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ANALYSIS OF THE BLOCK DIAGRAM

NOTE: Unless indicated otherwise, it should be assumed that
the components are assembled on the primary board or
machine.

: C1, C2, C3, C4, C5, C6, C7, L1 (input filter board)

Prevents noise from the machine from being transmitted along
the main power line and vice versa.

Consisting of: RV1, RV2, RV3 (input filter board)
Prevents spike noise from the mains, with amplitude greater
than 400V, from entering the machine.

Consisting of: D1, D2, D3
Converts the mains alternating voltage into continuous pulsed
voltage.

Consisting of: K1, K2, K3, R1, R2
Prevents the formation of high transitory currents that could
damage the main power switch, the rectifier bridge and the
electrolytic capacitors. When the power source is switched on
relays K1, K2 and K3 are de-energised, capacitors C1, C2, C3,
C4, C1A, C2A, C3A C4A and C39 are then charged by R1 and
R2. When the capacitors are charged the relays will be
energised.

Consisting of: C1, C2, C3, C4, C1A, C2A, C3A C4A, C39
Converts the pulsed voltage from the rectifier bridge into
continuous voltage.

Consisting of: IGBT 1, 2, 3, 4, 5, 6, 7, 8, 9, 10
Converts the continuous voltage from the filter into a high
frequency square wav

capable of piloting the power

transformer. Regulates the power according to the required
welding current/voltage.

Consisting of:TA
The C.T. is used to measure the current circulating in the power
transformer primary and transmit the information to block 14
(primary current reader and limiter).

Consisting of:T1
Adapts the voltage and current to the values required for the
welding procedure. Also forms galvanic separation of the
primary from the secondary (welding circuit from the power
supply line).

Consisting of: D1, D2, D3, D4, D5 (secondary board)
D1 and D2 convert the current circulating in the transformer to
a single direction, preventing saturation of the core.

D3, D4 and D5 recirculate the inductance output current (block
9) while the IGBT's are not conducting, bypassing the power
transformer(block 8).

Consisting of: L1, Hall1 and Hall2
The inductance levels the output current from the secondary
board diodes making it practically direct. Hall1 sensor reads
the current of the pilot arc, Hall2 sensor reads the current
circulating in the inductance and sends it to block 20 (Hall
sensor amplifiers) which will process the information.

Consisting of: C4, C5 (HF filter board)
Prevents noise from the power source from being transmitted
through the welding cables and vice versa.

Consisting of:T2
The HF transformer boosts the signal from block 40 (hf power
source), raising the voltage impulse in the secondary at the
instant when arc strike is generated.
It also isolates the welding circuit from the primary circuit

Consisting of: U4, Q6, T3, U1, U2, U3
Uses switching methods to transform and stabilise the voltage
obtained from block 5 (filter) and supply 2 voltage values of
27V that enable block 14 (driver) to be powered correctly.The
auxiliary power supply board, on the other hand, generates
four further stabilised voltages (U2, U3, U4, U5) equal to a
+12V, +5V, -12V and 5V which are mainly used to power the
control board.

Consisting of: U1 (opto-insulators board), Q7, Q8 and U2
(opto-insulators board), Q9, Q10.
Takes the signal from block 13 (flyback power supply) and,
controlled by block 16 (duty cycle maker), makes the signal
suitable for piloting block 6 (chopper).

Consisting of: D3, R1, R2, R3 and R9 and R16 (control board)
Detects and limits the signal from block 7 (current transformer)
and sets the maximum allowed primary current. This signal is
also scaled down so that it can be processed and compared in
block 16 (duty cycle maker).

Consisting of: U1(control board)
Processes the information from block 18 (adder) and block 15
(primary current reader and limiter) and produces a square
wave with variable duty cycle limiting the primary current to a
maximum pre-set value under all circumstances.

Consisting of: U4A, U4B (control board)
Collects all the information arriving from block 21 (maximum
current control) and from block 19 (microcontroller), and sends
it to block 16 (duty cycle maker).

Block 1

Block 2

Block 3

Block 4

Block 5

Block 6

Block 7

Block 8

Block 9

Block 10

Block 11

Block 12