ESAB ES 150i - Introduction to Welding Power Sources; Power Source Design and Modules

INTRODUCTION
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INTRODUCTION
The "ES 150i", "ES 180i", "ES 180i Pro" and "ES 200i Pro" are an inverter-based power
sources intended for MMA (Manual Metal Arc) and TIG (Tungsten Inert Gas) welding.
The "ET 180i", "ET 200iP" and "ET 200iP Pro" are an inverter-based power sources
intended for MMA (Manual Metal Arc), TIG (Tungsten Inert Gas) welding and HF TIG (High
Frequency Tungsten Inert Gas) welding.
Design structure of the power source
The "ES 150i", "ES 180i", "ES 180i Pro", "ES 200i Pro", "ET 180i", "ET 200iP" and
"ET200iPPro" power sources are transistor-controlled, operating on the inverter principle. It
consists of a number of function modules. Each module has a module number, which is
always included as the first part of the name/identification of components in the module. The
modules have the following main functions:
The modules have the following main functions:
Setting panel module
The main function is for the user to define welding process settings.
Input module
The main function is to convert power mains input voltage to stable voltage free from
conducted disturbances as required by the EMC directive.
TIG module (valid for ET 180iP, ET 200iP Pro)
The main function of the TIG module is to produce high voltage, high frequency pulses, thus
enabling non-contact ignition of the electric welding arc.
Primary module
The main function is a full bridge inverter operating at a switching frequency of 97kHz. IGBT
transistors are used as switching elements.
Transformer module
The main function is to transform high voltage / low current to high current / low voltage.
Output inductor module
The main function is to supply the welding current. The module contains an inductor and a
current sensor.
Control module
This is the master of the system. The module handles the system status. It is a hub for
events/errors occurring in the system, and it collects meta-data on other boards in the
system.
Secondary module
The main function is to supply the welding current. This module contains an additional board
for increasing the output voltage at low currents, to enable higher welding performance for
cellulosic electrodes.