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Section TOC
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Master TOC
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| THEORY OF OPERATION |
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| FIGURE E.3 - SWITCH BOARDS AND MAIN TRANSFORMER |
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| IGBT DRIVE | MAIN |
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| FROM | CT CURRENT |
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POWER WAVE 455/R |
| CONTROL | TO CONTROL | TRANSFORMER |
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| BOARD | BOARD |
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| OUTPUT DIODES |
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| ELECTRODE | |||||
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| D1 |
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| TERMINAL |
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| CAP. V/F |
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| FEEDBACK | LEFT |
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| CR1 |
| INPUT |
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| SWITCH |
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| BOARD |
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| +20 VDC FROM |
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| RECTIFIER |
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| POWER BOARD |
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| CURRENT | STT | |
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| RECONNECT | IGBT DRIVE |
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| ELECTRODE | ||
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| STT CHOPPER | TRANSDUCER | ||||||
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| TERMINAL | ||||||
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| SWITCH | CT CURRENT |
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| BOARD |
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| CONTROL |
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| TO CONTROL |
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| BOARD |
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| + | |
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| BOARD |
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| SW1 |
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| RIGHT |
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| STT |
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| SWITCH |
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| CURRENT |
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| CAP. V/F |
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| DRIVE |
| WORK | ||||
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| FEEDBACK |
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| TRANSDUCER |
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| BOARD |
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| OUTPUT TERMINAL | ||||||
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| CHOKE | |
| INPUT |
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| 67A |
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| S1 |
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| BOARD |
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| VOLT |
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| C |
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| 67B |
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| U |
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| SENSE |
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| S6 | VOLTAGE SENSE |
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| R | S |
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| CONTACTOR AND PRECHARGE | BOARD | OUTPUT |
| DEVICE NET | TO | TO | R | T |
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| CONTROL SIGNALS FROM |
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| E | T |
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| CONTROL BOARD |
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| S5 | LEFT | RIGHT | N |
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| VOLTAGE SENSE SELECT |
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| GATEWAY | CONNECTION | S.B. | S.B. | T | F |
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| 2 | FROM CONTROL |
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| ARC LINK | BOARD | TO |
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| F | B |
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| ROBOT |
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| 4 | BOARD |
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| FEED | 40 VDC |
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| B |
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| V |
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AUX | A |
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| 40 VDC | HEAD |
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| IGBT |
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| TO FAN RELAY |
RECONNECT |
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C |
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| 115 VAC |
| BOARD |
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| DRIVES |
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| CONTACTOR AND | ||||
| RELAY |
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| FAN |
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| ARC LINK |
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| PRECHARGE | |||
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| 115 VAC |
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| CONTROL SIGNALS |
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| +5V RS232 |
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| THERMOSTATS |
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| CONTROL |
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| 52 VAC |
| 65 VDC |
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| CONNECTION |
| +5 V ARC LINK |
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| S6 |
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| BOARD |
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| BUS BOARD | DC | TO WIRE | POWER | +5V SPI |
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| DRIVE |
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| T1 |
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| RECTIFIER | BUS |
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| BOARD | +15V SPI |
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| SENSE |
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| BOARD | 40 VDC |
| +5 V |
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| S3 | |
| 230 VAC |
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| +15 V |
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| RS232 |
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| WATER |
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| 40 VDC |
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| LEFT S.B. | |||||
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| COOLER |
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| CAP. V/F |
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| 40 VDC |
| +20 VDC |
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| RIGHT S.B. | ||
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| CAP. V/F | ||||
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| TO |
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| ARC LINK |
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| 115 VAC |
| CHOPPER |
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| RECP. |
| S1 | WIRE |
| BOARD |
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| 115 VAC |
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| LEFT CT | RIGHT CT |
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| FEEDER |
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| T2 |
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| CURRENT | CURRENT |
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| RECP. |
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| FB | FB | STATUS | THERMAL |
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| LIGHT | LIGHT |
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SWITCH BOARDS AND MAIN
TRANSFORMER
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There are two switch boards in the Power Wave 455/R machine. Each contains an input capacitor and insu- lated gate bipolar transistor (IGBT) switching circuitry. Refer to Figure E.3. When the machine reconnect switches are configured for a lower input voltage (below 300VAC), the input capacitors are connected in parallel. When the machine is configured for higher input voltages (300VAC and above), the input capaci- tors are connected in series.
When the input capacitors are fully charged, they act as power supplies for the IGBT switching circuits. The insulated gate bipolar transistors switch the DC power from the input capacitors "on and off," thus supplying pulsed DC current to the main transformer primary windings. See IGBT OPERATION DISCUSSION AND DIAGRAMS in this section.
Each switch board feeds current to a separate, oppo- sitely wound primary winding in the Main Transformer. The reverse directions of current flow through the main transformer primaries, and the offset timing of the IGBT switch boards induce an AC square wave output signal at the secondary of the main transformer. Current transformers located on the switch boards monitor the primary currents. If the primary currents become abnormally high, the Control Board will shut off the IGBTs, thus disabling the machine’s output. The DC current flow through each primary winding is clamped back to each respective input capacitor when the IGBTs are turned off. This is needed due to the induc- tance of the transformer primary windings. The firing of the two switch boards occurs during halves of a 50- microsecond interval, creating a constant 20 KHZ out- put.
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
