PW-SYS-034, TPSi SystemTechnology
PW-SYS-034 TPS/i System Technology
TSNA Training Team
Fronius USA
Perfect Welding
Tech Support – North America
21 SEPT 2015
PW-SYS-034, TPSi SystemTechnology
OVERVIEW
/ Power Sources TPS500i / TPS400i / TPS320i / TPS320iC
/ Concept and Block Diagrams
/ communication structure
/ Device-ID
/ Prints (line filter, control, performance parts, Elko prints, …)
/ Sensor interface
/ Cooling Unit
/ CoolingDock
/ Control board
/ Wire Feeder
/ Motors
/ Control board
21 SEPT 2015
2
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
3
TPS/i Systemtechnology
Power source
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
4
POWERSOURCE CONCEPT BLOCK DIAGRAM
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
5
BLOCK DIAGRAM – SPLIT SYSTEMS
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
6
BLOCK DIAGRAM – COMPACT SYSTEMS
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
7
BLOCK DIAGRAM – COMPACT SYSTEMS (SR63)
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
8
BLOCK DIAGRAM – COMPACT SYSTEMS /MV
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
9
TPS/i Systemtechnology
Communication
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
10
COMMUNICATION DIAGRAM
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
11
SPEEDNET
/ ControlBus
/ ProcessBus
PW-SYS-034, TPSi SystemTechnology
SPEEDNET – CONNECTORS
TORCH COUPLING
WITH SpeedNet
Coupling between hose SpeedNet CABLE
pack and drive unit with
SpeedNet connection cable
integrated SpeedNet
for all electronic boards
FSC WITH SpeedNet
Central connector for torches with
integrated SpeedNet
SYSTEM CONNECTOR
WITH SpeedNet
Central connector for all
peripheral components with
integrated SpeedNet
21 SEPT 2015
12
PW-SYS-034, TPSi SystemTechnology
SMART CARD & DEVICE ID
/ Generally, a distinction is made between
/ Smart Cards and
/ Device IDs
/ Smart Cards
/ Are used for cryptographic encryption
/ Device IDs
/ Are used tu save the Data for Assemblies!
For example; Pumps or motor data .
21 SEPT 2015
13
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
14
SMART CARD & DEVICE ID
PW-SYS-034, TPSi SystemTechnology
PROGRAMMING SMART CARDS
/ Smart Cards are programmed only in Fronius International Facilities and are then sent out
to the different organisations.
/ Smart Cards
/ can only be ordered if the specific serial number is given.
/ can not be programmed nation wide.
/ Same process as with CFM of the digital products
21 SEPT 2015
15
21 SEPT 2015 PW-SYS-034, TPSi SystemTechnology
16
Prints
TPS/i Systemtechnology
PW-SYS-034, TPSi SystemTechnology
OVERVIEW: BASIC PC BOARDS
Separated RP 5000 Mains filter and up-load circuit
systems
BPS 5000 Power module with transistor full bridge
BPS 4000 Power module with transistor full bridge
ELC 5000 Electrolytic capacitor (intermediate circuit)
SMB 5000 Control and regulation unit
Compact BPS 3200 C Power module with transistor full bridge – Compact
systems
ELC 3200 C Electrolytic capacitor (intermediate circuit) – Compact
SMB 2700 C Control and regulation unit & motor control
ASU 2700 Voltage switchover for MV systems
MCU Main Control Unit – User interface and Touch Display
NT 241 Power supply unit 24V DC internal and external
NT 601 Power supply unit 60V DC – supply for the wire feeder
Wire feeder SR 63 Motor control for wire feeder
Cooling unit FKS 3200 Control board for cooling unit
21 SEPT 2015
FKC 2500 MV switch for CU (Same as MW 2500)
17
PW-SYS-034, TPSi SystemTechnology
RP5000 (4,071,267)
Technical Data
/ 550V mains filter with varistors as surge
protection
/ Intermediate high-circle charging circuit via PTC's
and relays
/ LED green: indicator for a triggered relais
/ 10A Cooling circuit fuses
/ Maximum Voltage: Unet = 530V
/ Generation of the main switch signal
21 SEPT 2015
18
PW-SYS-034, TPSi SystemTechnology
BPS5000 (4,071,168)
Secondary
Technical Data
/ Phase-Shift Full Bridge (fs = 40kHz)
/ 1200V IGBT Modules (4 pieces)
/ Primary current measurement with current transformer
/ Mains voltage range: 380V – 480V (±10%) in connection
with ELC5000 (4,071,178)
/ Supply Voltage 17V (Power source for 5V and 3,3V
integrated)
/ Control and data acquisition via µProcessor
/ Measuring data transmission to the SMB5000 via RS-
485 interface (Module temperatures, board temperature,
UZWK, Umain, Sync, Main signal, phase failure)
/ EMC-Ground capacitor
21 SEPT 2015
/ On the print there is a primary-secondary separation point!
