Fronius TransSteel 2200 Service Manual
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Fronius TransSteel 2200 Service Manual

Mig/mag power source
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/ Perfect Charging / Perfect Welding / Solar Energy
TransSteel 2200
MTG 2100S
42,0426,0273,EN 007-01042021
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Service manual
MIG/MAG power source

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Summary of Contents for Fronius TransSteel 2200

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Service manual TransSteel 2200 MTG 2100S MIG/MAG power source 42,0426,0273,EN 007-01042021 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Contents General information Foreword and safety instructions Safety Fronius Technical Support National (TSN) General Tools and measuring devices Tools required Measuring and testing equipment Ancillary materials Error location aid LED checklists LSTMAG20 LED checklist Measuring points TSt 2200c measuring points...
  • Page 4 General Opening/closing the service menu Description of the menu contents Safety Inspections Safety Inspections Safety inspection Responsibility Test record Visual inspections General Mains supply and connecting lines Housing and covers Adjustment and display devices Rating plate and warning stickers Electrical tests Ground conductor resistance Insulation resistance Open circuit voltage...

  • Page 5: General Information

    General information...

  • Page 7: Foreword And Safety Instructions

    WARNING! Work that is carried out incorrectly can cause serious injury and damage. All activities described in the service manual must only be carried out by Fronius-trained service technicians. Read the "Safety rules" chapter in the power source operating instructions.

  • Page 8: Tools And Measuring Devices

    Tools and measuring devices Tools required Torx screwdriver (TX8) Torx screwdriver (TX10) Torx screwdriver (TX20) Torx screwdriver (TX25) Torx screwdriver (TX40) Box spanner, 8 mm Flat spanner, 17 mm 2 x flat spanner, 15 mm Flat spanner, 19 mm Slotted screwdriver, 3 mm Phillips screwdriver (PZ2) Phillips screwdriver (PH2) Torque wrench, 1 - 5 Nm...

  • Page 9: Error Location Aid

    Error location aid...

  • Page 11: Led Checklists

    LED checklists LSTMAG20 LED checklist RXD-A +15V +24Vint +24VMotor +14Vprim TXD-A ntc-1 ntc-2 TXD-B RXD-B ntc-4 ntc-3 Error TXprim LT-ON -15V TXsec Description Lights up when there is a supply voltage of + 5 V DC +14Vprim Lights up when there is a primary supply voltage of + 14 V DC +15V Lights up when there is a supply voltage of + 15 V -15V...
  • Page 12 Description TXprim Lights up when data is being transferred from the primary circuit to the secondary circuit LT-On Lights up when the power module is switched on Flashes when there are no errors on the PFC Error Lights up when the PFC is faulty or is not configured Temperature Description sensor...

  • Page 13: Measuring Points

    Measuring points TSt 2200c The image below shows the measuring points on the secondary diodes. measuring points The secondary diodes can be measured in the de-energised state with a multimeter in diode test mode. A voltage of approx. 0.15 V must be measured in the conducting direction of the diode (1).
  • Page 14 12,490 2986 917.7 10,000 2488 788.5 8057 2083 Maximum tolerance +/- 4.7% An example for the approximation of the target resistance for temperatures not specified in the table is shown below. Example: Ambient temperature = T = 23°C = (R ) / 5 = (12,490 ohm - 10,000 ohm) / 5 = 498 ohm diff high...

