Fronius TransPocket 1500 Service Manual
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Fronius TransPocket 1500 Service Manual

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Summary of Contents for Fronius TransPocket 1500

  • Page 1: Service Manual

    Service Manual...

  • Page 2: Dear Service Technician

    This Service Manual is intended to show you how to perform service and corrective General remarks maintenance work on the TransPocket 1500 (TP 1500). You will find it well worthwhile to read through the Service Manual carefully and to follow all the instructions it contains.

  • Page 3: Table Of Contents

    Contents Service Manual ............................. 1 Dear Service Technician ..........................2 General remarks ............................2 Safety ............................... 2 Safety rules ..............................7 General remarks ............................7 Utilisation for intended purpose only ......................8 Ambient conditions ........................... 8 Obligations of owner/operator ........................8 Obligations of personnel ...........................
  • Page 4 History ................................. 31 Modification ............................31 Measuring and testing equipment, tools ...................... 31 General remarks ............................ 31 Measuring and test equipment ....................... 31 Tools and appliances ..........................31 Additional needed tools .......................... 32 Filter attachment ............................32 Filter attachment with filter insert ......................32 Opening the housing ...........................
  • Page 5 Installation instructions: FPA15 board ......................69 Safety ..............................69 Scope of supply ............................69 Tools needed ............................69 Additional tools needed .......................... 69 Opening the housing ..........................69 Removing the FPA15 board ........................70 Fitting the FPA15 board .......................... 71 Closing the housing ..........................
  • Page 6 Removing the front of the housing ......................109 Fitting the front of the housing ....................... 110 Fitting the welding sockets ........................110 Fitting the seal for the remote-control unit connection socket ..............111 Fitting the FPA15 board ......................... 112 Closing the housing ..........................113 Fronius Worldwide...

  • Page 7: Safety Rules

    Safety rules Danger! “Danger!” indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. This signal word is to be limited to the most extreme situations. This signal word is not used for property damage hazards unless personal injury risk appropriate to this level is also involved.

  • Page 8: Utilisation For Intended Purpose Only

    Utilisation for The power source may only be used for jobs as defined by the “Intended intended purpose purpose” (see the section of the Operating Instructions headed “Starting to only use the welding machine”). Utilisation in accordance with the “Intended purpose” also comprises following all the instructions given in this service manual performing all stipulated inspection and servicing work exact compliance with the prescribed measurement, testing and...

  • Page 9: Personal Protective Equipment

    Personal For your personal safety, take the following precautions: protective equipment Wear stout footwear that will also insulate even in wet conditions Protect your hands by wearing insulating gloves Protect your eyes from UV rays with a safety shield containing regulation filter glass Only use suitable (i.e.

  • Page 10: Hazards From Mains And Welding Current

    Hazards from An electric shock can be fatal. Every electric shock is hazardous to life. mains and welding current All welding cables must be firmly attached, undamaged and properly insulated. Replace any loose connections and scorched cables immediately. Have the mains and the appliance supply leads checked regularly by a qualified electrician to ensure that the PE conductor is functioning correctly.

  • Page 11: Emc Precautions

    EMC precautions It is the responsibility of the owner/operator to ensure that no electromagnetic interference is caused to electrical and electronic equipment. If electromagnetic interference is found to be occurring, the owner/operator is obliged to take all necessary measures to prevent this interference. Evaluation of possible electromagnetic problems that may occur on equipment in the vicinity, and of the degree of immunity of this equipment as per the CE Declaration of Conformity:...

  • Page 12: Informal Safety Precautions

    Further information on corrective maintenance, modification and inspection of welding power sources is available from your regional or national Fronius service centre,who will be pleased to provide you with a copy of the Work Instruction "Safety Inspection of Welding Machinery”...

  • Page 13: Alterations To The Power Source

    The power source fulfils the fundamental requirements of the Low-Voltage and Electromagnetic Compatibility Directive and is thus CE-marked. Copyright Copyright to this service manual remains the property of Fronius International GmbH. Text and illustrations are all technically correct at the time of going to print.

  • Page 14: Technical Data - Rating Plate

    Technical data - Rating plate All the relevant data for the TP 1500 Rating plate power source may be found on the rating plate. Legend: (1) Identification (2) Data regarding weld process (3) Data regarding power supply Fig.1 Rating plate on the TP 1500 power source The “Identification”...

  • Page 15: Duty Cycle

    Duty cycle Important! When comparing duty-cycle data, remember that Fronius assumes an ambient temperature of 40 °C. Even if the ambient temperature is only marginally lower, considerably longer duty cycles are possible. The duty cycle is stated in % and refers to a 10-minute cycle.