19
PW-SYS-034, TPSi System Technology
BPS4000 (4,071,166)
Secondary
Technical Data
/ The BPS4000 is equipped with 3 IGBT modules.
Otherwise it is identical to the BPS5000
21 SEPT 2015
20
PW-SYS-034, TPSi System Technology
SECOND SOURCE
Microsemi Infineon
/ BPS 4000 MS / BPS 4000
/ BPS 5000 MS / BPS 5000
21 SEPT 2015
21
PW-SYS-034, TPSi System Technology
PRESSFIT & PHASE CHANGE
Remov
e
Residu
es!!!
Do not
Solder!!!
21 SEPT 2015
22
PW-SYS-034, TPSi System Technology
ELC5000 (4,071,178)
Technical Data
/ Series connection of 2 capacitors each
470μF/450V and that connected 7 times
parallel (= 14 Pieces)
/ Maximum voltage: UZWK = 800V dc
/ Balance and discharge resistors
/ 4 pcs 10μF/450V series capacitors for welding
transformer primary (DC current suppression)
/ Filter inductor and film capacitors (10µF/875V)
/ Device-ID for variant distinguishing (Standard,
MV, 600V)
21 SEPT 2015
23
PW-SYS-034, TPSi System Technology
BPS 3200 C
Technical Data
/ 82kHz MOS-FET
/ 2 Phaseshift-full bridges
/ 4 Module groups
/ 4 MOS-FET parallel
/ Direct plug-in to ElkoPrint
ELC3200C
/ Device-ID for variant
distinguishing
/ temperature sensor
21 SEPT 2015
24
PW-SYS-034, TPSi System Technology
ESD
7,000
7000
6000
Minimum and maximum manufacturers
5000
4000 3,000
Sensibility [Voltage]
3000
1,800
2000
data
25 0 38 0 100 100
1000 30 100 200
0
VMOS MOS FET CMOS Bipolar EPROM
Transistor
21 SEPT 2015
Components
25
PW-SYS-034, TPSi System Technology
ELC 3200 C
Technical Data
/ Supply Voltage 17V (Power source for 5V and 3,3V)
/ High charging circuit for the DC primary by means of
PTC's
/ Control and data acquisition via µProcessor
/ Transmission of measurement data to SMB5000 via
RS-485
/ Module temperatures, UZWK, supply voltage, board
temperature, HS (phase failure), sync
/ Primary current measurement using two current
transformers
/ Integrated symmetry / discharge resistors in the
intermediate circuit
/ Optocouplers for the electrical isolation of the signal
lines
21 SEPT 2015
/ Bypass capacitors to ground (EMC requirements)
26
PW-SYS-034, TPSi System Technology
SMB5000 (4,071,195)
Interface Print for SPIDER
21 SEPT 2015
27
PW-SYS-034, TPSi System Technology
SMB2700C (4,071,163)
Interface Print for SPIDER
21 SEPT 2015
28
PW-SYS-034, TPSi System Technology
UNIVERSAL SENSOR INTERFACE
/ One interface for sensor system
/ Identification of sensor by Device-ID
/ Each sensor (wire end, flow control, …) is
equipped with an device-ID
Supply Voltage 24V vom NT241
Device-ID identification
analog input 0 – 20mA
21 SEPT 2015
digital input < 3,5V = Low > 7V = High
29
PW-SYS-034, TPSi System Technology
CONNECTING UNIVERSAL SENSOR INTERFACE
Plug has to be
locked to the
connector.
