ESAB LHO 110 Service manual

LHO 110/150
Caddy 110/150
Welding rectifier
Service manual
0740 800 110
9804
LIST OF CONTENTS
Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION LHO 110/150 . . . . . . . . . . .
CONNECTION DIAGRAM LHO 110/150 . . . . . . . . . . . . . . .
FUNCTION DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . .
DISMANTLING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHARACTERISTIC . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
4
5
6
12
15
17
20
21
22
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT TRACING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . .
22
23
23
25
25
25
SPARE PARTS LIST LHO 110/150 . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
32
READ THIS FIRST
This service manual is intended for use by technicians with appropriate electro--technical
training when carrying out fault--tracing and repair work.
The connection diagram can be used as a Contents for the function and component
descriptions. The connection diagram is divided into numbered blocks, which are used to
identify the various parts in the function description.
The manual contains details of all design changes up to and including April 1998.
The LHO 110/150 is made in a special version, LHO 110B/150B, for the Belgian market. It
does not have a hot start facility, but does have open--circuit voltage control.
WARNING!
The components in the machine are at mains voltage.
Never make any measurements inside the machine when it is
energised in the normal manner.
ESAB reserves the right to make changes to the specification without prior notice.
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The LHO 110 and LHO 150 are designed and tested in accordance with the
international EN 60 974--1 (IEC 974--1) standard.
After service or repair, it is the responsibility of the person, company, section etc.
that have/has performed the work to make sure that the product does not depart
from the requirements of the above standard.
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
ELECTRIC SHOCK -- Can kill
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Install and earth the welding unit in accordance with applicable standards.
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Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
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Insulate yourself from earth and the workpiece.
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Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
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Keep your head out of the fumes.
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Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
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Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S
Protect bystanders with suitable screens or curtains.
FIRE HAZARD
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Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
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Protect your ears. Use ear defenders or other hearing protection.
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Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
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COMPONENT DESCRIPTION LHO 110/150
WARNING! The components in the machine are at mains voltage.
Never make any measurements in the machine when it is energised
in the normal manner.
Read and follow the fault-- tracing instructions on page 17.
AP01
Circuit board, power part, see the function description.
AP02
Circuit board with the control electronics. The board has a link between
contacts E6 and E7 for the hot start function. The LHO 110B/150B is a
special version without hot start, but with open--circuit voltage control
(provided by the link between contacts E3--E6), see pages 8 and 9 in the
function description.
AP03
Circuit board with EMC filter and rectifier bridge. See the circuit diagram
and description on pages 6 - 7.
C01
Capacitor, decoupling.
EV01
Cooling fan, 230 V AC.
L01
Ferrite ring, interference suppression (EMC).
L02
Ferrite ring, interference suppression (EMC).
LHO 110: fitted only around the earth wire (yellow/green).
LHO 150: fitted around all three wires.
L03 - L07
Ferrite ring, interference suppression (EMC); LHO 150 only.
QF01
Main On/Off switch.
RP01
Potentiometer for current setting. This potentiometer is of a special
insulated type: it is important to use only the correct replacement
potentiometer as shown in the spare parts list.
ST01
Thermal overload switch. See description on page 10.
V01
Rectifier bridge.
V03
LED, orange. Indicates overtemperature and low mains voltage.
See the description on page 10.
1 -- 6
These figures refer to the machine’s function description. The headings
and page numbers of the respective items are listed below.
Page
1 POWER SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
POWER SUPPLY, AP01
POWER SUPPLY, AP02
POWER SUPPLY WHEN STARTING
2 OPEN--CIRCUIT VOLTAGE SENSING . . . . . . . . . . . . . . . . . . . . . . 8
3 STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4 PULSE WIDTH MODULATOR / GATE DRIVE . . . . . . . . . . . . . . . 9
5 THERMAL SWITCH / LOW--VOLTAGE DETECTION . . . . . . . . 10
6 CURRENT MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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CONNECTION DIAGRAM LHO 110/150
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FUNCTION DESCRIPTION
This description refers to the circuit diagram on page 5.
