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

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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
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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)

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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
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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
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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
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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
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Connectors BLT5000

RS485 communication
SMB5000 Input voltage
Measurement of
supply voltage

Intermediate circuit
800V GND

Connection boost chokes

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PW-SYS-035, TPSi System Technology - Variants

Status information BLT5000

1
2 4-9

10 Supply voltages

11
Overvoltage
intermediate circuit
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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
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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
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 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
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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
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PW-SYS-035, TPSi System Technology - Variants

BLT5000 Semiconductor Test

Forward direction: Diodes

IGBTs

Disconnect boost
chokes and intermediate
circuit for measuring!
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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)
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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
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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)
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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
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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
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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
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