ESAB | LTO 160 | Service manual | ESAB LTO 160 User manual

ESAB LTO 160 User manual
LTO 160/250
Mechtig 160/250
Service manual
0740 801 004
0002
LIST OF CONTENTS
Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM LTO 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM LTO 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOCK DIAGRAM, CIRCUIT BOARD AP01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:2 + 5 V Power supply monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:3 Start / Stop input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:4 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:5 Shunt input with amplifier AP10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:6 Arc voltage monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:7 HF Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:9 Machine type indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:10 Thermal overload cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:11 Welding process control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:12 Motor control interface circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:13 Pulse width modulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:14 Gate circuit LTO 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gate pulses, LTO 160 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AP01:14 Gate circuit LTO 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking the gate pulses, LTO 250 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component positions, circuit board AP01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 160: TRANSISTOR BOARD AP02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 160: TRANSISTOR BOARD AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 250: TRANSISTOR BOARD AP02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 250: TRANSISTOR BOARD AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOSTESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 160: SOFT STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 250: SOFT STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUPPRESSION BOARD AP07 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 160: SUPPRESSION BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LTO 250: SUPPRESSION BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOTHER BOARD AP12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ROTATION AP13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WIRE FEED AP14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POWER SUPPLY AP15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR BOARD AP16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTOR BOARD AP17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PULSE GENERATOR INTERFACE BOARD AP18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX E01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Display board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Microprocessor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Battery replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FAULT/ERROR MESSAGES ON THE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Faults in the power electronic circuits of the machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Memory errors/faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Communication faults/errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors in the course of welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors in the course of sequential running . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Blocking messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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64
DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removal of transistor circuit boards AP02 and AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refitting the transistor circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assembling the diode modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fitting the main transformer, TC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of a complete welding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check--up and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONTROL BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Rights reserved to alter specifications without notice.
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96
READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.
All component names in the connection diagram are listed in the component description.
This manual contains details of all design changes that have been made up to and including
February 2000.
The LTO 160 and LTO 250 are designed and tested in accordance with European
standard EN 60974--1 and EN 50199.
On completion of service or repair work, it is the responsibility of the person(s) etc.
performing the work to ensure 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
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 earth and the workpiece.
S
Ensure your working stance is safe.
FUMES AND GASES -- Can be dangerous to health
S
Keep your head out of the fumes.
S
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.
S
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
S
Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S
Protect your ears. Use ear defenders or other hearing protection.
S
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
This component description refers to the connection diagrams.
The LTO 160 and LTO 250 are primary--switched power units, using parallel--connected
MOSFET--transistors as the switching elements.
The power units are programmable and provided with a memory so that different welding
programs can be set and stored by means of a control box. The welding programs can be
divided into sectors with different sets of parameters. The division into sectors is
time--controlled.
They are designed both for manual and mechanized welding.
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
ESD
S
Observe precautions for handling electrostatic
sensitive devices.
S
Use proper static--proof bags and boxes.
AP01
The main circuit board with control electronics. See block diagram on
page 12 and description on page 14.
AP02
Circuit board with power transistors for the positive pole, see description
for the LTO 160 on page 28 and for the LTO 250 on page 32.
WARNING! the transistors are connected to mains voltage potential.
AP03
Circuit board with power transistors for the negative pole, see description
for the LTO 160 on page 30 and for the LTO 250 on page 34.
WARNING! the transistors are connected to mains voltage potential.
AP07
Interference suppression circuit board: see circuit diagram on page 39.
AP08
Interference suppression circuit board, prevents mains--borne interference.
See circuit diagram on page 40.
AP10
Circuit board shunt amplifier, see description on page 16.
AP11
HF generator.
AP12
Circuit board. See description on page 42.
AP13
Circuit board, motor control, rotation. See description on page 46.
AP14
Circuit board, motor control, wire feed speed. See description on page 48.
AP15
Circuit board, voltage supply for rotation and wire feed. See description on
page 50.
AP16
Circuit board, distribution board for AP14. See diagram on page 52.
AP17
Circuit board, distribution board for AP15, see diagram on page 53.
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AP18
Circuit board, interface for pulse generator. See description on page 54.
C01
Capacitor, 0.1←F, 1000 VDC, transient protection.
C02, C03
Capacitor, 1000←F, buffer/smoothing capacitor.
Time to discharge after turning off the unit: about two minutes.
Capacitor C03 is only mounted in the LTO 250.
C04
Decoupling capacitor, 0.1←F, 1000 VDC, protects against HF.
C05
2 -- capacitors, 4.7←F, see L02.
C06--C09
Capacitor, 0.1←F.
C10
LTO 160: 2 -- capacitors, 12 nF. Protection against transient voltages.
LTO 250: 2 - capacitors, 1 nF. Protection against transient voltages.
E01
Control box. See description on page 56.
EV01
Fan, 24 VDC.
EV02
Fan, 24 VDC. Only monted in the LTO 250.
FU01
Fuse 315 mA, slow blow.
FU02
Fuse 630 mA, slow blow.
FU03
Fuse 1 A, slow blow.
FU04
Fuse 800 mA, slow blow.
FU06, FU07
Fuse 0.5 A, slow blow.
FU08, FU09
Fuse 1.25 A, slow blow.
HL01
Lamp, 28 V, white, lights when mains power is on.
L01
Secondary inductor.
L02
Inductor, forms an LC circuit with C05 and V06 to reduce the risk of arc
extinction at low welding currents.
When V03 conducts, the LC circuit charges up. The circuit is capable of
temporarily maintaining a high arc voltage at low current, thus reducing the
risk of arc extinction.
Diode V06 prevents capacitor C05 from going negative.
L03
LTO 160: Primary inductor, improves the machine’s form factor, i.e.
reduces the mains load.
LTO 250: Ferrite ring core, transient protection.
L04, L05
Ferrite ring core, transient protection. Only mounted in the LTO 250.
QF01
Mains power supply switch.
R01
Resistor, 3.9 kτ 5 W.
R02 -- R05
Current limit resistor, 3 τ 10 W.
R06 -- R07
Current limit resistor, 10 τ 10 W.
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RS01
LTO 160: Shunt, 119 mV at 140 A
LTO 250: Shunt, 119 mV at 250 A
ST01
LTO 160:
Thermal overload cutout, for overload protection, mounted on the main
transformer (TC02) winding. Breaks at 130 _C and resets at 100 _C.
LTO 250:
Thermal overload cutout, for overload protection, mounted on the winding
of inductor L01. Breaks at 130 _C and resets at 100 _C.
TC01
Control power transformer. Secondary output voltages: 9, 20, 26 and 42V.
TC02
Main transformer. For fitting instructions, see page 67.
TC03
Control power transformer for motor regulators.
TC04
Transformer for water cooler. Only mounted in the LTO 250.
TV01
HF transformer.
V01, V02
Mains rectifier bridge, 35 A, 1200 V. After replacing the rectifier bridges,
the machine must be soft--started: see instructions on page 37.
Rectifier bridge V02 is only mounted in the LTO 250.
V03, V04
Rectifier and freewheel diodes.
V03 rectifies the welding current.
During the time interval between two voltage pulses from transformer
TC02, the freewheel diode V04 maintain the welding current from inductor
L01.
On the cooling fins one respectively three diode modules are mounted.
Each diode module consists of two diodes.
For installation instructions, see page 66.
V05
LED, yellow. Lights when thermal cutout ST01 operates (breaks) as a
result of high temperature.
V06
Diode, see L02.
X..
Terminal block.
XP . .
Pin connector.
XS . .
Sleeve connector.
XS04
26--pole ribbon cable connector .
XS12
2--pole Cannon connector.
XS13--XS14
Welding current terminal, OKC type.
XS20
26--pole connector for ribbon cable.
XS32
Connector for voltage supply to cooling unit.
YV01
Solenoid valve.
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CONNECTION DIAGRAM LTO 160
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CONNECTION DIAGRAM LTO 250
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BLOCK DIAGRAM, CIRCUIT BOARD AP01
1 Power supply
2 +5 V Power supply monitoring
3 Start / Stop input
4 Gas valve
5 Shunt input with amplifier AP10
6 Arc voltage sensing
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7 HF unit
9 Machine type selection
10 Thermal overload switch
11 Welding process control
12 Interface circuits for motor control
13 Pulse width modulator
14 Gate circuit
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DESCRIPTION OF OPERATION, CIRCUIT BOARD AP01
This description refers to the block diagram on page 12 and to the components position
diagram on page 27.
Only those parts connected to the board’s inputs and outputs are described here. If the circuit
board is faulty, it must be replaced.
After replacing the circuit board, the machine must be soft--started. See the instructions
on page 37 och 38.
AP01:1
Power supply
The power supply to the board can be divided into three parts; a, b and c.
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Voltage regulator VR2 stabilises the supply to +5 ¦0.25 V DC.
Resistors R126 and R127, capacitor C104 and diode D27 form a voltage
monitoring circuit for the unregulated supply to voltage regulator VR2.
The voltage from potential divider R126/R127 is connected to pin 9 of IC7: see
AP01:2) below. The voltage is about 2.5 V.
Voltage regulator VR4 supplies fan EV01 and EV02 with +28V. Fan EV02 is
only fitted in the LTO 250.
Voltage regulator VR3 is not used.
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Voltage regulator VR1 produces an output voltage of +20 ¦1.0 V, which
supplies the pulse width modulator output stage (Block AP01:13).
Potential divider R100/R101 supplies 2.6 V to the processor in Block AP01:11.
This provides a signal that the power supply is available.
The +27 V supplies relay RE1 in Block AP01:7 and indicating lamp HL01.
The analogue circuits on the board are supplied by +15V and - 15V. The
microprocessor monitors the - 15V supply by a signal from the right--hand side
of resistor R54.
