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THEORY OF OPERATION
E-8 E-8
POWER WAVE 655/R
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NOTE: Unshaded areas of Block Logic
Diagram are the subject of discussion
OUTPUT RECTIFIER, OUTPUT
CHOKE
The output rectifier receives the AC output from the
main transformer secondary and rectifies it to a DC
voltage level. The output choke is in series with the
negative leg of the output rectifier and also in series
with the welding load. Due to the current "smoothing"
capability of the output choke, a filtered DC output
current is applied through the machine output termi-
nals to the welding arc.
FIGURE E.7 – OUTPUT RECTIFIER, OUTPUT CHOKE AND STT CHOPPER BOARD
+
I
NPUT
BOARD
LEFT
S
WITCH
BOARD
RIGHT
S
WITCH
BOARD
INPUT
RECTIFIER
C
R1
GATEWAY
BOARD
DC
BUS
B
OARD
FEED
HEAD
B
OARD
P
OWER
B
OARD
CONTROL
BOARD
O
UTPUT
C
HOKE
ELECTRODE
T
ERMINAL
THERMOSTATS
T1
T2
AUX
RECONNECT
RELAY
WATER
COOLER
115VAC
R
ECP.
115VAC
FAN
ARC LINK
W
IRE
F
EEDER
RECP.
S1
S6
CONNECTION
T
O WIRE
DRIVE
S
1
S
6
VOLT
S
ENSE
BOARD
MAIN
T
RANSFORMER
S5
C
ONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
F
ROM CONTROL
B
OARD
2
4
V
A
C
1
15 VAC
5
2 VAC
2
30 VAC
4
0 VDC
4
0 VDC
4
0 VDC
40 VDC
A
RC LINK
C
ONNECTION
T
O
R
OBOT
VOLTA GE SENSE
OUTPUT
C
AP.V/F
FEEDBACK
CAP.V/F
FEEDBACK
IGBT DRIVE
F
ROM
C
ONTROL
B
OARD
C
T CURRENT
TO CONTROL
BOARD
-15 V
+
15 V
+
5 V
+
5 V ARC LINK
+
5V RS232
+
15V SPI
S
TATUS THERMAL
LIGHT LIGHT
S
2 WORK
S
ENSE
L
EFT S.B.
C
AP.V/F
R
IGHT S.B.
C
AP.V/F
S3
RS232
L
EFT CT
CURRENT
FB
C
U
R
R
E
N
T
F
B
A
RC LINK
IGBT
DRIVES
TO
L
EFT
S
.B.
TO
R
IGHT
S
.B.
6
7A
67B
S
W1
BUS BOARD
R
ECTIFIER
CURRENT
T
RANSDUCER
OUTPUT DIODES
D1 -D4
115 VAC
40 VDC
D
EVICE NET
VOLTA GE SENSE SELECT
I
GBT DRIVE
F
ROM
C
ONTROL
BOARD
+5V SPI
RIGHT CT
CURRENT
FB
T
O FAN RELAY
C
ONTACTOR AND
P
RECHARGE
CONTROL SIGNALS
6
5 VDC
W
ORK
T
ERMINAL
POWER WAVE 655/R
380-
415
4
40-
460
5
50-
575
+
ETHERNET/
A
A
H
ARMONIC
FILTER
C
P
OS
NEG
Auxiliary
Fan