  • Page 16: Data Regarding Power Supply

    Data regarding The section on “Data regarding power power supply supply” provides information on the required mains power connection and the necessary mains fuse protection. Other data given here relate to the power consumption, the degree of protection and the CE-labelling of the power source. Fig.6 “Data regarding power supply”...

  • Page 17: Set-Up Regulations

    Set-up The power source is tested to “Degree of protection IP23”, meaning: regulations Protection against penetration by solid foreign bodies with diameters larger than 12 Protection against spraywater up to an angle of 60° to the upright The power source can be set up and operated outdoors in accordance with IP23. However, the built-in electrical components must be protected against direct wetting.

  • Page 18: General Basics - Functional Principle

    General basics - Functional principle Inverter principle The TP 1500 power source functions by - General (dm³) the inverter principle. The distinguishing feature of inverter power sources is that remarks the welding transformer’s location in the energy path does not come until after the switching transistor.

  • Page 19: Series Resonance Converter

    Resonance In spite of the complicated controlling Pmax! With PWM, max. power is needed converter system needed for use in welding, the (continued) resonance-converter principle offers a Characterisitic number of useful advantages: (for pulse-width modulation) The resonance structure makes it Ideal possible to achieve a nearly “ideal characteristic...

  • Page 20: Increasing The Output Voltage By Means Of Series-Parallel Resonance

    Series-parallel The voltage increase occurring in the “resonant frequency” region, in the capacitor resonance component, is thus available partly on capacitor C and partly on load resistor R . On converter resistor R , a voltage arises which may be higher than the input voltage. This effect is (continued) encouraged by a high load resistance, which shunts out the capacitor C to the...

  • Page 21: Applying The Resonance Converter Principle

    Complex A complex regulation strategy is called for regulation (3) The output voltage tends towards operating point (4) as a result of the load resistance becoming smaller At operating point (3), a decrease in the frequency corresponds to an increase in the output voltage (continued) Also at operating point (4), a decrease in the frequency corresponds to an increase in the output voltage By decreasing the frequency, then, the output voltage can be clearly brought back towards the value for operating...

  • Page 22: Hot-Start And Anti-Stick Functions

    Measuring and If a short circuit takes place, there is a regulating the brief rise in the amperage. In order to parameters obtain a stable arc, the welding current Adjustable “welding also increases briefly, in line with the pre- short-circuit current”...
  • Page 23 Hot-Start and Anti-Stick function (continued) 180 A 160 A 140 A Anti-Stick Hot-Start function function 0.5 s 1.5 s Sticking and burn-out are prevented (Anti-Stick) Burn-out is prevented (Anti-Stick) Fig.11 Anti-Stick The Anti-Stick function is also available when the “rod-electrode welding” process has been selected.

  • Page 24: Tig-Comfort-Stop" Function

    “TIG-Comfort- The “TIG Comfort-Stop” function is (1) welding (2) lift torch (3) lower (4) keep Stop” function available on the TP 1500 TIG power torch height source if either the “TIG welding” or “TIG (5) remove pulsed arc” welding process is selected. torch When the “TIG Comfort-Stop”...

  • Page 25: Gas Flow

    Gas flow The TP1500 TIG power source has an integrated gas connection and a built-in gas solenoid valve that permits intelligent control of the gas flow. This intelligent gas-flow control ensures that the weld seam is given optimum gas- shielding when either the “TIG welding” or “TIG pulsed arc”...
  • Page 26 VRD - Voltage Welding-circuit resistance is smaller than Reduction Device the minimum human-body resistance (continued) (smaller than 200 ohms): VRD is inactive No limitation of the output voltage, so as to ensure sufficient welding power Example: Start of welding Fig.13b VRD is not active Important! Within 0.3 seconds of the end of welding: VRD is active again The output voltage is once again limited to 12 V...

  • Page 27: General Basics - How To Handle Components

    General basics - how to handle components ESD precautions General remarks Development work on new products always aims to achieve improvements in particular product properties (e.g. optimised welding properties), as well as general improvements in terms of higher performance, longer maintenance intervals, unlimited reliability, and reduced weight and energy consumption.

  • Page 28: Heat Dissipation From Power Componentry

    ESD precautions Outside the EPA, use suitable containers (continued) Use specially labelled packaging and shipping materials If anything is unclear, notify the responsible ESD officer Protective equipment In the electrostatic protection areas (EPA’s), the following ESD protective equipment is used. All of this equipment is connected to the shared earthing facility via a defined resistance (uniform potential): Work surfaces Floors...
  • Page 29 Heat dissipation Heat-transfer compound from power componentry To ensure optimum heat dissipation, there is a heat-transfer compound applied onto the (continued) underside of the secondary diode and transistor module. After every separation of the secondary diode and transistor module from the heat sink, the heat-transfer compound must be renewed.

  • Page 30: General Basics - Packaging

    Heat dissipation Note! If the heat-transfer from power compound is not applied to the componentry component in a complete, gap- (continued) free layer, this may result in heat- transfer problems. If too thick a layer of heat-transfer compound is applied, this also impairs heat transfer, and the transistor module may break when the fixing screws are tightened.

  • Page 31: History

    History Modification No modifications have yet been made to the TP 1500 series. Measuring and testing equipment, tools General remarks Note! Observe the calibration intervals specified by your QM System for the measuring and testing equipment and tools that are used. Measuring and - Oscilloscope test equipment...

  • Page 32: Additional Needed Tools

    Additional - Soldering iron needed tools - Special solder for electronic applications - Solder absorption strand - Suction pump (as an alternative to the solder absorption strand) - Heat-transfer compound - Foamed plastic roller - Round-nut spanner Filter attachment Filter attachment Particularly when intended for use in with filter insert heavily dust-laden environments, the TP...

  • Page 33: Opening The Housing

    Opening the housing Opening the - Remove the carrying strap (34) housing - Undo the 5x25-TX20 screw (34) in the front of the housing - Undo the 5x25-TX20 screw (35) in the rear of the housing - Carefully lift the housing and unplug the “Housing earthing conductor”...

  • Page 34: Troubleshooting

    Troubleshooting Safety Warning! An electric shock can be fatal. Before opening up the power source, switch it off, unplug it from the mains and put up a warning sign to stop anybody inadvertently switching it back on again. If necessary, discharge the electrolytic capacitors.
  • Page 35 Troubleshooting Error Cause Remedy table No welding current Short-circuit (secondary side) Stop the short circuit (unplug (continued) After the machine is the electrode or earth cable switched on, all indicators from the bayonet socket). If are permanently lit up the fault persists: Open up the (longer than 2 seconds) housing and check all cables for insulation damage, and that...
  • Page 36 Error Cause Remedy Troubleshooting table LCA 15 board is faulty Replace the LCA 15 board (see (continued) “Installation instructions for LCA 15 board”) Not possible to set Remote-control unit socket is Replace the remote-control unit welding current on faulty (TP 1500 RC and TP socket on the FPA 15 board (otherwise fully functional) 1500 TIG)
  • Page 37 Troubleshooting Error Cause Remedy table Poor ignition Wrong welding process selec- Select the welding process (continued) characteristics "Rod-electrode welding" or (Rod-electrode welding) "Rod-electrode welding with CEL-electrode" Poor ignition Wrong welding process selec- Select the "TIG welding" or "TIG characteristics pulsed arc welding" process (TIG-welding) (TP 1500 TIG) TP 1500 TIG: Automatic gas...

  • Page 38: Measuring, Inspection And Adjustment Jobs - Checking And Setting The Parameters On The Welding Sockets

    Measuring, inspection and adjustment jobs - Checking and setting the parameters on the welding sockets General remarks Note! Whenever the LCA 15 board is exchanged, it is necessary to check and set the maximum welding amperage. Checking the - Shift the mains switch to the “O” maximum position and unplug the machine from welding...

  • Page 39: Checking The Minimum Welding Amperage

    Setting the - Open the housing (see the section headed: “Opening the housing”) maximum - Plug the machine into the mains and shift the mains switch to the “I” position welding - Select the welding process “rod-electrode welding“ amperage - Measure the max. welding current using the shunt and power resistor (continued) - Adjust the potentiometer (1) - Fig.3 - on the LCA15 board, until the exact value for the maximum welding current (140 A) is reached...

  • Page 40: Checking The Open-Circuit Voltage

    Checking the - Shift the mains switch to the “O” position and unplug the machine from the mains minimum - Connect the shunt and power resistor to the welding sockets of the power source welding - Set the welding-current dial to Minimum amperage (continued) Warnung! An electric shock can be fatal.

  • Page 41: Checking The Open-Circuit Voltage - Tp 1500 Vrd

    Checking the Variant 2: Measuring the RMS value open-circuit voltage N.B.! The RMS value can only be of any TP 1500 (continued) help in detecting a defect in the power source in the event of very severe deviations from the desired value. V/Amp.- meter - Plug the machine into the mains and...

  • Page 42: Cycle Test

    Check the arc- Warning! Work performed incorrectly can cause serious injury and damage. force and anti- Observe all safety measures and protective precautions for welding, as set out stick in the “Safety rules” section of the power source operating instructions. (continued) 180 A Anti-stick...
  • Page 43 Cycle test (continued) 140 A 10 A 6.5 min 3.5 min Fig.10 Cycle test - test procedure - Condition 1: After several seconds, the fan switches on, and the heat-sink warms up to 43 °C - Condition 2: Approx. three and a half minutes after being switched on, the power source switches off once the heat-sink has heated up to 93 °C Condition 3: The fan must continue to run Condition 4: The “Fault”...