WARNING! The components in the machine are at mains voltage.
Never make measurements in the machine when it is energised in
the normal manner.
Read and follow the fault-- tracing instructions on page 17.
1
POWER SUPPLY
POWER SUPPLY, AP01
Power supply circuit board AP01 is supplied at two different voltages:
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Rectified mains voltage, about +330 V to the switch transistors.
Power supply voltage from AP02: +22 V, tolerance 22--26V, power
supply to the gate drive circuit boards.
The winding on TR2 that is marked 1 TURN provides pulses to TY1,
which short--circuits charging resistor R25 about one second after
power--up.
S
Interference suppression is partly by ferrite rings around wires and partly
by twisting wire pairs. Most of the suppression is provided by the EMC
filter.
Cooling fan EV01 is supplied with 230V AC immediately after the EMC
filter via contacts I1 and I2, and starts when the main switch, QF01, is
turned on.
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POWER SUPPLY, AP02
Contact C6 on AP02 is supplied at +40V, tolerance 38--49V, which is then
converted to the following voltages:
+22V, tolerance 22--26V, for supplying the gate drive boards on AP01.
+10V, tolerance 10--11V, used internally on AP02 and for supply to
potentiometer RP01 (current setting).
+15V, tolerance 15--17.5V, used internally on AP02.
If a short circuit should occur in any of the diodes D13, D18 or D22, the
+40V supply will be too low to supply AP02.
POWER SUPPLY TO AP02 WHEN STARTING
When the mains power supply is turned on, AP02 is supplied from rectifier
bridge V01, the voltage from which is reduced by ten resistors R1--R10,
connected in parallel. This power supply is used during the starting
procedure, which takes about one second. The power supply is then taken
from the winding marked ’2 TURNS’ on the welding transformer via diodes
D1--D4.
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2
OPEN--CIRCUIT VOLTAGE SENSING
Optocoupler IC4 senses the open--circuit voltage. On open circuit, current
flows through the LED and the transistor conducts. Shorting the welding
electrode to the workpiece interrupts the current through the LED. The
threshold value for activation of IC4 is about 50V output voltage from the
machine. The optocoupler output is connected to AP02.
The open--circuit voltage from the machine is 70--90V. NOTE: this does
not apply for the LHO 110B/150B, for which see the next page.
3
START
The link between contacts E6 and E7 enables the hot start facility. A higher
current is required when the arc is struck, and this is known as hot starting.
The open--circuit voltage drops when the electrode contacts the workpiece.
AP02 receives a signal from optocoupler IC4 via contacts C3 and C4.
During hot starting. The current reference is raised for about 0.5 seconds.
The magnitude and duration of the starting current boost depends on the set
value of the current.
LHO 110: For current setting 110A, the starting current is about 190A.
LHO 150: For current setting 150A, the starting current is about 205 A.
The starting current is proportional to the set value of current.
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STARTING PROCEDURE FOR THE LHO 110B/150B
This version of the LHO has no hot start function. The link between
contacts E3 and E6 provides open--circuit voltage control: IC4 senses the
output voltage, and the open--circuit voltage is limited to about 50V.
4
PULSE WIDTH MODULATOR / GATE DRIVING
Input signals to the pulse width modulator
The PWM circuit controls the length of the gate pulses and thus the average
value of the welding current. The thermal overload switch and the
low--voltage monitor can turn off the pulses: with no pulses from the pulse
width modulator, there is no welding current.
The pulse width modulator controls the frequency and pulse duration of the
gate pulses to the MOSFET transistors. The pulse frequency is set to
70.5kHz ±0.5kHz. The maximum pulse factor is 41.6%--42.2%. The
proportion between pulse time and frequency depends on each of them,
which means that they must both be correctly adjusted.
LHO 110 having a serial number prior to 744, and LHO 150 machines with
a serial number prior to 745 have the following data for frequency and pulse
factor: 65kHz ±0.5kHz, 41%.
Do NOT make measurements when the machine is being
powered from the mains.
