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Theory of Operation .............................................................................................................Section E
Block Logic Diagram ...................................................................................................................E-1
General Description ....................................................................................................................E-2
Input Voltage and Precharge ......................................................................................................E-3
Switch Boards and Main Transformer.........................................................................................E-4
DC Bus Board, Power Board, Feed Head Board, Gateway Board
and Voltage Sense Board ...........................................................................................................E-5
Power Wave Communications Diagram .....................................................................................E-6
Control Board..............................................................................................................................E-7
Output Rectifier, Output Choke and STT Chopper Board ..........................................................E-8
Thermal Protection, Protective Circuits, Over Current Protection
and Under/Over Voltage Protection ............................................................................................E-9
General Description of STT (Surface Tension Transfer) Process.............................................E-10
Insulated Gate Bipolar Transistor (IGBT) Operation.................................................................E-11
Pulse Width Modulation ............................................................................................................E-12
Section E-1 Section E-1
TABLE OF CONTENTS
- THEORY OF OPERATION SECTION -
POWER WAVE 455M/MSTT
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+
INPUT
BOARD
RECONNECT
SWITCH
LEFT
SWITCH
BOARD
RIGHT
SWITCH
BOARD
INPUT
RECTIFIER
CR1
GATEWAY
BOARD
DC
BUS
BOARD
FEED
HEAD
BOARD
POWER
BOARD
CONTROL
BOARD
STT CHOPPER
BOARD
OUTPUT
CHOKE
STT
ELECTRODE
TERMINAL
ELECTRODE
TERMINAL
THERMOSTATS
T1
T2
AUX
RECONNECT
RELAY
WATER
COOLER
115 VAC
RECP.
115 VAC
FAN
ARC LINK
WIRE
FEEDER
RECP.
S1
S6
CONNECTION
TO WIRE
DRIVE
S1
S6
VOLT
SENSE
BOARD
MAIN
TRANSFORMER
S5
CONTACTOR AND PRECHARGE
CONTROL SIGNALS FROM
CONTROL BOARD
FROM CONTROL
BOARD
2
4
V
A
C
115 VAC
52 VAC
230 VAC
40 VDC
40 VDC
40 VDC
+20 VDC
TO
CHOPPER
BOARD
40 VDC
ARC LINK
CONNECTION
TO
ROBOT
VOLTA GE SENSE
OUTPUT
+20 VDC FROM
POWER BOARD
CT CURRENT
TO CONTROL
BOARD
CAP. V/F
FEEDBACK
CAP. V/F
FEEDBACK
IGBT DRIVE
FROM
CONTROL
BOARD
CT CURRENT
TO CONTROL
BOARD
-15 V
+15 V
+5 V
+5 V ARC LINK
+5V RS232
+15V SPI
STATUS THERMAL
LIGHT LIGHT
S2 WORK
SENSE
LEFT S.B.
CAP. V/F
RIGHT S.B.
CAP. V/F
S3
RS232
LEFT CT
CURRENT
FB
C
U
R
R
E
N
T
F
B
S
T
T
F
B
STT
DRIVE
ARC LINK
IGBT
DRIVES
TO
LEFT
S.B.
TO
RIGHT
S.B.
67A
67B
SW1
BUS BOARD
RECTIFIER
CURRENT
TRANSDUCER
CURRENT
TRANSDUCER
OUTPUT DIODES
D1 -D4
115 VAC
40 VDC
DEVICE NET
VOLTA GE SENSE SELECT
IGBT DRIVE
FROM
CONTROL
BOARD
+5V SPI
RIGHT CT
CURRENT
FB
TO FAN RELAY
CONTACTOR AND
PRECHARGE
CONTROL SIGNALS
65 VDC
WORK
TERMINAL
POWER WAVE 455/R
FIGURE E.1 – BLOCK LOGIC DIAGRAM