AP01:2
+ 5 V Power supply monitoring
A voltage of about 2.5 V is supplied to IC7, pin 9, from power supply circuit 1a.
If this voltage drops below the threshold voltage of 1.3 V, pin 10 of IC7 goes
low, providing the processor with a low power supply voltage signal.
If the +5 V supply to pin 3 of IC7 drops below 4.65 V, pin 15 goes low and
inhibits the pulse width modulator in block AP01:13, the processor also receives
a reset signal.
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-- 15 --
AP01:3
Start / Stop input
The output signal from IC14, pin 4, goes high (+5 V) when the torch contact
switch is not activated, and low (0 V) when it is activated.
AP01:4
Gas valve
Operating the torch trigger switch causes semiconductor relay RE2 to conduct
and energise solenoid valve YV01. C82 and R111 form an HF filter.
AP01:5
Shunt input with amplifier AP10
Shunt amplifier circuit board AP10 is supplied with ¦15 V from circuit board
AP01. At no--load voltage, the circuit board’s neutral voltage (0 V) is at the
same potential as the welding circuit negative connection.
In the LTO 160 and LTO 250 the welding current can be set in 1 A steps. The
lowest current that can be set is 3A.
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Component positions, AP10
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-- 16 --
LTO 160
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In the LTO 160, 119mV shunt voltage corresponds to 140 A welding current.
The signal from the shunt is amplified by the shunt amplifier, so that a 119 mV
input signal from the shunt produces a 6.66 V output signal.
Transistor Q1 is turned on by IC8. This connects resistor R9 to 0 V, connecting
resistors R8 and R9 in parallel with R6 and R7. With R10, these resistors form a
potential divider which divides the 6.66 V to 1.48 V, which is then supplied to
pin 3 of IC2.
IC2 is a buffer circuit. The processor receives a signal representing the welding
current from output pin 6 of IC2. Resistor R4 connects the shunt signal to the
control amplifier.
LTO 250
250A welding current produces 119mV ±1mV at the shunt. The signal from
the shunt is amplified by the shunt amplifier, so that a 119 mV input signal from
the shunt produces a 6.66V output signal. Resistors R10, R6 and R7 on circuit
board AP01 divide this voltage to 2.65V, which is then supplied to pin 3 of IC2.
IC2 is a buffer circuit. The processor receives a signal representing the welding
current from output pin 6 of IC2. Resistor R4 connects the shunt signal to the
control amplifier.
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-- 17 --
AP01:6
Arc voltage monitoring
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This circuit measures and scales the arc voltage to a suitable level for the
processor. 64 V arc voltage produces a voltage signal of 5.1 V at the cathode of
diode D3.
Open--circuit voltage control
The arc voltage is connected to input D2 and supplied to potential divider R29
and R30, the output from which is supplied to the voltage control circuit. The
open--circuit voltage must be about 70V.
AP01:7
HF Generator
WARNING: Dangerous voltages in this circuit.
When the welding torch switch is operated, and the open--circuit arc voltage is
over 50 V, relay RE1 closes and turns on HF generator AP11. It remains
activated for 0.75 seconds. If the arc has not struck within this time, the relay
drops off.
The voltage on the primary side of HF transformer TV01 is about 400 V, and the
secondary voltage is about 8 kV.
From serial number xxx--006--xxxx a new type of HF generator is used, see the
spare parts list. This generator produces about 500 V on the primary side of the
HF transformer and about 10 kV on the secondary side.
The new HF generator replaces the old type. When fitting the new generator to
older machines, three new mounting holes for the generator must be drilled. Fit
the generator with the connection terminal turned towards the base plate.
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-- 18 --
AP01:9
Machine type indicator
As the same circuit boards are used in other machines, it is necessary for the
processor to know what type of machine it is controlling. A link is therefore
provided connector G to short out a pull--up resistor. In the LTO 160 the link
connects G1 - G4, and in the LTO 250 it connects G1--G3.
AP01:10
Thermal overload cutout
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The thermal overload switch, ST01, is normally closed, which means that input
K2 is at 10 V. This voltage is dropped by the potential divider formed by
resistors R31 and R32 to 4.8 V, and used as an input voltage to the processor.
LED V05 indicates excessive temperature. When the thermal overload cutout
operates, the LED lights up.
AP01:11
Welding process control
The processor inputs are the set values of welding data and the arc voltage. The
processor also calculates a set value signal for welding current and supplies this
to the current control amplifier.
The process regulator control principle
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-- 19 --
AP01:12
Motor control interface circuits
The reference voltages for rotation and wire feed are generated on circuit board
AP01. The +15 V and 5 V voltages are power supplies for the galvanic
separation of the speed and direction signals on circuit board AP12.
Potentiometers R102, R104, R107 and R109 are adjusted and set at the time of
manufacture of the circuit board. They can be checked as described below:
Rotation
1
Remove circuit board AP07 and fit test board 0740 859 001 in its place.
2
Measure the voltage between B7 and B26.
3
Set a rotation speed of 100% on the control unit.
4
Adjust R109 to produce a voltage of --10.0 V 0.005 V.
5
Stop the rotation and adjust R107 until the voltage is 0 V +0.001 V.
6
Repeat points 4 and 5 until the values are within the tolerance limit.
Wire feed
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1
Remove circuit board AP07 and fit test board 0740 859 001 in its place.
2
Measure the voltage between B4 and B26.
3
Set the wire feed speed at 2.2 m/min.
4
Adjust R102 to produce a voltage of --7.8 V 0.005 V.
5
Stop the wire feed and adjust R104 until the voltage is 0 V +0.001 V.
6
Repeat points 4 and 5 until the values are within the tolerance limit.
-- 20 --
Test board 0740 859 001
AP01:13
Pulse width modulator
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The pulse width modulator determines the frequency and pulse time of the
MOSFET transistors’ control pulses.
It is important that the frequency and maximum pulse time are within the
specified tolerances. See the instructions for checking the gate pulses on the
following pages.
IC5 controls the pulse frequency, the pulse time and inhibition of pulses.
Transistor Q12 supplies the pulse transformer’s primary winding. Diodes D17
and D18 are squelch diodes that protect Q12 against back--emf from the
transformer.
NOTE
The frequency and pulse time is not the same for the LTO 160 and the LTO 250.
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-- 21 --
AP01:14
Gate circuit LTO 160
Pulse width modulator and gate circuit for the LTO 160
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The MOSFET transistors’ drive stage produces control pulses for the gate-source on the power transistors. There is a separate output for each switch unit.
All gate circuits are galvanically isolated from other circuits on the board.
The insulation voltage between the pulse width modulator and the gate circuits
is 4 kV.
WARNING! The gate circuits are at mains voltage.
The two gate circuits are identical, and so only one is described here.
When Q12 conducts, a voltage pulse is produced on the transformer’s secondary
winding. This pulse is conducted via D13, D14 and output E1 to the gate on the
MOSFET transistors. The pulse returns via the source, connection E2, D16 and
C36. The peak gate -- source voltage is 14 V.
The gate pulse between E1 and E2 charges C36 to 3.3 V. When Q12 turns off,
the voltage from the secondary of the pulse transformer changes polarity,
causing Q14 and Q13 to start to conduct. The gate voltage becomes --3.3 V,
turning off the MOSFET transistors.
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-- 22 --
Checking the gate pulses, LTO 160
If circuit board AP02 or AP03 has failed, the gate pulses must always be
checked.
Remove connections XS06 and XS07 (gate pulses). Connect a dummy gate load
to outputs E1 and E2 and to F1 and F2.
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Dummy gate load
IMPORTANT:
Never check the gate pulses when AP02 and AP03 are connected to AP01:
use a dummy gate load. AP02 and AP03 are at mains voltage.
The minimum gate pulse level must be - 2 to - 4 V and its maximum value must
be 13.5 to 16 V. The frequency must be 36.5 kHz ¦0.5 kHz. Check that the
maximum pulse time is
40.5 ¦1% of the cycle time, measured at a level of +5 V.
If the gate pulse does not lie within these tolerances, replace circuit board AP01.
The frequency and pulse time are very important parameters. If they are
incorrect, they can result in transistor failure in the main circuit.
After replacing AP01, check the gate pulses again and soft--start the machine, as
described on page 37.
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Gate pulses as measured across a dummy gate load on circuit board AP01 in the
LTO 160
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-- 23 --
AP01:14
Gate circuit LTO 250
Pulse width modulator and gate circuit for the LTO 250
The MOSFET transistors’ drive stage produces control pulses for the gate-source on the power transistors. There is a separate output for each switch unit.
All gate circuits are galvanically isolated from other circuits on the board.
The insulation voltage between the pulse width modulator and the gate circuits
is 4 kV.
WARNING! The gate circuits are at mains voltage.
The two gate circuits are identical, and so only one is described here.
When Q12 conducts, a voltage pulse is produced on the transformer’s secondary
winding. This pulse is conducted via D13, D14 and output E1 to the gate on the
MOSFET transistors. The pulse returns via the source, connection E2, D16 and
C36. The mean peak gate - source voltage is 12--15V.
The gate pulse between E1 and E2 charges C36 to 5.6V. When Q12 turns off,
the voltage from the secondary of the pulse transformer changes polarity,
causing Q14 and Q13 to start to conduct. The gate voltage becomes negative,
turning off the MOSFET transistors.
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-- 24 --
Checking the gate pulses, LTO 250
If circuit board AP02 or AP03 has failed, the gate pulses must always be
checked.
Remove connections XS06 and XS07 (gate pulses). Connect a dummy gate load
to outputs E1 and E2 and to F1 and F2.
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Dummy gate load
A set of different gate loads can be ordered from ESAB.