  • Page 44: Checking The Transistor Module

    Checking the - Shift the mains switch to “O” and unplug the machine from the mains transistor module Warning! An electric shock can be fatal. Before beginning with the test procedure, discharge all the electrolytic capacitors. - Open the housing (see section headed “Opening the housing”) - Measure the diode paths in the 0.2 - 0.7 V...
  • Page 45 Checking the Note! The following pictures show measurements being made in the Transistor conducting direction of the diode path. module (continued) 0.2 - 0.7 V Fig.12 First diode path: “Intermediate-circuit potential - primary-side transformer cable” 0.2 - 0.7 V Fig.13 First diode path: “GND potential - primary-side transformer cable”...
  • Page 46 Checking the transistor module (continued) 0.2 - 0.7 V Fig.14 Second diode path: “Intermediate-circuit potential - primary-side transformer cable” 0.2 - 0.7 V Fig.15 Second diode path: “GND potential -> primary-side transformer cable”...
  • Page 47 Checking the transistor module (continued) 0.4 - 1 V Fig.16 Diode path: “Rectifier - rectifier 0.2 - 0.7 V Fig.17 Diode path: “Rectifier AC -...

  • Page 48: Checking The Secondary Diode

    Checking the transistor module (continued) 0.2 - 0.7 V Fig.18 Diode path: “Rectifier AC Checking the - Open the housing (see the section headed: “Opening the housing”) secondary diode Warning! An electric shock can be fatal. Before beginning with the test procedure, discharge all the electrolytic capacitors.

  • Page 49: Checking The Potentiometer Ribbon Cable

    Checking the Before closing the housing: secondary diode - mount the screws (2) with cup springs (continued) (Fig.21) Note! When mounting the cup springs (3), make sure that they are fitted in the correct position (Fig.21) Fig.21 Fitting the cup springs Checking the Warning! An elelectric shock can be fatal.

  • Page 50: Insulation Test

    PE conductor Important! Special testing equipment is needed for testing the PE conductor. test - Cross-sectional area of PE conductor: 1.5 mm² (continued) - Adjust the PE-conductor testing unit to work with this cross-sectional area - Test current = 10 A - Place the test-prod of the PE-conductor testing unit up against the front fixing screw and hold it there, as shown in Fig.
  • Page 51 Insulation test 3rd test: Secondary circuit / earth (continued) - Place a test-prod against one of the welding sockets (e.g. socket) (Fig.25) - Place the second test-prod against the protective contact of the mains plug (Fig.25) - Carry out the measurement - Insulation resistance must be >...

  • Page 52: Maintenance And Repair Work

    Maintenance and repair work Installation On the following pages, you will find installation instructions for the most important instructions assemblies in the TP 1500 power source. The following list comprises all the installation instructions. For each set of installation instructions, the item numbers of the assemblies covered in this particular set of instructions are also given.

  • Page 53: Overall Circuit Diagram

    Overall circuit diagram...

  • Page 55: Installation Instructions: Lcg15 Board And Secondary Diode

    Installation instructions: LCG15 board and secondary diode Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 56: Removing The Lcg15 Board

    Opening the - Remove the housing stiffening element (21) (37) housing (21) (continued) - Remove the board insulator (37) Fig.2 Removing the - Disconnect the ribbon cable (42) from (33) (41) (42) LCG15 board the FPA15 board (5) - Cut through the cable binder (33) - Disconnect the 10-pole Molex plug (41) from the LCA15 board Fig.3...

  • Page 57: Removing The Secondary Diode

    Removing the - Carefully bend the “centre-tap LCG15 board transformer lead“ (59) to one side (continued) - Unscrew the 4 M4x20-TX20 screws (52) from the LCG 15 board (3) (52) (59) Fig.6 - Carefully detach the LCG15 board (3) Fig.7 Removing the - Undo the 2 M4x14-TX20 screws (31) secondary diode...

  • Page 58: Fitting The Secondary Diode

    Fitting the - Pre-clean the heat sink with contact secondary diode spray and a non-linting cloth - Remove any contamination or unevenness from the heat sink with fine abrasive paper (grain P 500 or finer) - Clean the heat sink with contact spray and a non-linting cloth Note! There already is a heat- transfer film affixed to the...

  • Page 59: Fitting The Lcg15 Board - Secondary Diode With Two Cup Springs

    Fitting the LCG15 If the secondary diode is equipped with two cup springs, please proceed according to the board - following procedure: secondary diode - Place the LCG15 board (3) onto the with two cup spacers on the diode holder, in the springs correct position - Slightly tighten the two M4x20-TX20...