21 SEPT 2015
30
21 SEPT 2015 PW-SYS-034, TPSi System Technology
31
TPS/i Systemtechnology
Cooling unit
PW-SYS-034, TPSi System Technology
COOLINGDOCK
/ Supply Voltage / Control and DC supply
400V bzw. 200 - 460V (MV) RS485 bzw. 24V DC
21 SEPT 2015
32
PW-SYS-034, TPSi System Technology
PIN ASSIGNMENT FKS3200
/ Communication via RS 485 -
4 Wire Full Duplex
/ Controls all cooling circuits
(DC and AC Pumps)
/ Control of the fan
/ Own device ID for cooling
circuit and pump
/ Inputs for sensors
/ Water-level sensor 24V & RS485 400V
/ 2x Thermosensor
/ 2x Sensor interface (e.g., flow
meter)
21 SEPT 2015
33
PW-SYS-034, TPSi System Technology
FKS 3200 LEDs 5Hz → Hardware working
rot → Error System/Software
25Hz → Operating
System is working
21 SEPT 2015
34
PW-SYS-034, TPSi System Technology
FKC 2500
/ For MultiVoltage only
/ Switching of the transformator
voltage
21 SEPT 2015
35
21 SEPT 2015 PW-SYS-034, TPSi System Technology
36
TPS/i Systemtechnology
Wirefeeder
PW-SYS-034, TPSi System Technology
MOTORS
/ WF25i / WF15i, WF15i n.S. (no Spool)
/ TPS320i C / WF30i
/ Elvi / Minebea
/ 42V DC / 42V AC
/ aircooled / watercooled
21 SEPT 2015
37
PW-SYS-034, TPSi System Technology
MOTORS
ELVI Motor Minebea Motor
Wire feed speed 25 m/min 15 m/min 30 m/min
Current 1,2 – 1,5 A
Gear Worm gear Spur gear
Dynamic 300 m/min/sec 300 m/min/sec 500 m/min/sec
Cooling Air Water
21 SEPT 2015
38
21 SEPT 2015 PW-SYS-034, TPSi System Technology
39
PIN ASSIGNMENT SR63
PW-SYS-034, TPSi System Technology
SR63 LEDs
Debug LEDs
Red
Fatal error
Red / green – 1 Hz
LED Phy1, Phy2
No firmware
& Phy 2 loaded
Indicators, if
SpeedNet Green – 10 Hz
communication
Wait for IP
to power
source is OK
(depending on Green – irregular
which plug the communication
SpeedNet is with MCU
connected, the
corresponding
LED shines)
21 SEPT 2015
40
PW-SYS-034, TPSi System Technology
COMPARISON TPS vs. TPS/i
TPS TPS/i
Bit rate ~ 10 msec ~ 100 µsec, deterministic
LocalNet vs Systembus
Acceleration ramp and slope 115 m/min/sec 300 m/min/sec
of motors
Motor control DC motor only DC- and AC motor
Update wire feeder software Localy on device Centraly on power source
Wire positioning No Yes, by ABI encoder
21 SEPT 2015
41
PW-SYS-034, TPSi System Technology
21 SEPT 2015
All information is without guarantee in spite of careful editing - liability excluded.
Intellectual property and copyright: all rights reserved. Copyright law and other laws protecting intellectual property apply to the not otherwise marked content of this presentation respectively documents (texts, pictures, graphics,
animations etc.). It is not permitted to use, copy or alter the content of this presentation for private or commercial purposes without express authorisation from Fronius.