The part number is 0468 469 003. The gate loads can be used to the following
machines: LUC, LHL 130/160, LHL 250/315, LTL 160, LTL315, LUB 315,
LHN, LTN, LTR, LTO, MechTig 315 and Protig 315.
IMPORTANT:
Never check the gate pulses when AP02 and AP03 are connected to AP01:
use a dummy gate load. AP02 and AP03 are at mains voltage.
The gate pulse minimum level must be - 3.5 to - 5.5V, and the average maximum
level 12 to 15V. Frequency must be 48.5 kHz ±0.5 kHz. Check that the
maximum pulse time, measured at a voltage level of +5V, is 43 ±1% of the
cycle time.
If the gate pulse does not lie within these tolerances, replace circuit board AP01.
The frequency and pulse time are very important parameters. If they are
incorrect, they can result in transistor failure in the main circuit.
After replacing AP01, check the gate pulses again and soft--start the machine, as
described on page 37.
Gate pulses as measured across a dummy gate load on circuit board AP01 in the
LTO 250
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-- 25 --
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-- 26 --
Component positions, circuit board AP01
WARNING:
High voltage within
the shaded area.
Terminals X1 to X6 are tied to
0 V on the circuit board, and
must have good electrical contact with the screen enclosure.
The contact numbers on
connector B at the circuit
board are not valid.
The numbers on this
component layout are
correct.
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-- 27 --
LTO 160: TRANSISTOR BOARD AP02
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Simpified circuit diagram for AP02 (transistor board positive) in the LTO 160
The --880 variant is used in the LTO 160.
Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced
in its entirety. In addition, circuit board AP03 must also be replaced.
Instructions for removing and fitting the circuit board are to be found on page 65.
A01, A02
Connections A01 -- A02 are for the gate pulses from circuit board AP01.
D1 -- D3
Transient voltage protection.
D5
Back--emf protection diode (squelch diode), for main transformer TC02
when the transistors turn off.
F1
Fuse, for protection of circuit board AP01 if circuit board AP02 fails.
Q1 -- Q8
MOSFET transistors. These require a special instrument.
See MOS TESTER on page 36 for testing.
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-- 28 --
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Component positions for circuit board AP02 in the LTO 160
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-- 29 --
LTO 160: TRANSISTOR BOARD AP03
Simpified circuit diagram for AP03 (transistor board negative) in the LTO 160
cmha2e08
The --880 variant is used in the LTO 160.
Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced
in its entirety. In addition, circuit board AP02 must also be replaced.
See page 65 for instructions for removing and fitting the circuit board.
A01, A02
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 B02, for use as gate
pulses in controlling thyristor TY1.
D1 -- D3
Transient voltage protection.
D5
Back--emf protection diode (squelch diode), for main transformer TC02
when the transistors turn off.
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-- 30 --
Q1 -- Q8
MOSFET transistors. These require a special instrument.
See MOS TESTER on page 36 for testing.
R21
Charging resistor, 12τ, 10W, for buffer capacitor C02.
When energising the power unit, pulses from control circuit board AP01 are
delayed by 300 ms to allow the buffer capacitor to charge.
R27
Discharge resistor for buffer capacitor C02. After turning off the mains
power supply, the discharge time for the capacitor is about two minutes.
TY1
Thyristor for shunting charging resistor R21 when the machine is loaded. If
TY1 did not conduct, resistor R21 would burn out when the unit is on load.
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Component positions for circuit board AP03 in the LTO 160
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-- 31 --
LTO 250: TRANSISTOR BOARD AP02
Circuit diagram circuit board AP02 (transistor board positive)
Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced
in its entirety. In addition, circuit board AP03 must also be replaced.
Instructions on removing and fitting the circuit board are to be found on page 65.
A01, A02
Connections A01 -- A02 are for the gate pulses from circuit board AP01.
D1 -- D3
Transient voltage protection.
D5
Back--emf protection diode (squelch diode) for main transformer TC02
when the transistors turn off.
D6
See R21.
F1
Fuse, for protection of circuit board AP01 if circuit board AP02 fails.
R21
R21, C3, C4 and D6 are limiting the peak voltage at transistors Q1 -- Q8.
Q1 -- Q8
MOSFET transistors. These require a special instrument
(see MOS TESTER on page 36) for testing.
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-- 32 --
Component positions for circuit board AP02 in the LTO 250
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-- 33 --
LTO 250: TRANSISTOR BOARD AP03
Circuit diagram circuit board AP03 (transistor board negative) in the LTO 250
Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced
in its entirety. In addition, circuit board AP02 must also be replaced.
See on page 65 for instructions on removing and fitting the circuit board.
A01, A02
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 B02, for use as
gate pulses in controlling thyristor TY1.
D1 -- D3
Transient voltage protection.
D5
Back--emf protection diode (squelch diode) for main transformer TC02
when the transistors turn off.
D12
See R29.
Q1 -- Q8
MOSFET transistors. These require a special instrument
(see MOS TESTER on page 36 for testing.
R21
Charging resistor, 12τ, 10W, for buffer capacitors C02 and C03. When
energising the power unit, pulses from control circuit board AP01 are
delayed by 300 ms to allow the buffer capacitor to charge.
R26
Discharge resistor for buffer capacitor C03. Discharge time for the
capacitor, after turning off the mains power supply, is about two minutes.
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-- 34 --
R27
Discharge resistor for buffer capacitor C02. After turning off mains
power supply, discharge time for the capacitor is about two minutes.
R29
R29, C7, C8 and D12 are limiting the peak voltage at transistors Q1 - Q8.
TY1
Thyristor for shunting charging resistor R21 when the machine is loaded.
If TY1 did not conduct, resistor R21 would burn out when the unit is on
load.
Component positions for circuit board AP02 in the LTO 250
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-- 35 --
MOSTESTER
The MOS tester is a special instrument, and can be ordered only from ESAB’s service
department in Laxå. Order number is 0468 469 001.
Connect the instrument as follows:
S
S
S
S
S
S
Disconnect the power unit from the mains.
Disconnect capacitor C02.
Remove the gate connections from AP01.
Connect the clip on the red wire of the instrument to the red wire (the gate wire) on the
transistor board.
Connect the clip on the yellow wire of the instrument to the yellow wire (the source) on
the transistor board.
Connect the black wire to the cooling fins (drain).
Testing:
S
S
S
S
Press the pushbutton marked TEST.
If the board is healthy, both the red and green LEDs should flash alternately, about once
a second.
If the transistor board is short--circuited, the red LED will light continuously. (Note that
the green LED may also flash, or be continuously lit.)
If the transistor board is open--circuited, the green LED will be continuously lit. Check
that there is good electrical contact between the clip of the black wire and the cooling
fins.
IMPORTANT
Even if only one transistor board is indicated as faulty, both boards must be replaced.
Check the gate pulses from AP01 before commissioning the new transistor boards.
See instruction for the LTO 160 on page 23 and for the LTO 250 on page 25.
After replacement of the boards, the machine must be soft--started.
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-- 36 --
LTO 160: SOFT STARTING
1.
Remove and insulate wires 07 and 08 from rectifier bridge V01: see the circuit diagram
on page 8.
2.
Connect an external power supply, having a current limit of 1 A, to the positive and
negative connections on V01.
3.
Adjust the power supply voltage to 30 V.
4.
Power the remaining parts of the unit from the normal power supply.
5.
Start a programme.
6.
Measure the output voltage from the machine, this must be 10 V ¦1 V.
7.
Measure the primary voltage to transformer TC02. With a voltage of 30 V across the
buffer capacitor, the waveform must appear as shown below.
cmha2p24
Primary voltage at TC02 in the LTO 160, for 30 V across the buffer capacitor
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-- 37 --
LTO 250: SOFT STARTING
1.
Remove and insulate wires 07 and 08 from rectifier bridge V01, also remove and insulate
wire 09 to rectifier bridge V02: see the circuit diagram on page 10.
2.
Connect an external power supply, having a current limit of 1A, to the positive and
negative connections on V01.
3.
Adjust the power supply voltage to 30V.
4.
Power the remaining parts of the unit from the normal power supply.
5.
Start a programme.
6.
Measure the output voltage from the machine. This must be 5.5V ±1V.
7.
Measure the secondary voltage from transformer TC02. With a voltage of 30V across
the buffer capacitor, the waveform must appear as shown below.
Secondary voltage at TC02 in the LTO 250, for 30V across the buffer capacitors
Measure the voltage with the oscilloscope probe connected to A and the screen to B
according to the picture below.
Measuring points for the secondary voltage at TC02
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-- 38 --
SUPPRESSION BOARD AP07
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Circuit diagram, circuit board AP07
Component positions, circuit board AP07
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-- 39 --
LTO 160: SUPPRESSION BOARD AP08
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Diagram and component positions for interference suppression board AP08 in the LTO 160
LTO 250: SUPPRESSION BOARD AP08
Most of the LTO 250 produced before October 1998 are deliverd with circuit board 0486 356
880. As spare part for those machines we recommend circuit board 0486 577 880. The new
circuit board suppresses noise better than the old board. To fit the new board in older
machines a new mounting hole must be drilled in the mounting plate.
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Diagram and component positions for the old version (0486 356 880) of circuit board AP08
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-- 40 --
Diagram and component positions for the new version (0486 577 880) of circuit board AP08
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-- 41 --
MOTHER BOARD AP12
The AP12 circuit board distributes the power supply from circuit board AP15 to motor circuit
boards AP13 and AP14. It also provides the respective motor circuit boards with connections
to the motors, the tachometers and the main AP01 circuit board.
The AP14 and AP15 circuit boards are connected to circuit board AP12 via their respective
connection boards, AP16 and AP17.
