Lincoln Electric POWER WAVE C300 Service Manual page 10

TABLE OF CONTENTS-THEORY OF OPERATION SECTION
E-1
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-2
Main Input Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-3
Planar Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-4
Chopper Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-5
FeedHead Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-6
Machine Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-7
Pulse Width Modulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-8
IGBT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .E-9
POWER WAVE C300 BLOCK DIAGRAM
INPUT
RELAY
MAIN
INPUT
SWITCH
RECTIFIER
100 Ohm
IN IN P P UT UT P P O O W W E E R R
FI FIR R S S T T & & S S E E C C O O N N D D
I I G G BT BT
S S TA TAG G E E
D D RI RIV V E E S S
S S I I G G N N AL ALS S
P P O O W W E E R R
O O N N L L E E D D
PFC CONTROL
BOARD
P P R R E E C C H H A A R R G G E E
B B UZZ UZZ E E R R
R R E E LA LAY Y
C C O O NT NTR R O O L L
FIGURE E.1 BLOCK LOGIC DIAGRAM
INPUT
CHOKE
FULL WAVE FULL WAVE
DC LINK
F F I I R R S S T T S S T T A A G G E E
B B U U C C K K - - B B O O O O S S T T
CAPACITOR
CR
4 4 8 8 V V D DC C
FA FAN N
FAN FAN
CONTROL CONTROL
4 4 8 8 V V D DC C
FA FAN N
SOLENOID
48 VDC 48 VDC
TH TH E E R R M M AL AL L L E E D D
P P U U S S H H - - P P U U L L L L
USER INTERFACE
BOARD
A A R R C-LI C-LIN N K K C C O O M M M M U U NI NIC C AT ATI I O O N N
C C O O M M M M U U NI NIC C AT ATI I O O N N
POWER WAVE® C300
SWITCH BOARD
( ( S S E E C C O O N N D D S S T T A A G G E E ) )
H H I I G G H H F FR R E E Q Q U U E E N N C C Y Y I IN N V V E E R R T T E E R R W W IT ITH H
P P L L A A N N E E R R
O O U U T T P P U U T T
T T R R A A N N S S F F O O R R M M E E R R
R R E E C C TIFI TIFIE E R R
100V 100V
60KHz 60KHz
IGBT IGBT
400V 400V
BRIDGE BRIDGE
CURRENT CURRENT
TRANSDUCER TRANSDUCER
4 4 8 8 V V D DC C
FOOT
GAS PURGE /
AMPTROL
COLD INCH
GEAR BOX
S S P P O O O O L L / /
FEEDHEAD
BOARD
G G U U N N
A A R R C-LI
S S TAT TATU U S S
E E R R R R O O R R
LI LIG G HT HT
O O U U T T P P U U T T
C C A A P P A A C C I I T T O O R R S S
(T (TH H I I R R D D S S T T A A G G E E ) )
M M U U LTI- LTI-P P H H A A S S E E B B U U C C K K
C C O O N N V V E E R R T T E E R R
C C U U R R R R E E N N T T
T T R R A A N N S S D D U U C C E E R R
120KHz 120KHz
CHOPPER
CONTROL
BOARD
CURRENT CURRENT
FEEDBACK FEEDBACK
C C H H O O P P P P E E R R
C C O O M M M M U U NI NIC C AT ATI I O O N N
FAN CONTROL FAN CONTROL
TO SWITCH TO SWITCH
BOARD BOARD
MOTOR /
GUN
CONTROL
TRIGGER
BOARD
C-LIN N K K C C O O M M M M U U NI NI C C AT ATI I O O N N
S S TAT TAT U U S S
LI LIG G HT HT
E-1
P P O O S S ITI ITIV V E E
T T E E R R M M I I N N A A L L
N N E E G G A A TI TIV V E E
T T E E R R M M I I N N A A L L
VOLTAGE VOLTAGE
FEEDBACK FEEDBACK
THE E R R M M O O S S TAT TH TATS S
E E TH TH E E R R N N E E T T
S S TAT TATU U S S
" " E E R R R R O O R R " "
LI LIG G HT HT