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0349 300 002

Valid for serial no. 618

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xxx

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040928

LKA 180/240

clka1p00

Service manual

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Summary of Contents for LKA 180

Page 1: ...0349 300 002 Valid for serial no 618 xxx xxxx 040928 LKA 180 240 clka1p00 Service manual ...

Page 2: ...180 3 phase 230 400 V 7 CONNECTION DIAGRAM LKA 240 3 phase 400 V 8 CONNECTION DIAGRAM LKA 240 3 phase 230 400 V 9 CIRCUIT DIAGRAM CIRCUIT BOARD AP1 10 COMPONENT POSITIONS CIRCUIT BOARD AP1 12 DESCRIPTION OF OPERATION CIRCUIT BOARD AP1 13 LOAD CHARACTERISTICS 17 TECHNICAL DATA 18 INSTALLATION 19 OPERATION 20 MAINTENANCE 21 WELDING DATA SELECTION 21 SPARE PARTS LIST LKA 180 240 24 ...

Page 3: ...LDING 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 ...

Page 4: ...es the maximum welding current 2 These symbols indicate that the LKA 240 incorporates a transformer and rectifier 3 This section indicates the voltage current characteristic when welding and a current range of 30 200 A The voltage values of 15 and 24 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 ...

Page 5: ...or use The symbol indicates that the rectifier 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 For example 341 indicates We...

Page 6: ...ut for protection against overload fitted in the winding of main transformer TM1 The switch operates opens at a temperature of 120 _C ST2 Thermal overload cutout for protection against overload fitted on the diode bridge cooling fins V1 V6 It operates breaks at 110 _C in the single phase version of the LKA 180 and at 130 _C in other machines TC1 Control power supply transformer Supplied at 230 or ...

Page 7: ...DIAGRAM LKA 180 Single phase 230 V clka1e11 The first 150 machines were delivered with switch 0408 8112 The part No in the spare parts list is referring to the other switch which has to be used as spare part for all machines ...

Page 8: ... clka1de1 CONNECTION DIAGRAM LKA 180 3 phase 400 V clka1e01 When checking the no load voltages load the machine with a dummy load of 5 6 kΩ 5 W connecting it between plus and minus on the rectifier bridge ...

Page 9: ...lka1de1 CONNECTION DIAGRAM LKA 180 3 phase 230 400 V clka1e12 When checking the no load voltages load the machine with a dummy load of 5 6 kΩ 5 W connecting it between plus and minus on the rectifier bridge ...

Page 10: ... clka1de1 CONNECTION DIAGRAM LKA 240 3 phase 400 V clka1e02 When checking the no load voltages load the machine with a dummy load of 5 6 kΩ 5 W connecting it between plus and minus on the rectifier bridge ...

Page 11: ...lka1de1 CONNECTION DIAGRAM LKA 240 3 phase 230 400 V clka1e13 When checking the no load voltages load the machine with a dummy load of 5 6 kΩ 5 W connecting it between plus and minus on the rectifier bridge ...

Page 12: ...clka1e03 10 clka1de1 CIRCUIT DIAGRAM CIRCUIT BOARD AP1 ...

Page 13: ...clka1e04 11 clka1de1 ...

Page 14: ... 12 clka1de1 COMPONENT POSITIONS CIRCUIT BOARD AP1 clka1e05 ...

Page 15: ...d C25 to produce an open circuit voltage of 38 V 10 This provides the power supply for the wire feeder motor Connections T6 and T7 supply 20 V AC from transformer TC1 to diodes D18 D21 The rectified voltage is about 24 V in the fan cooled machines and somewhat higher in the 3 phase LKA 180 This supply powers fan EV1 in the fan cooled machines Voltage regulator VR1 is supplied via diode D1 to provi...

Page 16: ...er switch circuit cannot be short circuited with the result that wire feed cannot be started When either of the thermal cutouts has operated LED V7 is energised to indicate this via diode D7 5 SPOT WELDING CIRCUIT Potentiometer R50 controls the spot welding time and incorporates a switch When in the zero position the switch is open When the switch in R50 and torch trigger switch SB1 are closed cap...

Page 17: ...delivered the burn back time is set to 170 milliseconds Adjusting the burn back time From machine number 618 R38 is not mounted the burn back time is not adjustable and set to 33 milliseconds with the resistors R36 and R37 Spare part circuit boards to machines with earlier machine numbers are also having a none adjustable burn back time which is set to 65 milliseconds 7 CONTROL AMPLIFIER AND PULSE...

