Fronius USA TPS/D

Tech Support – North America

Headquarters, Portage, IN
DETAILED COMPONENT BREAKDOWN
NETFILTER
General Information
Part Number: See next page
Part Name: Netfilter

Functional Overview
 Varistors provide protection against momentary overvoltage of
the mains.
 Capacitors and coils form a LC low-pass filter that moderates the
parasitic frequencies over 60 Hz
 Capacitors divert disturbances to earth and also between the
phases
 Resistors discharge the line filter capacitors
 The earth current watchdog is integrated on the line filter.

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NETFILTER - CONNECTIONS
X1 Mains Supply

U1 L1 in

V1 L2 in

W1 L3 in

PE PE conductor

X2 Connection to BPS

U2 L1 out

V2 L2 out

W2 L3 out

X3 Earth Current Watchdog

X4 Connection to ASU 40

U2 L1 out

V2 L2 out

W2 L3 out

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NETFILTER

/ TPS 4000-5000 MV, current model

/ Physically longer, able to handle 80-amp input
/ Integrated ground fault

/ TPS 3200MV, 4000-5000 460

/ Half the size, able to handle 40-amp input
/ Integrated ground fault

/ TPS 4000-5000, older machines (1428xxxx or earlier)

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NETFILTER
Pin Function
X1 Mains supply
U1: L1 in
V1: L2 in
W1: L3 in
PE: PE conductor

X2 Connection to BPS 42/50/53

U2: L1 out
V2: L2 out
W2: L3 out

X3 Earth current watchdog

X4 Connection to ASU 40 (on line filter 80 A only)

U2: L1 out
V2: L2 out
W2: L3 out

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ASU 40
General Information
Part Number: 4,070,685
Proper Name: PC-Board, ASU 40
Note(s): This is an optional component

Functional Overview
 Switches between 230V AC and 460V AC

 Generates a control voltage of +12V DC and +5V

 The switching mechanism on the PC board detects the input voltage and
changes the configuration of the BPS as follows:
• With an input voltage of 460V AC, the ASU PC board switches
both power modules on the BPS in series.
• With an input voltage of 230V AC, the ASU PC board switches
both power modules on the BPS in parallel.

 High charging connection by means of resistance; the relays for bridging

the resistances are controlled by the BPS PC board. The charging
connection is only active as an input voltage of 230V AC.

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ASU 40
X1 Connection to BPS PC Board

Pin 1 No Connection Pin 9 Intermediate circuit voltage 1+

Pin 2 No Connection Pin 10 No Connection

Pin 3 No Connection Pin 11 Intermediate circuit voltage 2-

Pin 4 No Connection Pin 12 No Connection

Pin 5 No Connection Pin 13 No Connection

Pin 6 No Connection Pin 14 No Connection

Pin 7 No Connection Pin 15 GND primary

Pin 8 +15V DC primary Pin 16 High charging connection signal

X2 Connection to Line Filter (load 2, L1 out)

X3 Connection to Line Filter (load 2, L2 out)

X4 Connection to Line Filter (load 2, L3 out)

X5 Connection to Lower Primary Rectifier (L1)

X6 Connection to Lower Primary Rectifier (L2)

X7 Connection to Lower Primary Rectifier (L3)

X8 No Connection

X9 Connection to Cooling Unit (230V AC)

X10 Connection to Cooling Unit (L2)

X11 Connection to Cooling Unit (L1)

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ASU 40
X12 Connection to Upper Primary Rectifier

Pin 1 Rectifier L1 Pin 9 No connection

Pin 2 No connection Pin 10 No connection

Pin 3 Rectifier L2 Pin 11 Rectifier L2

Pin 4 No connection Pin 12 No connection

Pin 5 Rectifier L3 Pin 13 No connection

Pin 6 No connection Pin 14 No connection

Pin 7 No connection Pin 15 No connection

Pin 8 No connection Pin 16 No connection

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ASU 40
LED Charge Unit Flashes once the intermediate circuit has been charged

LED 230 vac Flashes at an input voltage of 230 vac

LED +5 vdc Lights when 5 vdc is present.

LED +12 vdc Lights when 5 vdc is present.

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BPS POWER BOARD
General Information
Part Number: 4,070,738 (BPS 42); 4.070.771 (BPS 43)
Proper Name: PC-Board, BPS 42/43
Note(s): Primary voltage is ON!

Functional Overview
 Two individual power modules build into the same board (advantage: power
modules can be switched between series and parallel).
 Suitable for a mains supply of 3 x 460V AC and 3 x 230V AC .
 Inputs are electrically isolated by means of isolating transformers and optical
couplers.
 4 to 6 parallel transistor modules (based on part number and version number).
 Each transistor module has it’s own temperature sensor.
 Monitoring of both intermediate circuits for imbalance.
 High charging connection via resistors.
 Quick switch-off power modules in the case of module fault.

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BPS - CONNECTIONS

X1 Ribbon Cable Connection to UST

Pin 1 Primary current +T1 Pin 14 GND

Pin 2 Primary current GND T1 Pin 15 +5V DC

Pin 3 Primary current +T2 Pin 16 +15V DC

Pin 4 Primary current GND T2 Pin 17 +24V DC

Pin 5 Transistor control Pin 18 Main switch detection (5V On)

Pin 6 Transistor control Pin 19 Temperature value PWM signal

Pin 7 Transistor control Pin 20 Signal for high charging connection

Pin 8 Transistor control Pin 21 CFM data line

Pin 9 Transistor control Pin 22 CFM data line

Pin 10 Transistor control Pin 23 No connection

Pin 11 Transistor control Pin 24 +15V DC

Pin 12 Transistor control Pin 25 No connection

Pin 13 GND Pin 26 Intermediate circuit balance

detection

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BPS - CONNECTIONS
X2 Intermediate Circuits 1 and 2 Primary Connection

Pin 1 Intermediate circuit 1+ Pin 9 Intermediate circuit 1+

Pin 2 No connection Pin 10 No connection

Pin 3 Intermediate circuit 1- Pin 11 Intermediate circuit 1-

Pin 4 No connection Pin 12 No connection

Pin 5 Intermediate circuit 2+ Pin 13 Intermediate circuit 2+

Pin 6 No connection Pin 14 No connection

Pin 7 Intermediate circuit 2- Pin 15 Intermediate circuit 2- GNDP

GNDP

Pin 8 +15V DC primary Pin 16 +15V DC primary

X3 Main Switch Connection (primary voltage)

Pin 1 L1 Pin 9 No connection

Pin 2 No connection Pin 10 High charging resistor L1

Pin 3 L2 Pin 11 No connection

Pin 4 No connection Pin 12 High charging resistor L2

Pin 5 No connection Pin 13 No connection

Pin 6 Main switch detection Pin 14 No connection

Pin 7 No connection Pin 15 No connection

Pin 8 +15V DC primary Pin 16 High charging connection

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BPS - CONNECTIONS

X4 N1- Transformer Connection

X5 N2- Transformer Connection

X6 N2+ Transformer Connection

X7 N1+ Transformer Connection

X8 Primary Rectifier (L1)

X9 Line Filter (L1)

X10 Line Filter (L3)

X11 Primary Rectifier (L3)

X12 Line Filter (L2)

X13 Primary Recttifier (L2)

X14 Intermediate Circuit 2- (blue cable)

X15 Intermediate Circuit 2- (blue cable)

X16 Intermediate Circuit 2+ (red cable)

X17 Intermediate Circuit 2+ (red cable)

X18 Intermediate Circuit 1- (blue cable)

X19 Intermediate Circuit 1- (blue cable)

X20 Intermediate Circuit 1+ (red cable)

X21 Intermediate Circuit 1+ (red cable)

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BPS – LED’S

Main Switch LED Light up when the main switch is set to on.

Intermediate Circuit Light up when the imbalance between the capacitors are within an
Imbalance LED acceptable point.

LED +15V DC Light up when the board has +15V DC

High Charging Relay Active when the capacitor charging resistors are active
LED

Transistor Module Will light up when the BPS is putting out an output voltage.
Control LEDs

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BPS – MEASURING POINTS
Intermediate Circuit Voltage
Description Test Point Result

ICV 1 TP1(-) and TP3(+) 320V DC

ICV 2 TP5(-) and TP7(+) 320V DC

Diode Check (module M1, M2, M3)