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-- 42 --
IC2 and IC3 on the motor circuit boards provide galvanic isolation of the reference voltages
from circuit board AP01. The output voltages from IC2 and IC3 are equal to the input
voltages to the respective ICs.
The direction--controlling voltage levels are galvanically isolated from the motor circuit
boards via the optocouplers in IC1.
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-- 43 --
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-- 44 --
AP12, component positions
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-- 45 --
ROTATION AP13
Welding tool rotation
Circuit board AP13 is identical to circuit board AP14 (wire feed).
Circuit board AP13 is located under circuit board AP14.
Motor
Circuit board AP13 produces a pulse--width--modulated output at 2.25 kHz. The current to
the rotation motor is limited to about 0.5 A mean current.
Welding tools with pulse generator incorporate a motor with a maximum mean current of
1 A. A link is fitted between pins M and N in the connector to the power unit, raising the
current limit to 1 A by connecting resistors R1 and R48 in parallel, as shown in the diagram
above.
Reference voltage
At the maximum set speed, the reference voltage from circuit board AP01 is - 10.0 V.
A suitable test point for measuring it on circuit board AP13 is between connector pins A18
and C31 (0V). See page 20 for trimming instructions.
Speed control feedback
Two different types of speed control feedback may be used, depending on whether newer or
older welding tools are being used.
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-- 46 --
The older tools have an AC tachometer, connected to pins A16 and C16. At maximum set
speed, the rectified voltage between pins C18 and C31 is 1.62 V 0.05 V.
The motor speed is adjusted by a potentiometer on the tool.
New tools do not have a tachometer, but a two--channel pulse generator that produces
1480 Hz at the maximum set speed. The pulse voltage amplitude is about 14 V, and constant.
The pulse generator provides a frequency signal proportional to the motor speed. Interface
circuit board AP18 converts this frequency to a DC voltage that is proportional to the speed.
See the description of circuit board AP18.
At maximum speed, the voltage between pins C18 and C31 is 1.62 V 0.05 V.
Direction of rotation
The direction of rotation is selected from the control unit. The signal defining the direction is
connected to circuit board AP13 via pins A6 and A7.
Logic table for direction of rotation
AP13
A6 -- C31
AP13
C7 -- C31
AP07
AP07
B19 -- B26 B20 -- B26
5V
0V
The motor rotates anti--clockwise (+)
0V
5V
0V
5V
The motor rotates clockwise (--)
5V
0V
AP13, AP14 Component positions
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-- 47 --
WIRE FEED AP14
Circuit board AP14 is identical to circuit board AP13 (rotation).
Circuit board AP14 is located over circuit board AP13.
Motor
Circuit board AP14 produces a pulse--width--modulated output at 2.25 kHz. The current to
the wire feeder motor is limited to about 0.5 A mean current.
Reference voltage
The reference voltage is supplied from circuit board AP01. For a wire feed speed of
2.2 m/min., it is - 7.8 V. A suitable test point for measuring it on circuit board AP14 is
between connector pins A18 and C31 (0V). See page 20 for trimming instructions.
Speed control feedback
Three different types of speed control feedback may be used, depending on whether a Type
MEI 20 feed unit, a Type MEI 21 feed unit or a feed unit having a DC tachometer (such as a
PRI 18--220) is being used.
The MEI 20 has an AC tachometer, connected to pins A16 and C16. At a wire feed speed of
2.2 m/min., the rectified voltage between C18 and C31 is 1.27 V 0.05 V.
The wire feed speed is adjusted by a potentiometer in the wire feed unit.
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-- 48 --
At a wire feed speed of 2.2 m/min., wire feed units with DC tachometers produce a 1.27 V
signal between pins C18 and C31.
Instead of a tachometer, Type MEI 21 wire feed units have a two--channel pulse generator that
produces a 930 Hz signal at maximum wire feed speed of 2.2 m/min. The pulse voltage
amplitude is about 14 V and is constant.
The frequency is proportional to the wire feed speed. Interface board AP18 is a D/A
converter that converts this frequency to a DC voltage proportional to the wire feed speed:
see the description of circuit board AP18.
At maximum wire feed speed the voltage between C18 and C31 is 1.27 V 0.05 V.
Feed direction
The feed direction is selected from the control unit. The signal defining the direction is
connected to circuit board AP14 via pins A6 and A7..
Logic table for feed direction
AP13
A6 -- C31
AP13
C7 -- C31
5V
0V
Wire is fed out (+)
0V
5V
0V
5V
Wire is retracted (--)
5V
0V
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AP07
AP07
B21 -- B26 B22 -- B26
-- 49 --
POWER SUPPLY AP15
This circuit board provides power supplies for wire feed and the rotation drive.
+60V +36V 0VM
+60 V Smoothed but unregulated power supply, intended for the respective motor armature
circuits. On--load voltage is 42 - 49 V.
Fuse S1: 2.0 A slow--blow.
0 VM
Separate 0 V for the motor circuits, connected to 0 V on circuit board AP12.
+36 V Unsmoothed, unregulated and intended for field supply of those motors that have
field windings.
At no--load (open--circuit), this voltage is about 55 V.
+5V
+5 V
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Smoothed and regulated. Can be adjusted by trimming potentiometer R4, tolerance
0.1 V.
Fuse S2: 100 mA slow--blow.
-- 50 --
+12V --12V
+12 V Smoothed and regulated. Can be adjusted by trimming potentiometer R7,
tolerance 0.2 V.
Fuses S3 and S4: 0.5 A slow--blow.
--12 V Smoothed and regulated. Can be adjusted by trimming potentiometer R8,
tolerance 0.2 V.
AP15 Component positions
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-- 51 --
CONNECTOR BOARD AP16
Component positions and circuit diagram
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-- 52 --
CONNECTOR BOARD AP17
Component positions and circuit diagram
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-- 53 --
PULSE GENERATOR INTERFACE BOARD AP18
This circuit board converts the frequency from the pulse generator to an analogue DC
voltage, proportional to the motor speed.
The trimming potentiometers on the circuit board are adjusted when the board is
manufactured. Do not alter the settings of potentiometers R4 and R15: they cannot be
adjusted without the correct test equipment. On later equipment, these potentiometers will be
replaced by fixed resistors.
Trimming potentiometers R32 and R33 adjust the analogue voltage to a level to suit the
respective motor circuit boards.
With the motor connected, adjustments can be made as follows:
Rotation
1.
Connect a multimeter with frequency--measuring capability to pins A2 and A3 in
connector XS37.
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-- 54 --
2.
Set the speed of rotation to 100% and then adjust the actual motor speed by means of
potentiometer R32 to produce a frequency of 1480 Hz 20 Hz..
Wire feed
1.
Connect a multimeter with frequency--measuring capability to pins A4 and A5 in
connector XS37.
2.
Set the wire feed speed to 2.2 m/min. and then adjust the actual wire feed speed by
means of potentiometer R33 to produce a frequency of 930 Hz 15 Hz.
Component positions circuit board AP18
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-- 55 --
CONTROL BOX E01
The welding settings control box contains two circuit boards: a keyboard/display board 6) and
a microprocessor board 7). The microprocessor board has its own microprocessor and associated
memory capacity, in the same way as has the main AP01 control circuit board.
Communication between the power source and the control box is through a bidirectional
optical fibre cable 10). This cable also contains two ordinary copper conductors for power
supply to the control box. A third conductor is connected to screening enclosure of the
control box and to the machine casing. It is exteemely important that this conductor is
properly connected both to the machine and to the control box.
The 9 V AC power supply comes from a separate winding on control transformer TC03.
The welding settings control box contains functions for setting, measuring and storing the
required welding parameters. The unit also displays fault/error messages.
The welding parameters can be set manually, or divided into sectors.
100 sets of values can be stored. When the machine is turned off, a lithium battery 12)
maintains the power supply to the memory.
The display, which incorporates a HOLD function, can display welding current or voltage.
The Operator’s Instructions contain a description of use of the control box.
Construction of the welding settings control box.
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Display board
Circuit diagram display board
cny1ae26
Component positions display board
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-- 57 --
Microprocessor board
TC03
cny1ae25
Inputs and outputs to/from the microprocessor board
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-- 58 --
cny1ae24
Component positions microprocessor board
Description of operation, microprocessor board
A
Connector A links the display board to the microprocessor board by means of
a ribbon cable.
B
Connections B1 and B2 provide a 9 V AC supply to the board.
BA1--BA2 Battery for back--up power supply to memory chip IC6. Only one battery is
fitted: the empty position is intended for use when changing the battery.
See the description on page 61.
BR1
Rectifier bridge BR1 rectifies the supply, which is then stabilised to +5 V
±5% by voltage regulator VR1.
IC5
EPROM containing the software for the control box.
IC6
RAM, battery--backed memory with capacity for 100 welding data programs.
IC8
Optical fibre receiver for signals from the power source.
IC9
Transmitter for optical fibre signals to the power source.
Mp7
Test point Mp7, which is connected to pin 1 of IC2, enables the signal from
the optical fibre receiver to the processor in the box to be measured.
When the power source transmits information to the control box, the signal
pulses between +1.5 V and +5 V.
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-- 59 --
Mp8
Test point Mp8, which is connected to pin 8 of IC2, enables the signal from
the control box microprocessor to the optical fibre transmitter to be monitored.
When the control box transmits information to the power source, the signal
pulses between 0 V and +3.8 V.
In the event of failure of the optical fibre communication link, the following
fault messages may appear after turning the machine on:
S
WAITING FOR MACHINE IDENT.
S
COMM. ERROR: TIME OUT
R4
Potentiometer for adjusting the display contrast.
TR1
DC/AC converter, producing a power supply of about 100 V AC from the
+5 V DC supply. This supply is used to power the background illumination of
the display.
Transistor Q1 turns off the lighting about 10 minutes after the control box was
last used.
