THEORY OF OPERATION
E-2 E-2
POWER WAVE 655/R
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
GENERAL DESCRIPTION
The Power Wave 655/R power source is designed to
be a part of a modular, multi-process welding system.
It is a high performance, digitally controlled inverter
welding power source capable of complex, high-speed
waveform control.
The Power Wave 655/R is designed to be used with
the family of Power Feed wire feeders, operating as a
system. Each component in the system has special cir-
cuitry to "talk with" the other system components, so
each component (power source, wire feeder, electrical
accessories) knows what the other is doing at all times.
The components communicate with Arc-Link.
Robotic systems can communicate with other industri-
al machines via DeviceNET or Arc Link. The result is
highly integrated and flexible welding cell.
Depending upon configuration, it can support constant
current, constant voltage, and pulse welding modes.
Each machine is factory preprogrammed with multiple
welding procedures. Typically these procedures
include GMAW, GMAW-P, FCAW, GTAW for a variety
of materials such as mild steel, stainless steel, cored
wires and aluminum.
The Power Wave 655/R has an output rating of either
650 amps at 44 (at 100% duty cycle) volts or 800 amps
at 44 volts (at 60% duty cycle.
FIGURE E.2 – INPUT VOLTAGE AND PRECHARGE
+
INPUT
BOARD
LEFT
SWITCH
BOARD
RIGHT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
GATEWAY
BOARD
DC
BUS
BOARD
FEED
HEAD
BOARD
POWER
BOARD
CONTROL
BOARD
OUTPUT
CHOKE
ELECTRODE
TERMINAL
THERMOSTATS
T1
T2
AUX
RECONNECT
RELAY
WATER
COOLER
115VAC
RECP.
115VAC
FAN
ARC LINK
WIRE
FEEDER
RECP.
S1
S6 CONNECTION
TOWIRE
DRIVE
S1
S6
VOLT
SENSE
BOARD
MAIN
TRANSFORMER
S5
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
FROM CONTROL
BOARD
2
4
V
A
C
115VAC
52VAC
230VAC
40VDC
40VDC
40VDC
40VDC
ARC LINK CONNECTION
TO
ROBOT
VOLTAGE SENSE
OUTPUT
CAP.V/F
FEEDBACK
CAP.V/F
FEEDBACK
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
-15V
+15V
+5V
+5V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S2WORK
SENSE
LEFT S.B.
CAP.V/F
RIGHT S.B.
CAP.V/F
S3
RS232
LEFT CT
CURRENT
FB
C
U
R
R
E
N
T
F
B
ARC LINK
IGBT
DRIVES
TO
LEFT
S.B.
TO
RIGHT
S.B.
67A
67B
SW1
BUS BOARD
RECTIFIER
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
115VAC
40VDC
DEVICE NET
VOLTAGE SENSE SELECT
IGBT DRIVE
FROM
CONTROL
BOARD
+5V SPI
RIGHT CT
CURRENT
FB
TO FAN RELAY
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
65VDC
WORK
TERMINAL
POWER WAVE 655/R
380-
415
440-
460
550-
575
+
ETHERNET/
A
A
HARMONIC
FILTER
C
POS
NEG
Auxiliary
Fan