Transtig 2200 Magicwave 1700 / 2200 Fk 2200: Service Manual Spare Parts List Gb

TransTig 2200 MagicWave 1700 / 2200 FK 2200

42,0410,1121

GB

Service Manual Spare Parts List TIG power source

022003

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Contents Foreword and safety warnings ........ ................ ................. .................. ................. ................. ................. ................. ................. ................. ................. ............... ............... ................ .......... .. 4 Safety ....................... ................................................. .................................................... .................................................... ....................................................... .................................................. ..................... 4 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... ............... ................ .......... .. 4 Tools and measuring instrument instruments s ........ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ............... ............. ........... .... 4 Functional description ......... ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. ................ .............. .............. ................ ............. ..... 4 Troubleshootin Trou bleshooting g guide ......... ................. ................ ................. ................. ................ ................. ................. ................. ................. ................ ................. ............... .............. ................ ........... ... 5 Detailed explanat explanation ion ........ ................ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................ ................ .............. ...... 5 Exchanging assemblie assemblies s ....... ............... ................ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ .............. .............. ............. ..... 5 Terms and abbreviatio abbreviations ns used ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................ .............. ...... 5 Spare Spa re parts list and overall circuit diagram............... diagram........................ .................. ................. ................. .................. ................. ................. ................ ............... ............ .... 5 Tools and measuring instrumen instruments ts ........ ................ ................ ................ ................. ................. ................ ................ ................. ................. ................ .............. .............. ................ .......... 6 General remarks ........ ................ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. .............. ................ .......... .. 6 Tools needed ..................... ............................................ .............................................. .............................................. .............................................. .................................................. ........................... 6 Measuring and testing equipmen equipmentt ........ ................. ................. ................. ................. ................ ................. ................. ................. ................. ................. ............... .............. .......... 7 Auxiliary materials ...................... ........................................... ........................................... ............................................ ................................................... ............................................. ................ 7 Functional description ........ Functional ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................ ............... ............... ................ ................ .......... .. 8 General remarks ........ ................ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ............... ............... .............. .............. ................ .......... .. 8 Block diagram ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ .............. ...... 8 Legend for block diagram ........ ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ ................ .............. .............. ................ .......... 9 Troubleshooting Troubleshooti ng 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-electro “Rod-electrode de (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 Speciall indications in connectio Specia connection n with service codes .......... ................... .................. .................. .................. .................. .................. .................. ............. .... 27 Detailed explanatio Detailed explanation n ......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............... .............. ............... ............... .......... ... 28 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 28 Overview ........ ................ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............ ..... 28 BPS 17 - power-mod power-module ule board ......... ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... ............. ............... .......... 29 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 29 Functional description ......... ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. ................ .............. .............. ............... ........... .... 29 Connectorr pin assignmen Connecto assignmentt ........ ................. ................. ................ ................ ................. ................. ................ ................ ................ ................. ................. ............. ............. ............. ..... 30 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ............... ........... .... 31 LED checklist ........ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 32 BPS 22 - power-mod power-module ule board ......... ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... ............. ............... .......... 33 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 33 Functional description ......... ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. ................ .............. .............. ............... ........... .... 33 Connectorr pin assignmen Connecto assignmentt ........ ................. ................. ................ ................ ................. ................. ................ ................ ................ ................. ................. ............. ............. ............. ..... 35 Measuring points ........ ................. ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............. ............. ............... ........... .... 35 LED checklist ........ ................ ............... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ .............. ............. ............... ............. ..... 36 HFF22 - high-freque high-frequency ncy ignition unit, input filter ......... .................. .................. .................. ................... ................... .................. .................. ............... ............. ........... .... 37 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 37



























NTFK 24 - switched-m switched-mode ode power supply for the cooling unit ......... .................. .................. .................. .................. .................. .................. ................ ....... 40 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 40 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 40 Connectorr pin assignmen Connecto assignmentt ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............. ..... 41 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 42 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 42 Secondary power module.............. module...................... ................ ................. ................. ................ ................. ................. ................. ................. ................ ................ ............... ............... ............ .... 43 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 43 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 43 Connectorr pin assignmen Connecto assignmentt ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............. ..... 43 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 43 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 43 Shunt ....................... ................................................. .................................................... .................................................... ........................................................ ...................................................... ........................ 44 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 44 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 44 Connectorr pin assignmen Connecto assignmentt ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............. ..... 44 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 44 Special Spec ial features ....... ................ ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... ............... ............... .............. ....... 44 TP 592S tempera temperature ture sensor ........ ................. ................. ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... .............. .............. ....... 45 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 45 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 45 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 45 TTS 22 - IGBT driver and auxiliary voltage source......... source .................. .................. .................. .................. ................. ................. .................. ................ ............... ........ 46 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 46 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 46 Connectorr pin assignmen Connecto assignmentt ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............. ..... 46 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 47 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 47 UST2B - control and regulation unit ......... .................. ................. ................. .................. ................. ................. .................. ................. ................. ............... ............. ............... ........ 48 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 48 Functionall description ........ Functiona ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. .............. ............. ............... ............ .... 48 Connectorr pin assignmen Connecto assignmentt ........ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ ................. ............... .............. ............. ..... 49 Measuring points ........ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................. .............. ............ ............... ............ .... 50 LED checklist ....... ............... ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............. ............. ................ ............. ..... 50 Exchanging the UST2B p.-c. board ......... ................. ................. ................. ................ ................. ................. ................ ................. ................. ................. ............... ........... ..... 50 Exchanging assemblie Exchanging assemblies s ........ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ................ ............... .............. ............... ........ 51 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 51 Overview ........ ................ ............... ............... ................ ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ............... .............. ............... ............. ..... 51 Housing .......................... .................................................... .................................................... .................................................... ......................................................... ............................................... ................ 52 General remarks ....... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ .............. .............. ................ .......... 52 Opening the housing ........ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ................ ................. ................. ............... .......... ... 52 Closing the housing housing........ ................ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ .............. .............. ................ ........ 53 Exchanging the BPS 17 board ........ Exchanging ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... .............. .............. ......... .. 55 Note ....... ............... ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............... ............. ..... 55 Exchanging the BPS 22 board ........ Exchanging ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. ............... .............. .............. ......... .. 55 Note ....... ............... ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............... ............. ..... 55 Exchanging the inverter module ......... Exchanging ................. ................ ................. ................. ................. ................. ................. ................. ................. ................. .............. ............. ............... ........ 55 Note ....... ............... ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... .............. ............... ............... ............... ............. ..... 55 Exchanging the TP 592S temperat temperature ure sensor ........ ................. ................. ................. ................. ................. ................. ................. .................. ................. ............. ....... .. 55 Note 55



























