Fronius THP 120 - 300 SH Service Manual
  1. Manuals
  2. Brands
  3. Fronius Manuals
  4. Welding System
  5. THP 120 - 300 SH
  6. Service manual

Fronius THP 120 - 300 SH Service Manual

Tig manual welding torch
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
/ Perfect Charging / Perfect Welding / Solar Energy
THP 120 - 300 SH
THP 160 - 500d
THP 160 - 500i
HPT 220 - 400i
42,0426,0295,EA 007-13082020
Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).
Service manual
TIG manual welding torch

Advertisement

Table of Contents

Troubleshooting

loading
Need help?

Need help?

Do you have a question about the THP 120 - 300 SH and is the answer not in the manual?

Questions and answers

Related Manuals for Fronius THP 120 - 300 SH

Summary of Contents for Fronius THP 120 - 300 SH

  • Page 1 / Perfect Charging / Perfect Welding / Solar Energy Service manual THP 120 - 300 SH THP 160 - 500d TIG manual welding torch THP 160 - 500i HPT 220 - 400i 42,0426,0295,EA 007-13082020 Fronius prints on elemental chlorine free paper (ECF) sourced from certified sustainable forests (FSC).

  • Page 3: Table Of Contents

    Replacing the coupling housing Opening the F++ connection Replacing hose components Closing the F++ connection Closing the hand grip THP 120 - 300 SH, without 150 SH Changing the torch body Opening the hand grip Replacing the user interface Replacing the slide...
  • Page 4 Closing the hand grip HPT 220i and HPT 400i Preparing components for replacement Removing, replacing, and fitting the hosepack Replacing the protective hose Fitting components after replacement Testing Following Repairs Test process Mechanical inspection/PP-SER-2010 Insulation test/PP-SER-2010 Gas flow rate and leak test/PP-SER-2001 Water flow rate and leak test/PP-SER-2001 Electrical testing of operating elements and displays Current load test/voltage drop measurement...

  • Page 5: Foreword And Safety Instructions

    National Fronius If you have any questions about the failure analysis, your national Fronius Technical Technical Sup- Support team is at your disposal (TSN).

  • Page 6: General

    General The service manual can be found in the DownloadCenter under "downloadcen- ter.fronius.com." Each chapter of the service manual covers a different topic. Use each chapter as an independent source of information. The following provides a brief description of each...

  • Page 7: Tools And Measurement Devices

    Required tools Tool adapters Measuring and inspection equipment Auxiliary materials All the required special tools, measuring and inspection equipment can be found in the equipment lists at "downloadcenter.fronius.com". Required tools TX 6 screwdriver TX 8 screwdriver Torque screwdriver 1–6 Nm (42,0411,0013) Torque screwdriver 0.4–1.2 Nm (42,0435,0210)
  • Page 8 Equipment for testing electrical function Electrical testing of operating elements and displays Service software for test box manual torch - current version (Downloadcenter) Basic Load driver software (Downloadcenter) Test box manual torch (4,045,998) Test box FSC (4,100,673) Adapter FSC - TMC (4,078,000) Adapter cable for SH welding torch (43,0004,5991) Auxiliary materi- Contact spray cleaning agent (40,0009,0014)

  • Page 9: Function Overview

    Function Overview Torch Body The torch body is used to hold the TIG electrode. Hosepack Flexible connection between torch body and power source. which contains all lines required for welding operation. F++ connection The F++ is a compact interface between the hosepack and power source. Tool-free, simple, and quick hosepack replacement without operating errors Process safety due to defined current transfer Central connector for all TIG welding applications...

  • Page 10: Troubleshooting

    Troubleshooting General The error search tree is used to systematically find and correct errors. Troubleshooting Welding torch cannot be connected Table Cause: Bayonet lock bent Remedy: Replace bayonet lock No welding current Power source switched on, power source indication illuminates, shielding gas present Cause: Incorrect ground connection Remedy:...
  • Page 11 No shielding gas All other functions present Cause: Gas cylinder empty Remedy: Change gas cylinder Cause: Gas pressure regulator faulty Remedy: Replace gas pressure regulator Cause: Gas hose kinked, damaged, or not attached Remedy: Attach and straighten gas hose. Replace faulty gas hose Cause: Gas solenoid valve faulty Remedy:...

