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ESAB LKA 180, Руководство по обслуживанию

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ESAB LKA 180 Скачать руководство пользователя страница 32

−

 29 

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clka1se1

180= LKA180   240= LKA240           1ph= 1 phase 230V   rec= reconnectable 230/400V  400= 400 V mains supply voltage

C = component designation in the circuit diagram

Item

no

Qty

180

1ph

Qty

180

400

Qty

180

rec

Qty

240

400

Qty

240

rec

Ordering no.

Denomination

Notes

C

201

1

1

1

1

1

193 054

−

002

Gas valve

YV1

202

1

−

−

−

−

−

1

−

−

−

−

−

1

−

−

−

−

−

1

−

−

−

−

−

1

469 659

−

001

469 472

−

001

469 564

−

001

469 473

−

001

469 566

−

001

Switch

Switch

Switch

Switch

Switch

With knob (item 227)

Without knob (item 227)

With knob (item 227)

With knob (item 227)

With knob (item 227)

QF1

QF1

QF1

QF1

QF1

203

1

−

−

1

−

1

−

1

−

1

193 297

−

101

193 296

−

104

Contactor

Contactor

KM1

KM1

204

1

−

−

1

−

1

−

1

−

1

469 300

−

880

469 295

−

880

Inductor

Inductor

L1 

L1

205

1

−

−

1

1

−

−

1

1

−

469 563

−

001

469 470

−

001

Control transformer

Control transformer

Primary voltage 230/400 V

Primary voltage 400 V

TC1 

TC1

206

1

−

−

−

1

−

−

1

−

−

−

1

−

−

1

469 660

−

880

469 285

−

880

469 290

−

880

Main transformer 

Main transformer 

Main transformer

Thermal cutout ST1 included

Thermal cutout ST1 included

Thermal cutout ST1 included

TM1

TM1

TM1

207

1

−

−

−

1

−

−

−

1

−

1

−

−

−

1

2626 133

−

14

2626 134

−

05

192 106

−

117

Mains cable

Mains cable 

Mains cable

3 x 2.5 mm

2

  2.5 meter

4 x 1.5 mm

2

  2.5 meter 

4 x 2.5 mm

2

  2.5 meter

to be ordered per meter

208

1

1

1

1

1

190 315

−

102

Gas hose

To be ordered per meter

1.5 meter as delivered

209

1

−

−

−

1

−

−

1

−

−

−

1

−

−

1

469 662

−

880

469 318

−

880

469 346

−

880

Diode bridge 

Diode bridge 

Diode bridge

V1 

−

 V6

V1 

−

 V6

V1 

−

 V6

210

1

1

1

1

1

469 380

−

880

Capacitor

Set of 2 capacitors,  PME 0.1

ì

F

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

−

151

Connector

5

−

pole, before ser.no. 618 ...

2

−

pole, from ser.no. 618 ...

3

−

pole, from ser.no. 618 ...

XS2

216

1

1

1

1

1

193 260

−

153

Connector

5

−

pole,  to R50 on AP1

217a

−

1

1

−

1

−

1

−

1

−

469 477

−

002

469 477

−

001

Cable inlet

Cable inlet

With mains terminal

XT1

217b

1

1

−

−

−

−

−

−

−

−

162 781

−

011

468 882

−

005

Mains terminal

 

Insulation

Delivered as 12

−

pole, 

to be cut to 2

−

pole

With text

XT1

218

6

6

6

6

6

192 562

−

105

Cage nut

M6

219

3

3

3

3

3

469 381

−

001

Speednut

220

1

−

−

1

−

1

−

1

−

1

321 229

−

003

320 918

−

001

Thermal cutout

Thermal cutout

Opens at 110

°

C

Opens at 130

°

C

ST2

ST2

221

1

1

1

1

1

469 377

−

001

Connection block

XT2

222

1

1

1

1

1

469 378

−

001

Insulation

223

1

1

1

1

1

469 379

−

001

Bus bar

224

1

1

1

1

1

1

1

1

1

1

486 159

−

880

486 159

−

882

Circuit board 

Circuit board

Before ser.no. 618 ... ....

From ser.no. 618 ... ....

AP1 

AP1

225

1

1

1

1

1

193 759

−

002

Light

−

emitting diode

Yellow

V7

226

1

1

1

1

1

193 759

−

001

Indicating lamp

White, 28 V

HL1

227

−

1

1

−

−

1

−

1

−

1

366 296

−

001

Knob

Knob

Included in item 202

228

2

2

2

2

2

191 510

−

104

Knob

229

1

−

1

−

1

−

−

1

−

1

469 365

−

001

469 366

−

001

Panel

Panel

With text 

With text

230

1

−

−

1

1

469 479

−

001

Fan

24 V DC

EV1

231

1

−

−

−

−

467 169

−

001

Resistor

R1

232

1

−

−

−

−

369 864

−

881

Resistor

5.6 k

W

 5 W

R2

Содержание LKA 180

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

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

Страница 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 ...

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

Страница 13: ...clka1e04 11 clka1de1 ...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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...

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

Страница 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...

Страница 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...

Страница 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...

Страница 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 ...

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

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

Страница 26: ......

Страница 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 ...

Страница 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...

Страница 29: ... 26 clka1se1 ...

Страница 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...

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

Страница 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...

Страница 33: ...clka1p03 30 clka1se1 ...

Страница 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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