Description Test Point Result

D1 TP1(-) and TP2(+) 0.46V DC

D2 TP1(-) and TP4(+) 0.46V DC

D3 TP2(-) and TP3(+) 0.46V DC

D4 TP4(-) and TP3(+) 0.46V DC

D5 TP5(-) and TP6(+) 0.46V DC

D6 TP5(-) and TP8(+) 0.46V DC

D7 TP6(-) and TP7(+) 0.46V DC

D8 TP8(-) and TP7(+) 0.46V DC

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BPS – MEASURING POINTS
Intermediate Circuit Voltage
Description Test Point Result

Main Switch X1/18 and X1/14 5V

IC Imbalance X1/26 and X1/14 5V

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NT 24 – 24VDC POWER SUPPLY

General Information
Part Number: 4,070,626
Proper Name: PC-Board, NT 24 A

Functional Overview
 Internal and external components are supplied with +24V DC
 Power module is supplied with +15V DC primary. Can NOT be used for
supplying other components.
 Supply voltages are electricaly isolated and protected by PTC.
 Electrically isolated measurement of intermediate circuit voltage (the
evaluation of this measurement is done on the UST PC board).

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NT 24 - CONNECTIONS

X1 Primary Connection Intermediate Circuit 1 and 2

Pin 1 Intermediate circuit 1+ Pin 9 Intermediate circuit 1+

Pin 2 No connection Pin 10 No connection

Pin 3 Intermediate circuit 1- Pin 11 Intermediate circuit 1-

Pin 4 No connection Pin 12 No connection

Pin 5 Intermediate circuit 2+ Pin 13 Intermediate circuit 2+

Pin 6 No connection Pin 14 No connection

Pin 7 Intermediate circuit 2- Pin 15 Intermediate circuit 2- GNDP

GNDP

Pin 8 +15V DC primary Pin 16 +15V DC primary

X2 Secondary Connection +24V DC

Pin 1 +24V DC external Pin 5 GND external

Pin 2 No connection Pin 6 No connection

Pin 3 Intermed. circuit volt UZW Pin 7 GND UZW

Pin 4 +24V DC Pin 8 GND internal

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NT 24 – LED INDICATORS

LED 24V DC Internal Will light up when the board has 24V DC internal.

LED 24V DC External Will light up when the board has 24V DC external.

LED 15V DC Primary Will light up when the board has 15V DC primary.

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NT 24 – TEST POINTS

Circuit Voltage
Description Test Point Result

ICV 1 X1 (pin 1 and pin 3) Roughly 280VDC with 400V AC

mains or 320V DC with 230V AC
mains

ICV 2 X1 (pin 5 and pin 7) Roughly 280VDC with 400V AC

mains or 320V DC with 230V AC
mains

15V DC pri X1 (pin 7 and pin 8) 15V DC

24V DC int X2 (pin 4 and pin 8) 24V DC

24V DC ext X2 (pin 1 and pin 5) 24V DC

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NT 60 – 55VDC POWER SUPPLY

General Information
Part Number: 4,070,627
Proper Name: PC-Board, NT 60

Functional Overview
 Provides the 55V DC necessary to drive the wire feed motor.
 Output voltage is electrically isolated and protected by two parallel switched
PTC resistors.
 If there is a short circuit, the NT 60 restricts to a maximum of 15 A, using the
internal current limit, until the PTC resistors have reached the switch-off
temperature. In the case of a short circuit, the 55V DC supply LED does
NOT flash. As soon as the PTC resistors trip, the “Error” LED flashes.

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NT 60 – CONNECTIONS

X1 Connection to Wire-Feed Unit (secondary voltage)

Pin 1 +55V DC Pin 3 Ground

Pin 2 +55V DC Pin 4 Ground

X2 Primary Connection to Intermediate Circuit 1 and 2

Pin 1 Intermediate circuit 1+ Pin 9 Intermediate circuit 1+

Pin 2 No connection Pin 10 No connection

Pin 3 Intermediate circuit 1- Pin 11 Intermediate circuit 1-

Pin 4 No connection Pin 12 No connection

Pin 5 Intermediate circuit 2+ Pin 13 Intermediate circuit 2+

Pin 6 No connection Pin 14 No connection

Pin 7 Intermediate circuit 2- Pin 15 Intermediate circuit 2- GNDP

GNDP

Pin 8 +15V DC primary Pin 16 +15V DC primary

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NT 60 – LED’S

Intermediate Circuit 1 Will light up when intermediate circuit 1 has sufficient

Supply LED voltage.