See CHECKING AP02 on page 18.
Gate driving
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5
THERMAL OVERLOAD SWITCH / LOW VOLTAGE MONITOR
THERMAL OVERLAOD SWITCH
The thermal overload switch, ST01, which is fitted in the end of a heat sink,
interrupts the gate pulses if the temperature exceeds 75C ±5%. LED V03
on the front panel lights to indicate that it has operated. The switch resets
automatically when the temperature has fallen to 55C ±5%..
LOW--VOLTAGE MONITOR
The low--voltage monitor interrupts the welding current if the voltage from
rectifier V01 drops below about 220V DC. The signal to the monitor is
taken via contact B3. Operation of the monitor is indicated by LED V03 on
the front panel. See the circuit diagram above.
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6
CURRENT MEASUREMENT
Current transformer TR3, which has a ratio of 1:100, measures the current
in the primary winding of the main transformer. The secondary of the
current transformer is connected to AP02 via contacts J2 and J3.
The voltage is measured and the actual value of the welding current is
calculated. It is compared with the set value, and the difference is used to
control the reference to the PWM circuit, which controls the welding
current to the required set value.
HIGH--SPEED CURRENT LIMIT
The purpose of this current limit is instantaneously to interrupt the transistor
pulse if the welding current exceeds the permissible peak value. Control is
automatic, and operates for as long as the peak current is too high.
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DISMANTLING
WARNING: The components in the machine are at mains voltage
REMOVING THE CASE
It is important, when dismantling the machine, to note the positions of the parts, in order to
be sure of correct re--assembly.
1.
Disconnect the machine from the mains supply.
2.
Disconnect the welding current and return cables from the front of the machine.
3.
Using a Torx screwdriver, remove the four screws from the underside of the case. The
screwdriver can be ordered from ESAB: see SERVICE TOOLS on page 28.
4.
Starting from the back, separate the two halves of the case and then lift the upper half
straight up.
5.
Remove the lower wires, from upper circuit board AP03, from the mains switch in the
cover. Remove the yellow/green wire from AP03.
6.
Remove the rear grille from the lower half of the case.
7.
Remove the connector from the A contact on circuit board AP02. The wires, of which
there are five, come from the cover.
8.
Pull the fan forward and fold it out of the way.
9.
Remove the four screws at the front and rear edges of the power circuit board AP01.
10. Unscrew the nuts holding the current busbars and bend the bars out of the way.
11. Lift the power unit out of the lower half of the case.
When working on the power unit, place it such that it cannot be damaged.
Component positions, circuit board AP02
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Component positions, circuit board AP03
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REMOVING POWER CIRCUIT BOARD AP01
Component positions, circuit board AP01
1.
Remove the 11 nuts on the top of the machine.
2.
Remove all the contacts on AP03 and contacts A, B and C on AP02.
3.
Remove the bridge rectifier, the fan and circuit boards AP02 and AP03.
4.
Remove the 11 screws from the
slots in the heat sinks.
5.
Turn the machine upside down.
6.
Remove the springs (2) that
hold the board in position by
inserting a screwdriver (1)
between each spring and the
heat sink.
7.
Unscrew the four socket--head
screws in the bottom of the
board, and remove transformer
TR2 and inductor L2.
8.
Unsolder the wires (blue) to the
start1 and start2 thyristor
controls.
Removal/refitting of circuit board AP01
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FITTING
FITTING CIRCUIT BOARD AP01
When fitting the heat sinks, apply thermal compound to the heat sinks of the secondary side
and contact oil to the heat sinks of the primary side. Use only thermal compound and contact
oil recommended by ESAB, see SERVICE TOOLS on page 28.
1.
Fit the transformer and inductor.
2.
Solder the start1 and start2 wires back into position.
3.
Remove all traces of old varnish on the heat sink contact surfaces (3) if the old ones are
being refitted. Polish them with fine abrasive paper (P600). See the figure on the
previous page.
4.
Heat sinks, primary side: apply a thin layer of contact oil to the contact surfaces.