  • Page 15: Service Codes

    (for details see "Software update"). If the problem is not resolved by a software update, please contact Fronius Technical Support (TSN, TSI). When contacting them, please provide the following information: Service code displayed...
  • Page 16 ESr 18 <PA> Cause: A configuration memory is not supported, <PA> represents the error number Remedy: <PA> = 0 replace LSTMAG20 PC board <PA> = 4 replace wirefeeder motor, replace device ID on wirefeeder motor ESr 22 Cause: The bootloader must be updated Remedy: Contact TechSupport International (TSI) ------...
  • Page 17 PFC 58 Cause: Power module PC board has detected a mains overvoltage Remedy: Operate power source within the permitted voltage range PFC 60 Cause: PFC driver supply on the LSTMAG20 PC board faulty Remedy: Replace LSTMAG20 PC board PFC 62 Cause: Communication error on LSTMAG20 PC board Remedy:...
  • Page 18 EFd 13 Cause: The voltage for motor calibration is out of limits Remedy: Perform motor calibration (motor plate 2R pressure lever must be open), replace motor, replace LSTMAG20 PC board EFd 14 Cause: Fault in the wirefeed system (overcurrent in wirefeeder drive, motor blocked) Remedy: Arrange the hosepack in as straight a line as possible.
  • Page 19 to7<TMP> Cause: Overtemperature on the controller (Kernel), <TMP> is the temperature indic- ator Remedy: Allow power source to cool down, check that fan is running to8<TMP> Cause: Power module overtemperature error, <TMP> is the temperature indicator Remedy: Allow power source to cool down, check that fan is running to9<TMP>...
  • Page 20 Err tf0 Cause: Temperature sensor on the PC board LSTMAG20 faulty (secondary circuit) Remedy: Replace LSTMAG20 PC board Err tf2 Cause: Temperature sensor fault in power source secondary circuit (short circuit or interruption) Remedy: Check cable harness and replace temperature sensor on secondary rectifier Err tf3 Cause: Faulty temperature sensor on the PC board LSTMAG20 (motor controller)
  • Page 21 no ARC Cause: Arc break during TIG welding Remedy: Press the torch trigger repeatedly; clean the surface of the workpiece ECC 2 Cause: Error updating PFC firmware Remedy: Switch power source off and on again, if the error persists replace LST- MAG20 PC board ECC 3 Cause:...

  • Page 23: Replacing Modules

    Replacing modules...

  • Page 25: Replacing Modules

    WARNING! Work that is carried out incorrectly can cause serious injury and damage. All activities described in the Service Instructions must only be carried out by Fronius- trained service engineers. Read the "Safety rules" chapter in the product's Operating Instructions.

  • Page 26: Opening The Housing

    Opening the housing Opening the Undo the five TX25 screws (1) on the housing side panel and remove the side panel Disconnect the ribbon cable (2) for the control panel on the LSTMAG20 PC board Remove the two TX25 screws (3) on the control panel Remove the control panel...

  • Page 27: Replacing The Lstmag20 Pc Board

    Replacing the LSTMAG20 PC board Removing the Open housing as described in section LSTMAG20 PC "Opening the housing" board Unplug all connectors (1) from the LSTMAG20 PC board Undo the five TX25 screws (2) and (3) (3) remove the leads Undo the four TX20 screws (3) and remove the leads (3) (3)

  • Page 28: Installing The Lstmag20 Pc Board

    Installing the Remove the protective cover from the LSTMAG20 PC modules board Align the new LSTMAG20 PC board and place it on the cleaned heat sink Fit 13 M4x8 TX20 screws (1) to 0.5 Tightening torque = 1.5 Nm Fit four M4x13 TX20 screws (2) to 1.0 Nm, then secure Tightening torque = 1.9 Nm (1) (1)
  • Page 29 Configure the jumper (8) on the LST- MAG20 PC board Standard - no jumper connection, open MV - jumper connected, closed Close housing as described in section "Closing the housing"...

  • Page 30: Replacing Secondary Diodes

    Replacing secondary diodes Replacing the Open housing as described in section secondary diode "Opening the housing" Remove the LSTMAG20 PC board as described in section "Removing the LSTMAG20 PC board" Undo the two M4x10 mm TX20 screws (1) on the faulty diode Clean the heat sink and modules on the LSTMAG20 PC board NOTE!
  • Page 31 Fit the thermal foil (3) to the modules on the LSTMAG20 PC board as shown Install the PC board as described in section "Installing the LSTMAG20 PC board" Close housing as described in section "Closing the housing"...

  • Page 32: Replacing The Fan

    Replacing the fan Replacing the fan Open left side panel Undo the TX25 screw (1) and remove the cover (2) Remove the fan (3) and unplug the connector (4) Connect and install the new fan IMPORTANT! Install the fan with the air flow towards the inside.

