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A-13
INSTALLATION
POWER WAVE AC/DC
A-13
MULTI-ARC SYSTEM DESCRIPTION
The following is a general description of how the
PowerWave AC/DC can be configured in a multi-arc
set-up.
Each welding arc may be driven by one machine or up
to four machines connected in parallel. The hardware
for the power source has been designed so that the
power source can either operate as a master or a
slave. A few DIP switches must be configured proper-
ly to set the machine’s identity. Each power source
has a rating of 500 amps average current, with a peak
current of 725 amps. So, four machines are capable
of driving 2000 amps of output current with up to 2900
amps of peak current available. Each arc must have
one power source designated as the master. If only
one machine is required for an arc, then it must be set
up as the master. The master power source controls
the AC switching for the arc. The slaves respond to
what the master wants
Due to the flexibility of the platform the configuration
may vary. A typical subarc system will consist of four
welding arcs, which require ten power sources and
one synchronous generator. Arc # 1 & #2 will be three
machines in parallel. Arc #3 & #4 will be two machines
connected in parallel (each individual machine is con-
nected to the ethernet hub).
The PC will function as the control center for the
AC/DC system as well as the user interface. The
Ethernet hub splits the Ethernet port from the PC to all
the power sources and the phase generator. The PC
will act to coordinate the welding sequence of the mul-
tiple machines.
One machine will be designated the master, with the
rest of the machines connected in parallel considered
slaves. The master can generate it's own AC frequen-
cy or it can use an external signal as a reference. An
external Phase Generator provides the means to syn-
chronize the AC wave shape between multiple arcs.
The phase angle between arcs can be adjusted to
reduce "Arc Blow" and other welding related issues.
An external phase control signal is required to keep
the separate wave shapes synchronized with each
other
An Ethernet-Gateway board can be used as the exter-
nal Phase Generator. An Ethernet-Gateway PC board
that can be configured to generate four phase signals
onto four differential I/O lines. The phase signals can
then be used to synchronize the four different arcs to
a common carrier frequency. The frequency can
range from 10 hertz to 300 hertz, with the most practi-
cal range being from 50 to 100 hertz. It may be desir-
able that sync signals 2, 3, or 4 are some multiple of
the first signal. The frequency and phase shift are
controlled by software.
Ethernet Hub
PC
ARC
#1
ARC
#2
ARC
#3
ARC
#4
PULSE
GENERATOR