100K R3 XnF C11 47K R13 750K R2 XnF C3

TO INTERNAL CIRCUITRY 1 ERROR AMP 2 REFERENCE REGULATOR UNDER-VOLTAGE LOCKOUT OUTB /SYNC /Q 4 ~40KHZ OSC. 5 6 OUTPUT OSCILLATOR CT RT RD CSOFTSTART 5.0K COMPENSATION F/F Q PWM
DISCHARGE

HEAT TRIM

15 14

(SET @ 20.14K 14:15)

V+ Q1

4K7 R14 MMBT5551 (G1)

1R6 10 50K W1 15nF 1C7

D7 5.1 1W 1R4 5.1 1W 1R4 D4

D6 D5 D3 J1
CURRENT SENSE -START +START THERMAL CUTOFF

18

VREF VCC

16 15 14 13 12 11 10 9

Q3 MMBT5401 (2L) V+ MMBT5551 (G1) Q2

17

V+

15 1R2 10uF 50V 1C6 B3 15nF 1C2 15 1R3 15nF 1C3

B2

XnF C2

VC

XnF C1 MMBT5401 (2L) Q4

E1

GND R Q OUTA LATCH S SHUTDOWN 5.0K

GREEN LED - WELDING /WELDING ELECTRODE SENSE

6 5 4
GRN

B1

J3

150 R1

7 8

10K R5

U3

6.8nF C8

4.7nF C10

SG3525A 10uF C7
~0.5SEC TC

HEAT - HIGH

GND

RED

HEAT - SELECT

U1 270K R4 22nF C9 D1

U3

U3 10K R19

RED LED POWER T.C. PULLUP

8 9 10 16 11 12 13
(SET @ 717)