  • Page 12: Replacing Components

    Work performed incorrectly can cause serious injury and damage to property. All activities described in the Service Instructions must only be carried out by a trained Fronius service technician. Please note the information in the “Safety Rules” chapter of the Operating Instructions for your device.

  • Page 13: Thp 160 - 500I

    THP 160 - 500i Changing the WARNING! torch body Before removing the torch body, observe all safety-relevant notes and procedural steps according to the Operating Instructions. Removing the torch body Press the slide (1) and turn the torch body (2) 180° Note the arrows and carefully remove the torch body (2) Attaching the torch body...

  • Page 14: Replacing The User Interface

    Replacing the Removal user interface Unscrew one TX 8 screw (1) Disconnect the user interface (2) Installation Connect the user interface (2) Secure one TX 8 screw (1) Tightening torque: 0.6 Nm Replacing the Remove the user interface as per the slide "Replacing the user interface"...

  • Page 15: Opening The Hand Grip

    Opening the hand Open and push back the union nut (1) grip Unscrew three TX 8 screws (2), dis- connect the user interface and open the hand grip Replacing the NOTE! socket housing Socket housing: 43,0003,0800 Open the hand grip as per the “Open- ing the hand grip”...
  • Page 16 Carefully open the Minitek plug (2) lock Remove the socket housing (3) by pushing forwards NOTE! Observe the pin assignment (color- coded arrangement of the wires) for each interface version and note it down in advance. Release the wires (4) using tweezers and pull them out A B C D E F Replace the socket housing (3)

  • Page 17: Retrofitting Tigi Led Insulation(I Version Only)

    Retrofitting TIGi NOTE! LED insulation (i version only) If the LED insulation film is not present, it can be retrofitted. LED insulation film: 42,1600,0055 Open the hand grip as per the "Open- ing the hand grip" chapter If necessary, insert LED insulation film Close the hand grip as per the "Clos- ing the hand grip"...

  • Page 18: Replacing The Coupling Housing

    NOTE! Observe the pin assignment (color- coded arrangement of the wires) for each interface version and note it down in advance. Release the wires (4) using tweezers and pull them out Pull out and replace the LED (1) Insert the wires (4) into the socket housing (3) according to the color arrangement per interface version...
  • Page 19 NOTE! The coupling housing must be replaced as a closed unit. Remove the contact element (1) Carefully remove the coupling housing Installation Fit the coupling housing (2) Insert the contact element (1) Pre-mount the contact element (1) with 8 mm socket Secure the contact element (1) with a torque screwdriver and socket as per the “Required tools”...

  • Page 20: Opening The F++ Connection

    Opening the F++ Unscrew four TX 8 screws (1) connection Remove upper and lower base shell on the F++ connection Replacing hose Hand grip disassembly components Open the hand grip as per the “Open- ing the hand grip” chapter Remove the coupling housing as per the “Replacing the coupling housing”...
  • Page 21 Disassembling the F++ connection Disassemble the F++ connection as per the “Opening the F++ Connection” chapter Removing hose components Lay hosepack straight and pull out hose components via F++ connection Replacing components Water Replace components, connections and hoses as per the Spare Parts List Water-cooled version: Connect the power cable (1) Seal the gas connection (2) in the...
  • Page 22 Inserting hose components Screw M7 power connection (1) onto retractable adapter (2) Insert Minitek plug (3) into adapter recess 4,5 cm Place gas and optional water hoses onto the power cable 4.5 cm behind the power connection (4) Wrap Minitek plug and hoses in adhesive tape (5) and secure for drawing in Insert the hosepack via the F++ con-...

  • Page 23: Closing The F++ Connection

    Installing the hand grip Clip the gas and optional water con- nections into the insulating plate (1) and thread the power cable (2) in Fit the coupling housing as per chapter “Replacing the coupling hous- ing” Close the hand grip as per the “Clos- ing the hand grip”...
  • Page 24 Close the hand grip, connect the user interface and secure with three TX 8 screws (1) Tightening torque: 0.6 Nm Slide on the union nut (2) and close Attach torch body according to the “Attaching the torch body” chapter...

  • Page 25: Thp 160 - 500D

    THP 160 - 500d Changing the WARNING! torch body Before removing the torch body, observe all safety-relevant notes and procedural steps according to the Operating Instructions. Removing the torch body Press the slide (1) and turn the torch body (2) 180° Note the arrows and carefully remove the torch body (2) Attaching the torch body...

  • Page 26: Replacing The User Interface

    Replacing the Removal user interface Unscrew one TX 8 screw (1) Disconnect the user interface (2) Installation Connect the user interface (2) Secure one TX 8 screw (1) Tightening torque: 0.6 Nm Replacing the Remove the user interface as per the slide "Replacing the user interface"...

  • Page 27: Opening The Hand Grip

    Opening the hand Open and push back the union nut (1) grip Unscrew three TX 8 screws (2), dis- connect the user interface and open the hand grip Remove LED blanking plug (3) Replacing the NOTE! socket housing Socket housing: 43,0003,0800...
  • Page 28 Open the hand grip as per the “Open- ing the hand grip” chapter Remove the coupling housing (1) and Minitek plug (2) from the guide Carefully open the Minitek plug (2) lock Remove the socket housing (3) by pushing forwards NOTE! Observe the pin assignment (color-...

  • Page 29: Replacing The Coupling Housing

    Position the Minitek plug (2) in the handle NOTE! Observe the following when positioning the Minitek plug: ▶ Press the cable sheathing (6) right down to the bottom of the strain-relief device guide ▶ Lay the control line (7) in a loop underneath the handle screw connec- tion Insert the coupling housing (1) and...

  • Page 30: Opening The F++ Connection

    Installation Fit the coupling housing (2) Insert the contact element (1) Pre-mount the contact element (1) with 8 mm socket Secure the contact element (1) with a torque screwdriver and socket as per the “Required tools” chapter Tightening torque: 5 Nm Close the hand grip as per the “Clos- ing the hand grip”...

  • Page 31: Replacing Hose Components

    Remove upper and lower base shell on the F++ connection Replacing hose Hand grip disassembly components Open the hand grip as per the “Open- ing the hand grip” chapter Remove the coupling housing as per the “Replacing the coupling housing” chapter Pull the power cable (1) out of the insulating plate (2) and unclip the...
  • Page 32 Replacing components Water Replace components, connections and hoses as per the Spare Parts List Water-cooled version: Connect the power cable (1) Seal the gas connection (2) in the thread with Loctite 542, tighten and secure the gas hose with clamp 7 Seal the water connection (3) in the thread with Loctite 542, tighten and secure the water hose with clamp 8...
  • Page 33 Insert the hosepack via the F++ con- nection so that there is a gap of 12 cm between the ball joint (hand grip) and the power cable Close retractable adapter 12 cm Assembling the F++ connection Close the F++ connection as per the “Closing the F++ connection”...

  • Page 34: Closing The F++ Connection

    Closing the F++ Insert the F++ connection in the lower connection base shell as shown Position plastic parts A and B Fit the upper base shell Secure both base shells with four TX 8 screws (1) Tightening torque: 0.6 Nm Closing the hand NOTE! grip...
  • Page 35 Close the hand grip, connect the user interface and secure with three TX 8 screws (2) Tightening torque: 0.6 Nm Slide on the union nut (3) and close Attach torch body according to the “Attaching the torch body” chapter...

  • Page 36: Thp 120 - 300 Sh, Without 150 Sh

    THP 120 - 300 SH, without 150 SH Changing the WARNING! torch body Before removing the torch body, observe all safety-relevant notes and procedural steps according to the Operating Instructions. Removing the torch body Press the slide (1) and turn the torch body (2) 180°...

