ESAB LTR 160 Service Manual Download Page 13 | Manualshive

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Summary of Contents for LTR 160

Page 1: ...0740 800 104 Valid for serial no 704 xxx xxxx to 011 xxx xxxx 040830 LTR 160 200 Power Tig 160 200 Service manual...

Page 2: ...signal amplifier 20 9 Arc voltage sensing 21 10 Gate circuit 22 Checking the gate pulses 23 11 Thermal overload switch 24 Component positions circuit board AP01 0481 864 880 25 Component positions cir...

Page 3: ...from the requirements of the above standard WARNING READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS TAKE PREC...

Page 4: ...8 WARNING the transistors are connected to mains voltage potential AP03 Circuit board with power transistors for the negative pole see description on page 30 WARNING the transistors are connected to m...

Page 5: ...k RP01 Potentiometer 500 k For gas post flow time 5 20 seconds RP02 Potentiometer 500 k For slope down time 0 1 10 seconds RP03 Potentiometer 10 k 2 W for setting of the welding current RS01 Shunt 13...

Page 6: ...05 and XS06 has changed design Valid for LTR 160 from serial number 842 xxx xxxx and for LTR 200 from serial number 842 902 xxxx The sleeve numbering is reversed compared to the earlier version The wi...

Page 7: ...WIRING DIAGRAM LTR 160 Valid for ser no 704 726 7 cltr0de1...

Page 8: ...8 cltr0de1 WIRING DIAGRAM LTR 160 Valid from ser no 842 xxx xxxx...

Page 9: ...9 cltr0de1...

Page 10: ...10 cltr0de1 WIRING DIAGRAM LTR 200 Valid for ser no 722 xxx xxxx to 842 901 0271...

Page 11: ...11 cltr0de1...

Page 12: ...12 cltr0de1 WIRING DIAGRAM LTR 200 Valid from ser no 842 902 xxxx...

Page 13: ...13 cltr0de1...

Page 14: ...le for use with LTR160 200 machines that have not been converted by fitting the entire set Location of the L06 ferrite tube 1 Replace the AP01 control card and the AP09 interference suppression card 2...

Page 15: ...he circuit board the whole circuit board must be replaced After replacing the board the machine must be soft started as described on page 33 1 30 V 20 V 10 V Power supply 30 V Power supply to the gas...

Page 16: ...power supply from transformer TC01 is protected by a 630 mA slow blow fuse 3 Selection of welding method MMA LiftArc HF Switch SA02 selects the welding method by disabling through a diode network the...

Page 17: ...ntrol amplifier provide the correct maximum current This resistor is adjusted during manufacture of the circuit board and should not subsequently be adjusted Switch SA03 selects adjustment of the weld...

Page 18: ...HF unit AP11 The relay drops off when the arc voltage is less than 45 V or if the arc has not struck within 0 5 seconds In the MMA welding mode transistor Q7 is held off by 10 V from diode D18 In the...

Page 19: ...s pre flow time between 0 and 5 seconds When delivered it is set at 0 seconds The gas valve is activated briefly when the machine is energised 8a Shunt input Shunt input for the LTR 160 with serial nu...

Page 20: ...r R16 adjusts the offset voltage of amplifier IC1 This resistor is adjusted during manufacture of the circuit board and should not subsequently be adjusted The signal amplification is set by fixed res...

Page 21: ...us welding modes MMA 1 Open circuit voltage control Open circuit voltage LTR 160 65 80 V LTR 200 72 82 V 2 A voltage less than 45 V is interpreted as a welding start The control amplifier generates an...

Page 22: ...is important that the frequency and maximum pulse time are within the specified tolerances The pulse frequency is 36 5 0 5 kHz and the maximum pulse time is 41 1 5 of the cycle time Maximum pulse tim...

Page 23: ...g the gate pulses connect a dummy gate load to the circuit board see instructions on next page Checking the gate pulses If circuit board AP02 or AP03 has failed the gate pulses must always be checked...

