW1700/TT2200
42,0405,0421
2IS 41,0003,0282,Z - MW 1700/2200

W2
FM
4,070,949 - FMW22IS
41,0003,0279
41,0003,0203
12,0405,0365 33,0010,0326
43,0001,1177 43,0001,0600
43,0001,1176 - TT 43,0001,1178
43,0001,3280 - TT 2200
43,0001,3279 - MW1700/2200 42,0409,2935 - TT2200
43,0001,3258 - TT2200 Job 42,0409,2934 - MW1700
43,0001,3259 - MW1700/2200 Job 42,0409,2882 - MW2200
42,0406,0315
42,0405,0398 - MW1700/2200
42,0406,0093 42,0405,0399 - TT2200
42,0001,1501 43,0004,2328
42,0001,5477 43,0004,2330
32,0405,0183
42,0404,0024
TT 2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200

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_00545 032006
4,070,813 - BSV22 TT2200
4,070,798,Z - BPS17 MW 1700
4,070,804,Z - TTS22 MW1700/2200
4,070,799,Z - BPS22 TT/MW 2200
41,0001,0627
41,0009,0057
33,0024,0032
2
S2
TT 22 33,0010,0325 - MW/TT2200
V
BS
S
BP 43,0006,0168
43,0001,1191 - MW/TT 2200

42,0405,0420
4,070,960,Z - UST2C
T2
2 US
F2
HF
4,070,812 - HFF22
43,0004,1122 - 26pol.
TT 2200 Job, MW1700/2200 Job, TT 2200, MW1700/2200

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_00545 032006
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Transtig 2200 Magicwave 1700 / 2200 FK 2200: Service Manual Spare Parts List GB

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TransTig 2200

FK 2200 TIG power source

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

Caution! Inadequate PE conductor connections can cause serious injury and

Exchanging Exchanging assemblies describes how to exchange components which

(1) (7) (8) (16) (15) (14) (13) (4)

1. Socket spanner (8 mm)

Fig. 2 Tools and resources

1. Contact spray (40,0009,0014) or alcohol-based solvent

Torch control lead

PFC (Power Factor

(2) Mains filter (EMC):

(3) Primary rectifier:

(5) Indirect capacitors:

(6) Switching transistors:

(7) Welding transformer:

(8) Secondary rectifier:

(9) Inverter (only on MagicWave 1700 and MagicWave 2200):

(11) Welding current sensor:

General remarks The Troubleshooting guide consists of the following parts:

Poor ignition and welding properties

Poor welding properties where the

Mains switch in the No welding current, or the welding

Insufficient cooling of the welding torch

Control panel remains dark

Service codes in the display

Is the right shielding gas Connect up the right shielding gas

Gas-test button: Is shielding gas Check the shielding-gas solenoid

Parameters set correctly? - Check the settings on the

When the Rod-electrode (MMA) See Open-circuit voltage is faulty

Power source is OK; check the

Are the electrodes and grounding Connect up the cables correctly

Parameters set correctly? - Check the settings on the

When the Rod-electrode (MMA) See Open-circuit voltage is faulty

Power source is OK; check the

Control panel remains dark ? See Control panel remains dark

When the Rod-electrode (MMA) See Open-circuit voltage is faulty

- Welding amperage Ides can no Change current sensor A1 VAC

Power source is OK; check the

In set-up, is the cooling unit set to In set-up, change the setting to

Switch off the power source

Enough coolant ? Top up with coolant, then vent the

Coolant-pump fuse OK? Change the fuse (for one of the

Coolant pump blocked ? Using a screwdriver, slightly turn

Unplug X4 on the power pack A1

Is the On LED on power pack A1 Voltage on power pack A1 NTFK24

Check the cable harness, change

Are LEDs +15V, +24V, + 24V OK Change power pack A1 NTFK24

Change the coolant pump and/or

Is LED UZWK on power-module Check mains cable, mains switch,

Are the LEDs for supply voltage on Change control panel A6 FP 22

- Shift the mains switch to the

Are the LEDs for supply voltage on Change power-module board A2

- Shift the mains switch to the

Are the LEDs for supply voltage on Change power-module board A2

- Shift the mains switch to the

Connect plug X1 to control board

Connect plug X2 to control board

Connect plug X4 to control board

Connect plug X7 to control board

Connect plugs X9, X10 to control

Power source is OK; check the

Is there any open-circuit voltage - Change p.-c. board A4 TTS22