Exchanging the control-sy control-system stem fan ........ ................ ................ ................. ................. ................ ................. ................. ................. ................. ................ ............... .............. ........... .... 59 Removing the old fan ........ ................ ................ ................. ................. ................ ................. ................. ................ ................. ................. ................ ................ ................ ............... .......... ... 59 Fitting the new fan ........ ................. ................. ................ ................ ................. ................. ................ ................. ................. ................ ................. ................. ............... .............. ............... ........ 61 Exchanging the TTS 22 board.............. board...................... ................ ................. ................. ................ ................. ................. ................ ................. ................. ............. ............ ............... ........ 63 ESD precaution precautions s ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. .............. ............ ............... ............. ..... 63 Removing the old TTS 22 board ........ ................ ................ ................. ................. ................ ................. ................. ................ ................ ................. ................ .............. .......... ... 63 Fitting the new TTS 22 board ......... ................. ................. ................. ................. ................. ................. ................. ................. ................. ................. .............. ............. .............. ...... 65 Exchanging the BSV 22 board ......... ................. ................. ................. ................. ................. ................. ................. ................. ................. ................ ............... .............. ............... .......... 67 ESD precaution precautions s ........ ................ ................ ................. ................. ................ ................ ................ ................. ................. ................ ................ ................. .............. ............ ............... ............. ..... 67 Removing the UST2B board ......... ................. ................ ................ ................ ................. ................. ................ ................ ................. ................. ................ .............. .............. .......... 67 Removing the old BSV 22 board ......... ................. ................. ................. ................. .................. ................. ................. ................. ................. ................. ............. ............. .......... 68 Fitting the new BSV 22 board board........ ................. ................. ................. .................. ................. ................. .................. ................. ................. .................. .............. ............. ............. ..... 69 Fitting the UST2B board board......... ................. ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. .............. ............. ............... ........ 70 Exchanging the earth fault-curre fault-current nt watchdo watchdog g ........ ................. .................. ................. ................. .................. ................. ................. .................. ............... ............. .......... ... 71 Removing the old earth fault-curren fault-currentt watchdog........... watchdog................... ................. .................. .................. ................. ................. .................. .................. .............. ..... 71 Fitting the new earth fault-curren fault-currentt watchdog ......... .................. .................. ................. ................. .................. .................. .................. .................. ............... .......... .... 72 Exchanging the transform Exchanging transformer er ......... ................. ................ ................ ................ ................ ................ ................ ................ ................. ................. ................ .............. ............. ............... .......... 73 Removing the old transform transformer er ........ ................ ................ ................ ................. ................. ................ ................ ................ ................ ................ ................ .............. .............. .......... 73 Fitting the new transform transformer er ........ ................ ................ ................ ................. ................. ................ ................. ................. ................ ................. ................. .............. ............. ........... .... 77 Terms and abbreviati abbreviations ons used ........ ................ ................ ................. ................. ................ ................ ................. ................. ................ ................. ................. ............... .............. .......... ... 83 General remarks ........ ............... ............... ................ ................ ................ ............... ............... ................ ................ ................ ............... ............... ................ ............... .............. ............... .......... 83 Terms and abbreviations ...................... ............................................ ............................................ ............................................. ...................................................... ............................... 83 Overall circuit diagram Spare-parts lists Fronius worldwide



























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 Warning! Work 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 Warning! An Shif Sh iftt the the ma main ins s swi switc tch h int into o the the “O “O”” posi positi tion on Unpl Un plug ug th the e mac machi hine ne fr from om th the e mai mains ns Put up up an easy-t easy-to-u o-unde nderst rstand and warn warning ing sign sign to stop stop anybo anybody dy inadv inadvert ertent ently ly switching it back on again Using Us ing a suit suitabl able e meas measuri uring ng instr instrum ument ent,, check check to mak make e sure sure that 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 Warning! An for testing while its housing is still open: - Do not not touc touch h any any part parts s insid inside e the the housi housing ng - exce except pt with suit suitable able meas measuring uring probe probes s or test test-prod -prods s

