201 - TD, TPS-System, PW-SYS-031 TS-TPS Digital Welding System (US English), 20150921

PW-SYS-031, TS/TPS Digital Welding Systems
PW-SYS-031 Trans Synergic / Trans Puls Synergic
TSNA Training Team
Fronius USA
Perfect Welding
Tech Support – North America
21 SEPT 2015
CONTENT
INT-WT-SYS-030 Advanced Digital Power Sources
/ Digital Principle
/ Design of a Digital Power Source
/ Inverter-Principle
/ Turn on procedure and welding power circuit TPS
/ Block diagram TPS
/ Setup-Menu
/ Cooling System
/ Wire feeder
/ Error-Messages
21 SEPT 2015
2 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

PRODUCT GROUP DIG. POWER SOURCES

MIG/MAG / TPS 2700 / TPS 320i C / TSt 3500C
/ TPS 3200 / TPS 320i / TSt 3500
/ T(P)S 4000 / TPS 400i / TSt 5000
/ T(P)S 5000 / TPS 500i
TIG / MW 1700 / TT 1750

/ MW 2200 / TT 2200
/ MW 2500 / TT 2500
/ MW 3000 / TT 3000
/ MW 4000 / TT 4000
/ MW 5000 / TT 5000
E-Hand / TP 1500 / AccuPocket

/ TP 2500
/ TP 3500
21 SEPT 2015
/ TP 4000
/ TP 5000
DIGITAL Principle
digital control
/ measured value are immediatly converted to a digital value
/ electronic system can react quickly to events
software controls the system

/ adjustable parameters (no step-switch)
/ software gives the operating point
modular power supply

/ functions are strictly separated
/ thereby easier troubleshooting and repair
21 SEPT 2015

DIGITAL Principle
summary
/ simple possibility of system expansion
/ standardized interface (LocalNet) for easy system integration
/ crucial for the welding characteristics is the software
/ stepless control of the welding parameters
/ automatic documentation of welding data
/ fast internal control
21 SEPT 2015

DIGITAL Principle
/ layout
/ OS: Operating System

/ UST: Universal Control
/ DB: (Welding-) Database
/ CFM: Config Memory (additional to the firmware of the UST)
21 SEPT 2015

DESIGN OF A DIGITAL POWER SOURCE
2 main components
control-unit
/ controls the whole welding process
/ actual data are measured continuously
/ with special control-algorithms ensure that the
target status is maintained all the times
power-unit
/ creates the welding-voltage
/ creates the adjusted wave-form of the welding
power during the welding
21 SEPT 2015

INVERTER-Principle
Layout:
1.. input – AC from the main supply 5.. welding transformer
2.. primary rectifier 6.. Secondary rectifier
3.. intermediate circuit capacitors 7..welding current sensor
21 SEPT 2015
4..transistors
TURN ON PROCEDURE TPS

main supply 1
netfilter
primary power module

after certain time, relais switch fully
400 V AC
primary rectifier 2
intermediate circuite I
intermediate circuite II 3
on rectifier
switched mode power supply LocalNet, 55 V DC
control and regulation unit /

21 SEPT 2015
remaining prints
WELDING POWER CIRCUIT TPS Power supply

UST NT24
control and regulation unit IC I
IC II
BPS 4
power modul
Control and regulation line
Transformer 5
Secondary rectifier 6
Ground Output choke
Shunt 7
21 SEPT 2015
Output
BLOCK DIAGRAM TPS

21 SEPT 2015

MAIN-TASKS OF THE UST

temperature-sensor
regulation of welding options
power (DSP)
BPS UST SR41, SR43

power module Control, regulation, monitor stearing the
wire feeder
control panel (on data-transmission to the

Local- Net) peripherie
NT24, NT60
switched mode
21 SEPT 2015
power supply
SETUP MENU TPS
setup-menu
control panel
/ shielding gas
/ filler metal
/ firmware-versions
/ process selection
layer I: background-menu
layer II: 2nd menu

21 SEPT 2015

SOFTWARE/DATABASE
21 SEPT 2015

SYSTEM-COMPONENTS MIG/MAG
Setup of the power source to the

individual requirements
/ by various system-components
/ options
21 SEPT 2015

COOLING SYSTEM
cooling units
vibrating armature pump centrifugal pump

/ less lifetime than a centrifugal pump
/ magnetically coupled centrifugal pump
(FK 4000 Rob)
/ rotary pump with flow watchdog (FK 4000-
RFC)
21 SEPT 2015

COOLING UNIT
flow control
/ monitors the coolant-flow during welding
/ should a fault occur, the cooling unit turns the power source off (e.g error message: „No |
H2O“)
/ a fault can be caused by:
/ coolant level too low
/ insufficient bleeding of the cooling circuit
/ contaminated coolant
/ leak in the cooling circuit
/ defective coolant pumps
/ frozen coolant
21 SEPT 2015

MAINTENANCE OF THE COOLING UNIT

sequence task
check coolant level and cleanliness

every week
Check water filter on pollution -

every 2 months replace or clean if necessary
clean inside of machine with dry

every 6 months reduced compressed air
every 12 months replace coolant

21 SEPT 2015

COOLING UNIT
flow meassuring device
/ digital flow meassuring device LCD 0-6l/min.