Memory problems
If you suspect that the memory has become corrupted, all programmed data should be erased.
The data should also be erased when changing software.
Erasure of the welding data memory:
S
Press the four keys SEL, SET, MEM and OPE simultaneously until the display shows:
S
[ RAM XX = YYY]
SET RAM = ZZZ
S
Press the ARROW DOWN key
until the display shows:
SHOW VERSION
[ RESET WD--RAM ]
(In the lower line, the abbreviation WD means Weld Data.)
S
Press the NEXT key. This erases all the stored welding data. All other preset values
return to their default values.
S
The display shows the message NV--RAM INITIALIZED, as acknowledgement that the
memory has been erased.
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-- 60 --
Battery replacement
Construction of the weldings settings control box
S
Remove the clip (1) from the case.
S
Unscrew the right--hand end (8).
S
Disconnect the yellow--green earth wire from the casing.
S
Slide out circuit boards 6 and 7 and fold them apart so that the battery is accessible.
S
When replacing the battery, all programmed data will be lost unless the 3 V power supply
is maintained all the time. To avoid this, solder the new battery into position, in the
unused space, before removing the old battery.
S
The lithium battery can be expected to have a life of about two years of normal
operation.
The battery is a BR 2325 -- 1HC battery.
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-- 61 --
FAULT/ERROR MESSAGES ON THE DISPLAY
In general, fault/error messages remain displayed until a key is pressed on the control box, or
until the main welding power source is turned off and restarted.
Faults in the power electronic circuits of the machine
MACHINE ERROR:
+20V
Incorrect power supply voltage (should be 20 V), tolerance ¦1 V.
Use a voltmeter to verify this fault. Measure the voltage from
transformer TC01.
If the transformer output voltage is correct, but the 20 V supply voltage is
wrong, replace circuit board AP01.
MACHINE ERROR:
--15V
Incorrect power supply voltage (should be --15 V), tolerance +2/--1 V.
Use a voltmeter to verify this fault. Measure the voltage from
transformer TC01.
If the transformer output voltage is correct, but the --15 V supply voltage
is wrong, replace circuit board AP01.
MACHINE ERROR
HEATSINK TEMP.
High heat sink temperature. The thermal cutout has operated and
indicating lamp V05 lights. The machine has been overloaded.
Check that the cooling fan is running, and that the air filter is not blocked.
Memory errors/faults
The machine automatically performs a self--test of all memory cells on power--up.
If any of the cells is found to be faulty, one of the following fault/error messages will be
displayed. These messages are displayed only immediately after power--up.
It may be possible to use the machine despite the fault/error message. However, be careful
when using it, as welding performance may be affected, despite the fact the machine appears
to be operating normally.
RAM ERROR IN
POWER SOURCE
Check that each memory position can be written to and read from. If this
message appears, it indicates that a memory cell in the machine’s
read/write memory is defective.
Replace circuit board AP01
ROM ERROR IN
POWER SOURCE
Program memory is tested using a check sum. If this message appears,
it indicates that a memory cell in the machine’s EPROM program
memory is defective.
Replace circuit board AP01.
RAM ERROR IN
CONTROL UNIT
Check that each memory position can be written to and read from. If this
message appears, it indicates that a memory cell in the control unit’s
read/write memory is defective.
Replace the microprocessor circuit board in the control unit.
ROM ERROR IN
CONTROL UNIT
Program memory is tested using a check sum. If this message appears,
it indicates that a memory cell in the control unit’s EPROM program
memory is defective.
Replace the microprocessor circuit board in the control unit.
EXT.RAM ERROR IN
CONTROL UNIT
Check that each memory position can be written to and read from. If this
message appears, it indicates that a memory cell in the memory chip
(IC6) in the control unit is defective.
Replace the microprocessor circuit board in the control unit.
WELD DATA ERR. IN
CONTROL UNIT
Contents of welding data memory distorted. The 100 memory positions
have been erased. Switch the machine off and on. Contents of working
memory will be reset to basic values.
The most common cause of this fault is failure of the battery in the
control unit. Deal with this by replacing the battery: see the instructions
on page 61.
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Communication faults/errors
These fault/error messages relate to the serial communications link between the power source
and the control unit. They can occur as a result of random events. In such cases, deal with
them by turning the machine off and then on again. If these faults occur more frequently,
there is probably an underlying reason, which needs to be found.
WAITING FOR
MACHINE IDENT.
The control unit is waiting for the first message from the power source.
This message opens communication between the power source and the
control unit.
This message always appears briefly when the machine is powered up.
If however the message persists:
S
Check that the optical fibre contacts are correctly connected at
each end.
S
Check the +5V at circuit board AP01.
COMM. ERROR:
RECEIVE CH.SUM
An incorrect sum has been detected five times in succession when
transmitting from the power source to the control unit.
Check that the ends of the optical fibres are correctly aligned with the
receivers/transmitters.
COMM ERROR:
TRANSM. CH.SUM
An incorrect sum has been detected five times in succession when
transmitting from the control unit to the power source.
Check that the ends of the optical fibres are correctly aligned with the
receivers/transmitters.
COMM ERROR:
TIME OUT
The control unit has sent a message/instruction to the power source, but
has not received acknowledgement.
Check that the optical fibre contacts are correctly connected at each
end. Check too, that the fibres have not moved relative to their housings
so that a gap of some tenths of a millimetre has occurred between the
end of the fibre and the transmitter/receiver.
If the optical fibre cable appears to be fault--free, but communication is
still not working, check the +5 V voltage on circuit board AP01 on the
power source.
For further information possible location of the fault, use an oscilloscope
to measure the voltages at test points Mp7 -- Mp8.
See page 59 and 60.
POWER SOURCE
TIME OUT
The power source has sent a message/instruction to the control unit, but
has not received acknowledgement.
Check the optical fibre as described above.
COMM. ERROR:
RECEIVE BUFFER
COMM ERROR:
SEND BUFFER
The control unit has not processed incoming messages sufficiently
quickly, with the result that the receiver buffer has become full.
The machine has not succeeded in receiving messages from the control
unit at the same rate as which they have been transmitted, with the
result that the transmitter buffer has become full.
Errors in the course of welding
WELDING ERROR
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Comes up if the message ’arc extinguished’ is spontaneously sent from
the power source to the control unit during welding (between arc strike
and started down--slope phase) in case the welding has been started
from the control unit.
Comes up if HF ignition or gas is missing. Check the water fuse.
Compare with cases which do not lead to error state:
If welding is started via an external start signal, you return to the OPE
basic mode in case of arc extinction (or remain in SET or MEM if one of
these modes has been selected after start).
-- 63 --
Errors in the course of sequential running
These errors come up during sequential running when recalling the next sector.
MEMORY EMPTY
CONTROL UNIT
SEQUENCE SECTOR
OUT OF LIMITS
NON--SEQUENCE
SECTOR FOUND
WRONG TOOL
FOUND IN SECTOR
All sectors have been erased after start of the running sector.
(Including the case where the start sector is recalled automatically after
the last sector has run out.)
The end point of the new sector is outside the permissible interval.
(Applies to the POB tool.)
The new sector is non--sequential.
The tool indicated in the new sector is not the same as was previously
used in the sequence.
Blocking messages
Come up as temporary pictures (about 2 seconds) in case the key activated was not accepted.
After that return to the previous mode takes place.
When starting memory operations
No memory operations are executed in any of the following four situations.
MEMORY EMPTY
NO OPERATION
MEMORY FULL
NO OPERATION
MEMORY ALREADY
EMPTY
ACTIVITY STARTED
NO RECALL
All 100 memory positions in the library are empty.
Comes up when trying to recall a sector from the library.
All 100 memory positions in the library are occupied.
Comes up when trying to store a sector in the library.
All 100 memory positions in the library are empty.
Comes up when trying to erase a sector in the library.
An activity is going on.
Comes up when trying to recall a sector from the library.
When starting a sequence
No sequence start takes place in any of the following three situations
MEMORY EMPTY
NO OPERATION
SECTOR LIMITS
NO OPERATION
WRONG TOOL
NO OPERATION
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All 100 memory positions in the library are empty.
Applies to the POB tool. +/-- 1.5 rotary turns has been exceeded.
Different tools are used within the same sequence.
Comes up when trying to restart a sequence and the stop was caused
by the error of ’Wrong tool’.
-- 64 --
DISASSEMBLY / REASSEMBLY
Removal of transistor circuit boards AP02 and AP03
1.
Remove all wires and busbars connected to the board.
2.
Remove the springs that hold the board (2) in position by prising them off with a
screwdriver (1) between the cooling flange and the spring.
Removal/refitting of transistor circuit board
Refitting the transistor circuit board
1.
When replacing the transistor circuit board, both boards must always be replaced and
new springs must be fitted.
2.
Clean the contact surface (3) of the heat sink with extremely fine abrasive paper.
3.
Apply a thin film of contact oil (see item 604 in the spare parts list) to the contact
surfaces.
4.
Place the circuit board (2) on the cooling fins. Secure first one spring on each side of the
board by pressing the spring down with a screwdriver (4). Then secure the remaining
springs. NOTE: The springs must be fitted over the components that are to be in
contact with the heat sink.
5.
When fitting cable lugs and busbars to the boards, it is important that the washers are
fitted in the correct order. Start by placing the lug on the foil, and then fit a flat washer, a
spring washer and finally the screw.
Connections to circuit board AP03
a LTO 160: not connected.
LTO 250: wire 045 to the connection
between C02 and C03.
b LTO 160: busbar to positive on C02.
LTO 250: busbar to positve on C03.
c Busbar connected to negative on C02.
d LTO 160: wire 024 from inductor L03.