Caution! Inadequate PE conductor connections can cause serious injury and Caution! Inadequate 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 an d measuring instruments

Here you will find an overview and description of all the resources that you will need in order to service the power source properly. These include: - Tools - Mea Measur suring ing and tes testin ting g equ equipm ipment ent - Au Auxi xili liar aryy ma mate teri rial als s





























Troubleshooting guide

Helps you to systematically track down and remedy the causes of faults. Contains the following elements: The actu actual al diag diagno nosti stic c search search tree tree,, for for dealin dealing g with with gen genera erall faults faults Table of service service code codes s for deal dealing ing with error errors s in conn connectio ection n with with service service code codes s appearing on the display

Detailed explanation

Contains in-depth in-depth explanation explanations s on the relevant assemblies in the power source. For -

each assembly, the following topics are discussed: Genera Gen erall points points (des (design ignati ation on and and artic article le numb number er of the the assem assembli blies) es) Functional des description Meas Me asur urin ing g poin points ts (co (conn nnec ecto torr pin pin assi assign gnme ment nt)) LED checklists Poss Po ssib ible le set setti ting ngs s and and adju adjust stme ment nts s

Exchanging assemblies

“Exchanging assemblies” describes how to exchange components which do not not come come with with any att attache ached d instruc instructions tions expla explaining ining how to exchan exchange ge them, them, and which requir req uire e a com comple plete te des descri cripti ption on of the the exc exchan hange ge pro proced cedure ure

Terms and an d abbreviations used

Contains explanations explanations of key technical terms and abbreviations to help you understan understand d the Service Manual better

Spare parts list and overall circuit diagram

The sections headed “Spare parts list” and “Overall circuit diagram” contain the entire spare-parts lists and the complete circuit diagram of the power source.



























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 - Mea Measur suring ing and tes testin ting g equ equipm ipment ent - Au Auxi xili liar aryy ma mate teri rial als s

Tools needed need ed (11)

(18) (3) (5)

(9)

(12)

(10) (6)

(2)

(17)

(9)

(10)

(1)

(7)

(8)

(16)

Fig. Fi g. 1 Too ools ls nee neede ded d

1. 2. 3. 4. 5.

Socket Sock et sp span anne nerr (8 (8 mm mm) Point Poi nted ed plie pliers, rs, lar large ge (ap (appro prox. x. 160 160 mm) mm) Side Si de-c -cut utti ting ng pl plie iers rs,, sma small ll Manual Manu al torq torque ue screw screwdrive driverr (1-6 (1-6 Nm, 42,0 42,041 411,00 1,0013) 13) Screwd Scr ewdriv river er (sma (small) ll) for slo slot-t t-type ype scr screws ews

(15)

(14)

(13)

(4)



























Measuring and testing equipment

1. 2. 3. 4.

Digittal mu Digi mult ltii-me mete ter r PC wit with h MS MS Wind Windows ows op opera eratin ting g syst system em (the system requirements can be found in the software manual for BSL-Tool) “BSL “B SL-T -Too ool” l” (4 (4,0 ,050 50,0 ,082 82)) “Local “Lo calNet Net RS 232 232 conv convert erter” er” (4, (4,100 100,26 ,262) 2)

Auxiliary materials (1) (2)

(3)

Fig. Fi g. 2 Too ools ls and and reso resourc urces es

1. 2. 3.

Contact spray (40,0 Contact (40,0009, 009,0014 0014)) or alcoh alcohol-ba ol-based sed solve solvent nt Heat-t Hea t-tran ransfe sferr compou compound nd (40, (40,000 0009,0 9,0043 043)) Grinding Grind ing pape paperr (42,041 (42,0410,04 0,0436) 36) with grain P 500 500 or or finer finer



























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

t i n u l o r t n o c e t o m e R

h c r o t g n i d l e W

Torch control lead

t e N l a c o L

t c a

I

HF transformer

F H

) 1 (

t i n d u n n a o l i o t a r l t n u o g e C r

HF generator

U

d a e l l o r t n o C

d a e l l o r t n o C

r e w o p 0 0 2 2

Welding current sensor

t c a

l e n a p l o r t n o C

s e c r u o s r e w o p 0 0

y l p p u s V 4 2

k c a p r e w o P

e c e i p k r o W

*

r l e e u w d o o p m y r a d n o c e S

) 1 1 ( ) 0 1 (

Inverter

) 9 (

Secondary rectifier

) 8 (

ansformer Welding Weld ing tr transformer

) 7 (

Sw itching itching tr ansistors transistors

V 4

) 2 1 (

) 6 (

) 5



























Legend for block diagram

(1) Control and regulation unit: 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 - he helpi lping ng to to achie achieve ve opti optimu mum m effic efficien iency cy - pre preven ventin ting g distur disturban bances ces to to the main mains s netwo network rk (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 transf transforme ormerr can be built built to to be very very light lightweig weight ht and and compac compactt - the therma thermall losses losses due to the the low required required induc inductivit tivityy of the transf transforme ormerr windings windings can be kept extremely small (7) Welding transformer: - tran transform sforms s the high high primary primary volt voltage age into into a low low seconda secondary ry voltag voltage e - ensu ensures res that that the prima primary ry power power module module and and secondary secondary powe powerr module module are 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:





























