Dc Bus Board And Digital Control Board - Lincoln Electric POWER WAVE S500 Service Manual

E-6
FIGURE E.6 - DC BUS BOARD AND DIGITAL CONTROL 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
DC BUS BOARD AND DIGITAL
CONTROL BOARD
The DC Bus Board receives 48VDC from the upper
planar transformer. The DC Bus Board regulates and
controls that 48VDC to a constant 40VDC output sup-
ply. The 40VDC is applied to the PFC control board,
the Arclink receptacle and the Remote Control board.
The Digital Control Board receives commands and
feedback information via various channels. It receives
digital communications and commands from the PFC
control board, the Remote Control board, the Device
Net connector and the RJ45 connector. The Digital
Control Board also receives and processes output volt-
age and output current data. It receives and sends
output "on" and fan "on" signals from the 115Volt
Inverter board. The Digital Control Board uses this
feedback information and processes it with the digital
commands it receives and sends the appropriate PWM
signals to the Six Phase Chopper board to control the
welding output. It also controls the optional gas sole-
noid and sends a signal to the Power Conversion
board to control the speed of the two fans. The Digital
Control Board houses the software welding tables and
monitors the thermostat circuitry.
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
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-6
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