5. Heat sinks, secondary side: apply a thin layer of thermal compound to the contact
surfaces.
6.
Place the circuit board (2) on the heat sinks, and then fit a spring at each corner by
pressing it down with a screwdriver (4). See the figure on the previous page. Fit the rest
of the springs.
Note: make sure that the springs are fitted over the components that are to contact the
heat sinks. Always use new springs when re--assembling.
7.
Turn the machine over and insert the screws in the slots.
8.
Place circuit boards AP02 and AP03 and the diode bridge in position.
9.
Fit the wires and contacts. See ’Fitting AP02 and AP03’.
10. Screw the circuit boards and diode bridge into position.
11. Using a straightedge, check that the heat sinks are parallel with each other and at the
same height.
Aligning the heat sinks using a straightedge
FITTING POTENTIOMETER RP01
When replacing this potentiometer, the connections must face upwards.
For safety reasons, fit only a potentiometer with an insulated shaft.
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FITTING THE CONTACTS TO AP03
Contact
Wire
A1, A2
Blue (2--TURNS from TR2)
A3
009 black (+40 V DC)
C
010 from welding negative
D1
Yellow/green
F1
003
F2
004
G1
006
G2
005
J1
007
J2
008
I1, I2
230 V to the fan
FITTING THE CONTACTS TO AP02
Contact
Wire
A1 -- A3
To potentiometer
A4
011 to LED
A5
012 to LED
A6 -- A7
To the thermal overload switch
B1 -- B3
From AP01
C1 -- C7
From AP01
D
Not fitted
E6 -- E7
Link
FITTING THE CASE
Fit the case in the reverse order to that of removal. Take care to ensure good contact between
the busbars and the OKC connectors.
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FAULT TRACING
Measuring the open--circuit voltage:
1.
Remove the positive and negative welding current cables from the machine.
2.
Connect the mains supply plug to the mains and measure the voltage at the welding
terminals with a multimeter. The value must be between 70--90 V, and not be affected by
the potentiometer. The open--circuit voltage for the LHO 110B/150B must be 45--70 V.
This is the only measurement that may be made when the unit is connected to the mains
power supply. Never make any measurements in the machine when it is connected to
the mains power supply in the normal way.
Now make sure that the mains cable is not connected to the mains power supply.
Dismantle the machine as described by items 1--7 on page 12.
Check:
1.
Diode bridge V01: check the diodes with a multimeter.
2.
Charging resistor R25 on AP01: measure between J1 on AP03 and the heat sink not
having a copper strip. The value must be about 22τΚ
3.
The switching transistors: measure across the large heat sinks, using the multimeter in
the diode test position, with the positive connection on the heat sink having a copper
strip. The value must be 0.3 - 0.5 V.
Measuring with reverse polarity will indicate a higher value, which will rise as a result of
charging up capacitors. If a value of less than 0.3 V is found, it indicates that a transistor
has failed.
4.
The welding and freewheel diodes: measure the resistance across the current busbars,
with the positive terminal of the multimeter to the negative on the machine and the
instrument negative to the machine positive. Then reverse the connections and
re--measure. Both values must be about 2.3 kτ. Measuring using the diode test position
will give measured values of about 0.4 V and about 1.2 V respectively.
5.
Capacitors C12 - C14 on AP01: measure using the negative terminal of the multimeter
to contact AP03:J2 and the positive to the heat sink without a copper strip. The value
must be about 1500←F.
Heat sinks and busbars to the OKC connector
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Circuit board AP03
WARNING: The mains cable must be disconnected from the supply.
Never make any measurements in the machine when it is connected to the mains power
supply in the normal way.
CHECKING AP02
Follow items 1 to 5 under the headline SOFT STARTING below.
Turn circuit boards AP02 and AP03 so that the contacts on AP02 are accessible. Remove
contact C (7--pole) from AP02. Connect 30V DC between contacts C1 and C6 on circuit
board AP02; positive to C6 and negative to C1.
