PW-SYS-035, TPSi System Technology - Variants
PW-SYS-035-TPS/i System Technology - Variants
TSNA Training Team
Fronius USA
Perfect Welding
Tech Support – North America
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
TPS/i Variants
Multi Voltage
21 SEPT 2015
2
Fronius International GmbH / first name last name / Titel of presentation / xx.xx.20xx - v02
PW-SYS-035, TPSi System Technology - Variants
TPS/i /MV
Compact Systems
TPS 320i C PULSE /MV /nc 4,075,171,830
/ Input voltage range: 200V – 230V (-10%
/+15%)
380V – 460 V (-10% /+15%)
/ Voltage switch for intermediate circuit by ASU 2700
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Automatic voltage switch ASU2700
LED Voltage dependent switching of power module. The
180-265V
switching occurs in the rectified current.
ZWK 1 LED / 230V (265V Maximum) – Power modules parallel
340-530V
/ 400V (530V Maximum) – Power modules seriell
+5V Internal power supply for +5 and +12V DC
+12V
Direct mounting to the rectifiers (spring contact)
Two relays working parallel to avoid chatter
LEDs:
/ Voltage supply +5V, +12V
/ Input voltage range 340 – 530V
ZWK 2
/ Input voltage range 180 – 265V
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
TPS/i /MV
Separated Systems
TPS 320i /MV /nc 4,075,172,830
TPS 320i PULSE /MV /nc 4,075,178,830
TPS 400i /MV /nc 4,075,174,830
TPS 400i PULSE /MV /nc 4,075,179,830
TPS 400i LSC ADV /MV /nc 4,075,175,830
TPS 500i /MV /nc 4,075,176,830
TPS 500i PULSE /MV /nc 4,075,180,830
/ Input voltage range: 200 V – 460 V (-10% /+15%)
/ Intermediate circuit lined out to 800 V (input voltage-independent)
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Specific components
Booster choke
/ 3 x 33,0010,0405 (TPS
320i /MV)
/ 3 x 33,0010,0404
(TPS 400i a. 500i /MV)
DC choke
/ 33,0010,0430
Line filter
/ 43,0001,1418 Thyristor rectifier
/ TPS 400i /MV and / 3 x 43,0001,1457
TPS 500i /MV / TPS 400i /MV a. 500i /MV only
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Schematic
HLP5000: Upload of intermediate
circuit and ELA5000 BLT5000: Digital
Booster power module
HLP5000 Boost choke
Line filter
BLT5000
DC-Drossel ELA5000 ZWK
800V
Thyristor rectifier
ELA5000: Capacitor print in rectified
circuit supports the booster input
voltage
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Position of MV components
Boost choke
Upload circuit HLP5000 ELA5000
Line filter Primary rectifier
Booster power module BLT5000 DC inductivity
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Booster power module BLT 5000
BPS 4000 / BPS 5000
/ Standard power module for separated
systems
BLT 5000
/ Digital booster power module
/ Upgradeable by firmware
21 SEPT 2015
/ Line out intermediate circuit to 800V
PW-SYS-035, TPSi System Technology - Variants
Overview BLT5000
4,071,173 µProcessor
Two optical coupler for galvanic isolation
of communication to spider
Booster 1
/ Input voltage range: 180 to 530 Vac
Booster 2
/ Booster input rectified
/ Output voltage: 800Vdc
/ Switching frequency: 23 kHz / Booster
Booster 3
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Connectors BLT5000
RS485 communication
SMB5000 Input voltage
Measurement of
supply voltage
Intermediate circuit
800V GND
Connection boost chokes
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Status information BLT5000
1
2 4-9
10 Supply voltages
11
Overvoltage
intermediate circuit
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Normal Mode
Supply voltage LEDs shines
Communication LEDs flashes with operating communication to SMB5000
LED „Status 1“ flashes depending to system type
/ 0 Hz (shining) boot loader
21 SEPT 2015
/ 1 Hz (500iMV), ½ Hz (400iMV), ¼ Hz (320iMV);
/ 5 Hz system type (320/400/500) still unknown
PW-SYS-035, TPSi System Technology - Variants
Monitored Errors
Supply voltages gets monitored
by µController
/ Vss (=+17V)
/ 15Vp
/ -10V
Overcurrent booster gets monitored and indicated permanently in
case of failure (Reset by switch off of power source)
short cut on the power module, boost choke damaged
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Monitored Errors
Booster not Ready
UZWK > 850V
Overvoltage on intermediate circuit gets monitored
Attention! No permanent notification! LED goes off, if U ZWK < 850V
BLT5000 damaged or supply voltage to high
„Booster not Ready“ shines in case of
Overvoltage intermediate circuit
Overcurrent booster
21 SEPT 2015
Supply voltage failure
Incorrect rectification voltage (e.g. connection failure X1:3)
PW-SYS-035, TPSi System Technology - Variants
Booster Self Test
Booster passes self test at startup.
