Six Phase Chopper Board And Multi-Phase Output Choke - Lincoln Electric POWER WAVE S500 Service Manual

E-5
FIGURE E.5 - SIX PHASE CHOPPER BOARD AND MULTI-PHASE OUTPUT CHOKE
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
SIX PHASE CHOPPER BOARD AND
MULTI-PHASE OUTPUT CHOKE
The Six Phase 20KHz. chopper is connected to the
100VDC bus that is generated by the two 100 volt sec-
ondary windings on the two planar transformers. The
six high speed electronic switches are connected in
parallel to the 100VDC bus. However, the gate drives
are 60 degrees out of phase with independent PWMs
drive signals received from the Digital Control Board.
The system is equivalent to a 120KHz. chopper. The
output of the Six Phase Chopper is connected to the
Multi-Phase Output Choke. The Multi-Phase Output
Choke consists of three independent chokes with two
windings on each choke core. Each choke coil is con-
nected to one phase of the Six-Phase Chopper. This
coupled inductor acts like a transformer providing low
ripple current and low output inductance to the welding
circuit. The output of the Multi-Phase Choke is con-
nected to the negative output terminal.
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-5
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