  • Page 33: Replacing The Transformer

    Replacing the transformer Removing the Open housing as described in section transformer "Opening the housing" Unscrew the three TX25 screws (1) from the secondary transformer leads on the LSTMAG20 PC board Unscrew the two TX25 screws (3) from the primary transformer leads on the LSTMAG20 PC board Unscrew the 17 mm screw from the transformer lead (3) on the current...
  • Page 34 Fit the transformer lead (3) to the cur- rent socket using a 17 mm screw as shown Tightening torque = 20 Nm Connect the two leads (4) to the LST- MAG20 PC board Fit the primary transformer leads to the LSTMAG20 PC board using two M4x8 mm TX25 screws (5) Tightening torque = 1.5 Nm Fit the secondary transformer leads to...

  • Page 35: Replacing The Solenoid Valve

    Replacing the solenoid valve Replacing the Undo the six screws (1) from the back solenoid valve panel of the device and swing the back panel to one side Unplug the cable (2) from the PC board (2) Undo size 17mm nut (3) from the solenoid valve Unplug cable (4) Remove the hose clamp (5) and the...
  • Page 36 NOTE! When inserting the solenoid vlalve, ensure that the hose is not trapped in any way. Insert the solenoid valve (7) into the holder Fit the nut (8) (size 17 mm), Tighten- ing torque = 3 Nm Plug in the cables (9) to the PC board Insert the back panel Fit the back panel using 6 screws (10), Tightening torque = 3 Nm...

  • Page 37: Replacing The Drive

    Replacing the drive Removing the Open housing as described in section drive "Opening the housing" Remove the driver roller and pressure roller Unplug the motor lead (1) from the LSTMAG20 PC board Undo the three PH2 screws (2) Remove the drive (3)

  • Page 38: Installing The Drive

    Installing the Insert the drive (1) drive Fit the drive using three PH2 screws Tightening torque = 2.1 Nm Plug in the motor lead (3) on the LST- MAG 20 PC board Fit the driver roller and pressure roller Calibrating the motor Close housing as described in section "Closing the housing"...
  • Page 39 Select the relevant menu items: FdA menu item If Aut is selected, automatic calibration can be carried out in the "FEd" menu item If OFF is selected, manual calibration can be carried out in the "FEd" menu item FEd menu item Automatic calibration: Open the clamping lever Press the "Wire threading"...

  • Page 40: Replacing The Motor Plate

    Replacing the motor plate Removing the Open housing as described in section motor plate "Opening the housing" Remove the wearing parts from the motor plate Undo the TX25 screw (1) on the polar- ity reverser lead Undo the two TX25 screws (2) Undo the three PH2 screws (3) Undo the three TX25 screws (4) Swivel the motor plate outwards and...

  • Page 41: Installing The Motor Plate

    Installing the Align the holes (2) on the motor plate motor plate (1) with the locating pins (3) in the power source Gently push the motor plate (1) in until it engages (2) (3) Fit the motor plate using three TX25 screws (4) Tightening torque = 1.5 Nm Position the drive in the motor plate...
  • Page 42 Fit the polarity reverser lead to the motor plate using a TX25 screw (7) Tightening torque = 3.0 Nm Close housing as described in section "Closing the housing"...

  • Page 43: Closing The Housing

    Closing the housing Closing the hous- Insert the control panel Fit the control panel using two PT 5x14 mm TX25 screws (2) Tightening torque = 1.5 Nm Connect the ribbon cable (2) for the control panel to the LSTMAG20 PC board Insert the side panel and secure using five M5x12 TX25 screws (3)

  • Page 44: Mtg 2100 S

    MTG 2100 S MTG2100S weld- Open the strain-relief device (1) ing torch/trigger/ Remove the three 2.5x12 mm TX 8 coaxial cable screws (2) Disconnect the flat connectors using a small slotted screwdriver Remove the trigger Connect the new trigger using the BT1 fitting tool (3) Insert the trigger into the grip Undo the coaxial cable using 2x15...

