Lincoln Electric 405M, 355M Theory of Operation, Input Line Voltage, TRANSFORMER, & Precharge

E-2	THEORY OF OPERATION	E-2
	FIGURE E.2 - GENERAL DISCRIPTION

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		Main Switch Board
Input switch	Input	Primary
	Rectifier
		Current
		Sensor
		Reconnect
		Switch
		Primary
		Current
		Sensor
		Fan

220 VAC	Transformer			olntrCoFan	Primary Current Feedback(2)			IGBTDriveSig
		115VAC Fan Supply			Input Relay Control
		Auxiliary			Soft Start Control
					V/F Capacitor Feedback (2)
								nal
		40VDC	Machine Control Supply
			+15VDC, -15VDC, +5VDC
		Power
		Board	RS232 Supply +5VDC					Control Board
220	42VAC
			Can Supply +5VDC
Receptacle	65VAC
		DC			Arc		Electrode
		Bus			Link	Wire	Sense
		Board	40VDC
						Feeder
						Recp.		Thermostats
								2

Board
	Feedbac	Curre nt
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Choke

ltagoV Se seen

Ou ttpu

21 Lead

Voltage

Sense

Recp.

Positive

Output

Terminal

Negative

Output

Terminal

Yellow

Thermal

LED

Status

Red/Green

LED

R232

Connector

Return

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GENERAL DESCRIPTION		develops three different secondary voltages.				The
The Power Wave semi-automatic	power source is	115VAC is applied, via the main switch board, to the
		fan motor. The 42VAC is rectified and filtered.				The
designed to be a part of a modular, multi-process		65VDC produced by the Bus board rectifier is used by
welding system. Depending on configuration, it can		the Bus board to provide 40VDC to the power board.
support constant current, constant voltage, and pulse		40VDC is also applied to the wire feeder receptacle.
welding modes.		PW405 models have an additional 220VAC winding
The Power Wave power source is designed to be used		that is connected to a 220 AC receptacle.
with the semi-automatic family of power feed wire		The input voltage is rectified by the input rectifier and
feeders, operating as a system. Each component in		the resultant DC voltage is applied to the switch board
the system has special circuitry to “talk with” the other		through the reconnect switch assembly located at the
system components, so each component (power		rear of the machine. The reconnect switch connects
source, wire feeder, user interface) knows what the		the two pairs of input capacitors either in a parallel
other is doing at all times. These components com-		(lower voltage) or series (higher voltage) configuration
municate with Arc Link (a digital communications sys-		to accommodate the applied input voltage.
tem).		During the precharge time the DC input voltage is
The POWER WAVE 355M/405M is a high performance,
		applied to the input capacitors through a current limit-
digitally controlled inverter welding power source
		ing circuit. The input capacitors are charged slowly
capable of complex, high speed waveform control.
		and current limited. A voltage to frequency converter
Properly equipped, it can support the GMAW, GMAW-
		circuit located on the switch board monitors					the
P FCAW, SMAW, GTAW, and CAC-A processes. It car-
		capacitor voltages. This signal is coupled to the con-
ries an output rating of 350 Amps, 34 Volts at 60%
		trol board. When the input capacitors have charged
duty cycle and 300 Amps, 32 volts at 100% duty cycle.
		to an acceptable level, the control board energizes the
INPUT LINE VOLTAGE,	AUXILIARY	input relays,		that are located on	the switch board,
		making all of		the input power, without current limiting,
TRANSFORMER, & PRECHARGE
		available to the input capacitors.			If the capacitors
The POWER WAVE 355M/405M can be connected for		become under or over voltage the control board will
		de-energize the input relays and the 355M/405M out-
a variety of three-phase or single-phase input volt-
		put will be disabled. Other possible faults may also
ages. The initial power is applied to the 355M/405M
		cause the input relays to drop out.
through a line switch located on the front of the
machine. Two phases of the input voltage are applied
			NOTE: Unshaded areas of Block Logic
to the auxiliary transformer. The auxiliary transformer			Diagram are the subject of discussion

POWER WAVE 355M/405M