LTO 250: wire 013 from negative of V02.
e Gate connection from circuit board AP01.
f Connector XS17 from transformer TC02.
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-- 65 --
Assembling the diode modules
Heat sink with diode module (LTO 160)
1.
Clean the contact surface of the heat sink with extremely fine abrasive paper.
2.
Apply a thin film of contact oil (see item 604 in the spare parts list) to the contact
surfaces.
3.
Fit the diode modules 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 description above is valid for the LTO 160, which has one diode module. Assemble the
thtee diode modules in the LTO 250 in a similar way.
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-- 66 --
Fitting the main transformer, TC02
When replacing the main transformer, it is also necessary to replace the transformer core.
This is because the core is bonded with adhesive, and cannot be disassembled.
Adhesive and tape are required when fitting a new transformer, in addition to the coil and
core. Part numbers for the requisite adhesive and tape are shown as Item 528 in 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 020
2.
Apply a layer of tape (t) to each of the three airgaps in the transformer core. Use the tape
specified in the spare parts list.
3.
Apply Loctite 648 (see the spare parts list) to the contact faces between the cores and
between the core and coil. Secure the transformer in position in the machine. The
adhesive takes about 20 minutes to harden.
cmha2p33
Airgap (t) in the transformer core
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-- 67 --
TECHNICAL DATA
LTO 160
LTO 250
Mains voltage
230 V, 1
400 V, 3
Mains frequency
50--60 Hz
50--60 Hz
Permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
160 A / 16 V
110 A / 15 V
80 A / 13 V
250 A / 20 V
180 A / 17 V
140 A / 16 V
No--load power
55 W
50 W
Power factor
0.68
0.61
Efficiency
0.70
0.80
Dimensions L x W x H
515 x 285 x 505 mm
515 x 285 x 505 mm
Weight
32 kg
33 kg
Temperature class
F (155 _C)
F (155 _C)
Enclosure type
IP 23
IP 23
Capacity of internal memory,
number of parameter sets
100
100
Battery back--up Control box
2 years
2 years
Application class
Arc strike for tube welding
HF
tools
Arc strike for manual welding HF and LIFT ARC
HF
HF and LIFT ARC
Setting range
LTO 160
LTO 250
Pulse, background and cont.
current
3--160 A
3--250 A
Steps of adjustment, current
1A
1A
Wire feed speed
0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
Rotation speed
5--100 % of max. speed
5--100 % of max. speed
Pulse and background time
0.02--5.0 s
0.02--5.0 s
Pre--heat time
0--99.8 s
0--99.8 s
Gas pre--flow
1--250 s
1--250 s
Gas post--flow
3--250 s
3--250 s
Slope--up and slope down
0--25 s
0--25 s
Sector time
0.01--33.59 min
0.01--33.59 min
Steps of adjustment, sector
time
0.1 s
0.1 s
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.
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-- 68 --
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
The symbol
hazard.
indicates that the power source is designed for use in areas with increased electrical
LOAD CHARACTERISTICS
LTO 160
LTO 250
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-- 69 --
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-- 70 --
INSTRUCTIONS
This chapter contains an extract from edition 9909 of the LTO 160/250 Instruction Manual.
The part of the instruction manual which deals with the control box is not included in this
extract. Please see the instruction manual for this information.
Instruction manual Ordering no.
Language
Edition
Serial no.
LTO 160 / 250
SE GB
SE DK NO FI
GB DE FR NL
ES IT PT GR
SE DK NO FI
GB DE FR NL
ES IT PT GR
RU GB
971125
980902
980902
980902
990913
990913
990913
990913
728 / 745
745
745
745
837
837
837
837
0456 779 100
0456 779 040
0456 779 041
0456 779 042
0456 779 140
0456 779 141
0456 779 142
0456 779 027
SAFETY
Users of ESAB welding equipments have ultimate responsibility for ensuring that anyone
who works on or near the equipment observes all the relevant safety precautions.
Safety precautions must meet the requirements that apply to this type of welding equipment.
The following recommendations should be observed in addition to the standard regulations
that apply to the work place.
All work must be carried out by trained personnel who are familiar with the operation of the
welding equipment.
Incorrect operation of the equipment may lead to a hazardous situation which can result in
injury to the operator and damage to the equipment.
1.
Anyone who uses the welding equipment must be familiar with:
S
its operation
S
its function
S
relevant safety precautions
S
welding
2.
The operator must ensure that:
S
no unauthorized person is stationed within the working area of the equipment when it is
started up.
S
that no--one is unprotected when the arc is struck
3.
The work place must:
S
be suitable for the purpose
S
be free from draughts
4.
Personal safety equipment
S
Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S
Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S
Make sure the return cable is connected securely.
S
Work on high voltage equipment may only be carried out by a qualified electrician.
S
Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S
Lubrication and maintenance must not be carried out on the equipment during its operation.
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-- 71 --
INTRODUCTION
General
LTO 160 and LTO 250 are transistor--controlled welding power sources for TIG welding.
They are programmable and provided with a memory so that different welding programs can
be set and stored by means of a control box. The welding programs can be divided into
sectors with different sets of parameters. The division into sectors is time--controlled.
They have battery backup so that the settings remain in memory even when the machine is
switched off or disconnected from the power supply.
The machines are of inverter type, which means that the mains voltage first is rectified and
then converted back to alternating current of very high frequency. After this it is transformed
to welding current.
Rectifier
Inverter
Transformer
Rectifier
Control system
The inverter principle makes it possible to control every sequence of the welding process by
means of electronics, which results in better welding properties.
The microprocessor is programmed to provide for optimal starting properties. The processor
supervises the welding procedure and provides for the right static and dynamic qualities.
LTO 160 and LTO 250 are designed both for manual and mechanized welding, and as a result
they can drive the ESAB welding tools PRB, PRG, PRI, POB, POC and PRH. For manual
welding a TIG torch for OKC connection is used.
LTO 160 / LTO 250 is composed of the following units:
S
Power module containing power units and control electronics. Here the incoming mains
voltage is transformed to high--frequency alternating voltage which is then transformed to
welding voltage.
S
Control box for the selection of welding procedure (sequence or non--sequence), HF or
LIFTARC start, programming, parameter changes, memory handling, sector
classification, manual gas pre--flow, manual rotation, manual wire feed, start and stop.
The values for current and voltage are continuously displayed on the control box during
the welding process. The communication between the control box and the power source
is very reliable from interference point of view as the signals are transmitted via optical
fibres. (L=10m.)
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-- 72 --
INSTALLATION
WARNING
This product is intended for industrial use. In a domestic environment this product may
cause radio interference. It is the user’s responsibility to take adequate precautions.
Installation must be carried out by a qualified electrician.
Place the machine so that there is nothing to prevent the cooling air from passing through it.
Lifting instructions
Mains voltage connection
The rating plate with production number and connection data is located on the rear panel of
the welding eqipment.
Make sure the machine is connected for the correct mains voltage and properly fused. Earth
according to applicable directives.
LTO 160
LTO 250
Mains voltage
230 V
400 V
Mains frequency
50--60 Hz
50--60 Hz
Fuse, slow rupture
16 A
16 A
Mains cable, cross section
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3 x 2.5
mm2
4 x 1.5 mm2
-- 73 --
Connection of a complete welding system
B -- B
Motor cable --wire feed
L -- L
Torch contact
C -- C
Motor cable -- rotation
M -- M
Gas hose out
G -- G
Cooling--water hose in
N -- N
Gas hose in
H -- H
Cooling--water hose out
Q -- Q
Return cable +
J -- J
Welding cable --
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-- 74 --
B -- B
Motor cable --wire feed
L -- L
Torch contact
C -- C
Motor cable -- rotation
M -- M
Gas hose out
G -- G
Cooling--water hose in
N -- N
Gas hose in
H -- H
Cooling--water hose out
Q -- Q
Return cable +
J -- J
Welding cable --
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-- 75 --
OPERATION
General safety regulations for the handling of the equipment appear from page 71.
Read through before you start using the equipment.
WARNING!
Rotating parts can cause injury, take great care
1.
2.
3.
4.
Make sure the welding and return cables and the welding tool are properly connected.
Make sure there are no gas leaks.
Set the starting switch to position 1. The indicating lamp goes on to show that mains
voltage is supplied.
Set data according to instructions under CONTROL BOX.
Controls and connections
10. Connection rotation PRB 9--20, 18--40, 36--80,
71--160, 140--220, PRG, PRI, POB
1.
Mains power switch
2.
Indicating lamp thermostat (yellow)
3.
Indicating lamp mains (white)
4.
Control box
5.
Connection for return cable (+)
6.
Connection for welding cable (--),
cross section 25 mm 2
7.
Connection wire feed MEI 21, POC
16. Control box cable
8.
Connection rotation PRB 17--49,
33--90, 60--170, PRH 6--40, 25--90,
40--115, POC
17. Fuse, slow rupture 1.25 A (connection 230 V)
9.
11. Connection for cooling unit 230 V, 1.25 A
12. Connection for shielding gas
13. Connection for remote start -- TIG torch
14. Mains cable
15. Gas nipple, connection of gas bottle
18. Connection for water flow--guard
Connection wire feed MEI 20, POB,
PRI
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-- 76 --
Overheating protection
The machine has been equipped with an integrated thermostat that trips if the temperature
becomes too high. When this occurs the welding current is cut out and the yellow indicating
lamp comes on. When the temperature has dropped the thermostat automatically resets.
MAINTENANCE
Note:
All supplier guarantees will expire if the customer himselft during the
guarantee period takes measures in order to order to remedy an error in the
machine.
Check--up and cleaning
Generally LTO 160 / LTO 250 does not require any maintenance. Normally, it is sufficient to
blow out the machine using clean, compressed air (reduced pressure) annually, and the dust
filter should be cleaned regularly. If the machine is set up in dusty or dirty environment the
machine and the dust filter should be cleaned more often.