  • Page 60: Mounting The Shunt And Connecting The Leads

    Mounting the shunt and (57) (41) connecting the leads (54) (64) (56) (55) (64) Fig.16 - Fasten the shunt (54) and the two leads “Socket X3” (blue) (64) to the copper bracket (55) tighten the M5x12-TX20 screw (56) with a torque of 2 Nm - Insert the welding-voltage measuring lead (red) (57) into the 10-pole Molex plug (41) 1X10/Pin3 - Plug the 10-pole Molex plug (41) onto...

  • Page 61: Closing The Housing

    Closing the - Insert the board insulator (37) (21) (37) housing - Insert the housing stiffening element (21) Fig.18 - Plug the “housing earth conductor” (36) (34) onto the housing box, in the correct position - Replace the housing box - Screw the 5x25-TX20 screw (35) back onto the rear of the housing - Screw the 5x25-TX20 screw (34) back...

  • Page 62: Installation Instructions: Lca15 Board

    Installation instructions: LCA15 board Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 63: Removing The Lca15 Board

    Opening the - Remove the housing stiffening element (21) (37) housing (21) (continued) - Remove the board insulator (37) Fig.2 Removing the - Unplug the mains leads for the LCA15 (38) (39) LCA15 board board from the mains switch L (white) from 1A (38) N (blue) from 2A (39) Fig.3 (40)

  • Page 64: Fitting The Lca15 Board

    Removing the Note! When detaching the (44) (45) LCA15 board LCA15 board (1), make sure that (continued) you do not kink or pinch any cables, or subject them to tensile strain. - Carefully detach the LCA15 board (1) from the heat sink Note! When disconnecting the transformer leads (44) for the LCA15 board, squeeze the...
  • Page 65 Fitting the LCA15 (44) board (continued) (45) Fig.11 - Arrange the “LCA15 board transformer leads” (44) in such a way that the WAGO connectors (45) are resting on the transformer coil body, as shown in Fig.11 Note! When fitting the LCA15 board in place, make sure that the “LCA15 board transformer leads”...
  • Page 66 Fitting the LCA15 - Carefully place the LCA15 board (1), board underside first, onto the heat sink (continued) Fig.13 - To position the LCA15 board (1), gently screw the M4 screw (43) into the M4x17 earthing stud (48) - see Fig.10 - by hand.
  • Page 67 Fitting the LCA15 Note! Before inserting the board M4x14-TX20 screws (31) into (31) (continued) their holes, push the cup springs (32) onto the M4x14-TX20 screws (31), as shown in Fig.16. (32) Fig.16 - Carefully turn the M4x14-TX20screws (31) (31) (43) (31), alternately, until you start to feel gentle resistance Note! Before you tighten the...

  • Page 68: Closing The Housing

    Fitting the LCA15 - Plug the mains leads for the LCA15 (38) (39) board board back onto the mains switch (continued) L (white) (38) to 1A N (blue) (39) to 2A Fig.20 Closing the - Insert the board insulator (37) (21) (37) housing...

  • Page 69: Installation Instructions: Fpa15 Board

    Installation instructions: FPA15 board Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 70: Removing The Fpa15 Board

    Removing the - Disconnect the ribbon cable (42) from (40) (41) (42) FPA15 board the FPA15 board (5) - Unplug the 2-pole Molex plug (40) from the LCA15 board - Disconnect the 10-pole Molex plug (41) from the LCA15 board Fig.3 - Take off the cap from the “Welding- amperage setting dial“...

  • Page 71: Fitting The Fpa15 Board

    Removing the - Swing the copper bracket (55) to one FPA15 board side (continued) Note! First carefully detach the FPA15 board (5) from the front alignment pins. - Carefully lift the FPA15 board (5) and remove it (55) Fig.9 Fitting the FPA15 Note! Before fixing the FPA15 board (5) on the alignment pins, do the following: board - TP 1500 RC / 1500 TIG: Apply a thin layer of lubricant to the seal of the remote-...
  • Page 72 Fitting the FPA15 - Fasten the X3 cable (blue) (72) and board the by-pass capacitors (73) onto the (continued) copper bracket (55), using the 5x12 - TX20 screw (68) - Tighten the 5x12 - TX20 screw (68) with a torque of 2 Nm (68) (55) (72)

  • Page 73: Closing The Housing

    Closing the - Insert the board insulator (37) (21) (37) housing - Insert the housing stiffening element (21) Fig.16 - Plug the “housing earth conductor” (36) (34) onto the housing box, in the correct position - Replace the housing box - Screw the 5x25-TX20 screw (35) back onto the rear of the housing - Screw the 5x25-TX20 screw (34) back...