  • Page 45: Mtg2100S Fsc

    MTG2100S FSC Undo the four 2.5x12 mm TX 10 screws (1) and open the FSC Disconnect the coaxial cable using a 15 mm flat spanner (2) Unpin the control lines (3) IMPORTANT! When unpinning the control line, note the position of the tool to fully undo the locking hooks.

  • Page 46: Mtg2100S Inspection Following Repairs

    Fit four 2.5x12 TX 10 screws (6) and close the FSC Tightening torque= 0.8 Nm MTG2100S Test equipment: insulation measuring inspection follow- device (e.g. Metriso 5000) ing repairs Test voltage: 500 V DC Measuring points: Between the outer pipe of the torch body and contact tip;...
  • Page 47 Test equipment: manual torch testbox (4,045,998) Check that control elements are working properly - for details see the "Manual torch testbox" Operating Instructions. NOTE! While the control elements are being tested, the hosepack should be flexed and twisted along its entire length so that any breaks in the control line can be detected.

  • Page 49: Software

    Software...

  • Page 51: Software Update

    Software update Software update The operating system and the welding process database are constantly being enhanced. The power source operating system and the welding process database can be updated separately using the LocalNet USB converter. The latest programs can be downloaded from the DownloadCenter.

  • Page 52: Service Menu

    Service menu General The service menu provides service technicians with detailed information about the respective power source (e.g. firmware version, welding programs, arc time). In addition, specific functions can be activated or deactivated and date and time settings can be entered.
  • Page 53 Sequence Menu item (display) Description Date setting for the year (0 to 99) To change the value, press the right-hand control dial. Date setting for the month (1 to 12) To change the value, press the right-hand control dial. Date setting for the day (1 to 31) To change the value, press the right-hand control dial.

  • Page 55: Safety Inspections

    Safety Inspections...

  • Page 57: Safety Inspections

    Please be aware of the requirements and standards relevant to your country, as the measured values or steps taken during the tests may vary. Even if there are no relevant requirements and standards in your country, Fronius recom- mends that this inspection should still be carried out.

  • Page 58: Visual Inspections

    Visual inspections General The following must be visually inspected without any further dismantling of the device. Obvious defects in any safety-related device components are unacceptable. Defects that could pose a risk during the visual inspection must also be recorded. Any defects that could cause other hazards must be repaired immediately or restrictions placed on the further use of the system until repairs have been effected.

  • Page 59: Electrical Tests

    Electrical tests Ground con- The device to be tested must be safely isolated from the AC mains supply. The ductor resistance mains cable (L, N, PE) and charger lead must not be connected. Follow the safety rules. The measurement is taken between the ground conductor contact of the mains plug and any touchable conductive part connected to the ground conductor.

  • Page 60: Open Circuit Voltage

    Measurement Measuring point Measured value Primary → secondary Mains plug L/N → Current sockets ³ 5 MW Primary → Earth Mains plug L/N → Earth ³ 2.5 MW Secondary → Earth Current socket → Earth ³ 2.5 MW Primary → Gas preheater Mains plug →...

  • Page 61: Documentation

    Any device that fails a test must be clearly marked as unsafe and the operator informed. The device may no longer be used. Once a device passes the test, an inspection sticker (42,200,101) must be affixed to The "Safety inspection" test record is available from the Fronius Download Center.

  • Page 62: Function Tests

    Function tests Mains on/off Evidence of proper operation must be provided by measurement or visual inspection. devices Indicators and Check display for correct function control elements Check that controls work in line with the operating instructions Gas solenoid The correct operation of the gas solenoid valve must be tested by activating the valve torch trigger several times To check the gas solenoid valve and the gas lines for leaks, the gas line to the gas...
  • Page 64 FRONIUS INTERNATIONAL GMBH Froniusstraße 1 A-4643 Pettenbach AUSTRIA contact@fronius.com www.fronius.com Under www.fronius.com/contact you will find the addresses of all Fronius Sales & Service Partners and locations...

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