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GENERAL DESCRIPTION
The Power Wave 455M/MSTT power source is
designed to be a part of a modular, multi-process weld-
ing system. It is a high performance, digitally con-
trolled inverter welding power source capable of com-
plex, high-speed waveform control. Depending upon
configuration, it can support constant current, constant
voltage, surface tension transfer and pulse welding
modes. Each machine is factory preprogrammed with
multiple welding procedures. Typically these proce-
dures include GMAW, GMAW-P, FCAW, GTAW and
STT (Surface Tension Transfer) for a variety of materi-
als such as mild steel, stainless steel, cored wires and
aluminum. The STT process supports mild steel and
stainless steel welding. PW455M/STT only.
The Power Wave 455M/STT has an output rating of
either 450 amps at 38 volts or 400 amps at 36 volts.
The two output ratings are dependent upon input volt-
age and frequency. Both have a duty cycle of 100%.
The STT process is rated at currents up to 325 amps
at a 100% duty cycle.
E-2 E-2
THEORY OF OPERATION
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.2 – INPUT VOLTAGE AND PRECHARGE
NOTE: Unshaded areas of Block Logic Diagram are the subject of discussion.