  • Page 74: Installation Instructions: Varistor

    Installation instructions: Varistor Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 75: Removing The Varistor

    - Unplug the mains-cable earthing Removing the varistor conductor (74) - Unplug the heat-sink earthing conductor (75) (75) (74) Fig.3 (76) Fig.4 Fig.5 Note! Never use force to detach the varistor (2) from the LCA 15 board. Before any work involving the soldering iron, always clean the tip of the soldering iron. - Completely remove the solder from the soldering points (76), using a solder absorption strand or suction pump - Using a pair of pointed pliers, carefully detach the varistor (2) from the LCA 15 board...

  • Page 76: Fitting The Varistor

    Fitting the Note! Before any work involving the soldering iron, always clean the tip of the varistor soldering iron. - Use the soldering iron to heat up the soldering points (76), and remove the liquid soldering tin as completely as possible with the aid of a suction pump or solder absorption strand.

  • Page 77: Installation Instructions: Transformer

    Installation instructions: Transformer Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 78: Removing The Lca15 Board

    Opening the - Remove the housing stiffening element (21) (37) housing (21) (continued) - Remove the board insulator (37) Fig.2 Removing the - Unplug the mains leads for the LCA15 (38) (39) LCA15 board board from the mains switch L (white) from 1A (38) N (blue) from 2A (39) Fig.3 (40)

  • Page 79: Removing The Transformer

    Removing the Note! When detaching the (44) (45) (48) LCA15 board LCA15 board (1), make sure that (continued) you do not kink or pinch any cables, or subject them to tensile strain. - Carefully detach the LCA15 board (1) from the heat sink Note! When disconnecting the transformer leads (44) for the LCA15 board, squeeze the...

  • Page 80: Fitting The Transformer

    Fitting the - Clean the heat sink with a dry and non- transformer linting cloth Fig.10 - Fasten the transformer in place by means of the four M4x14 - TX20 screws (31) on the transformer Tighten the M4x14 - TX20 screws (31) with a torque of 2 Nm - TP 1500 TIG: Fasten the transformer / gas-hose cable binder (33) (Fig.8)
  • Page 81 Fitting the LCA15 - Clean the underside of the transistor board module with contact spray and a non- (continued) linting cloth Fig.14 - Place a blob of heat-transfer compound on a flat, clean and smooth surface (e.g. coated wooden board) - Using an application roller, spread the heat-transfer compound evenly across the surface...
  • Page 82 Fitting the LCA15 - Carefully place the LCA15 board (1), board underside first, onto the heat sink (continued) Fig.18 - To position the LCA15 board (1), gently screw the M4 screw (43) into the M4x17 earthing stud (48) - see Fig.10 - by hand.
  • Page 83 Fitting the LCA15 Note! Before inserting the board M4x14-TX20 screws (31) into (31) (continued) their holes, push the cup springs (32) onto the M4x14-TX20 screws (31), as shown in Fig.16. (32) Fig.21 - Carefully turn the M4x14-TX20screws (31) (31) (43) (31), alternately, until you start to feel gentle resistance Note! Before you tighten the...

  • Page 84: Closing The Housing

    Fitting the LCA15 - Plug the mains leads for the LCA15 (38) (39) board board back onto the mains switch (continued) L (white) (38) to 1A N (blue) (39) to 2A Fig.25 Closing the - Insert the board insulator (37) (21) (37) housing...

  • Page 85: Installation Instructions: Temperature Sensor

    Installation instructions: Temperature sensor Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 86: Removing The Temperature Sensor

    Removing the - Cut through the cable binder (33) temperature - Unplug the 2-pole Molex plug (40) from sensor the LCA15 board (40) (33) Fig.3 - Undo the M4x14-TX20 screw (31) - Detach the temperature sensor (9) (31) (9) (79) Fig.4 - Mount the temperature sensor (9) and the suppressor circuit (79) using a M4x14- Fitting the...

  • Page 87: Closing The Housing

    Closing the - Insert the board insulator (37) (21) (37) housing - Insert the housing stiffening element (21) Fig.6 - Plug the “housing earth conductor” (34) (36) onto the housing box, in the correct position - Replace the housing box - Screw the 5x25-TX20 screw (35) back onto the rear of the housing - Screw the 5x25-TX20 screw (34) back...

  • Page 88: Installation Instructions: Fan

    Installation instructions: Fan Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 89: Removing The Fan

    Removing the fan - Disconnect the ribbon cable (42) from (40) (33) (41) (42) the FPA15 board (5) - Cut through the cable binder (33) - Unplug the 2-pole Molex plug (40) from the LCA15 board - Disconnect the 10-pole Molex plug (41) from the LCA15 board Fig.3 - Remove the following cables from the...