HEAT - LOW

YELLOW LED OVERLOAD

J2
7
YEL

1K 1R7 1D8 D8 220uF 1C17 3K 1R8 IRFD110 K

POWER SWITCH

IGBT DRIVE

E2

10nF 1C12

U3

D4 4K7 R12

THERMAL CUTOFF (N.C. TO GND) PWM FREQUENCY TRIM

10K R16 6K2 R8 XnF C4 100K R22 V+ 4K7 R25 V+ 15K R11 V+ 47K R24
633mV

50K R1 MAC97A6 1U2 3K R100 2K W2

J
TO GAS SOLENOID

15K R17 15K R18 V+ D5 10K R7

14 6 SET 1 5 D1 3 CLK1 4 CLR1
t1

4K7 R15

V+
WELD HEAT

16

START HEAT

VDD
1 14 ZA

CD4053B
Y0A 12 SA 11 Y1A 13 Y0B 2 SB 1 Y1B 10 Y0C 5 SC 9 Y1C 3

30nF 1C18

P525G

8 2 3

+VCC
1

13

12
t0

VDD
Q1

U3 V+ 2M2 R9 100 R21

2.4K 1R9 U5

U4

CD4013B

80mV

/Q1 Q2

2 15 13 ZB

100 R10

L7812

2.9V

1000uF 1C11

100K R6

100nF 1C13

15K R23

5
t3

D2

/Q2

12

ZC

100nF 1C9

V+

1000uF 1C8

IN

OUT

LM393

8 SET2 9 D2 11 CLK2 10 CLR2 7

t4

V+

D1 D2

B2

VCC
1

XnF C6

~2SEC TC

-VCC
4

VSS XnF C12 U4

GND 2

U5

VSS 10uF C13

8
~1SEC TC

VEE
7

/E 6

10uF C5

V+
OPEN 48

V+ CD4069
10 9 8 POWER ON RESET

10nF 1KV 1C10

ELECTRODE OPEN VOLTAGE DETECT @ 49.7V

U2

2 GND 3 GND

FAN

U2
t2

100 1W 1R1 10nF 1KV 1C1 470uF 400V

0: START 1: WELD

WELD 24 IDLE 12 CONTACT 0 t0 t1 t2 t3 t4

11

D3

100K R20

PWM CONTROL BOARD

IGBT FEED

GBPC3510 BD1

J5
SWAPPED RELATIVE TO PCB LEGEND TO DRIVE IGBTS OUT OF PHASE IGBT FEED C1 CURRENT TRANSFORMER 2MBI 100N-060 50:1

SHADED BOX DENOTES COMPONENT MOUNTED TO HEAT SINK

F30U60DN x8

POWER SWITCH
GRN YEL RED

FAN 240 VAC

M 2K2 2K2 2K2

WELDING OVERHEAT POWER GND

B1
IGBT DRIVE

B1 E1 E1 C2

E1 E2 B2

CORE GAPPED PRIMARY 160uH

GAS SOLENOID

J 240 VAC J2

L1

E2 E2

J3

10uF 600V B1

3.5T

WELDING OUTPUT +

B2

10uF 600V 11T

3.5T 10nF 1KV

HEAT CONTROL 10K W3

10 MAX HEAT 1 MIN

THERMAL SWITCH KDS-R303 65C +START -START

HEAT - HIGH HEAT - SELECT HEAT - LOW

J1

FRONT PANEL

KENDE TIG WELDER AKA: HARBOR FREIGHT #91811 OEM SCHEMATIC

PWR IN

U3

240VAC 20 A

U3

470uF 400V

14

J5

J3

PAGE 1 of 4

REV 0.6 UNIFIED

Reverse IP by uhmgawa@third-harmonic.com. Modifications, Documentation, Copyright (c) 2008-2009 uhmgawa@third-harmonic.com

Q3

Q1

PHASE B DRIVE
18

Q4

Q2

PHASE A DRIVE
17

U1

PWM FREQUENCY TRIM

16

R12 C7

R1

HEAT TRIM IN
15

R13

R2

HEAT TRIM GND

14

C11 C8

R3

HEAT - LOW
13

R14

R4

U2

HEAT - SELECT
12

R15

D1

HEAT - HIGH
11

R16 C9

C1

THERMAL CUTOFF
10

R17

C2

T.C. PULLUP
9 8 7 6 5 4 3 2 1

R18

C3

(POWER) RED LED

R19

R5

U3

(OVERLOAD) YELLOW LED

D4

R6 C10

(WELDING) GREEN LED

R20

D2

/WELDING ELECTRODE SENSE GND

R21 R10

D3

R22

R7

U4

R23 GND

C4

R24 V+

R8 R11

R25

R9 U5

C12 D5 C13

C5

C6

KENDE TIG WELDER PAGE 2 of 4 AKA: HARBOR FREIGHT #91811 PWM CONTROL BOARD SMD COMPONENT MAP REV 0.6 UNIFIED

Reverse IP by uhmgawa@third-harmonic.com. Modifications, Documentation, Copyright (c) 2008-2009 uhmgawa@third-harmonic.com

FRONT PANEL HEAT CONTROL 10K W3

10 MAX HEAT 1 MIN

WELDING OVERHEAT POWER GND HEAT - LOW HEAT - SELECT HEAT - HIGH

J2

VREF_LOW VREF_HIGH INTERNAL CONTROL

PEDAL CONTROL

100nF

V+ V+
4 2 3 PEDAL "DOWN" HEAT LIMIT
UP

TO WELDER MAIN BOARD 100nF GND U5.3 U5.2

10

PEDAL "UP" HEAT LIMIT

1K~ 100K

LM324-4
14 14 13

100nF

DOWN

DOWN

6 PEDAL HEAT SELECT 11

100nF

100nF

10uF

LM324-2

100nF

LM324-3 AND LM342-4 BUFFER HIGH/LOW HEAT LIMITS OF ORIGINAL DIVIDER. PEDAL LIMITS DEFINE UP/DOWN RANGE WINDOW THROUGH WHICH PEDAL HEAT POT SWEEPS

8 9

VCC

1
UP V+ OUT V+ OUT

100nF

1K~ 10K

10K

10K

LM324-1

10uF

LM324-3

BUFFERING LINE TO WELDER FOR HIGH IMPEDANCE PEDAL POTENTIOMETER

PEDAL HEAT SELECT

KENDE TIG WELDER PAGE 3 of 4 AKA: HARBOR FREIGHT #91811 EXTERNAL HEAT CONTROL MODIFICATION

REV 0.6 UNIFIED

Reverse IP by uhmgawa@third-harmonic.com. Modifications, Documentation, Copyright (c) 2008-2009 uhmgawa@third-harmonic.com

100K R3 XnF C11 47K R13 750K R2 XnF C3

TO INTERNAL CIRCUITRY 1 ERROR AMP 2 REFERENCE REGULATOR UNDER-VOLTAGE LOCKOUT OUTB /SYNC /Q 4 ~40KHZ OSC. 5 6 OUTPUT OSCILLATOR CT RT RD CSOFTSTART 5.0K COMPENSATION F/F Q PWM
DISCHARGE

15
HEAT TRIM

(SET @ 20.14K 14:15)

V+ Q1 MMBT5551 (G1)

