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TOC
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TOC
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| THEORY OF OPERATION |
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| FIGURE E.6 – CONTROL 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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| 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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CONTROL BOARD
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The Control Board performs the primary interfacing functions to establish and maintain output control of the Power Wave 455R machine. The function generator and weld files exist within the Control Board hardware and software. Digital command signals and feedback information is received and processed at the Control Board. Software within the Control Board processes the command and feedback information and sends the appropriate pulse width modulation (PWM) signals (see PULSE WIDTH MODULATION in this section) to the switch board IGBTs. In this manner, the digitally controlled
The Control Board also monitors and controls the STT (Surface Tension Transfer) circuitry incorporated in the Power Wave 455R. STT output currents and arc volt- ages are monitored, and the appropriated gate firing signals are applied (or removed) from the STT Chopper Board and switch boards to create a low spat- ter, low fume MIG welding process. See GENERAL
DESCRIPTION OF STT (SURFACE TENSION TRANSFER PROCESS) in this section.
In addition, the Control Board monitors the ther- mostats, the main transformer primary currents and input filter capacitor voltages. Depending on the fault condition, the Control Board will activate the thermal and/or the status light and will disable or reduce the machine output. In some conditions the input contac- tor will be