Troubleshooting guide General remarks

The “Troubleshooting guide” consists of the following parts: - Di Diag agno nost stic ic sea searc rch h tree tree - Tab able le of se serv rvic ice e co code des s 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. display Before starting to use the “Troubleshooting “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 Important! If troubleshooting on the MagicWave 1700 / 2200 and TransTig 2200 power sources: Before you start work with the “Troubleshooting “Troubleshooting guide”, read the following sections of this manual: “Fu “F unc ncti tio onal desc scri rip ptio ion n” “Ov “O ver era all ci cirrcu cuiit dia diagr gra am”



























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 checklist”” for each of the various assemblies and p.-c. boards (with LEDs). Poor ignition and welding properties where the “TIG welding” weldin g” process has been selected

Poor welding properties where the “Rod-electrode (MMA) welding” process has been selected

Mains switch in the “On” position

No welding current, or the welding current does does not correspond to the value set for I des



























Poor ignition and welding properties in “TIG welding”

Start

Is the right shielding gas connected up, and the right l/min set?

No

Connect up the right shielding gas and check l/min

Yes

Gas-test button: Is shielding gas flowing out?

Check the shielding-gas solenoid valve, including the addressing

No

Yes

Are the welding torch and grounding (earthing) cable OK?

Check the welding torch and grounding (earthing) cable

No

Yes

Parameters set correctly?

No

Check the settings on the control panel Check the set set-u -up p pa para ram mete ters rs - If nec neces essa sary ry,, rest restor ore e the the fact factor oryy settings (FAC) (see instruction manual)



























Poor welding properties in “Rod-electrode (MMA) welding”

Start

Are the electrodes and grounding ground ing (earthing) cable connected correctly and in good working order ?

Connect up the cables correctly No

Yes

Has the right process been set?

Select the correct process No

Yes

-

Parameters set correctly? No

Check the settings on the control panel Check the se set-u -up p pa para ram mete ters rs - If nec neces essa sary ry,, rest restor ore e the the fact factor oryy settings (FAC) (see instruction manual)



























No welding current, or incorrect welding amperage

Start

Are the welding torch and grounding (earthing) cable connected correctly and in good working order ?

No

Check the welding torch and grounding (earthing) cable

Yes

Control panel remains dark ?

See “Control panel remains dark” Yes

No

When the “Rod-electrode (MMA) welding” process proc ess is selected, does the open-circuit voltage = 50 V (+/- 1 V ?

See “Open-circuit voltage is faulty” No

Yes

-

Welding am amperage Ides can no longer be adjusted, or Weld ldin ing g ampe pera rag ge is alw lway ays s I ?

Yes

Change current sensor A1 VAC





























Torch not being cooled adequately

Start

In set-up, is the cooling unit set to “Off” ?

Yes Ye s

In set-up, change the setting to “Auto” or “On”

No

Switch off the power source

Enough coolant ? No

Top up with coolant, then vent the cooling unit



























Torch not being cooled adequately (continued)

A

Is the “Power” LED on power pack A1 NTFK24 always lit li t up?

No

Check fuse F1 and the 230 V AC voltage supply on power pack A1 NTFK24 X2. Change power pack A1 NTFK24

Yes

Is the “On” LED on power pack A1 NTFK24 lit up ?

No

Voltage on power pack A1 NTFK24 X3/2, X3/8 < 1 V DC

No Check the cable harness, change



























Control panel remains dark

Start

Is LED UZWK on power-module board A2 BPS 17 / BPS 22 always lit up?

No

Check mains cable, mains switch, supply voltage

Yes

Are the LEDs for supply supp ly voltage on power-module board A2 BPS 17 / BPS 22 and on control board A5 UST2B always lit up ?

No

Change control panel A6 FP 22 Yes



























Control panel remains dark (continued)

A

Are the LEDs for supply supp ly voltage on control board A5 UST2B always lit up ?

No

-

Shift tth he ma mains sw switch to to th the "Off" position Connect plug X6 to control board A5 UST2B Disc Di sco onne nect ct pl plu ugs X1, X1, X2 X2,, X4 X4, X7, X9, X10 from control board UST2B Shift th the ma mains sw switch to to th the "On" position

Yes

Change power-module board A2 BPS 17 / BPS 22




























B

Connect plug X2 to control board A5 UST2B

Are the LEDs for supply supp ly voltage on control board A5 UST2B always lit up ?