  • Page 37: Opening The Hand Grip

    Opening the hand Remove the rocker switches (1) and grip carefully open the operating element NOTE! Push the lock in the front slit of the operating element back and carefully lever the operating element on the torch body side and pull it off back- ward.

  • Page 38: Replacing The Slide

    Position the user interface PCB (1) and coupling housing (2) in the handle Apply the HF insulation (3) Close the hand grip as per the “Clos- ing the hand grip” chapter Replacing the Open the hand grip as per the “Open- slide ing the hand grip”...

  • Page 39: Replacing The Socket Housing

    Position the user interface PCB (3) and coupling housing (4) in the handle Apply the HF insulation (5) Close the hand grip as per the “Clos- ing the hand grip” chapter Replacing the NOTE! socket housing Socket housing: 43,0003,0800 Open the hand grip as per the “Open- ing the hand grip”...
  • Page 40 NOTE! Observe the pin assignment (color- coded arrangement of the wires) for each interface version and note it down in advance. Release the wires (2) using tweezers and pull them out A B C D E F Replace the socket housing (3) Insert the wire cords (2) into the socket housing (3) according to the color arrangement...

  • Page 41: Replacing The Coupling Housing

    Replacing the Removal coupling housing Open the hand grip as per the “Open- ing the hand grip” chapter NOTE! Carefully place the socket onto the con- tact element to prevent damage. Open the contact element (1) with the 8 mm socket NOTE! The coupling housing must be replaced as a closed unit.

  • Page 42: Opening The F++ Connection

    Pre-mount the contact element (1) with 8 mm socket Secure the contact element (1) with a torque screwdriver and socket as per the “Required tools” chapter Tightening torque: 5 Nm Close the hand grip as per the “Clos- ing the hand grip” chapter Opening the F++ Unscrew four TX 8 screws (1) connection...

  • Page 43: Replacing Hose Components

    Replacing hose Hand grip disassembly components Open the hand grip as per the “Open- ing the hand grip” chapter Remove the coupling housing as per the “Replacing the coupling housing” chapter Pull the power cable (1) out of the insulating plate (2) and unclip the existing connections NOTE! Before removal, align sharp-edged...
  • Page 44 Gas-cooled version: Connect the power cable (1) Seal the gas connection (2) in the thread with Loctite 542, tighten and secure the gas hose with clamp 8 Inserting hose components Screw M7 power connection (1) onto retractable adapter (2) Insert the socket housing (3) into adapter recess 4,5 cm Place gas and optional water hoses...

  • Page 45: Closing The F++ Connection

    Assembling the F++ connection Close the F++ connection as per the “Closing the F++ connection” chapter Installing the hand grip Clip the gas and optional water con- nections into the insulating plate (1) and thread the power cable (2) in Fit the coupling housing as per chapter “Replacing the coupling hous- ing”...

  • Page 46: Closing The Hand Grip

    Secure both base shells with four TX 8 screws (1) Tightening torque: 0.6 Nm Closing the hand NOTE! grip In the case of the water-cooled versions, the hand grip must not be closed until the water flow rate and leak test has been carried out according to the “Testing fol- lowing repairs”...
  • Page 47 Close the hand grip and secure with three TX 8 screws (3) (3b) NOTE! Screw 3a: TX 8 - 2.5 x 12 mm Tightening torque: 0.6 Nm Screw 3b: TX 8 - 2.5 x 6 mm Tightening torque: 0.35 Nm (3a) (3a) Slide on the union nut (4) and close...

  • Page 48: Hpt 220I And Hpt 400I

    HPT 220i and HPT 400i Preparing com- Removing the coupling connector ponents for replacement Fix the insulating tube (1) in vise jaws and remove it with light jolts Unscrew four TX 8 screws (2) Remove the insert pieces (1) Feed out the control line (2) Water-cooled version only: Thread out water flow (3) and return (4) hoses in front of the control line...
  • Page 49 Removing the control line plug at the coupling connector end Open the control line plug Remove wires using the extractor tool Disconnect the control line plug from the cable Removing the central connector Unscrew four TX 8 screws (1) Remove cover...