„Status 3 LED“ indicates errors by
flashing periodically:
1x flash Booster 1
2x flash Booster 2
3x flash Booster 3
Possible causes:
Current transducer
Boost choke damaged or not connected
Short cut on BLT5000
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
BLT5000 Semiconductors
IGBTS:
TPS 320i MV: each with 2x PT50GT120JRDQ2
TPS 400i MV: each with 3x PT50GT120JRDQ2
TPS 500i MV: each with 3x APT75GT120JRDQ2
Diodes:
each with 1x APT2x31DQ120J
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
BLT5000 Semiconductor Test
Forward direction: Diodes
IGBTs
Disconnect boost
chokes and intermediate
circuit for measuring!
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Upload circuit HLP5000
4,071,175
Upload circuit for TPS 400i /MV, TPS 500i /MV and TPS 600i
LED supply voltage
/ Upload of intermediate
circuit and ELA5000 at
start up
/ Activation of thyristor
rectifier
/ Generation of signals for measuring of supply voltage (main voltage signal)
/ Connection / fuse of Cooling Dock (cooling unit)
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
HLP5000 Connectors
Drive connector rectifier
(Gate und kathode) main supply signal Cooling Dock
Supply voltage 17V
Cooling unit fuse
Upload by PTCs
Upload ELA5000
Thyristor driver
Measuring signal BLT5000
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
ELA5000
4,071,176
/ EMC
/ Stabilization of booster input voltage
/ Stabilization of mains because high frequency of the booster
/ Prevents from revers transfer to the mains
/ Connector to booster chokes
/ Connects the upload circuit to power
/ No effect to welding process
/ Because parallel connection to intermediate circuit, a
damaged film capacitor on ELA5000 (short-circuited) affects
like a damaged capacitor on intermediate circuit.
/ No error information from ELA5000 (In case of damaged
capacitors under voltage error is possible)
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
ELA5000 Connectors
Upload circuit
Film capacitors on
ELA 5000 get loaded
by upload circuit
(HLP5000).
+ Connector for
boost choke and
DC choke
- Connector
cable to rectifier
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Comparison TPS/i vs. TPS/i /MV
TPS/i TPS 320i /MV TPS 400i 500i /MV TPS 600i
Line filter RP5000 RP3200MV Schaffner 82A 3x460V
Primary rectifier Bridge three-phase Thyristor rectifier
Upload circuit RP5000 RP3200MV HLP5000
Intermediate circuit ELC5000 ELC5000MV ELC5000MV Film capacitor
Booster BLT3200 BLT5000
2 x NTC
3 x Boost choke
DC choke DC choke DC choke
Voltage stabilization ELA5000
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
Compatible Cooling Units
Model Voltage Range Certification
CU 1100i /MV 200 – 230V CE/CSA
400 – 480V
CU 1400i Pro 200 – 600V CE/CSA
CU 1400i Pro /MC 200 – 600V CE/CSA
CU 1
1
CU 1 00i /MV
4
C U 1 0 0 P ro
400
P ro
/MC
21 SEPT 2015
PW-SYS-035, TPSi System Technology - Variants
21 SEPT 2015
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