ESAB LKA 150 Service Manual Download Page 2

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INTRODUCTION

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RATING PLATE

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COMPONENT DESCRIPTION, LKA 150

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CONNECTION DIAGRAM, LKA 150

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CIRCUIT DIAGRAM, CIRCUIT BOARD AP1

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COMPONENT POSITIONS, CIRCUIT BOARD AP1

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DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1

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MOTOR DIAGRAMS

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LOAD CHARACTERISTIC, LKA 150

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TECHNICAL DATA

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INSTALLATION

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OPERATION

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MAINTENANCE

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WELDING DATA SELECTION

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SPARE PARTS LIST, LKA 150

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Summary of Contents for LKA 150

Page 1: ...0349 300 001 Valid for serial no 923 xxx xxxx 040928 LKA 150 clka0p00 Service manual ...

Page 2: ...0 5 CIRCUIT DIAGRAM CIRCUIT BOARD AP1 6 COMPONENT POSITIONS CIRCUIT BOARD AP1 7 DESCRIPTION OF OPERATION CIRCUIT BOARD AP1 7 MOTOR DIAGRAMS 10 LOAD CHARACTERISTIC LKA 150 11 TECHNICAL DATA 12 INSTALLATION 13 OPERATION 14 MAINTENANCE 14 WELDING DATA SELECTION 15 SPARE PARTS LIST LKA 150 16 ...

Page 3: ... AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PRECAU TIONS WHEN WELDING ASK FOR YOUR EMPLOYER S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURERS HAZARD DATA ELECTRIC SHOCK Can kill S Install and earth the welding unit in accordance with applicable standards S Do not touch live electrical parts or electrodes with bare skin wet gloves or wet clothing S Insulate yourself from earth...

Page 4: ... current 2 These symbols indicate that the LKA 240 incorporates a transformer and rectifier 3 This section indicates the voltage current characteristic for MMA welding and a current range of 20 100 A The voltage values of 15 and 19 V in the heading indicate that we comply with the in ternational arc characteristic as defined in IEC 974 1 X The duty cycle indicating for how long a time welding can ...

Page 5: ...ine is designed for use in areas of elevated electri cal risk 6 The machine s serial number in the form of three groups of figures xxx yyy zzz The first group xxx indicates the version The figures represent the year and week of approval of the version The second group yyy shows the year and week of final testing of the machine The second group yyy shows the year and week of final testing of the ma...

Page 6: ...SB1 Welding torch trigger switch ST1 Thermal overload cutout for protection against overload fitted in the winding of main transformer TM1 The switch operates opens at a temperature of 130 C ST2 Thermal overload cutout for protection against overload fitted on the diode bridge cooling fins VC1 It operates breaks at 110 C TM1 Main transformer V1 LED yellow Lights if thermal overload cutouts ST1 or ...

Page 7: ...clka0e01 5 clka0de1 CONNECTION DIAGRAM LKA 150 ...

Page 8: ...clka0e02 6 clka0de1 CIRCUIT DIAGRAM CIRCUIT BOARD AP1 ...

Page 9: ...nected in series with the relay and drops the voltage to it Capacitor C1 220µF smoothes the voltage It also delays the drop off of relay RE1 by about 25 ms to provide a back burn time 2 THERMAL OVERLOAD CUTOUT In the event of a thermal overload thermal overload cutouts ST1 or ST2 interrupt the secondary circuit from TR1 causing relay RE1 to drop off and de energising the welding circuit When not o...

Page 10: ...ltage C2 charges via R2 R4 and R5 When the voltage on C2 reaches the trigger voltage 0 5 1 5 V thyristor TY1 fires This means that TY1 conducts each half cycle when Q1 is not conducting D5 protects C2 against negative voltage when Q1 conducts MOTOR VOLTAGE CONTROL C3 R11 and potentiometer R13 form a low pass filter circuit for the motor supply R13 picks off a suitable fraction of the motor voltage...

