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E-7

 

THEORY OF OPERATION

E-7

 

 

 

 

 

FIGURE E.6 – CONTROL BOARD

 

 

 

 

IGBT DRIVE

 

MAIN

 

 

 

 

FROM

CT CURRENT

 

POWER WAVE 455/R

 

CONTROL

TO CONTROL

TRANSFORMER

 

 

BOARD

BOARD

 

 

 

 

 

 

 

OUTPUT DIODES

ELECTRODE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

D1 -D4

TERMINAL

 

 

CAP. V/F

 

 

 

 

 

+

 

 

FEEDBACK

 

LEFT

 

 

 

 

 

 

 

 

 

 

 

 

 

CR1

INPUT

 

 

SWITCH

 

 

 

 

 

 

 

BOARD

 

 

 

 

+20 VDC FROM

RECTIFIER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

POWER BOARD

 

 

 

 

CURRENT

STT

RECONNECT

IGBT DRIVE

 

 

ELECTRODE

 

STT CHOPPER

TRANSDUCER

FROM

CT CURRENT

TERMINAL

SWITCH

CONTROL

BOARD

 

 

 

 

TO CONTROL

 

 

 

 

 

BOARD

 

 

 

 

+

 

 

BOARD

 

 

 

 

SW1

RIGHT

 

 

 

 

 

CAP. V/F

STT

CURRENT

 

 

 

SWITCH

DRIVE

 

 

WORK

FEEDBACK

BOARD

TRANSDUCER

OUTPUT

 

TERMINAL

 

 

 

 

 

CHOKE

 

 

 

 

 

INPUT

 

 

 

 

 

67A

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S1

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

VOLT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

C

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

67B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

U

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SENSE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S6

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

R

 

S

 

 

 

 

 

 

 

CONTACTOR AND PRECHARGE

VOLTAGE SENSE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

OUTPUT

 

 

 

DEVICE NET

 

 

 

 

 

TO

 

 

R

 

T

 

 

 

 

 

 

 

CONTROL SIGNALS FROM

 

 

 

 

 

 

 

 

 

 

TO

 

 

 

E

 

T

 

 

 

 

 

 

 

CONTROL BOARD

 

 

 

 

 

 

 

 

S5

 

 

LEFT

 

RIGHT

 

 

N

 

 

 

 

 

 

 

 

 

 

VOLTAGE SENSE SELECT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

GATEWAY

CONNECTION

 

 

S.B.

 

S.B.

 

 

T

 

F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2

 

 

 

FROM CONTROL

 

 

 

 

 

ARC LINK

BOARD

TO

 

 

 

 

 

 

 

 

 

F

 

B

 

 

 

 

 

 

 

 

 

 

 

 

ROBOT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

4

 

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

B

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FEED

40 VDC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

AUX

A

 

 

 

 

 

 

 

 

40 VDC

HEAD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

IGBT

 

 

 

 

TO FAN RELAY

RECONNECT

C

 

 

 

 

 

 

 

115 VAC

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RELAY

 

 

 

 

 

 

 

 

 

 

 

DRIVES

 

 

 

 

CONTACTOR AND

 

 

 

 

 

 

FAN

 

 

 

 

 

ARC LINK

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

PRECHARGE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115 VAC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CONTROL SIGNALS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

+5V RS232

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

52 VAC

65 VDC

 

 

 

CONNECTION

 

 

 

+5 V ARC LINK

 

 

 

CONTROL

 

 

 

 

THERMOSTATS

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BUS BOARD

DC

S6 TO WIRE

POWER

+5V SPI

 

 

 

 

 

 

 

 

S2 WORK

 

 

 

 

 

 

 

 

 

 

 

 

 

DRIVE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

SENSE

 

 

 

T1

 

 

 

 

RECTIFIER

BUS

 

 

 

BOARD

+15V SPI

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

BOARD

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

40 VDC

 

 

 

 

+5 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

S3

 

 

 

 

 

 

230 VAC

 

 

WATER

 

 

 

 

40 VDC

 

 

 

 

+15 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RS232

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

-15 V

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LEFT S.B.

 

 

 

 

 

 

 

 

 

COOLER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAP. V/F

 

 

 

 

 

 

 

 

 

 

 

 

40 VDC

 

 

 

+20 VDC

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RIGHT S.B.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

CAP. V/F

 

 

 

 

 

 

 

 

 

 

 

 

 

 

ARC LINK

 

 

TO

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115 VAC

 

 

 

 

CHOPPER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115 VAC

 

 

RECP.

S1

 

 

WIRE

 

 

 

BOARD

 

LEFT CT

RIGHT CT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

FEEDER

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

T2

 

 

 

 

 

 

 

 

 

 

 

 

CURRENT

CURRENT

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

RECP.

 

 

 

 

 

 

FB

FB

 

 

STATUS

THERMAL

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

LIGHT

 

LIGHT

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 high-speed welding waveform is created.

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 de-energized.

POWER WAVE 455M/MSTT

Page 41
Image 41
Lincoln Electric SVM173-A service manual Figure E.6 Control Board

SVM173-A specifications

The Lincoln Electric SVM173-A is a highly regarded welding power supply that stands out for its advanced features, robust performance, and innovative technologies. This machine is specifically designed to meet the demands of both industrial and commercial welding applications, making it a versatile choice for professionals.

One of the main features of the SVM173-A is its high efficiency, which contributes to reduced energy costs and enhanced productivity. The device operates on a powerful DC output, ensuring stable and reliable arc performance. This is particularly beneficial when working with various materials, allowing for smooth and consistent welds.

The SVM173-A leverages Lincoln Electric's proprietary inverter technology. This innovation allows for a lighter weight and more compact design without compromising on power. The inverter technology also enables precise control of the welding parameters, which is critical for maintaining quality across different welding tasks. Additionally, the machine features a wide input voltage range, accommodating various power sources and enhancing its adaptability on job sites.

Another key characteristic of the SVM173-A is its user-friendly interface. The machine is equipped with an intuitive control panel that allows users to easily adjust settings, making it accessible for both novice and experienced welders. The digital display provides clear readouts of output parameters and error notifications, facilitating quick troubleshooting in the field.

Safety is paramount in welding operations, and the SVM173-A incorporates several protection features. These include overcurrent protection, overheating protection, and circuit protection, ensuring that the machine operates safely and efficiently under various conditions.

The SVM173-A also supports a wide range of welding processes, including MIG, TIG, and stick welding. This flexibility makes it an ideal choice for workshops that require a multi-process machine capable of handling diverse applications. Furthermore, the SVM173-A supports spool gun operation, which is particularly useful for aluminum welding, enhancing its versatility even further.

In summary, the Lincoln Electric SVM173-A is a powerful and adaptable welding machine that combines innovative technologies, user-friendly features, and robust safety mechanisms. Its high efficiency, precision control, and multi-process capabilities make it an excellent investment for professionals seeking reliable performance in demanding environments. Whether for heavy-duty industrial use or more specialized applications, the SVM173-A stands as a testament to Lincoln Electric's commitment to quality and innovation in welding solutions.