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LKB 400W

WELDING RECTIFIER

Service manual

0349 300 020 01-01-24

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Summary of Contents for LKB 400W

Page 1: ...LKB 400W WELDING RECTIFIER Service manual 0349 300 020 01 01 24 ...

Page 2: ...START STOP 10 3 1 3 CONTROL MODES 2 STROKE MOTOR TEST 4 STROKE 10 3 1 4 WIRE FEED SPEED 11 3 1 5 MOTOR CONTROL DYNAMIC BRAKING 12 3 1 6 BURNBACK TIME CONTACTOR GAS VALVE 13 3 2 V A METER OPTION STANDARD CONTROL 13 4 TECHNICAL DATA 15 5 LOAD CHARACTERISTIC 15 6 INSTALLATION 16 7 INSTRUCTION FOR USE 16 8 COOLING CIRCUIT DIAGRAM 17 9 MAINTENANCE 18 10 ACCESORIES 18 10 1 V A METER ALLEMBLY INSTRUCTION...

Page 3: ...our health Keep your head away from fumes Use ventilation and or extraction to keep fumes and gases away from your breathing zone and surroundings ARC RAYS Can injure eyes and burn skin Protect your eyes and skin Use correct welding screens filter lens and wear protective clothes Protect bystanders with suitable screens or curtains FIRE HAZARD Sparks spatter can cause fire Make therefore sure ther...

Page 4: ...1 Diode bridge B1 B2 Temperature switch L1 Inductor B3 Flow switch RI Shunt RV Wire speed reference potentiometer K1 Contactor R2 Resistor Q1 Rotary cam switch F1 Fuse 2A slow blow Q3 Rotary cam switch F2 Fuse 10A slow blow Q4 Rotary cam switch F3 Fuse 4A slow blow Q2 Circuit breaker H1 LED green yellow T2 Control transformer H2 LED yellow C1 C2 C3 Capacitor 2uF 450V H3 LED green C5 C6 C7 Capacito...

Page 5: ...5 LKB 400W 400V ...

Page 6: ...6 2 COMPONENT POSITIONS CIRCUIT BOARD LA07 A1 ...

Page 7: ...7 DIAGRAM LA07 A1 ...

Page 8: ...m liquid pressure sensor NO contact is not supplied wire feeding unit power supply shall be disconnected Power supply shall be restored on signal from pressure sensor Proper pressure liquid flow is indicated by green diode placed on the front panel of the unit H3 Wire feeder power supply is disconnected as well by means of signal from external thermal NC type switches Overheating is indicated by y...

Page 9: ...9 3 COMPONENT POSITIONS CIRCUIT BOARD LKC31 A2 ...

Page 10: ...on from 15 to 10 26V intermediate voltage for A1 is also used for powering of relays K1 and K2 on PCB and for input control circuit START STOP 3 1 2 START STOP Closing contact S1 on the welding torch starts the welding process or only motor M3 depending on control mode selection see section 3 1 3 3 1 3 CONTROL MODES 2 STROKE MOTOR TEST 4 STROKE By the switch S3 on the PCB pos M in the motor compar...

Page 11: ...e wire feed speed setting range is 1 6 to 25 meter minute the upper speed may be adjusted by R6A minimum speed is adjusted by R15A V REF voltage is reference signal for motor speed control circuit Note By the potentiometer R6A and R15A there is set the ratio Vmax Vmin fine adjusting of the motor speed depending on the motor characteristic is performed by the R22A see section 3 1 5 As well the moto...

Page 12: ...ctronic with signal proportional to the motor voltage R22 R22A R23 Current limit The current limit is set at 12 A The motor current is measured by resistor R36 which produces a voltage drop proportional to the current 1A 33mV The current limit restricts the conduction time of the gate pulses to transistor V6 Compensation of motor I x R voltage Potentiometer R45 allows to compensate voltage drop on...

Page 13: ...s see section 9 1 connections are also shown in section 1 V A meter is supplied with 11VAC input signal for current is delivered from standard 60mV shunt voltage is measured directly across welding rectifier output Depending on required current range determined by applied shunt rating first the jumpers X3 X4 on the PCB must be properly arranged and the reference voltage U REF must be adjusted by R...

Page 14: ...ration of the factory setting is necessary V A meter has HOLD function i e after stop of welding there is memorised the last displayed value current or voltage depending on S1 position There is also possibility to compensate the voltage drop on current wires i e to get indication of the actual welding arc voltage Compensation is adjusted by potentiometer R28 on the bottom side of PCB when utmost C...