Measure the voltages on the E connector, relative to C1 (= 0 V). The link between B3 and E2
disables the undervoltage protection.
a.
E2: +10 V, tolerance 10--11 V.
b.
E4: +15 V, tolerance 15--17.5 V. With link B3--E2 connected: 12.2 V.
c.
E5: +22 V, tolerance 22--26 V. With link B3--E2 connected: 20 V.
d.
Measuring the PWM pulses: The thermal overload switch must be connected, or contacts
A6--A7 be linked in order to obtain gate pulses.
Using an oscilloscope, measure the pulses from the PWM circuit across C1 and C2.
Frequency and duty cycle for the pulses are to be found on page 9. The edges of the
pulses need to be square (not rounded).
If the measurements above are within the tolerances AP02 is OK. Reassemble the contacts
and check that they are correctly connected.
SOFT STARTING
Three contacts are needed in order to make the link connections and measurements on circuit
board AP02. See under SERVICE TOOLS on page 28 for details of the ordering numbers of
the contacts.
1.
Dismantle the machine as in items 1 - 7 on page 12.
2.
Place the fan so that it cannot short--circuit the welding current busbars.
3.
Remove circuit boards AP02 and AP03, and remove connections A6--A7 (the thermal
overload switch) from AP02.
4.
Transfer the hot start link (E6--E7) to A6--A7 to replace the thermal overload switch
during soft starting.
5.
Remove contact B (3--pole) from AP02. Connect contact B3 to contact E2, which
disables the under--voltage monitoring function.
6.
Replace circuit boards AP02 and AP03, but do not screw them down.
7.
Connect AP03:A3 to the positive on V01, Connector A3 must remain connected.
8.
Connect 30V from a DC power supply to AP03. Connect to plus and minus on V01.
9.
Measure the voltage between the busbars. The value must be about 7.5 V.
The current from the DC power supply is about 0.4A.
10. Remove the thermal overload switch connections (A6--A7). The current must now drop
to not more than 0.1 A. Then reconnect the thermal switch to A6 -- A7.
If the measurements above are within the tolerances, reassemble the machine and make a test
weld.
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Test and connection points on circuit board AP03
Test and connection points on circuit board AP02
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TECHNICAL DATA
Caddy 110
Caddy 150
Performance:
at 25% duty cycle
at 35% duty cycle
at 60% duty cycle
at 100% duty cycle
110 A/24 V
95 A/24 V
80 A/23 V
150 A/26 V
140 A/26 V
110 A/25 V
90 A/24 V
Setting range
13--110 A
13--150 A
Open circuit voltage
70--90 V
LHO 110B: 45--70 V
70--90 V
LHO 150B: 45--70 V
Mains supply:
voltage
fequency
fuse
mains cable, area
230 V AC
50/60 Hz
16 A slow*
3x1.5 mm2**
230 V AC
50/60 Hz
16 A slow*
3x1.5 mm2**
Enclosure class
IP 23
IP 23
Dimensions L x W x H
375 x 145 x 280 mm
375 x 145 x 280 mm
Weight
6.7 kg
6.7 kg
Application class
The welding power source comply with the requirements set out in IEC 974--1
*When welding below 100 A a 10 A slow fuse is adequate..
**Power cable ratings complies with Swedish regulations..
Duty cycle
The duty cycle refers to the time in per cent of a ten--minute period that you can weld at a
certain load without overloading the welding power source.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by
solid objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
Application class
indicates that the power source is designed for use in areas where there is an
The symbol
increased electrical hazard.
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LOAD CHARACTERISTIC
Load characteristic, LHO 110
Load characteristic, LHO 150
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INSTRUCTIONS
INSTRUCTIONS
This chapter contains an extract from the instruction manual for LHO 110/150.
INTRODUCTION
Note!
This product is solely intended for arc welding.
Caddy 110 and Caddy 150 are two rectifying welding power sources based on the inverter
technique, intended for welding with coated electrodes (MMA welding).
Caddy also has very good TIG welding characteristics.