Page 24: ...11 Thermal overload switch Thermal overload sensor ST01 is fitted in the main transformer TC02 winding LTR 160 opens at 130 _C and resets closes at 100 _C LTR 200 opens at 150 _C and resets closes at...

Page 25: ...Component positions circuit board AP01 0481 864 880 R58 Slope up R30 Gas pre flow 25 cltr0de2 WARNING High voltage within the shaded area...

Page 26: ...Component positions circuit board AP01 0481 818 880 R58 Slope up R30 Gas pre flow 26 cltr0de2 WARNING High voltage within the shaded area...

Page 27: ...27 cltr0de2...

Page 28: ...nd fitting the circuit board are to be found on page 37 A01 A02 Connections A01 A02 are for the gate pulses from circuit board AP01 D1 D3 Transient voltage protection D5 Back emf protection diode sque...

Page 29: ...29 cltr0de3 Component positions circuit board AP02 cmha2e07...

Page 30: ...Connections A01 A02 are for the gate pulses from circuit board AP01 B01 B02 When the machine is loaded pulses from a trigger pulse winding on main transformer TC02 are supplied to connections B01 and...

Page 31: ...only fitted in LTR 200 After turning off the mains power supply the discharge time for the capacitor is about two minutes R27 Discharge resistor for buffer capacitor C02 After turning off the mains po...

Page 32: ...o the cooling fins drain Testing S Press the pushbutton marked TEST S If the board is healthy both the red and green LEDs should flash alternately about once a second S If the transistor board is shor...

Page 33: ...he positive and negative connections on V01 S Adjust the power supply voltage to 30 V S Power the remaining parts of the unit from the normal power supply S Select MMA mode S Measure the output voltag...

Page 34: ...version 0486 356 880 of circuit board AP08 Most of the machines produced before October 1998 are deliverd with circuit board 0486 356 880 As spare part for those machines circuit board 0486 356 880 o...

Page 35: ...35 cltr0de3 Diagram and component positions for the new version 0486 577 880 of circuit board AP08 SUPPRESSION CIRCUIT BOARD AP09 cltn0e27 cltn0e29 Circuit diagram Component positions...

Page 36: ...es and tighten the screws A M6 to a torque of 6 Nm Tighten the screws B M4 to a torque of 1 Nm The screws C 1 4 20UNC2B are to be tightened to a torque of 6 Nm The picture above is valid for the LTR 1...

Page 37: ...e board by pressing the spring down with a screwdriver 4 Then secure the remaining springs NOTE The springs must be fitted where there are components that are to be in contact with the heath sink Due...

Page 38: ...the spare parts list 1 Transfer wire 020 and connector XS17 to the new transformer If the wire needs to be replaced it is important to use the correct type of insulation Teflon cmha2p32 Fitting wire 0...

Page 39: ...39 cltr0de3 LOAD CHARACTERISTICS LTR 160 LTR 200...

Page 40: ...kVA 10 6 kVA Power factor at max current MMA 0 69 0 64 Efficiency at max current MMA 0 75 0 82 Mains connection 230 V 10 3 400 V 10 Mains frequency 50 60 Hz 50 60 Hz Fuse slow rupture 16 A 10 A Mains...

Page 41: ...el Two different trolleys are available to facilitate transport with a gas cylinder and cooling unit INSTALLATION WARNING This product is intended for industrial use In a domestic environment it may c...

Page 42: ...use of pulsed current in TIG mode To take your mind off the risk of overloading the machine it has been equipped with an integrated thermostat that trips if the temperature becomes too high When this...

Page 43: ...de Lift Arc The torch electrode is positioned at the point where you want to start welding when you press the trigger and raise the torch the arc is struck Using the built in slope up function the cur...

Page 44: ...cleaned regularly If the machine is set up in dusty or dirty environments the machine and dust filter should be cleaned more often NOTE All warranty undertakings given by the supplier cease to apply i...

Page 45: ...45 notes NOTES...

Page 46: ...l 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...

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