Project Fronius Repair #5: No More Smoke!
After I posted a call for help to the shackspace mailinglist, asking for someone who owns or knows someone who owns a similar welding machine to take a peek at, chris suggested to just give Fronius a call.
He even went one step further and actually called Fronius Germany!
From Fronius Germany he got a digital copy of the manual, troubleshooting guide and a high-level wiring diagram. While the latter did help in identifying the two stray wires, it didn’t help much in figuring out where they should be connected to.
Fronius Germany was also not able to give out any more details circuit diagrams or repair tips, since they only handle replacements.
This didn’t stop chris. He called up Fronius Austria and ended up talking to a very kind technician who offered to identify blown parts if we send him a photo (the resistor I couldn’t ID turned out to be 33 Ohm 5 W) and in the end sent a photo himself showing how to connect the two stray wires!
I already had a hunch that one wire had to be connected in an H-Bridge fashion since it was part of a pair, both connected to a transformer. The Fronius technician verified that hunch.
Cautiously turning on the machine for the first time after repairing bits and pieces here and there I was half expecting it to blow up again.
Nothing of the sort happened! The machine booted up nicely and I could toy around with the settings on the front panel.
So far I’ve not had any of the torches or the water cooling system connected. I’ll do that once I’ve got someone with me who knows how the machine is supposed to operate to verify all is in order :)
So far it’s looking good!