Page 18: ...f the voltage across R4 exceeds 1 1 V 60 mV the gate pulses to Q1 are inhibited This provides a current limit of about 11 A clka1p13 Motor voltage when the wire feed speed control potentiometer is in its centre position The motor is unloaded 9 BRAKING CIRCUIT When wire feed is to stop the pulse width modulator turns off the pulses to Q1 Transistors Q3 and Q4 turn on transistor Q4 provides a path f...

Page 19: ... 17 clka1de1 LOAD CHARACTERISTICS LKA 180 single phase clka1p04 LKA 180 3 phase clka1p06 LKA 240 clka1p05 ...

Page 20: ...0 6 0 8 mm 1 0 mm 0 8 0 9 mm 0 6 0 8 mm 0 6 0 8 mm 1 0 mm 0 8 0 9 mm 0 6 0 8 mm 0 6 0 8 mm 1 0 mm 0 8 0 9 mm 0 6 0 8 mm 0 6 0 8 mm 1 0 mm 0 8 0 9 mm Power supply 230V 50Hz 1 phase 400V 50Hz 3 phase 230 400V 50Hz 3 phase 400V 50Hz 3 phase 230 400V 50Hz 3 phase Maximum primary current 30A 9A 16 9A 11A 19 11A Mains fuse rating 20A slow blow 10A slow blow 10 10A slow blow 10A slow blow 16 10A slow blo...

Page 21: ...ake the appropriate connections as required at terminal block XT3 and transformer TC1 Make the necessary earth connections in accord ance with safety regulations S Fit the filler wire as shown below clka1p09 The picture above is valid for machines with serial numbers before 618 The picture above is valid from serial number 618 If the drive rollers slip or wire feed does not work properly it may be...

Page 22: ...out through the contact tip F S Select suitable welding data with the voltage con trol selector L and the wire feed control knob H as shown in the tables on page 21 23 S Start welding Adjust the settings if necessary S The yellow LED J 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 t...

Page 23: ...ng parts replaced at regular inter vals in order to ensure smooth reliable wire feed Do not tension the pressure roller too hard as this will result in abnormal wear to the pressure roller the feed roller and the wire guide S Welding torch Blow the wire guide clean and clean the gas nozzle at regular intervals WELDING DATA SELECTION MACHINE SETTINGS LKA 180 single phase clka1p15 ...

Page 24: ... 22 clka1de1 MACHINE SETTINGS LKA 180 3 phase clka1p16 ...

Page 25: ... 23 clka1de1 MACHINE SETTINGS LKA 240 clka1p17 ...

Page 26: ......

Page 27: ...tachées Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover Kindly indicate type of 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 ...

Page 28: ...et With text 104 107 1 1 1 1 0700 200 002 0469 572 881 0469 443 880 Welding gun MXL 200 Return cable Return cable Complete Complete 109 1 1 469 361 001 Front panel 110 2 8 2 8 469 468 001 Link wheel Screw M6 x 16 mm 111 1 1 368 265 001 Securing strap 120 121 122 123 124 2 1 2 2 2 2 1 2 2 2 469 453 001 469 516 001 469 469 001 192 859 126 Attachment Shaft Washer Wheel Locking washer D 21 36 125b 1 1...

Page 29: ... 26 clka1se1 ...

Page 30: ...sure transducer 314 2 368 750 001 Insulating sleeve 315 1 455 894 001 Insert tube 316 1 455 885 001 Outlet nozzle 317 1 455 882 001 Current sleeve 318 1 455 883 001 Spacer sleeve Ĭ 16 8 2x0 9 319 1 Washer Ĭ 16 8 4x1 5 320 1 Screw M8x20 321 1 455 881 001 Protection plate 322 1 2152 012 02 O ring 323 1 455 898 001 Screw M5x12 324 1 Screw M4x12 326 1 193 104 002 Washer Ĭ 16 5x1 327 1 367 556 001 Feed...

Page 31: ... 28 clka1se1 WIRE FEED UNIT ...

Page 32: ...1 V6 V1 V6 210 1 1 1 1 1 469 380 880 Capacitor Set of 2 capacitors PME 0 1ìF 400V with cable lugs C1 C2 211 1 1 1 1 466 884 006 469 569 001 Terminal Insulation 6 pole With text XT3 212 1 1 1 1 1 193 260 006 Connector 7 pole XS3 213 1 1 1 1 1 193 260 151 Connector 3 pole to R49 on AP1 214 1 1 1 1 1 193 260 157 Connector 9 pole XS1 215 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 193 260 153 193 260 150 193 260 15...

Page 33: ...clka1p03 30 clka1se1 ...

Page 34: ...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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