Line Switch, Input Board And Power Factor Control (Pfc) Board - Lincoln Electric POWER WAVE S500 Service Manual

E-3
FIGURE E.3 - LINE SWITCH, INPUT BOARD AND POWER FACTOR CONTROL (PFC) BOARD
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
LINE SWITCH, INPUT BOARD AND
POWER FACTOR CONTROL (PFC)
BOARD
The Power Wave S500 can be connected to a variety
®
of both three-phase or single-phase AC input voltages.
The Power Wave S500 automatically adjusts to oper-
®
ate with different AC input voltages.
switch settings are required. The initial input power is
applied through a line switch located on the front panel
of the machine. This AC input voltage is applied to an
input board where it is rectified to a DC voltage. The
DC voltage is then applied to a soft-start circuit con-
sisting of two PTC thermistors and two DC relays. This
soft-start circuit limits the initial inrush current to the DC
link capacitors to prevent damage to the input rectifier.
Two seconds after the input line switch is activated the
two relays, which are in parallel with the thermistors,
are closed thus applying the full input potential to the
DC link capacitor. The two DC relays are activated by
the Power Factor Correction board.
THEORY OF OPERATION
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
No reconnect
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
The rectified input power is also connected to the
Power Factor Correction board. The PFC board
receives this unregulated DC voltage and converts it
to several DC supplies that are used to power the
electronics housed on the PFC board. A 36VDC sup-
ply is also connected to the Digital Control Board.
The PFC board receives feedback information in the
form of buck-boost currents, the 400VDC bus voltage,
the rectified AC input voltage, the full bridge inverter
currents and power module temperatures. The elec-
tronic circuits and firmware on the PFC board generate
Pulse Width Modulation (PWM) signals to regulate the
400VDC bus, drive the buck-boost circuit, shape the
input current, drive the full bridge inverters and control
the pre-charge relays.
® S500
USER INTERFACE
REMOTE AMPTROL
+
ARCLINK RECEPTACLE
ARCLINK
RECEPTACLE
+
CURRENT
FEEDBACK
ARC LINK AND
VOLTAGE SENSE FROM
REMOTE BOARD
GAS
SOLENOID
E-3
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