ST STEVAL-ISW001V1 User Manual
ST STEVAL-ISW001V1 User Manual

ST STEVAL-ISW001V1 User Manual

2.5 kw/135 a mma welding machine

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STEVAL-ISW001V1 2.5 kW/135 A MMA welding machine
Introduction
The STEVAL- ISW001V1 is a 2.5 kW welding machine capable of 135 A of welding current.
It is designed for small industrial applications and domestic use in many DIY applications.
The machine is ready-to-use and designed to implement the Manual Metal Arc (MMA)
welding process and to weld iron and steel following MMA process recommendations.
The board is intended for demonstration purposes in order to evaluate the potential of silicon
devices on high power/current applications where the robustness/efficiency of the silicon
part is the key point for a reliable system.
The whole system is made up of two boards. A power board, where all the power devices
involved in the power conversion are fitted, and a small control board, which includes a
PWM generator and an analog control circuitry necessary to manage the MMA welding
process.
The design is:
Quick to set up and install
Re-usable (the Gerber files are available free)
Ready to downsize if required
Note:
Please read the safety and operating instructions section before attempting any operation
with this manual. Further technical and theoretical information on this board can be found in
the application note AN3200; 2.5 kW MMA welding machine.
Figure 1.
September 2010
www.BDTIC.com/ST
Typical low-end welding machine topology
Doc ID 17386 Rev 1
UM0933
User manual
1/16
www.st.com

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Summary of Contents for ST STEVAL-ISW001V1

  • Page 1: Figure 1. Typical Low-End Welding Machine Topology

    UM0933 User manual STEVAL-ISW001V1 2.5 kW/135 A MMA welding machine Introduction The STEVAL- ISW001V1 is a 2.5 kW welding machine capable of 135 A of welding current. It is designed for small industrial applications and domestic use in many DIY applications.
  • Page 2: Table Of Contents

    2.5 kW/135 A welding machine board connection ....8 STEVAL-ISW001V1 main description ......9 STEVAL-ISW001V1 circuital description .
  • Page 3 Typical low-end welding machine topology ........1 Figure 2. 2.5 kW/135 A welding machine STEVAL-ISW001V1 top view ..... . . 7 Figure 3.
  • Page 4: Board Description

    A power stage made up of a power IGBT or MOSFET and power ultrafast diodes. ● A ferrite power high frequency transformer designed and manufactured for this application ● An output free air inductor with an auxiliary winding needed to implement the patented output current sensing. 4/16 Doc ID 17386 Rev 1 www.BDTIC.com/ST...
  • Page 5: Safety And Operating Instructions

    No contact should be made with electronic components and contacts ● Do not put the heatsinks together in electric contact ● The heatsinks are not electrically insulated from high voltage potential. There is a danger of electric shock present. Doc ID 17386 Rev 1 5/16 www.BDTIC.com/ST...
  • Page 6: Electronic Connection

    The work environment needs sufficient ventilation to assure the dispersion of smoke caused by rod and metal fusion. Any person involved in the operation must wear protective clothing, compliant with relevant accident prevention rules. 6/16 Doc ID 17386 Rev 1 www.BDTIC.com/ST...
  • Page 7: Hardware Layout

    Hardware layout Figure 2. 2.5 kW/135 A welding machine STEVAL-ISW001V1 top view The main input connector can be seen on the left-hand side in the image, near the fuse connector. Connect a sinusoidal supply voltage with an amplitude in the range of between...
  • Page 8: Environmental And Equipment Considerations

    Section 2.2.2 carefully for environmental considerations. Also, in the case of testing on a resistive dissipative dummy load, the STEVAL-ISW001V1 must only be used in a power laboratory equipped with a ventilation system or smoke extractor fan system. The high voltage involved in the system presents a serious danger of shock.
  • Page 9: Steval-Isw001V1 Main Description

    STEVAL-ISW001V1 main description The STEVAL-ISW001V1 demonstration board, developed by STMicroelectronics, provides a ready-to-use demonstration solution for the implementation of an MMA welding machine. The board can be used for demonstration purposes but is not, however, optimized for industrial use or production machinery.
  • Page 10: Steval-Isw001V1 Circuital Description

    – Output short-circuit protection – Hot start function STEVAL-ISW001V1 circuital description Figure 3 the electronic schematic of the power board is shown. Starting from the main supply input, a common mode filter and a power diode bridge can be found. After the bridge, a DC bus, filtered by the electrolytic capacitor C35 and C36, is available.
  • Page 11 SC_Detection signal is also fixed to ground. In this condition it is simulating that the voltage at the output of the welding machine is at the right level. Warning: In this case no kind of short-circuit protection or duty cycle limitation is present. Doc ID 17386 Rev 1 11/16 www.BDTIC.com/ST...
  • Page 12: Igbt Or Power Mosfet Compatibility

    II family device, and for this reason, on the electric schematic, the graphic symbol is related to this kind of switch. In terms of power MOSFET, the suggested part to be fitted to the application is the new STW77N65M5 device. 12/16 Doc ID 17386 Rev 1 www.BDTIC.com/ST...
  • Page 13: Schematics

    UM0933 Schematics Schematics Figure 3. Power board schematic diagram Doc ID 17386 Rev 1 13/16 www.BDTIC.com/ST...
  • Page 14: Figure 4. Control Board Schematic Diagram

    Schematics UM0933 Figure 4. Control board schematic diagram 14/16 Doc ID 17386 Rev 1 www.BDTIC.com/ST...
  • Page 15: Revision History

    UM0933 Revision history Revision history Table 1. Document revision history Date Revision Changes 07-Sep-2010 Initial release. Doc ID 17386 Rev 1 15/16 www.BDTIC.com/ST...
  • Page 16 No license, express or implied, by estoppel or otherwise, to any intellectual property rights is granted under this document. If any part of this document refers to any third party products or services it shall not be deemed a license grant by ST for the use of such third party products or services, or any intellectual property contained therein or considered as a warranty covering the use in any manner whatsoever of such third party products or services or any intellectual property contained therein.

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