Yes

Connect plug X4 to control board A5 UST2B

Change control panel A6 FP22 No






























C

Connect plugs X9, X10 to control board A5 UST2B



























Open-circuit voltage is faulty

Start

Is there any open-circuit voltage when the “Rod-electrode “Rod-electro de (MMA) welding” process proc ess is selected ? No

Yes

-

Chan ang ge p. p.-c -c.. bo board A4 TTS TS22 22 (driver for inverter) Chan ange ge p. p.-c -c.. bo boar ard d A3 BS BSV2 V22 2 (for voltage doubling)



























Table of service codes

For every service code, this table tells you - how the the servi service ce code code is indi indicat cated ed (e.g. (e.g. “Err “Err | Arc Arc”) ”) - the code code n°(e.g. n°(e.g. where where the servic service e code is is outputte outputted d via a robot robot interface interface)) - wha whatt has caus caused ed the the servic service e code code to be disp display layed ed - app approp ropria riate te ways ways of of remedy remedying ing the the prob problem lem dsP | Axx (Code n° 20) Cause Ca use:: Remed Re medy: y:

DSP out output puts s a ge gener neral al err error, or, xx sta stands nds fo forr add additi ition onal al da data ta tha thatt are are not necessary for external service Update Upd ate sof softwa tware. re. Cha Change nge p. p.-c. -c. boa board rd US UST2. T2.

dsP | A21 (Code n° 20)



























Table of service codes (continued)

EFD | xx.y (Code n° 30) Cause: Cau se: Reme Re medy dy::

Fault in the wir Fault wirefe efeed ed sys system tem;; xx xx and and y can can be see seen n from from the lis listt of of serv service ice codes for the wirefeed system. Chec Ch eck k the the wi wire refe feed ed sy syst stem em

EIF | xx.y (Code n° 63) Cause: Cau se: Remedy: Reme dy:

Error in con Error connec nectio tion n with with a robot robot int interf erface ace;; xx and y can can be see seen n from from th the e list list of service codes for your robot interface. Check Che ck robo robott inter interface face,, updat update e softw software, are, chan change ge robo robott inter interface face

Err | Arc (Code n° 61)




























Err | tF7 (Code n° 34) Cause se:: Reme Re medy dy::

Temper Tem erat atu ure re-s -se enso sorr err rro or on on UST Chan Ch ange ge p. p.-c -c.. bo boar ard d US UST T

Err | tF8 (Code n° 64) Caus Ca use: e: Remed Re medy: y:

in con conju junc ncti tion on wi with th th the e opt optio iona nall ther thermo most stat at:: Fa Faul ultt in co cool olin ingg-un unit it temperature sensor Check Ch eck cab cable le harn harness ess.. Chan Change ge tem temper perat ature ure sen sensor sor..

Err | 027 (Code n° 27) Caus Ca use: e:

One On e of of the the su supp pply ly vo volt ltag ages es is ou outs tsid ide e the the to tole lera ranc nce e ran range ge






























Err | 068 (Code n° 68) Caus Ca use: e:

Seco Se cond ndar aryy-ci circ rcui uitt sa safe fety ty cu cutt-ou outt ha has s be been en tr trig igge gere red d




























Err | 70.x (Code n° 70) Caus Ca use: e:

Erro Er rorr in conn connec ecti tion on wit with h opti option onal al Dig Digit ital al Gas Gas Con Contr trol ol;; x stan stands ds for for::




























tp1 | xxx (Code n° 5), tp2 | xxx (Code n° 6), tp3 | xxx (Code n° 7), tp4 7), tp4 | xxx (Code n° 8), tp5 | xxx (Code n° 9)



























Detailed explanation



























BPS 17 - power-module board























































































































































































































































































































































































































































































































































































































-

Removing the old fan (continued)

Undo th Undo the e sc scre rew w (3 (3)) fr from om th the e fa fan n holding plate

(3) Fig. 10 Undoing the the screw (3) from the the fan holding holding plate

(5)

(6)

(7)

(8) (9) (10) Fig. 11 11 Undoin Undoing g the screws for the holding holding plate plate

-

Undo Un do the the six scr screws ews - (5) (5) to (10 (10)) - on on the the oppo opposit site e side side (12)

(11)

(13) (11) (12)



























Note! When mounting the fan, make sure that the arrow symbol on the black Note! When fan-housing points towards the inside of the housing after the fan has been inserted.

Fitting the new fan

-

Mount the Mount the fan fan (11) (11) on the fan fan holdin holding g plate plate (12), (12), with four screw screws s at the locat locations ions shown as Item (13) Inse In sert rt the en enti tire re as asse sem mbly

(5)

(6)

(7)

(8) (9) (10) Fig. 13 Tighteni Tightening ng the screws for the the holding plate plate

-

Tigh Ti ghten ten the six scr screw ews s - (5) (5) to (10 (10)) - for for the the fan fan hold holding ing pla plate te -

(3) Fig. 14 Tightening Tightening the screw on the the fan holding holding plate

Tig ight hten en th the e scr screw ew (3 (3)) on on th the e fan fan holding plate



























Fitting the new fan (continued)

-

(4)

Plug th Plug the e tab tab co conn nnec ecto torr (4) (4) on onto to th the e gas-solenoid valve

Fig. 15 Pluggin Plugging-on g-on the tab connector connector

-

-

(2) Fig. 16 Pluggin Plugging-on g-on the Molex 4-pole 4-pole connector connector

4-pole 4-po le Mo Mole lex x con conne nect ctor or (2 (2)) at at X5 X5 on on UST2B board: Attach the red lead for the th e fan to Pin 3, and the black lead for the fan to Pin 4 Plu Pl ug on on th the Mo Mole lex x co conn nne ect cto or Fix Fi x the the re red d and and bl blac ack k fan fan-l -lea eads ds us usin ing g cable-ties



























Exchanging the TTS 22 board Note! There is a risk of the TTS 22 board being damaged by electrical Note! There discharge. Suitable ESD precautions must be taken before the p.-c. board TTS 22 is exchanged exchanged.. These include:

ESD precautions

-

-

The workpl workplace ace where where it is inte intended nded to remove remove this p.-c p.-c.. board board must must be fitt fitted ed out out with with the following ESD-compatible equipment: - Worktops - Floors - Di Disc scha harg rgin ing g wr wris istt-ba band nds s - Seating Outside Outs ide the ESDESD-comp compatib atible le workp workplace, lace, use suit suitable able tran transport sport cont containe ainers rs

Removing the old TTS 22 board

(2)

(1) (2) (1)

(11)

(1) Fig. 1 UST2B: Separati Separating ng the plug-in plug-in connector connectors s and unscrewing unscrewing the spacers spacers

UST2B board: Unpl Un plug ug th the e plu plugg-in in co conn nnec ecto tors rs (1 (1)) Unscre Uns crew w the the 5 space spacers rs (2) (2) and the met metal al spa spacer cer (1 (11) 1) Tak ake e ou out p.p.-c. c. boa oard rd UST2 T2B B



























Removing the old TTS 22 board (continued)

(4)

-

Uns nscr crew ew 2 sp spac ace ers (4 (4)) on on the the insulation film

-

Unplug Unpl ug th the e Mol Molex ex co conn nnec ecto torr (5) (5) an and d tab connectors (6) from p.-c. board TTS 22

-

Undo Un do 2 sp spac acer ers s (3) (3) an and d 4 sc scre rews ws (9 (9))

-

Tak ake e out out p. p.-c -c.. boa board rd TT TTS S 22 22 (7) (7),, complete with its holding plate (10) Undo Un do 5 sp spac acer ers s (8 (8)) on on th the e TT TTS S 22 board Tak ake e out out th the e TTS TTS 22 bo boar ard d (7) (7) fr from om it its s holding plate (10)

(4)

Fig. Fi g. 2 Un Undo doin ing g the the spac spacers ers

(5)

(6)

Fig.. 3 Und Fig Undoing oing the plugplug-in in conne connector ctors s

(9) (3)

(9)

(9)

(3)

(9)

Fig.. 4 Undo Fig Undoing ing the screw screws s and and space spacers rs

(8)

(10)





























Fitting the new TTS 22 board

-

Place Pla ce p.-c. p.-c. boar board d TTS TTS 22 (7) (7) onto onto the the space spacers rs (8) (8) on the the holdi holding ng plat plate e -

Tig ight hten en th the e 5 sp spac acer ers s (8) (8) on th the e TTS TTS 22 board Pla Pl ace dow own n the the ne new w TT TTS S 22 22 bo boar ard d (7), complete with its holding plate

(8)

(7) Fig.. 6 Fig

Fasteni Fas tening ng the the new TTS TTS 22 board board,, using using spacers

-

Using Usin g 2 sp spac acer ers s (3) (3) an and d 4 sc scre rews ws (9 (9), ), screw down the TTS 22 p.-c. board, complete with its holding plate

-

Plug th Plug the e Mol Molex ex co conn nnec ecto torr (5) (5) to th the e TTS 22 board

(9) (3)

Fig.. 7 Fig

(9)

(9)

(3)

(9)

Tighten Tig htening ing the the screw screws s and spac spacers ers

Important! When plugging-on the five tab connectors (6), proceed as follows: Plug Pl ug th the e sin singl gle e tab tab co conn nnec ecto torr ont onto o the the “Common X1” slot The Th e ot othe herr tab tab co conn nnec ecto tors rs - joi joine ned d in into to 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)



























-

Fitting the new TTS 22 board (continued)

Fitt the Fi the p. p.-c -c.. boa board rd US UST2 T2B B in in pla place ce

Fig. 10 Fitting the UST2B UST2B board in in place

(2)

(1)

(2)

(1)

(11)

(1) Fig. 11 11 UST2B: Making Making the plug-in connections connections and tightening the spacers

UST2B board: - Res Resto tore re the the plu plug-i g-in n conn connect ection ions s (1) (1) Note! When Note! When fastening the spacers (2), screw the metal spacer to the location



























Exchanging the BSV 22 board Note! There is a risk of the BSV 22 board being damaged by electrical Note! There discharge. Suitable ESD precautions must be taken before the p.-c. board BSV 22 is exchanged. These include:

ESD precautions

-

-

The workpl workplace ace where where it is inte intended nded to remove remove this p.-c p.-c.. board board must must be fitt fitted ed out out with with the following ESD-compatible equipment: - Worktops - Floors - Di Disc scha harg rgin ing g wr wris istt-ba band nds s - Seating Outside Outs ide the ESDESD-comp compatib atible le workp workplace, lace, use suit suitable able tran transport sport cont containe ainers rs

Removing the UST2B board

(2)

(1) (2) (1)

(11)

(1) Fig. 1 UST2B: Separati Separating ng the plug-in plug-in connector connectors s and unscrewing unscrewing the spacers spacers



























Removing the old BSV 22 board

(4)

-

Uns nscr cre ew 2 spac ace ers (4 (4)) on on the the insulation film

-

Unplug Unpl ug th the e Mol Molex ex co conn nnec ecto torr (5) (5) an and d tab connectors (6) from p.-c. board BSV 22