  • Page 90: Fitting The Fan

    Removing the fan - Lift the fan (10) slightly and carefully (continued) pull it out to the side (10) Fig.7 Fitting the fan Note! When inserting the fan, make sure that it snaps into the catches (83). (83) Fig.8 - TP 1500 TIG: Pivot the gas solenoid (16) (33) valve (16) back into its original position...

  • Page 91: Closing The Housing

    Fitting the fan - Insert the following cables into the 10- (80) (81) (41) (continued) pole Molex plug (41): Fan lead, red (80), Pin 1 Fan lead, black (81), Pin 2 Fig.11 - Plug the 10-pole Molex plug (41) onto (40) (33) (41)

  • Page 92: Installation Instructions: Mains Switch And Mains Cable

    Installation instructions: Mains switch and mains cable Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 93: Unplugging The Mains Leads

    Opening the - Remove the housing stiffening element (21) (37) housing (21) (continued) - Remove the board insulator (37) Fig.2 Unplugging the - Unplug the mains leads for the LCA15 (12) (38) (39) mains leads board from the mains switch L (white) from 1A (38) N (blue) from 2A (39) Fig.3...

  • Page 94: Removing The Mains Cable

    Removing the - On the mains leads L - brown (84) and mains cable N - blue (85), detach the insulating sleeves (86) from the flat-pin plugs Insert a small screwdriver on the step-shaped side of an insulating sleeve and prise off the sleeve (84) (85) (86)

  • Page 95: Mounting The Mains Cable

    Mounting the - Push the mains cable into the housing (87) (88) mains cable - Wind the mains-cable earthing conductor (87) onto the ferrite core (88), with 5 windings - Carefully pull the mains cable a short way out of the housing, until the ferrite core (88) with the wound-on earthing conductor (87) can be stowed away well...

  • Page 96: Fitting The Mains Switch

    Fitting the mains - Working from the outside, insert the switch mains switch (12) into the rear of the housing and press it in until it snaps into the catches (12) (85) (84) Fig.13 Plugging on the - On the mains switch (12), plug on the mains leads for the mains cable (Fig.13) mains leads L - brown (84) to 1 N - blue (85) to 2...

  • Page 97: Installation Instructions: Gas Solenoid Valve

    Installation instructions: Gas solenoid valve Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 98: Removing The Gas Solenoid Valve

    Removing the - TP 1500 TIG: Undo the hexagon nut gas solenoid (82) - width-across 17 - on the gas valve connector (82) Fig.3 - Take out the gas solenoid valve (16) (16) (18) (17) (88) from the rear of the housing - Open the hose clamp (18) and take out the gas hose (17) - Disconnect the 2 earthing conductors...

  • Page 99: Closing The Housing

    Closing the - Remove the board insulator (37) (21) (37) housing - Remove the housing stiffening element (21) Fig.6 - Plug the “housing earth conductor” (36) (34) onto the housing box, in the correct position - Replace the housing box - Screw the 5x25-TX20 screw (35) back onto the rear of the housing - Screw the 5x25-TX20 screw (34) back...

  • Page 100: Installation Instructions: Potentiometer, Connection Socket + Seal For Remote Control Unit

    Installation instructions: Potentiometer, connection socket + seal for remote control unit Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 101: Opening The Housing

    Opening the - Take off the carrying strap (34) housing - Undo the 5x25-TX20 screw (34) on the front of the housing - Undo the 5x25-TX20 screw (35) on the rear of the housing - Carefully lift the housing box and disconnect the “housing earth conductor”...
  • Page 102 Removing the - Undo and remove the round nut (66) FPA15 board (continued) (66) Fig.5 - Undo the M5x12 - TX20 screw (68) on the copper bracket (55) (68) (55) Fig.6 - TP 1500 TIG: Loosen the hexagon nut (69) (width-across=13) for the screw- fixing of the socket - TP 1500 / 1500 RC: In the...

  • Page 103: Removing The Seal For The Remote-Control Unit Connection Socket

    - Carefully pull the seal (7) for the Removing the remote-control unit connection socket seal for the out of the front of the housing remote-control unit connection socket Fig.10 Removing the Note! Never use force to detach the potentiometer (29) and the remote-control potentiometer unit connection socket (30) from the LCA 15 board.

  • Page 104: Fitting The Seal For The Remote-Control Unit Connection Socket

    Fitting the seal - Carefully insert the seal (7) for the for the remote- remote-control unit connection socket control unit into the front of the housing connection socket Fig.13 Fitting the FPA15 Note! Before fixing the FPA15 board (5) on the alignment pins, do the board following: - TP 1500 RC / 1500 TIG: Apply a thin layer of lubricant to the seal of the remote-...