Dismantling the filter
CONTROL BOX
The part of the instruction manual which deals with the control box is not included in this
extract from the instruction manual. Please see the instruction manual for this information.
The ordering number for the instruction manual is on page 71.
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-- 77 --
ACCESSORIES
Order number
Tube welding tool A21 PRB, water--cooled . . . . . . . . . . . . . . . . . . . . 17--49 . . . . . . . 0443 750 880
33--90 . . . . . . . 0443 760 880
60--170 . . . . . . 0443 770 880
Tube welding tool A21 PRB, air--cooled . . . . . . . . . . . . . . . . . . . . . . . 17--49 . . . . . . . 0443 750 881
33--90 . . . . . . . 0443 760 881
60--170 . . . . . . 0443 770 881
Tube welding tool A21 PRH, enclosed . . . . . . . . . . . . . . . . . . . . . . . . 6--40 . . . . . . . . . 0456 940 880
25--90 . . . . . . . 0456 941 880
40--115 . . . . . . . 0456 942 880
Tube welding tool A22 POC, wire feed . . . . . . . . . . . . . . . . . . . . . . . 12--60 . . . . . . . 0443 930 880
TIG, hand torch HW 17R OKC 3,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0588 000 722
HW 20 OKC 3,8 m . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0588 000 744
Wire feed unit MEI 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0443 830 880
Cooling unit OCF 2M . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0457 216 882
Trolley (carriage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0301 100 880
Extension cable a, programming box (15 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0369 143 887
Extension cable b, wire (10 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 904 880
Extension cable c, rotation (10 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 906 880
Extension cable f, return cable (8 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0152 349 893
Extension set 1, current, water, gas (8 m) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0456 905 880
Extension set 2, current, water, gas, torch contact (8m) . . . . . . . . . . . . . . . . . . . . . . . . 0466 705 881
clto0de6
-- 78 --
clto0de6
-- 79 --
clto0de6
-- 80 --
LTO 160/250
Edition 000229
Spare parts list
Valid for serial no. 636--xxx--xxxx to serial no. 837--xxx--xxxx
Ordering numbers for LTO 160 and LTO 250
0456 770 880 LTO 160, Mechtig 160
0457 220 880 LTO 250, Mechtig 250
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.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.
clto0se1
-- 81 --
LTO 160/250
Edition 000229
C = component designation in the circuit diagram
Item
Qty
Ordering no.
201
202
203
1
1
1
0468 543 880
0468 529 001
0468 278 001
Handle
Rubber mat
Cover
204
205
206
207
208
209
10
2
1
1
1
0192 859 006
0468 532 001
0193 392 119
0456 765 880
0456 743 880
0469 402 880
Locking washer
Screw
Insulating bushing
Holder
Front panel
Rubber seal
210
211
212
213
214
215
216
1
1
1
1
2
1
1
0193 759 001
0193 759 002
0366 296 002
0456 769 001
0441 819 001
0468 275 001
0468 519 001
Indicating lamp
Light--emitting diode
Knob
Side panel
Screw
Grill
Filter
White, 28 V
Yellow
0192 562 103
0192 562 104
0192 562 106
Cage nut ”low”
Cage nut ”high”
Cage nut
M5
M5
M6
1
1
1
1
0456 725 001
0457 223 001
0456 725 002
0457 223 001
Front cover
Front cover
Front cover
Front cover
LTO 160 before ser.no. 837--844--xxxx
LTO 250 before ser.no. 837--844--xxxx
LTO 160 from ser.no. 837--844--xxxx
LTO 250 from ser.no. 837--844--xxxx
222
223
224
225
1
1
1
1
1
1
1
1
0193 307 104
0212 602 208
0369 761 001
0468 516 882
0456 767 001
0456 768 001
0192 784 006
0192 784 005
Cable bushing
Nut
Mains cable
Mains cable
Side panel
Rear panel
Connector
Connector
226
1
0366 295 004
Switch
227
228
229
2
2
2
0193 701 002
0193 701 001
Fuse holder
Fuse
Fuse holder cap
0320 029 002
Earth contact washer
217
218a
218b
219
220
221
230
clto0se1
Denomination
Notes
C
Complete
When the cover is replaced, items 204 and 209
must also be replaced
Must be pressed with 50 kg pressure, when fitted
12 pcs of item 204 included
HL01
V05
Left
LTO 160 3 x 2.5 mm2 with plug
LTO 250 4 x 1.5 mm2
Right
XS30
XP31
QF01
1.25 A slow
-- 82 --
FU08, FU09
LTO 160/250
clto0se1
Edition 000229
-- 83 --
LTO 160/250
160 = LTO 160
Edition 000229
C = component designation in the circuit diagram
250 = LTO 250
Item
Qty
160
Qty
250
Ordering no.
Denomination
Notes
301
1
1
0367 268 001
HF unit
From ser.no. xxx-- 006-- xxxx
Replacing 0367 268 002
302
5
5
0365 534 001
Spacer washer
Rubber washer
303
2
2
0193 312 101
Ferrite core
304
1
1
0455 043 880
HF coil
305
2
2
0192 859 006
Locking washer
306
1
1
0468 527 001
Holding plate
307
2
2
0365 584 002
Nail
308
2
2
0320 029 002
Earth contact washer
310
0192 547 001
Speednut
311
1
1
0468 295 001
Control transformer
312
1
1
0193 045 011
Terminal block
313
1
1
0193 054 002
Solenoid valve
314
1
1
0190 315 102
Hose
315
1
1
0365 803 002
Nipple
316
1
1
0193 045 011
Terminal block
317
1
1
0455 861 880
Holding plate
318
1
--
0468 545 001
Sign
--
1
0468 545 002
Sign
1
--
0486 343 880
--
1
322
2
324
AP11
TV01
Busbar
309
C
(G+F) Included in item 601 and 605
TC01
Delivered as 12--pole, to be cut to 4--pole
X02
YV01
To be ordered per metre
0.3 metre as delivered
Delivered as 12--pole, to be cut to 3--pole
X01
Circuit board
Suppression board
AP08
0486 577 880
Circuit board
Suppression board
AP08
2
0156 868 880
Welding current connector
OKC 50
XS13, XS14
2
2
0466 325 001
Gasket
325
1
1
0538 500 902
Connector, socket
2--pole
XS12
326
1
1
0443 693 003
Cap
329
--
1
1
---
0467 809 880
0040 953 611
Primary inductor
Cable tie
330
1
--
0468 521 001
Insulation
331
1
--
0367 269 880
Capacitor
0.1←F 400V with cable lugs (M6+M10)
C06
--
1
0367 269 882
Capacitor
0.1←F 275V AC X2 with cable lugs (M6+M10)
C06
1
--
0468 534 881
Capacitor
0.1←F 400V PME with cable lugs (2xM10)
C07
--
1
0468 534 882
Capacitor
0.1←F 400V PHE427 with cable lugs (2xM10)
C07
333
1
1
0468 534 880
Resistor
3.9kτ 5W with cable lugs (2xM10)
R01
334
1
1
0457 230 001
Panel jack
335
1
1
0457 228 880
Cover
336
1
1
0457 229 880
Support
337
--
1
0457 252 001
Transformer
338
--
1
0457 519 001
Fan
319
332
clto0se1
L03
Heat resistant (to be used for L03)
XS53
TC04
24V DC
-- 84 --
EV02
LTO 160/250
clto0se1
Edition 000229
-- 85 --
LTO 160/250
160 = LTO 160
Edition 000229
C = component designation in the circuit diagram
250 = LTO 250
Item
Qty
160
Qty
250
Ordering no.
401
402
403
1
1
1
--
1
1
-1
0468 542 001
0468 544 001
0486 112 881
0486 112 882
Lid
Insulation
Circuit board
Circuit board
----
1
1
1
1
1
1
0193 260 154
0193 260 003
0193 260 156
Connector
Connector
Connector
6--pole for 0.75 mm2 conductor
4--pole for 0.35 mm2 conductor
8--pole for 0.75 mm2 conductor
XS01
XS02
XS03
--
5
5
0193 260 001
Connector
2--pole for 0.35 mm2 conductor
------
1
1
1
2
2
1
1
1
2
2
0193 260 151
0193 260 153
0193 669 002
0193 590 302
0193 260 152
Connector
Connector
Connector
Sleeve
Connector
3--pole for 0.75 mm2 conductor
5--pole for 0.75 mm2 conductor
2--pole
For connector XS17
4--pole for 0.75 mm2 conductor
XS06, XS07,
XS15, XS16,
XS18
XS08
XS09
XS17
404
405
1
2
1
2
0468 541 001
0457 327 001
Screening box
Insulation
406
1
1
0486 192 880
Circuit board
407
408
409
1
2
1
1
2
1
0468 310 001
0468 279 001
0468 280 001
Insulation
Insulation
Insulation
410
411
1
1
1
1
412
1
1
413
414
415
4
1
2
416
417
418
420
421
422
423
424
425
426
clto0se1
Denomination
Notes
C
AP01
AP01
Suppression board
XS19, XS22
AP07
Busbar
Busbar
Included in item 601 and 605
Included in item 601 and 605
0486 166 880
Circuit board
Shunt amplifier
AP10
4
1
2
0366 588 001
0468 274 001
0468 520 001
Nut
Holding plate
Grill
4
4
2
4
4
2
0162 532 001
0158 619 001
0468 547 881
Bushing
Bushing
Capacitor
0.1←F 275VAC X2 with cable lugs
C08, C09
1
1
-1
1
-1
1
1
1
1
1
1
2
0192 903 506
Busbar
Busbar
Connection bar
Busbar
Busbar
Busbar
Capacitor
Included in item 600
Included in item 600
Included in item 600
Included in item 600
Included in item 600
Included in item 600
1000←F
C02, C03
-- 86 --
LTO 160/250
clto0se1
Edition 000229
-- 87 --
Edition 000229
LTO 160
C = component designation in the circuit diagram
160 = LTO 160
Item
Qty
160
Ordering no.
