INT-PW-SYS-035-TPS/i Variants

Team Training

Fronius International GmbH

Division Perfect Welding
Froniusplatz 1
4600 Wels
TPS/i Variants

Multi Voltage

2
Fronius International GmbH / first name last name / Titel of presentation / xx.xx.20xx - v02
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

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
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)

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
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
Position of MV components
Boost choke
Upload circuit HLP5000 ELA5000

Line filter Primary rectifier

Booster power module BLT5000 DC inductivity
Booster power module BLT 5000
BPS 4000 / BPS 5000
/ Standard power module for separated
systems

BLT 5000
/ Digital booster power module
/ Upgradeable by firmware
/ Line out intermediate circuit to 800V
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
 Connectors BLT5000

RS485 communication
SMB5000 Input voltage
Measurement of
supply voltage

Intermediate circuit
800V GND

Connection boost chokes

Status information BLT5000

1
2 4-9

10 Supply voltages

11
Overvoltage
intermediate circuit
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
/ 1 Hz (500iMV), ½ Hz (400iMV), ¼ Hz (320iMV);
/ 5 Hz system type (320/400/500) still unknown
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
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
 Supply voltage failure
 Incorrect rectification voltage (e.g. connection failure X1:3)
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
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
BLT5000 Semiconductor Test

Forward direction: Diodes

IGBTs

Disconnect boost
chokes and intermediate
circuit for measuring!
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)
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
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)
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
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
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
All information is without guarantee in spite of careful editing - liability excluded.
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