Intermediate Circuit 2 Will light up when intermediate circuit 2 has sufficient

Supply LED voltage.

“Error” LED (PTC Will start to flash when the PTC resistors have switched off.
highly resistive)

+55V DC supply LED Will light up when NT60 is supplying +55V DC.

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NT 60 – TEST POINTS

Circuit Voltage
Description Test Point Result

ICV 1 X2 (pin 1 and pin 3) Roughly 280VDC with 400V AC

mains or 320V DC with 230V AC
mains

ICV 2 X1 (pin 5 and pin 7) Roughly 280VDC with 400V AC

mains or 320V DC with 230V AC
mains

+55V DC X1 (pin 7 and pin 8) 57V - 61V DC in idle

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UST – SYSTEM PROCESSOR
General Information
Part Number: 4,070,960
Proper Name: PC-Board, UST2C

Functional Overview
 Controls the power module through driver switches.
 Proves control of the operating panel through a databus connection
(LocalNet).
 Evaluates the mains switch signal from the BPS PC Board as follows:
• Mains Switch “On”: Once the intermediate circuit voltage reaches a
certain value, the relays on the BPS are controlled by the UST.
• Mains Switch “Off”: UST stores present settings and activates the
ventilators to discharge the intermediate circuit capacitors.
 Controls the ventilator based on temperature and firmware.
 Provides data transmission to peripheral devices via LocalNet interface.
 Regulates the welding current and voltage through the integral digital signal
processor (DSP).

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UST - CONNECTIONS
X1 Not Assigned

X2 Connection to Control Panel

X3 Supply

Pin 1 +24V DC external Pin 5 Ground external

Pin 2 No connection Pin 6 No connection

Pin 3 Intermediate circuit voltage Pin 7 Intermediate circuit voltage (GND)

Pin 4 +24V DC internal Pin 8 Ground internal

X4 Temperature Transmission, Voltage Command Value, Current Command Value

Pin 1 Voltage, actual value Pin 13 Voltage, actual value (+)

Pin 2 No connection Pin 14 No connection

Pin 3 Shunt C, 4000 Pin 15 Shunt D, 5000

Pin 4 Shunt A, 3000 Pin 16 No connection

Pin 5 Shunt B, 2000 Pin 17 Ground, shunt

Pin 6 -15V DC shunt Pin 18 +15V DC shunt

Pin 7 TH error 1 Pin 19 TH error 2

Pin 8 UP 400 (GND A) Pin 20 UP 400

Pin 9 CFM(-) Pin 21 CFM(+)

Pin 10 ESC 1 Pin 22 ESC 2

Pin 11 Temperature 2(-) Pin 23 Temperature 2(+)

Pin 12 Temperature 1(-) Pin 24 Temperature 1(+)

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UST - CONNECTIONS

X5 Ventilator Control

Pin 1 +24V DC Pin 3 +24V DC

Pin 2 Fan Pin 4 Fan

X6 Power Module PC Board Control

Pin 1 Primary current T1(+) Pin 14 Voltage, actual value (+)

Pin 2 Primary Current T1 GND Pin 15 +5V DC

Pin 3 Primary Current T2(+) Pin 16 +15V DC

Pin 4 Primary Current T2 GND Pin 17 +24V DC

Pin 5 OUT A1 Pin 18 Main Switch

Pin 6 OUT A3 Pin 19 PWM temperature

Pin 7 OUT A2 Pin 20 High charging connection

Pin 8 OUT A4 Pin 21 SCL (clock)

Pin 9 OUT B1 Pin 22 SDA (data)

Pin 10 OUT B3 Pin 23 FAST OUT 1

Pin 11 OUT B2 Pin 24 +15V DC

Pin 12 OUT B4 Pin 25 SYNC

Pin 13 GND D Pin 26 OV/UV

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UST - CONNECTIONS
X7 Cooling Unit Control

Pin 1 Temperature(+) Pin 6 Temperature(-)

Pin 2 Cooling unit ON Pin 7 +24V DC

Pin 3 Water control Pin 8 Water Control (GND)

Pin 4 CFM(+) Pin 9 CFM(-)

Pin 5 No connection Pin 10 Supply (GND)

X8 Programming Interface (for updating firmware via BSL tool)