-

Undo Un do 2 sp spac acer ers s (3) (3) an and d 4 sc scre rews ws (9 (9))

-

Tak ake e out out p. p.-c -c.. boa board rd BS BSV V 22 22 (7) (7),, complete with its holding plate (10) Undo Un do 4 spa space cers rs (8 (8)) on on p.p.-c. c. bo boar ard d BSV 22 Tak ake e out out th the e BSV BSV 22 bo boar ard d (7) (7) fr from om

(4)

Fig. Fi g. 2 Un Undo doin ing g the the spac spacers ers

(5)

(6)

Fig.. 3 Und Fig Undoing oing the plugplug-in in conne connector ctors s

(9) (3)

(9)

(9)

(3)

(9)

Fig.. 4 Undo Fig Undoing ing the screw screws s and and space spacers rs

(8)

(7) (8)

(10)

-



























Fitting the new BSV 22 board

-

Place Pla ce p.-c p.-c.. board board BSV 22 (7) (7) onto onto the sp space acers rs (8) (8) on on the the holdi holding ng pla plate te (8)

(7) (8)

(10)

-

(8) Fig.. 6 Fig

(8)

Fasteni Fas tening ng the the new BSV BSV 22 board board,, using using spacers

-

Using Usin g 2 sp spac acer ers s (3) (3) an and d 4 sc scre rews ws (9 (9), ), screw down the BSV 22 board, complete with its holding plate

-

Plug th Plug the e Mol Molex ex co conn nnec ecto torr (5) (5) to X9 on the BSV 22 board Plug Pl ug on tab co conn nnec ecto tors rs X1 to X4 (6 (6)) in in accordance with the labelling on the cables and on the BSV22 board.

(9) (3)

Fig.. 7 Fig

Tig ight hten en th the e 4 sp spac acer ers s (8) (8) on th the e BSV BSV 22 board (7) Plac Pl ace e dow down n th the new new BSV 22 bo boar ard d (7), complete with its holding plate

(9)

(9)

(3)

(9)

Tighte Tig htenin ning g the scre screws ws and and space spacers rs

(5)

(6)

-

Fig.. 8 Maki Fig Making ng the the plug-i plug-in n connec connection tions s





























-

Fitting the UST2B board

Fitt the Fi the p. p.-c -c.. bo boar ard d UST UST2B 2B ba back ck in place

Fig. 10 Fitting UST2B in in place

(2)

(1)

(2)

(1)

(11)



























Exchanging the earth fault-current watchdog Removing the old earth faultcurrent watchdog

(1)

(2)

Unpl Un plug ug th the e 2424-po pole le Mo Mole lex x con conne nect ctor or (1) X4 from p.-c. board UST2B Usin Us ing g a Mo Mole lex x rem remov over er to tool ol,, rem remov ove e lead (2) from Pin 10 and lead (3) from Pin 22 on the 24-pole Molex connector

(3)

Fig.. 1 Fig

Removin Rem oving g leads leads from the the Molex Molex connecto connector r

-

(4) Fig.. 2 Fig

Uncover Unc overing ing the the cable cable of of the earth earth faultfault-

Cut th Cut thro roug ugh h the the ca cabl ble e ti tie e th that at fa fast sten ens s the cables (4) for the earth faultcurrent watchdog, and unthread the cables (4)



























Fitting the new earth faultcurrent watchdog

-

Place the eart earth h fault-c fault-curre urrent nt watch watchdog dog in posit position ion (10) and moun mountt it usin using g two two screws (8) Insert Inse rt the the yellowyellow-gree green n earthin earthing g (groun (grounding) ding) lead (7) in in the the lamp-w lamp-wire ire conn connector ector (6) and fasten it by tightening the screw (5)

(1) (2)

Insert the following leads to the 24-pole Molex connector (1) X4: Lead (2) to Pin 10 Lead (3) to Pin 22 -

Plug th Plug the e 2424-po pole le Mo Mole lex x con conne nect ctor or (1 (1)) X4 to p.-c. board UST2B

(3)

Fig.. 4 Fig

Insertin Inse rting g the leads leads into into the Molex Molex conne connector ctor

Arrange the cables cable s for the earth fault-current fault-c urrent watchdog, and fix fi x them using cable ties.



























Exchanging the transformer Removing the old transformer

(1)

-

Undo th Undo the e two two sc scre rews ws (1 (1)) for for th the e rac rack k at the front

-

Unpl Un plug ug th the e rib ribbo bon n cab cable le (2 (2)) for for th the e control panel from X2 on the UST2B board Dettach the co De con ntr tro ol pan ane el

(1)

Fig.. 1 Und Fig Undoin oing g screw screws s on rac rack k at front front

(2)

Fig.. 2 Fig

UST2B: UST 2B: Unplu Unpluggin gging g the ribb ribbon on cable cable



























Removing the old transformer (continued)

-

Und ndo o 2 sc scre rew ws (4 (4)) on th the e HF transformer (5)

-

Lifft the Li the HF tr tran ansf sfor orme merr (5) (5) and and un undo do the 2 screws (6) behind the HF transformer

-

Dismou Dism ount nt th the e se seco cond ndar aryy tr tran ansf sfor orme mer r leads (7): Unscrew the 2 screws with with serrated lock washers (not illustrated)

