UM0933
Safety and operating instructions
Doc ID 17386 Rev 1
7/16
In any case, avoid contact with metallic parts during welding and for some minutes after.
The welding process creates high temperatures to fuse the metal and therefore there is a
risk of serious burns.
Do not leave the rod unattended just after the welding operation. The tip of the rod remains
incandescent for some minutes and can be a cause of fire, damage to the environment, or
personal harm.
The welding process starts by putting the rod in contact with the metal sample connected to
the negative output through the clamp, supplied by the positive output of the board. Do not
directly touch the rod or the metal piece, the output voltage, at open load, can cause electric
shock.
An AC which is insulated and protected against overload and short-circuit is preferable to be
used during the evaluation test of the 2.5 kW/135 A welding machine.
In case of a resistive and dissipative dummy load, attention should be paid to the
temperature that the load could reach. The required equipment must be provided in order to
avoid hot surfaces and fire risk during the tests (fan, water cooled load, etc.).
Note:
Do not touch the board and its components after disconnection from the voltage supply, as
several parts and power terminals, which may contain energized capacitors, need to be
allowed to discharge.
2.3 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
185 VAC
rms
to 265 VAC
rms
or a DC voltage between 310 Vdc and 375 Vdc. The power
source must be able to supply the power required by the system, according to the welding
current required on the output. The two output connectors are present on the right-hand side
(close to the output free air inductor). On the centre of the board the ferrite high frequency
power transformer, made up of the double switch forward converter, can be found. The two
big heatsinks on the left-hand side are sized to allow power dissipation of the four power
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