X9 Connection to Wire-Feed Unit

Pin 1 +24V DC external Pin 4 Ground external (+24V DC)

Pin 2 RXDL-485 Pin 5 TXDL-485

Pin 3 RXDH-485 Pin 6 TXDH-485

X10 Control for Gas Solenoid Valve and TIG Welding Torch (optional)

Pin 1 High Frequency on/off Pin 7 High Frequency (GND)

Pin 2 Gas 1 Pin 8 Gas 1 (+24V DC)

Pin 3 Gas 2 Pin 9 Gas 2 (+24V DC)

Pin 4 Crater fill BRT Pin 10 Main current BRT

Pin 5 BRT UP Pin 11 BRT DOWN

Pin 6 GND (gun trigger) Pin 12 Detection

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UST – LED’S

LED +24V DC external Will light up when +24V DC external is present

LED +24V DC internal Will light up when +24V DC internal is present

LED +5V DC (RS 485) Will light up when +5V DC (RS 485) is present

LED +15V DC Will light up when +15V DC is present

LED -15V DC Will light up when -15V DC is present

LED +5V DC Will light up when +5V DC is present

LED STAT Will flash when there is NO firmware loaded.

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MAINS RECTIFIER
General Information
Part Number: 41,0002,0060
Part Name: Silicon Rectifier

Functional Overview
 Converts incoming AC voltage to DC
Voltage for the two intermediate circuits.
 Multi-voltage machines have 2 rectifiers
while 460 machines have only one.

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CAPACITORS
General Information
Part Number: 41,0005,0288
Part Name: Electrolytic Capacitor (Cap)

Functional Overview
 The capacitors are responsible for storing and
smoothing the intermediate circuit voltage. There are
two capacitors in each power source (3200 and above).
 The charged voltage is around 300V DC. More
importantly is how one capacitor compares with the
other. If the two capacitors are more than 35 volts from
one another, then the machine will error out with an
“Err 50”. This is not necessarily characteristic of a bad
capacitor, simply a problem with the machine.

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HF TRANSFORMER
General Information
Part Number: 33,0005,4120
Part Name: Welding Transformer

Functional Overview
 The welding transformer has two
individual high frequency transformers.

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CHOKE

General Information
Part Number: 33,0010,0335
Part Name: Choke

Functional Overview
 The choke is used for blocking high
frequencies while passing lower
frequencies.

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SHUNT

General Information
Part Number: 43,0001,1139
Proper Name: Shunt, VAC, 700a + Adapter

Functional Overview
 Operates according to the compensation principle, where a magnetically soft
probe functions as a magnetic field detector.
 The shunt is supplied by a bipolar operating voltage of +/- 15V DC and
provides an output signal which is proportional to the measured welding
current (ration of 1:2000)
 Electric isolation between high voltage circuit and electronic circuit

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SHUNT – CONNECTIONS AND TEST POINTS

X1 Molex Plug from Adapter Cable

Pin 1 +15V DC Pin 3 I Real (-)

Pin 2 -15V DC Pin 4 Ground

Circuit Voltage
Description Test Point Result

Welding Current X4 (pin 5 and pin 17) .33V DC per welding current of 100a

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TEMPERATURE SENSOR

General Information
Part Number: 43,0001,0600
Proper Name: TP 592S/1

Functional Overview
 The temperature sensor is fitted to the cooling element and measures the
elements temperature.
 The temperature sensor emits a current of exactly 1µA per K (kelvin),
provided that there is a voltage of 4V to 30V DC
 0 K corresponds to a temperature of -460° F (-273° C)
 32° F corresponds to a temperature of 273 K (0° C)
 273 K corresponds to 273µA

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TEMPERATURE SENSOR – CONNECTIONS

X1 2-pin Molex Plug

Pin 1 Temperature 1(+) Pin 3 Temperature 1(-)

• Measure the current flowing through the temperature sensor as follows:

• Remove lead at pin 1 from Molex plug using Molex extractor tool.

• Switch multimeter between removed lead and now free Molex plug pin in series

• The temperature can now be calculated using the measured current, as described in „functional
overview“.

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SECONDARY DIODES
General Information
Part Number: 41,0003,0203 (module made up of four
diode packs)
Part Name: Silicon Diode

Functional Overview
 Four diode packs go together to make up the
secondary rectifier.
 Transforms the welding transformer’s alternating
current into a direct current.

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