General Description; Theory Of Operation - Lincoln Electric POWER WAVE S500 Service Manual

E-2
FAN
INPUT
BOARD
MAIN
INPUT
RECTIFIED AND
SWITCH
FILTERED LINE
RELAY
+15VDC
RELAY
DRIVE
RECTIFIED
LINE VOLTAGE
POWER FACTOR (PFC)
CONTROL BOARD
40VDC FROM
DC BUS BOARD

GENERAL DESCRIPTION

The Power Wave ® S500 is a welder featuring an invert-
er type power source with Tribrid Converter
Technology and Automatic PowerConnect Technology.
It is a multi-process machine with high-end functionali-
ty capable of Stick, DC TIG, MIG, Pulsed MIG and
Flux-Cored welding. The Power Wave
lates the current, voltage and power of the welding arc.
It also provides premier welding performance solutions
for specific areas such as aluminum, stainless and
nickel especially where machines size and weight are
considerations. This machine is designed to be a very
flexible welding power source. Like all machines in the
Power Wave product line the software based architec-
ture allows for future upgradeability. An Ethernet port
is standard which allows for effortless software
upgrades through Powerwavesoftware.com.
Ethernet communication also gives the Power Wave
S500 the ability to run Production Monitoring™ 2. The
Power Wave S500 is recommended for semiautomat-
®
ic welding and may also be suitable for basic hard
automation applications. It is compatible with the cur-
rent range of Power Feed™ systems including future
versions of ArcLink feeders.

THEORY OF OPERATION

FIGURE E.2 - GENERAL DESCRIPTION
FAN
POWER CONVERSION
P.C. BOARD ASSEMBLY
FAN SPEED
TOP PLANAR
CONTROL
INPUT
TRANSFORMERS
CHOKE
POWER BOARD
OUTPUT
RECTIFIER
400V BUS
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
48
VDC
VOLTAGE
BOTTOM PLANAR
TRANSFORMERS
INPUT
CHOKE
200VAC
POWER BOARD
BUCK/BOOST
OUTPUT
DRIVE
RECTIFIER
400V BUS
BUCK-BOOST FULL BRIDGE
INVERTER
PLANAR
TRANSFORMERS
THERMAL
200VAC
FAN
FAULT
P.C. BOARD
CONTROL
FAN ON
SIGNAL
FAST FAULT SIGNAL
36 VDC
CAN COMMUNICATIONS
RJ45
CONNECTOR
S500 regu-
®
The
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
POWER WAVE
ARCLINK AND
VOLTAGE SENSE TO
REMOTE
DIGITAL CONTROL BOARD
CONTROL
BOARD
40 VDC TO
PFC BOARD
40 VDC
DC
BUS
48 VDC
BOARD
SIX PHASE
CHOPPER BOARD
MULTI-PHASE
OUTPUT CHOKE
OUTPUT
CURRENT FEEDBACK
CONTROL
115 VAC
115 VAC
RECEPTACLE
OUTPUT ON
SIGNAL
DIGITAL CONTROL BOARD
VOLTAGE
DEVICENET
SENSE
CONNECTOR
RECEPTACLE
®
® S500
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
ARCLINK
RECEPTACLE
+
CURRENT
FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
E-2
-