/ order number: 4,001,673
21 SEPT 2015

WIRE FEEDER
concept of the wire feeder

/ used as an internal or external feed
/ wire feed speed: between 1 and 22 m/min
(high performance welding up to 30 m/min)
wire feed motor

/ DC shunt-wound motor
/ permanent-magnet motor
/ high class disc-rotor motor (advantage: long lifetime)
21 SEPT 2015

WIRE FEEDER
2 types
2-roller drive 4-roller drive

/ with soft wires (e.g. cored wire)
/ with long wire extraction drift
21 SEPT 2015
VR 2000 VR 4000 VR 4000 Yard VR 7000

DRIVE ROLLERS
types
trapezoidal groove, semi-circular groove, semi-circular groove,

smooth smooth ribbed
21 SEPT 2015

CONCEPT OF THE VR 4000
/ to operate the wire-feeder, it must be first configurated for use

with the corresponding power source
/ VR 4000-30 and VR 4000-30 Time wirefeeders are equipped with a water-cooled electric
motor with disc-shaped rotor – operation only possible with cooling unit
/ suitable for wire-coils up to 300 mm / 4-roller drive standard
VR 4000 VR 4000-30 VR 4000-30 TIME
TransSynergic 4000 / 5000 X X -
TransSynergic 7200 / 9000 X X -
TransPuls Synergic 3200 / 4000 / 5000 X X -
TransPuls Synergic 7200 / 9000 X X -
TIME 5000 Digital - X X
TransPuls Synergic 2700 Duo X - -
21 SEPT 2015
TransPuls synergic 2700 Duo Tig X - -

DIGITAL GAS-CONTROL
/ is used for a digital control of the shielding-gas flowrate

/ a exact control avoids an increase in gas consumption at the weld start
/ example: output signal at 0 l CO2: 1 V
calculation of the flow

/ by temperature difference
/ heat capacity of the used gas
/ shielding gasflow factory set to 15 l/min.
21 SEPT 2015

SOFTWARE-OPTIONEN
Order Power Source Demo Licence Licence Key

(Parallel / USB) (Parallel / USB)
(4,045,896 / 898) (4,045,932 / 934)
4,061,101 SynchroPuls Option Integriert* not available
4,061,102 SFI Option Integriert* not available
4,061,103 JobExplorer Option not available not available
4,061,107 JobExplorer Enterprise not available Option Option
4,061,104 GunTrigger Option Integriert* not available
4,061,105 WeldProcessData Option not available not available
4,061,108 WeldProcessData E. not available Option Option
4,061,109 WeldOffice Option not available not available
4,061,111 WeldOffice Enterprise not available Option Option
4,061,106 Mode CC / CV Option Integriert* not available
4,061,112 TCS Option Integriert* not available
4,061,113 Drive Option Integriert* not available
4,061,110 TimeTwin Digital Option not available not available
4,061,120 Documentation Option not available not available
4,061,121 Documentation E. not available Option Option
21 SEPT 2015

ERROR-MESSAGES
service-codes
...from the UST

e.g. dsP | xxx
Err | xxx
- Stop -
...from the wire feeder

- feeder: Efd | xxx
- calibrating the Push-Pull unit: Stx | xxx
...from the interface

21 SEPT 2015

21 SEPT 2015 PW-SYS-031, TS/TPS Digital Welding Systems

201 - TD, TPS-System, PW-SYS-031 TS-TPS Digital Welding System (US English), 20150921

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PW-SYS-031, TS/TPS Digital Welding Systems

PW-SYS-031 Trans Synergic / Trans Puls Synergic

TSNA Training Team

INT-WT-SYS-030 Advanced Digital Power Sources

2 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

PRODUCT GROUP DIG. POWER SOURCES

TIG / MW 1700 / TT 1750

E-Hand / TP 1500 / AccuPocket

software controls the system

modular power supply

4 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

5 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

/ OS: Operating System

6 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

DESIGN OF A DIGITAL POWER SOURCE

7 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

TURN ON PROCEDURE TPS

primary power module

switched mode power supply LocalNet, 55 V DC

control and regulation unit /

WELDING POWER CIRCUIT TPS Power supply

Ground Output choke

BLOCK DIAGRAM TPS

11 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

MAIN-TASKS OF THE UST

BPS UST SR41, SR43

control panel (on data-transmission to the

SETUP MENU TPS

layer II: 2nd menu

13 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

14 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

Setup of the power source to the

15 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

vibrating armature pump centrifugal pump

16 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

17 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

MAINTENANCE OF THE COOLING UNIT

check coolant level and cleanliness

Check water filter on pollution -

clean inside of machine with dry

every 12 months replace coolant

18 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

flow meassuring device

/ digital flow meassuring device LCD 0-6l/min.

19 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

concept of the wire feeder

wire feed motor

20 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

2-roller drive 4-roller drive

VR 2000 VR 4000 VR 4000 Yard VR 7000

trapezoidal groove, semi-circular groove, semi-circular groove,

22 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

CONCEPT OF THE VR 4000

/ to operate the wire-feeder, it must be first configurated for use

TransPuls synergic 2700 Duo Tig X - -

/ is used for a digital control of the shielding-gas flowrate

calculation of the flow

24 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

Order Power Source Demo Licence Licence Key

25 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011

...from the UST

...from the wire feeder

...from the interface

26 Fronius International GmbH / TSI Team Training / INT-PW-SYS-031 TS TPS/ 27.07.2011