Equipment
The welding power sources Caddy 110 and Caddy 150 are delivered with:
S
Mains cable (3 metres)
S
Welding cable with electrode holder (3 metres)
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Return cable with earth clamp (2.5 metres)
Field of application
Caddy 110 and Caddy 150 both supply direct current, which allows you to weld most alloyed
and non--alloyed steels, stainless steels and cast iron.
With the Caddy 110 you can use coated electrodes from 1.6 to
Caddy 150 coated electrodes from 1.6 mm to 3.25 mm.
2.5 mm, and with the
TIG welding
TIG welding is particularly useful when high quality standards are required and when
welding thin sheet.
Before using the Caddy for TIG welding it must be equipped with a TIG torch and gas valve,
a cylinder of argon, an argon regulator, tungsten electrodes and, if necessary, suitable filler
metal.
The best method to use is the touch start, where you gently stroke the tungsten electrode
against the workpiece to establish the arc.
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INSTRUCTIONS
INSTALLATION
WARNING
This product is intended for repair and maintenance welding
In domestic or office environment this product may cause radio interference.
It is the responsibility of the user to take adequate precautions.
Placing
Place the machine so that there is nothing to prevent the cooling air from passing through it.
Mains connection
The rating plate including connection data is placed on the underside of the welding power
source.
Connect the welding power source to an earthed mains terminal. Make sure the welding
power source is connected for the correct mains voltage and properly fused.
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Mains voltage 230 V
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Mains frequency 50--60 Hz
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Fuse, slow rupture 16 A
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Mains cable, area 3 x 1,5 mm2
Connection of welding and return cable
The welding power source has two terminals, one plus and one minus pole, for the connection
of the welding and the return cable. Connect the welding cable to the pole indicated on the
package of the electrode to be used.
Connect the return cable to the other terminal. Fit the earth clamp of the return cable to the
work--piece and make sure there is good contact between the work--piece and the return cable
terminal on the welding power source.
OPERATION
Start--up
S
Make sure that the cables and the earth clamp are properly connected.
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Start the welding power source by setting the mains switch to position 1.
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Set the welding current, using the knob on the front panel of the power source. Follow
the instructions on the electrode package for the recommended welding current.
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INSTRUCTIONS
Overload protection
Caddy 110 and Caddy 150 are provided with a thermal cut--out to prevent overheating of the
welding power source. In the event of overload the supply voltage is interrupted and the
orange lamp on the front goes on. Resetting takes place automatically as soon as the welding
power source has cooled down.
Mains voltage compensation
Caddy 110 and Caddy 150 both have mains voltage compensation, which means that 10%
fluctuation in the supply voltage produces only 0.2% variation in the welding voltage.
Controls and connections
1.
Orange indicating lamp (overheating)
2.
Knob for adjusting the welding current
3.
Terminal, minus pole, for connecting welding or return cable
4.
Terminal, plus pole, for connecting welding or return cable
5.
Mains switch
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INSTRUCTIONS
MAINTENANCE
Cleaning
Normally it is sufficient to blow the welding power source clean regularly using dry
compressed air (reduced pressure), and to clean the filter in the front regularly.
In dusty and dirty environment the welding power source should be cleaned at shorter
intervals.
FAULT TRACING
Possible faults and measures to take
Type of fault
Measure
No arc is generated by the welding power source.
The welding current is interrupted in the course
of welding.
The thermal cut--out trips frequently.
Poor welding result.
S
Make sure the mains switch is on.
S
Check that the welding and return cables
are properly connected.
S
Make sure the welding current set is correct.
S
Check if the thermal cut--out has tripped (the
orange indicating lamp on the front panel is
on).
S
Check the mains fuse.
S
Check that the filter is not packed with dust.
S
Check that the ratings of the welding power
source have not been exceeded (overload
of the power source).
S
Check that the welding and return cables
are properly connected.
S
Make sure the welding current set is correct.
S
Check that there is nothing wrong with the
electrodes.
ORDERING OF SPARE PARTS
When ordering a spare part, please state the type and serial number of the machine as well as
number of the spare part, according to the spare parts list.