Page 11: ...clka0e02 9 clka0de1 CIRCUIT DIAGRAM CIRCUIT BOARD AP1 ...

Page 12: ...a0p04 Motor voltage and current when R13 is at its minimum position and QF1 is in position 3 The motor is unloaded clka0p05 Motor voltage and current when R13 is in its maximum position and QF1 is in position 3 The motor is unloaded ...

Page 13: ... 11 clka0de1 LOAD CHARACTERISTIC LKA 150 clka0p06 ...

Page 14: ... mm Aluminium 1 0 mm Gasless wire 0 8 mm Teflon wire guide feed roller for 1 0 mm wire and contact tip for 1 0 mm wire are required Voltage steps 7 Wire bobbin capacity 1 5 kg maximum spool diameter 200 mm Power supply Voltage 230 V Primary current 22 A Frequency 50 Hz Fuse 10 A slow blow Mains cable area 3 x 1 5 mm2 See also INSTALLATION on page 13 Enclosure class IP21 Application class Weight 36...

Page 15: ... obstructed S Check that the mains voltage is 230 240 V Make the necessary earth connections in accordance with safety regulations S Fit the filler wire as shown below clka0p09 If the drive rollers slip or wire feed does not work properly it may be necessary to adjust the roller pressure as shown in Figure 5 above clka0p10 SOLID WIRE GASLESS WIRE When welding with gasless wire the return current c...

Page 16: ...e on page 15 S Start welding Adjust the settings if necessary S The yellow LED G on the front panel will light if the thermal overload cutout operates as a result of overload The overload cutout resets automatically when the machine has cooled to a safe tempera ture MAINTENANCE S Cleaning away dust Blow the unit clean with compressed air at reduced pressure S Wire feed mechanism The wire feed mech...

Page 17: ... 15 clka0de1 WELDING DATA SELECTION clka0p13 ...

Page 18: ......

Page 19: ...f unit serial number denominations and ordering numbers according to the spare parts list Reservdelar beställs genom närmaste ESAB representant se sista sidan Vid beställning var vänlig uppge typ och tillverkningsnummer samt benämningar och beställningsnummer enligt reservdelsförteckningen Die Ersatzteile können bei der nächsten ESAB Vertretung bestellt werden siehe letzte Seite Bitte geben Sie Ty...

Page 20: ... Connector XS4 113 1 193 498 107 Connector 114 1 Inlet nozzle See item 150 115 1 Pressure arm With pressure roller See item 150 117 1 Feed roller See item 150 and 151 118 1 469 475 880 Wire feed unit Complete 120 2 469 391 001 Attachment 121 1 469 390 001 Shaft 122 2 Washer D 10 5 22 123 2 192 859 115 Locking washer 124 2 469 467 001 Wheel 125 1 469 310 880 Brake hub Complete 1 5 kg 126 1 2 469 43...

Page 21: ...clka0p02 18 clka0se1 ...

Page 22: ...ains plug Only for the Australian market 3 x 1 5 mm2 with mains plug Only for the British market 206 1 190 315 102 Gas hose To be ordered per meter 1 3 meter as delivered 207 1 469 662 880 Diode bridge VC1 208 1 469 380 880 Capacitor Set of 2 capacitors PME 0 1 mF 400 V with cable lugs C1 C2 210 1 193 260 001 Connector 2 pole XS1 211 1 193 260 153 Connector 5 pole XS2 212 1 193 260 150 Connector 2...

Page 23: ...clka0p03 20 clka0se1 ...

Page 24: ...nal AB Gothenburg Tel 46 31 50 90 00 Fax 46 31 50 93 60 SWITZERLAND ESAB AG Dietikon Tel 41 1 741 25 25 Fax 41 1 740 30 55 North and South America ARGENTINA CONARCO Buenos Aires Tel 54 11 4 753 4039 Fax 54 11 4 753 6313 BRAZIL ESAB S A Contagem MG Tel 55 31 3369 4333 Fax 55 31 3369 4440 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A M...

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