Page 15: ...ing on ambient temperature Distilled water Solution of 30 Antifreeze Coolant 70 distilled water from 0 C to 40 C from 10 C Tank capacity 6 dm 3 Duty cycle is based on 10 minute period Duty cycle 30 means that after 3 minutes of unit operation 7 minutes break is required Duty cycle 100 means that unit can operate continuously Warning The unit is characterised by the following Enclosure class IP 23 ...

Page 16: ...ry current at 100 duty cycle 16A 35 duty cycle 26A Conductor 4x4mm Fuse slow blow 25A 7 INSTRUCTION FOR USE The LKB 400W is step switched welding power unit intended for welding with solid filler wires of steel stainless steel or aluminium and cored wires with or without shielding gas The power units can be fitted with an instrument for display of current and voltage It incorporates a sample and h...

Page 17: ...nd 7 step switch of precise regulation It means that it is possible to select 35 values of welding voltage WARNING Setting of voltage by means of switches during welding loaded power source can cause damage to unit E OVERHEATING causes automatic switching off of unit welding is stopped and it is not possible to activate welding process with trigger switch on torch Signal LED diode is on E It is po...

Page 18: ... control circuits must be isolated during the test by means of disconnecting the connectors X6B A2 X9 A2 X14 A2 10 ACCESSORIES V A meter kit 0349 302 118 10 1 V A METER ALLEMBLY INSTRUCTION 1 Take off side panels of unit 2 Put plastic sleeve on the axle of switch on meter s board 3 Fasten meter s board and sleeve to front panel of unit 4 Assemble cover of meter to partition of unit 5 Disconnect cu...

Page 19: ...49 302 150 0349 302 190 0349 302 151 0349 302 191 0349 302 133 0457 290 003 0349 302 026 0457 290 004 0457 290 006 0455 172 001 0455 174 001 0349 302 022 0349 302 136 0349 302 092 0349 302 119 0192 859 126 0349 302 173 Front grill Front panel Panel Rotary cam switch Rotary cam switch Rotary cam switch Rotary cam switch Rotary cam switch Potentiometer LED holder socket LED green yellow LED green LE...

Page 20: ...2 144 0349 302 145 0349 302 005 0457 290 063 0349 302 146 0349 302 147 0349 302 194 0469 689 002 0469 868 001 0349 302 007 0349 302 175 0349 302 177 0349 302 029 0349 302 196 Temperature switch 90o Temperature switch 135o Transformer Transformer Transformer with switches Transformer with switches Inductor Diode bridge Circuit board LA07 Fan Water tank Mains cable Mains cable Lid Handle Cooler Top ...

Page 21: ... 192 0349 302 153 0349 302 027 0349 302 193 0146 967 881 0349 302 037 0349 302 174 0349 302 169 0349 302 176 0349 302 178 0349 302 171 0349 302 172 0349 302 199 0349 302 200 0349 302 201 Feed unit Circuit board LKC31 Contactor Contactor Control transformer Circuit breaker Circuit breaker Brake hub Wheel Swivel wheel assy Flow switch Cover of reel Side plate Bottom plate Clamp Bolt Washer Plate of ...

Page 22: ......

Page 23: ... 96 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0349 302 030 0349 302 032 0349 302 031 0349 302 138 0349 302 139 0349 302 195 0457 289 032 0457 290 079 0457 289 033 0457 290 080 Fuse element Fuse element Fuse element Gas valve Rear shield Rear shield Cable gland Cable gland Locknut Locknut F1 F2 F3 ...

Page 24: ...le W A For aluminium 322 1 0481 004 880 Printed circuit board NA Current relay 323 1 0455 079 001 Plate NA 324 1 0455 047 001 Front flange 325 1 0455 044 001 Current junction 326 2 0368 750 001 Insulating sleeve 327 1 0469 964 882 Cable set 328 1 0455 045 001 Insulating sleeve 329 1 Screw M8x25 330 1 1 Washer 16 8 4x1 5 331 1 Spring washer 16 8 2x0 9 332 1 Nut M8 333 1 Screw M4x12 334 1 Washer 16 ...

Page 25: ...25 ...

Page 26: ...0 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 31 333 43 33 Fax 55 31 361 31 51 CANADA ESAB Group Canada Inc Missisauga Ontario Tel 1 905 670 02 20 Fax 1 905 670 48 79 MEXICO ESAB Mexico S A Monterrey Tel 52 8 350 5959 Fax 5...

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