  • Page 50: Removing, Replacing, And Fitting The Hosepack

    Remove the insert pieces (1) Feed out the control line (2) Water-cooled version only: Thread out the water flow hose (3) and the water return hose (4) in front of the control line Removing, repla- Pull out all components from the central connector end cing, and fitting the hosepack Disassemble the components to be...
  • Page 51 5 cm 5 cm 6,50 cm 6,50 cm 29 cm 33 cm HPT 220i (gas-cooled) Item Name Central connector end Clutch connector end Control line incl. plug (green) Power cable incl. connections (orange) Gas hose (purple) Strain-relief device Protective hose...

  • Page 52: Replacing The Protective Hose

    40 cm 5 cm 5 cm 6,50 cm 6,50 cm 29 cm 33 cm 73 cm 50 cm 76 cm HPT 400i (water-cooled) Item Name Central connector end Clutch connector end Water return hose outside the protective hose (yellow) Water flow hose (red) Control line incl.

  • Page 53: Fitting Components After Replacement

    Fitting compon- Mounting the central connector ents after replacement Insert the insert pieces (1) Thread in control line (2) Water-cooled version only: Thread in water flow hose (3) and water return hose (4) Apply the cover Screw in four TX 8 screws (1) Tightening torque: 0.6 Nm...
  • Page 54 Mounting the control line plug at the coupling connector end Thread the control line plug onto the cable Plug in wires as follows: Green → A Yellow → B White → C Brown → D Close the control line plug Mounting the coupling connector Connect the power cable (1) Connect the gas hose (3) and secure...
  • Page 55 Screw in four TX 8 screws (2) Tightening torque: 0.6 Nm Fit insulating tube (1) and position cor- rectly...

  • Page 56: Testing Following Repairs

    Testing Following Repairs Test process The “Testing following repairs” must be carried out in the following order: Mechanical inspection Insulation test Gas flow rate and leak test Water flow rate and leak test Electrical testing of operating elements and displays Current load test/voltage drop measurement Mechanical Wearing parts such as gas nozzles, fixing sleeve, clamping nut, torch cap, lock...

  • Page 57: Gas Flow Rate And Leak Test/Pp-Ser-2001

    Gas flow rate and Inspection equipment: Test box “torch flow rate” (4,078,016) leak test/PP- SER-2001 The “gas flow rate” limit values can be found in the “PP-SER-2001” test schedule. Check the hosepack for flow rate. Straighten the hosepack with the attached torch body and place it down Insert flow tester as shown and start gas flow...

  • Page 58: Water Flow Rate And Leak Test/Pp-Ser-2001

    Water flow rate Inspection equipment: Torch test bench with option for “water flow rate and leak test” and leak test/PP- SER-2001 NOTE! This type of test must only be carried out on water-cooled systems. Carry out the “Water flow rate and leak test” with the hand grip open, as shown. Check soldering points, screw, or clamp connections, etc.

  • Page 59: Electrical Testing Of Operating Elements And Displays

    Electrical testing Inspection equipment: Test box “manual torch” (4,045,998) of operating ele- ments and dis- Check the operating elements and displays for electrical function. plays ATTENTION! ? For proper testing, the lastest version of the service software for the test box “manual torch”...
  • Page 60 d-type manual torch: Connect the test box manual torch (1) directly to the d-manual torch’s control line (2), as shown Make settings on the test box: Up/Down = TIG-torches Check the operating elements are working correctly for each interface version Example: Electrical test Up/Down as per PP-3208 test schedule: Rocker switch left long, press forwards = LED final current Rocker switch left long, press backwards = LED main current...

  • Page 61: Current Load Test/Voltage Drop Measurement

    SH-type manual torch - Poti: Connect the test box manual torch (1) to the test box FSC (2) as shown Connect the adapter FSC - TMC (3) to the test box FSC (2) (switch set to Up/ Down) Connect the manual torch’s control line (4) to the adapter FSC - TMC (3) Make settings on the test box: Poti = LocalNet-devices...
  • 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.

This manual is also suitable for:

Thp 160 - 500dThp 160 - 500iHpt 220 - 400i

Table of Contents