This will simplify dispatch and ensure you get the right part.
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-- 25 --
page
-- 26 --
SPARE PARTS LIST LHO 110/150
SPARE PARTS LIST LHO 110/150
Edition 980529
Ordering numbers for LHO 110/150
0456 540 880 LHO 110
Caddy 110
0456 545 880 LHO 150
Caddy 150
0456 540 881 LHO 110B
Caddy 110B, special version for Belgium
0456 545 881 LHO 150B
Caddy 150B, special version for Belgium
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-- 27 --
SPARE PARTS LIST LHO 110/150
C = component designation in the circuit diagram
Item
LHO
110
LHO
150
Ordering no.
100
1
1
0456 538 001
Cover
101
1
1
0456 539 001
Inner grating
102
1
1
0456 537 001
Cover
103
1
1
0456 192 881
Mains cable
104
1
1
0193 307 104
Cable bush
105
1
1
0193 317 001
Switch
106
1
1
0212 602 208
Nut
107
1
1
0468 208 001
Strap
108
2
2
0456 572 001
Clamp
109
1
1
0321 475 885
Knob
110
1
1
0193 995 501
Potentiometer
RP01
111
1
1
0455 201 002
Light--emitting diode
V03
112
1
1
0456 541 001
Front grating
113
1
1
0456 574 001
Filter
Denomination
Notes
Lower part
Upper part
QF1
114
2
2
0366 306 881
Connector
OKC 25
114b
2
2
0366 306 882
Connector
OKC 25 See 1) below
115
2
2
0160 362 005
Nut
115b
2
2
0192 238 327
Screw
See 1) below
--
1
0194 034 001
Ferrite ring core
Mounted only on earth cable (yellow/
green)
1
0194 034 002
Ferrite ring core
116
--
1
1
0457 051 880
Return welding cable
--
1
1
0457 049 001
Electrode holder
L02
L02
Complete
1) Items 114b and 115b are only used in some of the machines with machine numbers as listed below:
LHO 110:
from no. 744 750 . . . . to no. 744 807 . . . .
LHO 150:
from no. 745 750 . . . . to no. 745 807 . . . .
LHO 110B/150B: from no. 750 750 . . . . to no. 750 807 . . . .
This is also valid for item 221b on page 30.
SERVICE TOOLS
Qty
Ordering no.
1
0192 058 106
Contact oil
To be used when mounting the heat sinks on the primary side.
1
0192 058 101
Thermal compound
To be used when mounting the heat sinks on the secondary side.
1
0193 260 062
Connector
3--pole, to be used on contact B on AP02
1
0193 260 066
Connector
7--pole to be used on contact C on AP02
1
0193 260 068
Connector
9--pole to be used on contact E on AP02
1
0457 488 001
Torx screw driver
For dismantlig the machine
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C
Denomination
Notes
-- 28 --
SPARE PARTS LIST LHO 110/150
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-- 29 --
SPARE PARTS LIST LHO 110/150
C = component designation in the circuit diagram
Item
no.
Qty
LHO
110
Qty
LHO
150
Ordering no.
200
1
1
0193 316 208
Rectifier bridge
201
1
1
0486 457 880
Printed circuit board
EMC
AP03
202
1
0486 509 884
Printed circuit board
Before machine no. 744 . . . . . . .
AP02
1
Denomination
Notes
C
V01
0486 509 890
Printed circuit board
From machine no. 744 . . . . . . .
AP02
1
0486 509 882
Printed circuit board
Before machine no. 745 . . . . . . .
AP02
1
0486 509 892
Printed circuit board
From machine no. 745 . . . . . . .
