Pulsing Module for ESAB

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anyone know of a COTS pulsing module that works on a ESAB heliarc 161? i am about to make a module but wanted to see if one already exists before i start building a module, etc.and then my 2nd Q is, for those who have pulsing ability in your TIG now, what freq can you adjust the pulse to, and can you adjust duty-cycle of the pulse? i was initially thinking of adjusting 1-5Hz and 10-90% duty cycle.Last edited by welding_kid; 04-24-2014 at 09:38 AM.
Reply:Can I have one?L-tec Heliarc 306Miller 210Victor O/A rig
Reply:Originally Posted by arqangel67Can I have one?
Reply:Very interested on how this comes out, keep us posted.L-tec Heliarc 306Miller 210Victor O/A rig
Reply:initial schematic is finished and i ordered some parts to breadboard it and then scope it for functionality. will update with pics as soon as i have them.its a very simple circuit4 IC's2 pots13 resistors6 caps2 switches1 bridge rectifierthe freq range has two scales, 1-68Hz and 52-200HzPWM on those scales will be ~10-100%the regular pedal can be integrated with this module, but the 1st beta module will not have the ability to use pedal.the module itself will be powered via a wall-wart, any 7-30vdc or vac wall-wart will work, and i will supply it as an option, etc.and i should be able to cram it all into a 1x2x3.5" case.Last edited by welding_kid; 05-06-2014 at 01:50 PM.
Reply:1st stage testing completed. the opto driver works good. i havent scoped it yet for switching. next up is the comparator. slowly but surely as they say.
Reply:Great progress!L-tec Heliarc 306Miller 210Victor O/A rig
Reply:Originally Posted by arqangel67Great progress!
Reply:made another tweak to get 10-95% PWM.right now the two freq ranges are 3.3-48.4Hz, and then 55.8-196.3Hz. from what i see online the low frequencies are not all that useful, so i dont see the need to reach down to 1Hz.Last edited by welding_kid; 05-15-2014 at 04:49 PM.
Reply:ok, i ordered the Amphenol connector. why in the world did ESAB use a 97 series 14pin -20 connector ??!! they are so damn expensive. any reason to have 14pins when only 7 are used for the foot pedal, what are the other 7 pins for (do other machines use the other pins for something other, maybe for a spool gun or something)??? anyways, buying just one connector with strain relief is $43. the final module which will allow the use of the foot pedal will require two Amphenol connectors !! just to note for anyone else who needs one, the connector that plugs into the machine is Amphenol 97-3106A-20-27P, which is commonly listed as MS3106A20-27P. and then they have various strain reliefs to go with (such as AN-3057-12). very nice connectors, but way overkill on the ESAB. i know there are less expensive connectors that work, my thumb switch cable has a plastic molded end with metal barrel that connects to the machine, i think these are less $$ and need to find it.as soon as i get the connector i will make the cable to my test board and give it run.Last edited by welding_kid; 05-16-2014 at 04:37 PM.
Reply:a few minor tweaks today and now i have better freq range selections2.6-60Hz or 48-205Hzwith10-90% PWMand just to note, this module is fully isolated from the machine.
Reply:ok folks, got my Amphenol connector today, wired it up, works awesome !!! perhaps the worlds 1st pulsing module for these older ESAB machines (2.6-205Hz 10-90% PWM) 100% isolated from the machine !!! i will post up some videos as soon as i get them downloaded/converted and up on you tube.next thing i need to know, how many people are interested in this, so i can order my parts in bulk w/o ordering for a ghost army, etc...????Last edited by welding_kid; 05-20-2014 at 07:31 PM.
Reply:Great to here you got this done. I can't wait to see the video's. I unfortunately do not have a ESAB but an L-tec instead and don't have a pulse module for it but would like one someday.L-tec Heliarc 306Miller 210Victor O/A rig
Reply:Originally Posted by arqangel67Great to here you got this done. I can't wait to see the video's. I unfortunately do not have a ESAB but an L-tec instead and don't have a pulse module for it but would like one someday.
Reply:I'm currently out of state so I can't get any model #'s for you. but on that link my pedal is the last one on the list for the linde 305. This is my welder it has some type of module that attaches to the unit itself. http://weldingweb.com/vbb/showthread.php...ec-Heliarc-306ILast edited by arqangel67; 05-21-2014 at 10:10 PM.L-tec Heliarc 306Miller 210Victor O/A rig