4K7 R14

14

1R6 10 50K W1 15nF 1C7

D7 5.1 1W 1R4 5.1 1W 1R4 D4

D6 D5 D3 J1
CURRENT SENSE -START +START THERMAL CUTOFF

18
PHASE B DRIVE

VREF VCC

16 15 14 13 12 11 10 9

Q3 MMBT5401 (2L) MMBT5551 (G1) V+ 10uF 50V 1C6 B3

V+

15 1R2 Q2
PHASE A DRIVE

B2

XnF C2

17

15nF 1C2 15 1R3 15nF 1C3

IGBT DRIVE

VC

XnF C1 MMBT5401 (2L) Q4

E2 E1

GND R Q OUTA LATCH S SHUTDOWN 5.0K

GREEN LED - WELDING /WELDING ELECTRODE SENSE

6 5 4
GRN

B1

J3

150 R1

7 8

10K R5

U3

6.8nF C8

4.7nF C10

SG3525A 10uF C7
~0.5SEC TC

HEAT - HIGH

GND

RED

HEAT - SELECT

U1 270K R4 22nF C9 D1 4K7 R12

U3

U3 10K R19

RED LED POWER T.C. PULLUP THERMAL CUTOFF (N.C. TO GND) PWM FREQUENCY TRIM

8 9 10 16 11 12 13
(SET @ 717)

HEAT - LOW

YELLOW LED OVERLOAD

J2
7
YEL

1K 1R7 1D8 D8 220uF 1C17 3K 1R8 IRFD110 K

POWER SWITCH

10nF 1C12

U3

10K R16 6K2 R8 XnF C4 100K R22 4K7 R25 D4 V+ D5 V+

START HEAT

50K R1 MAC97A6 1U2 3K R100 2K W2

J
TO GAS SOLENOID

15K R17 15K R18

4K7 R15

10K R7

V+ 15K R11

V+ 47K R24

633mV

V+ 10K
8
t1

WELD HEAT

V+ 10K
14 6 SET 1 5 D1 3 CLK1 4 CLR1 16 Q1 1 14 /Q1 Q2 2 13 15 ZB

30nF 1C18

P525G

2 3

+VCC

13

12
t0

VDD

VDD
ZA

CD4053B
Y0A 12 SA 11 Y1A 13 Y0B 2 SB 1 Y1B 10 Y0C 5 SC 9 Y1C 3

U3 V+ 2M2 R9 100 R21

2.4K 1R9 100nF U5

U4

80mV

CD4013B

100 R10

L7812

2.9V

1000uF 1C11

100K R6

100nF 1C13

15K R23

5
t3

100nF 1C9

~2SEC TC

XnF C6

-VCC
4

VSS XnF C12

7
t4

D2

/Q2

12

V+

1000uF 1C8

IN

OUT

LM393

8 SET2 9 D2 11 CLK2 10 CLR2

V+

D1 D2

B2

ZC

GND 2

U5

U4 V+

10uF C13

V+
14 11

10nF 1KV 1C10

~1SEC TC

ELECTRODE OPEN VOLTAGE DETECT @ 49.7V

1 V+ 2 GND 3 GND

FAN

POWER ON RESET

VSS
8

VEE
7

/E 6

OPEN 48 WELD 24 IDLE 12 CONTACT 0 t0 t1 t2 t3 t4

D3

CD4069
10 9 8

10uF C5 100K R20 1K

U2 10nF 1KV 1C1

100 1W 1R1 470uF 400V 470uF 400V

t2

U3
7

0: START 1: WELD

PWM_SHUTDOWN

GND

WELD_OFF

ELECTRODE_CONTACT

OVERHEAT_DETECT

OCV_DETECT

/EXT_SEL

PWM CONTROL BOARD

EXT_HEAT

GND

VREF

V+

GBPC3510 BD1
/GAS_SOLENOID (DRIVE VIA OPEN COLLECTOR) CURRENT SENSE

V+

100nF

100nF

100nF

INTERNAL CONTROL PEDAL CONTROL

8 2 3

VCC

10K

PEDAL "DOWN" HEAT LIMIT

PEDAL "UP" HEAT LIMIT

LM358

10K

10K

1K~ 10K

1K~ 100K

100nF

MODIFICATION OF WELDER TO PROVIDE FULL EXTERNAL CONTROL ACCESS (EXTERNAL HEAT SELECT SHOWN AS EXAMPLE USAGE)
EXTERNAL HEAT CONTROL EXTERNAL TIMING CONTROL EXTERNAL CIRCUITRY

10K

1
UP UP V+ OUT V+ OUT

4K7

4K7

7 6

DOWN

DOWN

PEDAL HEAT SELECT

4
ALTERNATE PEDAL HEAT SELECT (POTENTIOMETER VALUE NOT CRITICAL)

100nF

100nF

10uF

KENDE TIG WELDER PAGE 4 of 4 REV 0.6 AKA: HARBOR FREIGHT #91811 UNIFIED FULL EXTERNAL HEAT/TIMING CONTROL MODIFICATION Reverse IP by uhmgawa@third-harmonic.com. Modifications, Documentation, Copyright (c) 2008-2009 uhmgawa@third-harmonic.com

EXTERNAL HEAT CONTROL

240VAC 20 A

U3

J5
IGBT FEED

J3

PWR IN