AP02
---
---
0486 509 886
0486 509 880
Printed circuit board
Printed circuit board
Only for LHO 110B
Only for LHO 150B
AP02
AP02
203
1
1
0365 539 001
Fan
204
1
EV01
0457 875 880
Printed circuit board
Item 205, 16 springs are included
AP01
1
0457 875 881
Printed circuit board
Item 205, 23 springs are included
AP01
205
16
23
0457 002 001
Spring
Included in item 204
206
3
3
0193 965 019
Capacitor
400V 470 μF included in AP01
207
1
1
0194 017 117
Resistor
9W 22 τ included in AP01
208
1
1
0468 940 002
Thermal switch
75_C
ST01
209
1
1
0457 044 001
Cover
210
1
1
0457 232 001
Heat sink
211
1
1
0457 232 002
Heat sink
212
1
1
0456 576 080
Heat sink
213
1
1
0456 576 075
Heat sink
214
1
1
0456 699 060
Heat sink
215
1
0456 546 880
Transformer*
Before machine no. 744 . . . . . . .
TR2
1
0456 568 880
Transformer*
From machine no. 744 . . . . . . .
TR2
1
0456 546 880
Transformer*
Before machine no. 745 . . . . . . .
TR2
1
0456 568 880
Transformer*
From machine no. 745 . . . . . . .
TR2
0456 547 880
Inductor*
Welding current inductor
1
0456 569 880
Inductor*
Welding current inductor
216
1
217
1
1
0320 805 884
Capacitor
218
1
1
0457 081 001
Angle
219
2
2
0457 265 001
Insulation
220
2
2
0457 254 001
Spacer
221
2
2
0456 575 002
Bus bar
221b
2
2
0456 575 001
Bus bar
6
0193 494 003
Ferrite ring cores
L01, L03--L07
0193 494 003
Ferrite ring core
L01
222
222
1
C01
For item 215 and 216
See 1) on page 28
*Items 215 and 216 are mounted on item 204, but they are not included in item 204
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-- 30 --
SPARE PARTS LIST LHO 110/150
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-- 31 --
NOTES
notes
-- 32 --
notes
-- 33 --
ESAB subsidiaries, representative offices and agents
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Vamberk
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 2 97 96 81
Fax: +39 2 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 661 55 80
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International 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
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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: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
AUSTRALIA
ESAB Australia Pty Ltd
Ermington
Tel: +61 2 9647 1232
Fax: +61 2 9748 1685
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 2 89 81 11
Fax: +82 551 289 88 63
THAILAND
ESAB (Thailand) Ltd
Samutprakarn
Tel: +66 2 393 60 62
Fax: +66 2 748 71 11
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
ALGERIA
ESAB Algeria
Alger
Tel: +213 2 67 24 93
Fax: +213 2 68 32 90
IRAN
Kavosh Azmoon
Teheran
Tel: +98 21 884 39 14
Fax: +98 21 884 13 46
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 211 75 02
RUSSIA-- CIS
ESAB Representative Office
Moscow
Tel: +7 095 93 79 820
Fax: +7 095 93 79 580
ESAB Representative Office
St Petersburg
Tel: +7 812 325 6688
Fax: +7 812 325 6685
Agents
For addresses and phone
numbers to our agents, please
contact ESAB International AB,
Sweden
EUROPE
Cyprus, Greece, Malta
AFRICA
Angola, Cameron, Ethiopia,
Gabon, Ghana, Kenya, Liberia,
Morocco, Mocambique, Nigeria,
Senegal, South Africa, Tanzania,
Togo, Tunisia, Zambia, Zimbabwe
ASIA
Bahrain, Hongkong, Israel,
Japan, Jordania, Korea, Kuwait,
Lebanon, New Guinea, Oman,
Pakistan, The Philippines,
Quatar, Saudi Arabia,
Sri Lanka, Syria, Taiwan,
Turkey, Vietnam, Yemen
LATIN AMERICA
Bolivia, Chile,
Colombia, Costa Rica, Curacao,
Equador, El Salvador,
Guatemala, Honduras, Jamaica,
Paraguay, Peru, Trinidad,
Uruguay, Venezuela
BULGARIA
INTESA
Sofia
Tel: +359 2 980 17 15
Fax: +359 2 980 08 42
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ESAB Welding Equipment AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
Fax +46 584 123 08
www.esab.com
990922