(5) (4)

Fig.. 4 HF tran Fig transfor sformer mer:: Und Undoin oing g the the scre screws ws

(5)

(6) Fig.. 5 Fig

Undoin Und oing g the scre screws ws behin behind d the HF transformer





























-


(12) (10) (11) (9)

Fig.. 8 Fig

Dismou Dis mountin nting g the centre-ta centre-tap p transform transformer er lead

Undo th Undo the e he hexa xago gona nall bo bolt lt (9 (9)) - wid width th-across 19 Tak ake e of off the the he hexa xago gona nall bol boltt (9) (9),, together with the serrated lock washer and plain washer

The following leads will now have been detached: Cent Ce ntre re-t -tap ap tr tran ansf sfor orme merr lea lead d (10 (10)) Meas Me asur urin ing g lea lead d (1 (11) - whi white te ca cabl ble e labelled “Massebuchse” (meaning “earthing socket”) Seco Se cond ndar aryy pr prot otec ecti tive ve-c -cir ircu cuit it le lead ad (1 (12) 2) - unlabelled white cable -

Undo the spacers (13)



























-


(18)

(16)

-

Rem emov ove e th the wel weld din ingg-vo volt ltag age e measuring lead (16) Unth Un thre read ad th the e ce cent ntre re-t -tap ap tr tran ansf sfor orme mer r lead (17) from the current sensor (18)

(17)

Fig. 11 11 Unthrea Unthreading ding the centre-tap centre-tap transformer lead lead

(20) (21) (19)

-

Loose Loo sen n th the 2 sc scre rew ws (19 (19)) on on th the lamp-wire connector Tak ake e out out th the e pri prima mary ry le lead ads( s(20 20)) Undo the screw (21)




























-

Unthre Unth read ad th the e ce cent ntre re-t -tap ap tr tran ansf sfor orme mer r lead (17) from the ferrite rings (25) (see also Fig.14)

-

Undo Un do th the e fo four ur sc scre rews ws (2 (26) 6) on th the e transformer, and take off the side plates (27)

(25)

(17)

Fig. 15 Unthrea Unthreading ding the centre-tap transformer transformer lead

(27)



























Fitting the new transformer (continued)

-

Insert Ins ert the tra transf nsform ormer er (22 (22)) into into the pow power er sou source rce (22)

Tighten th the sc screws (2 (22)

Important! If there is an earthing (grounding) lead, tighten the 3 screws (22) and use the middle screw (22) to screw down the earthing lead as well.

Fig. 18 Fasteni Fastening ng the transformer transformer

(16)



























-


(18) -

Pass th Pass the e ce cent ntre re-t -tap ap tr tran ansf sfor orme merr le lead ad (17) through the current sensor (18) in the direction shown by the arrow Arra Ar rang nge e the the me meas asur urin ing g lea lead d (16 (16)) for for the “X1 Common” tab connector (see Fig.19)

(17)

(16)

Fig. 22 Arrangin Arranging g the transformer transformer lead

(15)

(16)

When plugging-on the five tab connectors (15) and (16), proceed as follows: Plug Pl ug th the e sin singl gle e tab tab co conn nnec ecto torr (16 (16)) onto the “Common X1” slot The Th e ot othe herr tab tab co conn nnec ecto tors rs (1 (15) 5) - joi joine ned d into pairs using silicone hoses - can





























Fitting the new transformer (continued) (12) (10) (11) (9)

(9)

(29) (30) (11) (12) (10)




























(5)

(6) Fig. 28 Tightening Tightening the screws behind behind the HF transformer

-

Lift th Lift the e HF HF tra trans nsfo form rmer er (5 (5)) and and ti tigh ghte ten n the screws (6) behind the HF transformer




























-

(1)

Fig. 32 32 Screws on rack at at front

(1)

Press Pres s ag agai ains nstt th the e ra rack ck at fr fron ontt Tig ight hten en th the e two two sc scre rews ws (1 (1)) for for th the e rack at the front



























Terms and abbreviations used General remarks

“Terms and abbreviations” is a glossary of specific technical terms that are important for understanding understand ing the Service Manual.

Terms and an d abbreviations

BSL-Tool: 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.



























Terms and an d abbreviations (continued)

NTC resistors: NTC = Negative Temperature Coefficien oefficient. t. These resistors have high resistance at low temperatures. temperature s. As long as operating temperature 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 ositive T Temperature emperature C Coefficient. oefficient. The higher the temperature of these resistors, the greater their resistance. As As the temperature of the resistor rises as the current increases, limitation of the current takes place automatically. PFC: P Factor Control. This ensures sine-wave power input, for





























TransTIG 2200



























MagicWave 1700



























MagicWave 2200



























FK 2200



























MagicWave 2200 Job G/F MagicWave 2200 Job G/ G/F/US TransTig 2200 Job G/F TransTig 2200 Job G/F/US

4,075,119 4,075,119,800 4,075,120 4 075 120 800

MagicWave 2200 G/F MagicWave 22 2200 G/ G/F/US TransTig 2200 G/F TransTig 2200 G/F/US

4,075,125 4,075,125,800 4,075,126 4 075 126 800



















































Transtig 2200 Magicwave 1700 / 2200 Fk 2200: Service Manual Spare Parts List Gb

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