  • Page 105: Closing The Housing

    Fitting the FPA15 - Fasten the X3 cable (blue) (72) and board the by-pass capacitors (73) onto the (continued) copper bracket (55), using the 5x12 - TX20 screw (68) - Tighten the 5x12 - TX20 screw (68) with a torque of 2 Nm (68) (55) (72)

  • Page 106: Installation Instructions: Front Of Housing, With Adhesive Label And Welding Sockets

    Installation instructions: Front of housing, with adhesive label and welding sockets Safety Warning! Work performed incorrectly can cause serious injury and damage. This modification may only be performed by suitably trained and skilled electricians! Before opening up the machine, shift the mains switch to the "0" position and unplug the machine from the mains! Note! Follow the safety rules given in the Operating Instructions, especially the section headed "Safety inspection".

  • Page 107: Opening The Housing

    Opening the - Take off the carrying strap (34) housing - Undo the 5x25-TX20 screw (34) on the front of the housing - Undo the 5x25-TX20 screw (35) on the rear of the housing - Carefully lift the housing box and disconnect the “housing earth conductor”...

  • Page 108: Removing The Seal For The Remote-Control Unit Connection Socket

    Removing the - Undo and remove the round nut (66) FPA15 board (continued) (66) Fig.5 - Undo the M5x12 - TX20 screw (68) on the copper bracket (55) (68) (55) Fig.6 - TP 1500 TIG: Loosen the hexagon nut (69) (width-across=13) for the screw- fixing of the socket - TP 1500 / 1500 RC: In the...

  • Page 109: Removing The Welding Sockets

    Removing the - TP 1500 TIG: Open the hose clamp welding sockets (18) and take out the gas hose (17) (18) (17) Fig.11 - TP 1500 TIG: Loosen the hexagon nut (69) (69) (width-across=13) for the screw- fixing of the socket Fig.12 - TP 1500 TIG: In the...

  • Page 110: Fitting The Front Of The Housing

    Removing the - Prise the front of the housing (23) off front of the the floor of the housing housing (continued) (23) Fig.16 Fitting the front Note! Before affixing the adhesive label (26), (27) or (28), clean the front of the of the housing housing.

  • Page 111: Fitting The Seal For The Remote-Control Unit Connection Socket

    Fitting the - TP 1500 TIG: Loosely screw on the (69) welding sockets hexagon nut (69) (width-across = 13) (93) (continued) of the threaded join between the socket and the copper bracket. Fig.18 Note! TP 1500 TIG: Use a new hose clamp (18) to fasten the gas hose (17).

  • Page 112: Fitting The Fpa15 Board

    Fitting the FPA15 - Carefully press the FPA15 board until board all the alignment pins have snapped into place Fig.21 - Swing the copper bracket (55) back into its original position (55) Fig.22 - TP 1500 TIG: Tighten the hexagon nut (69) (width-across=13) for the screw- fixing of the socket...

  • Page 113: Closing The Housing

    Fitting the FPA15 - Plug the 10-pole Molex plug (41) onto (40) (41) (42) board board LCA15 (continued) - Plug the 2-pole Molex plug (40) onto board LCA15 - Arrange the ribbon cable (42) above the cable harness, as shown in Fig.15 - Plug the ribbon cable (42) to board FPA15 (5) Fig.24...
  • Page 115 Transpocket 1500 4,075,108 Transpocket 1500 VRD 4,075,108,638 Transpocket 1500 RC 4,075,109 Transpocket 1500 RC HD 4,075,109,631 Transpocket 1500 TIG 4,075,110 Transpocket 1500 TIG VRD 4,075,110,638 42,0406,0295 45,0200,0924 * gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée...
  • Page 116 Transpocket 1500 Erdstrom 4,075,108,632 Transpocket 1500 RC Erdstrom 4,075,109,632 Transpocket 1500 TIG Erdstrom 4,075,110,632 42,0406,0295 45,0200,0924 * gewünschte Länge angeben * Specify the length required * Indiquer la longueur désirée * Indicar la longitud deseada * Indicare la lunghezza desiderat...
  • Page 117 Tel: +49 (0)9901 2008-0 Fax: +49 (0)9901 2008-10 500 04 HRADEC KRÁLOVÉ, Pra•ská 293/12 Tel.: +420 495 070 011 Fax: +420 495 070 019 E-Mail: sales.h.kralove@fronius.com Under http://www.fronius.com/addresses you will find all addresses of our sales branches and partner firms! ud_fr_st_so_00082 022006...

This manual is also suitable for:

Tp 1500

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