Dc Bus Board, Power Board, Feed Head Board, Gateway Board And Voltage Sense Board - Lincoln Electric POWER WAVE SVM156-A Service Manual

E-5
FIGURE E-4 – DC BUS BOARD, POWER BOARD, FEED HEAD BOARD,
POWER WAVE 455/R
CR1
RECTIFIER
SW1
INPUT
BOARD
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
2
FROM CONTROL
4
BOARD
V
AUX
A
RECONNECT
C
RELAY
115 VAC
52 VAC
T1
230 VAC
115 VAC
T2
DC BUS BOARD, POWER BOARD,
FEED HEAD BOARD, GATEWAY
BOARD AND VOLTAGE SENSE
BOARD
The DC Bus Board receives approximately 65VDC
from the Bus Board rectifier. The DC Bus Board regu-
lates that 65VDC to a +40VDC supply. This regulated
40VDC is applied to the Feed Head Board, the Power
Board, and the wire feeder receptacle.
The switching power supplies on the Power Board sup-
ply a variety of regulated DC voltages to the Control
Board and a +20VDC to the STT Chopper Board. The
Control Board uses these regulated voltages to power
the many circuits and communication functions incor-
porated within the Control Board.
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.
THEORY OF OPERATION
GATEWAY BOARD AND VOLTAGE SENSE BOARD
IGBT DRIVE
CT CURRENT
FROM
TO CONTROL
CONTROL
BOARD
BOARD
CAP. V/F
FEEDBACK
LEFT
SWITCH
INPUT
BOARD
IGBT DRIVE
RECONNECT
FROM
CT CURRENT
SWITCH
CONTROL
TO CONTROL
BOARD
BOARD
RIGHT
SWITCH
CAP. V/F
FEEDBACK
BOARD
67A
S1
VOLT
67B
SENSE
S6
VOLTAGE SENSE
BOARD OUTPUT
VOLTAGE SENSE SELECT
FEED
40 VDC
HEAD
BOARD
115 VAC
FAN
65 VDC
CONNECTION
S6
TO WIRE
DC
BUS BOARD
RECTIFIER
BUS
BOARD
40 VDC
WATER
40 VDC
COOLER
40 VDC
ARC LINK
115 VAC
WIRE
RECP.
S1
FEEDER
RECP.
POWER WAVE 455/R
MAIN
TRANSFORMER
OUTPUT DIODES
D1 -D4
DEVICE NET
S5
GATEWAY
CONNECTION
ARC LINK TO
BOARD
ROBOT
40 VDC
ARC LINK
+5V RS232
+5 V ARC LINK
POWER
+5V SPI
DRIVE
BOARD
+15V SPI
+5 V
+15 V
-15 V
+20 VDC
TO
CHOPPER
BOARD
LEFT CT
CURRENT
FB
When the Feed Head Board activates the Voltage
Sense Board, the actual arc voltage is sensed (lead
67), and this information is delivered through the volt-
age sense board to the Control Board.
The Power Wave 455R uses two digital communication
platforms. Internally the PC boards communicate via
ArcLink. Externally the Power Wave 455R communi-
cates using the industry standard Device Net protocol.
The Gateway Board makes the translation between the
two platforms possible. The Power Wave 455R does
not have a dedicated interface device or board. The
robot (or other input device – PLC, etc.) acts as the
user interface, issuing commands through the Device
Net protocol that are translated by the Gateway Board
to ArcLink compatible messages. The following block
diagram (Figure E.5) depicts the flow of communica-
tion information.
ELECTRODE
TERMINAL
+
+20 VDC FROM
POWER BOARD
STT
CURRENT
ELECTRODE
STT CHOPPER TRANSDUCER
TERMINAL
BOARD
+
STT
DRIVE CURRENT
WORK
TRANSDUCER
OUTPUT
TERMINAL
CHOKE
C
U
R
S
R
T
TO
TO
E
T
RIGHT
LEFT
N
S.B.
S.B.
T
F
B
F
B
TO FAN RELAY
IGBT
DRIVES
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
THERMOSTATS
CONTROL
BOARD
S2 WORK
SENSE
S3
RS232
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
RIGHT CT
CURRENT
FB
STATUS THERMAL
LIGHT LIGHT
E-5