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THEORY OF OPERATION
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
GATEWAY BOARD AND VOLTAGE SENSE BOARD
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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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| + |
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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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| +15 V |
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| RS232 |
| 230 VAC |
| 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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DC BUS BOARD, POWER BOARD, FEED HEAD BOARD, GATEWAY BOARD AND VOLTAGE SENSE BOARD
The DC Bus Board receives approximately 65VDC from the Bus Board rectifier. The DC Bus Board regu- lates that 65VDC to a +40VDC supply. This regulated 40VDC is applied to the Feed Head Board, the Power Board, and the wire feeder receptacle.
The switching power supplies on the Power Board sup- ply a variety of regulated DC voltages to the Control Board and a +20VDC to the STT Chopper Board. The Control Board uses these regulated voltages to power the many circuits and communication functions incor- porated within the Control Board.
When the Feed Head Board activates the Voltage Sense Board, the actual arc voltage is sensed (lead 67), and this information is delivered through the volt- age sense board to the Control Board.
The Power Wave 455R uses two digital communication platforms. Internally the PC boards communicate via ArcLink. Externally the Power Wave 455R communi- cates using the industry standard Device Net protocol. The Gateway Board makes the translation between the two platforms possible. The Power Wave 455R does not have a dedicated interface device or board. The robot (or other input device – PLC, etc.) acts as the user interface, issuing commands through the Device Net protocol that are translated by the Gateway Board to ArcLink compatible messages. The following block diagram (Figure E.5) depicts the flow of communica- tion information.
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NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
