STEVAL-ISW001V1

2.5 kW manual arc welder demonstration board

Data brief

Features

Vin: 185 Vac to 265 Vac

Vout: 80 V (peak)

Iout_max: 135 A

Frequency switching: 70 kHz

Efficiency > 75%

RoHS compliant

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Description
The STEVAL-ISW001V1 demonstration board is
a complete 2.5 kW arc welding system capable of
135 A of welding current. It is designed for small
industrial applications and domestic use for do-ityourself applications. The system is ready-to-use
and designed to perform manual metal arc (MMA)
welding of iron and steel, following MMA process
recommendations.

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STEVAL-ISW001V1

The design is quick to set up and install, and is reusable (the Gerber files are available for
download from the ST website).

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The purpose of the demonstration board is to

provide a platform for evaluation of
STMicroelectronics silicon devices in high
power/current applications, where the robustness
and efficiency of the silicon devices used are the
keys to a reliable system.

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The complete system consists of two boards. One

is a power board, where all the power conversion
devices needed for the application are mounted.
The other is a small control board that includes
the PWM generator and analog control circuitry
necessary to manage the MMA arc welding
process.

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The layout of the power board is designed to

achieve a low level of interference, taking into
consideration the high power delivered and the
current levels present on many parts of the board.
The shape of the board and the position of the
magnetic/silicon components mounted on it are
optimized to guarantee sufficient air flow to the
parts involved in heat dissipation.

March 2010

Doc ID 17270 Rev 1

For further information contact your local STMicroelectronics sales office.

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www.st.com

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Power board schematic

Figure 1.

Schematic diagrams

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Schematic diagrams
STEVAL-ISW001V1

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Doc ID 17270 Rev 1

C4
7nF
4.7nF

33

D5 D1N4148
4148 R19
19

OUT_Winding_
inding_sen
ense

TA_
A_Current
urrent

TS

22k

R27
27

10k

R20
20

100nF

C3

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15V

18k

R21
21
10k

R38
38

R28
28

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C6 2.2nF
2nF

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R11
11

1k

R29
29

10k

R26
26

102
TSM102

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R30
30

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10nF

R9
100k

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R24
24

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_op2
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4148

1
2
3
4
5
6
7
8

R12
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1Meg
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R10
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13
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11
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9

Vref

Vref

1k

R25
25

10uF 25V
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4148
D1N4148

+15V
15V

R13
13
15k

C1 22nF

R1 43k

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15V

R17
17

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R22
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100k

1K

R32
32

C11
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1n

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R34
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dut

D4 D1N4148
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R18
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eg

R16
16
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R23
23
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R14
14
10k

BC847
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R6 22k

SET = 0.5
SE

D1
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4148

R2
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Welding Current Set

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Temperature protectio
protection

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R8

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R35
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R31
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2k

SG3525

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J2

65Khz PWM frequency

frequenc

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2
3
4
5
6
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8

R4
100k

16
15
14
13
12
11
10
9

C8
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R15
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BUS Moni
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2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
28
CON28

J3

BF13
BF1

BF11
BF1

BF1
BF10

BF9
BF

BF8
BF

BF7
BF

BF1
BF12

BF
BF6

BF5
BF

BF4
BF

BF
BF3

BF2
BF

BF1
BF

Figure 2.

STEVAL-ISW001V1
Schematic diagrams

Control board schematic

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AM06108v1

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Revision history

STEVAL-ISW001V1

Revision history
Table 1.

Document revision history

Date

Revision

18-Mar-2010

Changes
Initial release.

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Doc ID 17270 Rev 1

STEVAL-ISW001V1

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