501
1
0467 801 001
502
1
503
1
504
1
505
Denomination
Notes
C
Fan
24 VDC
EV01
Circuit board
Transistor board, positive pole.
Included in item 602
AP02
0192 883 150
Capacitor
0.1 ←F 1000 VDC
C01
0193 316 208
Rectifier bridge
1
0467 800 001
Insulation
508
2
0467 797 001
Guide
509
2
0467 793 180
Heat sink
510
1
Circuit board
Transistor board, negative pole
Included in item 602
511
15
Spring
Included in item 602
512
1
0468 016 880
Inductor
Secondary
513
1
0192 716 004
Diode
514
2
0193 529 017
Capacitor
515
1
0468 496 001
Holder
516
1
0468 215 880
517
1
518
V01
AP03
L01
V06
4.7 ←F
C05
Inductor
Complete
L02
Winding
Included in item 516
1
Bobbin
Included in item 516
519
2
Core
Included in item 516
520
2
Clip
Included in item 516
521
522
523
524
1
1
2
1
0468 961 880
0192 883 017
0212 913 108
Shunt
Capacitor
Spacer
Busbar
119 mV at 140 A
0.1←F 1000 VDC
M8
Included in item 601 and 605
RS01
C04
525
1
0320 655 009
Thermal cutout
ST01
526
--
1
1
0467 792 880
0466 602 001
Transformer coil
Conductor
Opens at 130˚C, closes at 100˚C
Included in item 526
Includes item 525
To be ordered per metre 0.6m/transformer
527
1
0467 799 001
Clip
528
4
0193 312 101
0365 652 002
0191 124 021
Ferrite core
Tape
Glue
0193 669 002
0193 590 302
0455 646 880
0457 292 001
0193 948 001
Connector
Sleeve
Rectifier unit
Heat sink
Diode module
Busbar
Busbar
Capacitor
529
1
530
531
532
533
534
535
1
1
1
1
1
2
0467 648 883
For air gap
Loctite 649, for ferrite core
2--pole
2 per connector
Complete, includes items 531 -- 535
TC02
020
XS17
V03, V04
Included in item 601
With insulation Included in item 601
Complete with cable lugs
C10
SPARE PARTS SETS, LTO 160
Item
Ordering no.
600
0468 881 880
Busbars, primary
Contains items 420 -- 425
601
0468 881 885
Busbars, secondary
Contains items 308, 410, 411, 524, 533 and 534
602
0468 881 882
Transistor boards LTO 160
Contains items 502, 510 and 15 springs (item 511)
604
0192 058 106
Contact oil
To be used when mounting item 502 and 510
clto0se2
Denomination
Notes
-- 88 --
Edition 000229
LTO 160
clto0se2
-- 89 --
LTO 250
Edition 000229
250 = LTO 250
Item
Qty
250
Ordering no.
501
1
0467 801 001
502
1
503
1
504
2
505
C = component designation in the circuit diagram
Denomination
Notes
C
Fan
24V DC
EV01
Circuit board
Transistor board positive pole
Included in item 603
AP02
0192 883 150
Capacitor
0.1 ←F 1000 VDC
C01
0193 316 208
Rectifier bridge
1
0467 800 001
Insulation
508
2
0467 797 001
Guide
509
2
0467 793 180
Heat sink
510
1
Circuit board
Transistor board negative pole
Included in item 603
511
19
Spring
Included in item 603
512
1
0468 016 881
Inductor
Secondary (item 525 is included)
513
1
0192 716 004
Diode
514
2
0193 529 017
Capacitor
515
1
0468 496 001
Holder
516
1
0468 215 880
517
1
518
519
V01, V02
AP03
L01
V06
4.7 ←F
C05
Inductor
Complete
L02
Winding
Included in item 516
1
Bobbin
Included in item 516
2
Core
Included in item 516
520
2
Clip
Included in item 516
521
522
523
524
1
1
2
1
0457 304 880
0320 805 886
0212 913 108
Shunt
Capacitor
Spacer
Bus bar
119 mV at 250 A
0.1←F 400 VDC
M8
Included in item 605
RS01
C04
525
1
0320 655 009
Thermal cutout
Opens at 130˚C,
Included in item 512
ST01
526
-527
528
1
1
1
4
0457 308 880
0466 602 001
0467 799 001
0193 312 101
0365 652 002
0191 124 021
Transformer coil
Conductor
Clip
Ferrite core
Tape
Glue
0193 669 002
0193 590 302
0455 646 883
0457 292 001
0193 948 001
Connector
Sleeve
Rectifier unit
Heat sink
Diode module
Bus bar
Bus bar
Capacitor
Bus bar
Spacer sleeve
Ferrite ring core
Ferrite ring core
Bus bar
Bus bar
Copper washer
Resistor
529
1
530
531
532
533
534
535
536
537
538
539
540
541
542
543
1
1
3
1
1
2
1
2
2
1
1
1
2
1
clto0se3
0467 648 884
0191 745 011
0455 569 002
0455 569 003
0468 538 002
0468 538 002
0457 695 001
0457 557 880
Tobe ordered per metre 0.6 m/transformer
TC02
020
For air gap
Loctite 649, for ferrite core
2--pole
2 per connector
Complete, includes items 531 -- 535
XS17
V03, V04
With insulation. Included in item 605
With insulation. Included in item 605
Complete with cable lugs
Included in item 605
C10
L04, L05
L03
Included in item 605
Replaces item 542. Included in item 605
Replaced by item 541
Complete 8,2 kτ 5W
-- 90 --
R02
LTO 250
Edition 000229
SPARE PARTS SETS, LTO 250
Item
Ordering no.
Denomination
Notes
600
0468 881 880
Bus bars, primary
Contains items 420 -- 425
603
0468 881 887
Transistor boards LTO 250
Contains items 502, 510 and 21 springs (item 511)
605
0468 881 888
Bus bars, secondary
Contains items 308, 410, 411, 524, 533, 534, 536, 540 and 541
606
0192 058 106
Contact oil
To be used when mounting items 502 and 510
clto0se3
-- 91 --
LTO 160/250
Edition 000229
C = component designation in the circuit diagram
Item
Qty
Ordering no.
701
1
0456 750 880
Base plate
702
703
1
1
0368 544 003
0366 285 001
Connector socket
Cap
12--pole
XS33
704
705
1
1
0368 544 005
0455 516 001
Connector socket
Cap
23--pole
XS34
706
707
1
1
0538 500 008
0443 693 005
Connector socket
Cap
8--pole
XS36
708
709
1
1
0538 500 111
0443 693 006
Connector socket
Cap
10--pole
XS35
710
711
1
1
0456 749 001
0456 749 002
Connection socket
Connector
712
4
0319 455 002
Rubber foot
713
714
1
1
1
0456 774 001
0456 742 001
0457 226 001
Insulation
Control transformer
Control transformer
715
1
0481 982 880
Circuit board
0192 041 139
Grommet
716
Denomination
Notes
C
XS32
For LTO 160
For LTO 250
TC03
TC03
AP12
717
1
0481 651 880
Circuit board
718
719
720
6
1
0192 292 101
0192 041 131
0456 739 001
Guide
Grommet
Bracket
721
722
723
1
1
1
0486 437 880
0486 437 882
0456 740 001
Circuit board
Circuit board
Attachment
AP17
AP18
724
725
1
1
0341 046 882
0341 046 882
Circuit board
Circuit board
AP14
AP13
726
727
728
1
4
4
0486 432 880
0455 226 004
0192 579 009
Circuit board
Spacer
Resistor
AP18
729
1
0456 746 001
Plate
730
731
2
0192 579 015
0193 634 001
----
1
1
6
-------
clto0se4
AP15
3 Ω 10 W
R02, R03,
R04, R05
Resistor
Board lock
10 Ω 10 W
R06, R07
0192 784 002
0192 784 001
0193 260 150
Connector
Connector
Connector
2--pole (sleeve)
2--pole (pin)
2--pole
3
0193 260 152
Connector
4--pole
1
1
1
1
1
0193 260 153
0193 260 154
0193 260 155
Connector
Connector
Connector
Connector
Connector
5--pole
6--pole
7--pole
3--pole
5--pole
XS50
XP51
XS41, XS42,
XS43, XS44,
XS53, XS38
XS39, XS45,
XS46
XS37
XS40
XS49
XS47
XS48
-- 92 --
LTO 160/250
clto0se4
Edition 000229
-- 93 --
LTO 160/250
Edition 000229
C = component designation in the circuit diagram
Item
Qty
Ordering no.
800
1
0442 085 882
Control box
Complete with cable (item 810)
801
802
1
1
0369 138 880
0369 130 001
Clamp
Side panel
Complete
Left
803
804
1
1
0442 075 880
0369 134 001
Key cloth
Display window
805
1
0456 802 880
Casing
806
1
0481 417 880
Circuit board
807
1
0481 404 894
Circuit board
808
1
0369 129 001
Side panel
Right
809
810
1
1
0212 602 201
0369 143 886
Nut
Cable
L = 10m
811
1
Ribbon cable
Included in item 806
812
1
0193 069 201
Battery
813
1
0369 135 001
Rubber stud
clto0se4
Denomination
Notes
Complete, with text
-- 94 --
C
E01
LTO 160/250
clto0se4
Edition 000229
-- 95 --
NOTES
notes
-- 96 --
notes
-- 97 --
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
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: +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, Turkey
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
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