Filter
Top Products
GENERAL DESCRIPTION
The Power Wave semi-automatic power source is
designed to be a part of a modular, multi-process
welding system. Depending on configuration, it can
support constant current, constant voltage, and pulse
welding modes.
The Power Wave power source is designed to be used
with the semi-automatic family of power feed wire
feeders, operating as a system. Each component in
the system has special circuitry to “talk with” the other
system components, so each component (power
source, wire feeder, user interface) knows what the
other is doing at all times. These components com-
municate with Arc Link (a digital communications sys-
tem).
The POWER WAVE 355M/405M is a high performance,
digitally controlled inverter welding power source
capable of complex, high speed waveform control.
Properly equipped, it can support the GMAW, GMAW-
P, FCAW, SMAW, GTAW, and CAC-A processes. It car-
ries an output rating of 350 Amps, 34 Volts at 60%
duty cycle and 300 Amps, 32 volts at 100% duty cycle.
INPUT LINE VOLTAGE, AUXILIARY
TRANSFORMER, & PRECHARGE
The POWER WAVE 355M/405M can be connected for
a variety of three-phase or single-phase input volt-
ages. The initial power is applied to the 355M/405M
through a line switch located on the front of the
machine. Two phases of the input voltage are applied
to the auxiliary transformer. The auxiliary transformer
develops three different secondary voltages. The
115VAC is applied, via the main switch board, to the
fan motor. The 42VAC is rectified and filtered. The
65VDC produced by the Bus board rectifier is used by
the Bus board to provide 40VDC to the power board.
40VDC is also applied to the wire feeder receptacle.
PW405 models have an additional 220VAC winding
that is connected to a 220 AC receptacle.
The input voltage is rectified by the input rectifier and
the resultant DC voltage is applied to the switch board
through the reconnect switch assembly located at the
rear of the machine. The reconnect switch connects
the two pairs of input capacitors either in a parallel
(lower voltage) or series (higher voltage) configuration
to accommodate the applied input voltage.
During the precharge time the DC input voltage is
applied to the input capacitors through a current limit-
ing circuit. The input capacitors are charged slowly
and current limited. A voltage to frequency converter
circuit located on the switch board monitors the
capacitor voltages. This signal is coupled to the con-
trol board. When the input capacitors have charged
to an acceptable level, the control board energizes the
input relays, that are located on the switch board,
making all of the input power, without current limiting,
available to the input capacitors. If the capacitors
become under or over voltage the control board will
de-energize the input relays and the 355M/405M out-
put will be disabled. Other possible faults may also
cause the input relays to drop out.
THEORY OF OPERATION
E-2 E-2
POWER WAVE 355M/405M
Return to Section TOC Return to Section TOC Return to Section TOC Return to Section TOC
Return to Master TOC Return to Master TOC Return to Master TOC Return to Master TOC
FIGURE E.2 - GENERAL DISCRIPTION
C
ontrol Board
C
hoke
Positive
Output
Terminal
Negative
Output
Terminal
To Control
Board
C
u
rre
n
t
Fe
e
d
b
a
c
k
Reconnect
Switch
Output V
ol
tage Sense
Input switch
Input
Rectifier
Auxiliary
Transformer
F
an
Power
Board
220
Receptacle
RS232 Supply +5VDC
Machine Control Supply
+
15VDC, -15VDC, +5VDC
40VDC
42VAC
220 VAC
M
ain Switch Board
115VAC Fan Supply
Fa
n
Co
n
tro
l
V
/F Capacitor Feedback (2)
Soft Start Control
Input Relay Control
P
rimary Current Feedback(2)
I
G
B
T
Dr
i
ve
S
i
g
n
a
l
Primary
C
urrent
Sensor
Primary
C
urrent
Sensor
{
P
o
w
e
r
W
a
v
e
4
0
5
o
n
l
y
6
5
VAC
D
C
Bus
Board
Wire
F
eeder
Recp.
40VDC
C
an Supply +5VDC
Arc
Link
Electrode
Sense
21 Lead
V
oltage
Sense
Recp.
R232
Connector
Yellow
Thermal
LED
Status
Red/Green
LED
Thermostats
2
To
Feeder
NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion