ESAB | LKA 180 | Service manual | ESAB LKA 180 User manual

ESAB LKA 180 User manual
LKA 180/240
Welding power source
clka1p00
Service manual
0740 800 049
9606
Valid for serial no. 337--xxx--xxxx to serial no. 618--xxx--xxxx
This is h1
LIST OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RATING PLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION, LKA 180/240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM, LKA 180 Single--phase, 230 V . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM, LKA 180 3--phase, 400 V . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM, LKA 180 3--phase, 230/400 V . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM, LKA 240 3--phase, 400 V . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONNECTION DIAGRAM, LKA 240 3--phase, 230/400 V . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT DIAGRAM, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT POSITIONS, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . .
LOAD CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WELDING DATA SELECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REPLACING THE WIRE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING / REFITTING THE GAS NOZZLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOVING / REFITTING THE GAS DIFFUSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST, LKA 180/240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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14
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26
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27
INTRODUCTION
This service manual is intended for use by technicians with electrical training when carrying
out fault tracing and repair of the equipment.
At the end of the manual, there is a brief guide to using the machine in order to assist in
understanding the machine.
The manual contains all design modifications introduced up to and including June 1996.
Use the diagrams in the manual when tracing faults. The machine components are described
in alphabetical order on the pages following the connection diagram.
The LKA 180 and 240 are designed and tested in accordance with international
standard EN 60 974--1 (IEC 974--1).
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.
Rights reserved to alter specifications without notice.
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-- 2 --
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
S
S
S
Install and earth the welding unit in accordance with applicable standards.
Do not touch live electrical parts or electrodes with bare skin, wet gloves or
wet clothing.
Insulate yourself from earth and the workpiece.
Ensure your working stance is safe.
FUMES AND GASES - Can be dangerous to health
S
S
Keep your head out of the fumes.
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
S
Protect your eyes and body. Use the correct welding screen and filter lens
and wear protective clothing.
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.
MALFUNCTION
S
Call for expert assistance in the event of malfunction.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE
INSTALLING OR OPERATING THE EQUIPMENT
PROTECT YOURSELF AND OTHERS!
mvarnen1
-- 3 --
RATING PLATE
The rating plate is secured to the back of the machine. The example shown below is the rating
plate for an LKA 240 with an explanation of how the plate should be read and interpreted.
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1.
LKA 240 is the type designation for this power source. The first letter, L, indicates that
the LKA 240 is a rectifier, while K indicates Compact (Kompakt in Swedish) and A indicates the design generation.
The 240 indicates the maximum welding current.
2.
These symbols indicate that the LKA 240 incorporates a transformer and rectifier.
3.
This section indicates the voltage/current characteristic when welding and a current range
of 30 - 200 A.
The voltage values of 15 and 24 V in the heading indicate that we comply with the international arc characteristic as defined in IEC 974--1.
X = The duty cycle, indicating for how long a time welding can be carried out at the
specified welding data, expressed as a percentage of a ten--minute period.
I2 = The current at the respective duty factors.
U2 = The arc line characteristic voltage.
Uo = The open--circuit voltage.
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-- 4 --
4.
Indicates that the unit is intended for connection to a 400 V three--phase supply at 50 or
60 Hz.
I1
5.
=
primary currents at the various load points.
IP21 indicates the enclosure class in respect of protection against penetrating objects and
water. Enclosure class IP21 indicates that the equipment is intended for indoor use,
while IP23 equipment is also suitable for outdoor use.
The
symbol indicates that the rectifier is designed for use in areas of elevated electrical risk.
6.
The machine’s serial number, in the form of three groups of figures (xxx yyy zzz).
The first group (xxx) indicates the version. The figures represent the year and week of
approval of the version.
The second group (yyy) shows the year and week of final testing of the machine. For
example, 341 indicates Week 41, 1993.
The final group (zzz) consists of three or four figures, and is a serial number in the range
0001 to 9999.
7.
Shows that ESAB complies with the international standard, IEC 974-- 1.
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-- 5 --
COMPONENT DESCRIPTION, LKA 180/240
The following component description refers to the connection diagrams on the following
pages.
AP1
Circuit board with control electronics: see the diagram on page 12 and
description on page 15.
C1--C3
Capacitor PME 0.1←F, 400 VDC, transient and HF protection.
EV1
Fan, 24 VDC, fitted in the LKA 240 and the single--phase version of the
LKA 180.
HL1
Lamp, 28 V, white, lights when the main switch is On.
KM1
Contactor, 42 V operating voltage.
L1
Inductor.
M1
Wire feed unit motor.
QF1
Switch, 7--way in the LKA 180 and 10--way in the LKA 240.
R1
Resistor, 1 τ, only fitted in the single--phase version of LKA 180.
R2
Resistor, 5.6 kτ 5 W, only fitted in the single--phase version of LKA 180.
SB1
Welding torch trigger switch
ST1
Thermal overload cutout, for protection against overload, fitted in the winding of
main transformer TM1. The switch operates (opens) at a temperature of 120 _C.
ST2
Thermal overload cutout, for protection against overload, fitted on the diode
bridge cooling fins (V1 -- V6). It operates (breaks) at 110 _C in the single--phase
version of the LKA 180 and at 130 _C in other machines.
TC1
Control power supply transformer.
Supplied at 230 or 400 V and protected by a 1.6 A anti--surge fuse.
Secondary output voltages of 42, 27 and 20 V to circuit board AP1.
TM1
Main transformer.
V1--V6
Diode bridge, rectifier.
V7
LED, yellow. Lights if thermal overload cutouts ST1 or ST2 operate as a result of
high temperature.
XS1
9--pole connector.
XS2
5--pole connector.
XS3
7--pole connector.
XS4
2--pole connector.
XT1
Mains terminal block, 5--way.
XT2
Terminal block, positive and negative welding voltages.
XT3
6--pole terminal block for mains voltage selection.
Fitted only in the multi--voltage versions of the machine.
YV1
Solenoid valve
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-- 6 --
CONNECTION DIAGRAM, LKA 180 Single--phase, 230 V
The first 150 machines
were delivered with
switch 0408/8112.
The part No. in the
spare parts list is
referring to the other
switch, which has to be
used as spare part for
all machines.
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-- 7 --
CONNECTION DIAGRAM, LKA 180 3--phase, 400 V
When checking the no--load
voltages, load the machine with
a dummy load of 5.6 kτ 5 W,
connecting it between plus and
minus on the rectifier bridge.
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clka1de1
-- 8 --
CONNECTION DIAGRAM, LKA 180 3--phase, 230/400 V
When checking the no--load
voltages, load the machine with
a dummy load of 5.6 kτ 5 W,
connecting it between plus and
minus on the rectifier bridge.
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clka1de1
-- 9 --
CONNECTION DIAGRAM, LKA 240 3--phase, 400 V
When checking the no--load
voltages, load the machine
with a dummy load of 5.6 kτ 5
W, connecting it between plus
and minus on the rectifier
bridge.
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clka1de1
-- 10 --
CONNECTION DIAGRAM, LKA 240 3--phase, 230/400 V
When checking the no--load
voltages, load the machine
with a dummy load of 5.6 kτ
5 W, connecting it between
plus and minus on the
rectifier bridge.
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-- 11 --
CIRCUIT DIAGRAM, CIRCUIT BOARD AP1
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-- 12 --
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-- 13 --
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COMPONENT POSITIONS, CIRCUIT BOARD AP1
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-- 14 --
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1
This description relates to the circuit diagram on page 12 and to the component positions
diagram on page 14.
Only those items connected to the inputs and outputs of the board are described here. If the
board is faulty, it must be replaced.
1
POWER SUPPLY
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Transformer TC1 supplies indicating lamp HL1 and rectifier bridge BR1
with 27 V AC. The unsmoothed DC output from BR1 is smoothed by capacitors C5 and C25
to produce an open--circuit voltage of 38 V ”10%.
This provides the power supply for the wire feeder motor.
Connections T6 and T7 supply 20 V AC from transformer TC1 to diodes D18 -- D21.
The rectified voltage is about 24 V in the fan--cooled machines and somewhat higher in the
3--phase LKA 180. This supply powers fan EV1 in the fan--cooled machines.
Voltage regulator VR1 is supplied via diode D1 to provide a regulated 15 0.6 V supply.
2
REFERENCE CIRCUIT
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Potentiometer R49 controls the wire feed speed and is connected to terminals P1 - P3.
It is energised via resistors R51 - R55 and R23. The reference voltage is supplied through
resistor R20 to the error amplifier.
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-- 15 --
START/STOP CIRCUIT, THERMAL OVERLOAD CIRCUIT AND SPOT
WELDING CIRCUIT
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3
START AND STOP CIRCUIT
When the torch trigger switch SB1 is not activated, the voltage between M3 and M4 is
24 V. Pressing the trigger switch shorts the circuit, producing a voltage of 0 V
between M3 and M4.
4
THERMAL OVERLOAD CIRCUIT
The machine contains two thermal overload cutouts, wired in series and connected to
inputs T8 and T9. If either of them operates, the torch trigger switch circuit cannot be
short--circuited, with the result that wire feed cannot be started.
When either of the thermal cutouts has operated, LED V7 is energised to indicate this
via diode D7.
5
SPOT WELDING CIRCUIT
Potentiometer R50 controls the spot welding time and incorporates a switch. When in
the zero position, the switch is open.
When the switch in R50 and torch trigger switch SB1 are closed, capacitor C22
charges up through resistors R32 and R50. Wire feed stops when the voltage on C22
reaches 8.8 V. The trigger switch must be released and then pressed again before a
new spot weld can be made.
The spot welding time can be adjusted between 0.2 and 2.5 seconds 30%.
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6
BURN--BACK TIME
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The burn--back time is the time from when wire feed ceases until contactor KM1
drops off.
During welding, the voltage at pin 13 of IC2 is low. The output of the inverter at pin
14 is therefore high, turning on transistor Q2 and activating relay RE1.
When the torch trigger switch is released, or when the spot welding time expires,
capacitor C23 charges up via resistors R36, R37 and R38. When the voltage across
C23 reaches 8.8 V, output 14 of IC2 goes low, turning off Q2 and causing relay RE1
to drop off.
Potentiometer R38 is used to adjust the burn--back time
between 15 and 250 milliseconds. As delivered, the
burn--back time is set to 170 milliseconds.
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Adjusting the burn--back time
From machine number 618 ... .... R38 is not mounted, the burn--back time is not
adjustable and set to 33 milliseconds with the resistors R36 and R37.
Spare part circuit boards to machines with earlier machine numbers are also having a
none adjustable burn--back time, which is set to 65 milliseconds.
7
CONTROL AMPLIFIER AND PULSE WIDTH MODULATOR
The control amplifier compares the set value speed signal with the actual speed and
supplies a control signal to the pulse width modulator. The actual value speed signal
is provided by measuring the motor voltage.
The pulse width modulator controls the frequency and pulse time of current to the
wire feed motor.
The switching frequency is about 2.5 kHz. The frequency is constant: it is the
mark/space ratio that is varied.
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MOTOR DRIVE AND BRAKING
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8
MOTOR DRIVE CIRCUIT
The output stage of the pulse width modulator is connected to transistor Q1 via
resistor R16.
A motor current signal is provided by measuring the voltage across resistor R4,
connected to transistor Q1.
If the voltage across R4 exceeds 1.1 V 60 mV, the gate pulses to Q1 are inhibited.
This provides a current limit of about 11 A.
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Motor voltage when the wire feed speed control potentiometer is in its centre position. The motor is
unloaded.
9
BRAKING CIRCUIT
When wire feed is to stop, the pulse width modulator turns off the pulses to Q1.
Transistors Q3 and Q4 turn on: transistor Q4 provides a path for dynamic braking
current to flow through resistor R47 and diode D17.
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-- 18 --
LOAD CHARACTERISTICS
LKA 180 single phase
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LKA 180 3-- phase
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LKA 240
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-- 19 --
TECHNICAL DATA
LKA 180
230V
Permissible loading
At 10% duty cycle
At 15% duty cycle
At 60% duty cycle
At 100% duty cycle
LKA 180
400V
LKA 180
230/400V
LKA 240
400V
LKA 240
230/400V
180A/19V
180A/19V
180A/19V
75A/19V
60A/17V
75A/18V
60A/17V
65A/20V;75/18
60A/17V;60/17
240A/22V
110A/19V
85A/18V
240A/22V
120A/20V;110/19
85A/19V;85/18
No-- load voltage
16-- 33V
15-- 33V
15-- 33V
18-- 36V
18-- 36V
Voltage steps
7
7
7
10
10
Wire feed speed
1-- 15 m/min
1-- 15 m/min
1-- 15 m/min
1-- 15 m/min
1-- 15 m/min
Spot welding time
0.25-- 2.5 s
0.25-- 2.5 s
0.25-- 2.5 s
0.25-- 2.5 s
0.25-- 2.5 s
Wire drum capacity
5-- 15 kg
5-- 15 kg
5-- 15 kg
5-- 15 kg
5-- 15 kg
Wire sizes
Non-- alloyed steel
Stainless steel
Aluminium
Gasless filler wire
0.6-- 0.8 mm
0.6-- 0.8 mm
1.0 mm
0.8-- 0.9 mm
0.6-- 0.8 mm
0.6-- 0.8 mm
1.0 mm
0.8-- 0.9 mm
0.6-- 0.8 mm
0.6-- 0.8 mm
1.0 mm
0.8-- 0.9 mm
0.6-- 0.8 mm
0.6-- 0.8 mm
1.0 mm
0.8-- 0.9 mm
0.6-- 0.8 mm
0.6-- 0.8 mm
1.0 mm
0.8-- 0.9 mm
Power supply
230V 50Hz
1-- phase
400V 50Hz
3-- phase
230/400V 50Hz
3-- phase
400V 50Hz
3-- phase
230/400V 50Hz
3-- phase
Maximum primary current
30A
9A
16/9A
11A
19/11A
Mains fuse rating
20A slow-- blow
mm2
10A slow-- blow
4x1.5
mm2
10/10A slow-- blow
4x2.5
mm2
10A slow-- blow
4x1.5
mm2
16/10A slow-- blow
4x2.5 mm2
Mains cable, area
3x2.5
Weight
53 kg
53 kg
53 kg
56 kg
56 kg
Enclosure class
IP21S
IP21
IP21
IP21
IP21
Application class
The
symbol indicates that the machine has been designed and built for use in areas of
elevated electrical risk.
IP21 indicates the enclosure class in respect of protection against penetrating objects and
water. Enclosure class IP21 indicates that the equipment is intended for indoor use, while
IP23 equipment is also suitable for outdoor use.
Main dimensions, LKA 180 and LKA 240
clka1p08
clka1de1
-- 20 --
INSTALLATION
S
Place the machine in a suitable position and check that cooling is not obstructed.
S
Check that the machine is connected to suit the
mains supply voltage. In the machines that can be
connected for different supply voltages, make the
appropriate connections as required at terminal
block XT3 and transformer TC1.
Make the necessary earth connections in accordance with safety regulations.
S
TC1
XT3
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Fit the filler wire as shown below.
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The picture above is valid for machines with serial numbers before 618 ... ....
The picture above is valid from serial number 618 ... ....
If the drive rollers slip or wire feed does not work properly, it may be necessary to adjust the roller pressure, as
shown in Figure 5 above.
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-- 21 --
GASLESS WIRE
SOLID WIRE
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When welding with gasless wire, the return current
cable must be connected to the positive terminal on the
terminal block above the wire feed unit.
OPERATION
S
Connect the return current conductor clamp (E)
to the workpiece.
S
When welding with solid wire, open the gas
valve (A) on the gas bottle and adjust the gas flow
by reducer valve (B).
The gas flow must be 8 -- 12 litres per minute.
S
Turn on the power unit and set a suitable voltage
with knob (L). The white indicating lamp (K) must
be lit.
S
Hold the welding torch trigger switch (D)
pressed until filler wire is fed out through the
contact tip (F).
S
Select suitable welding data with the voltage control selector (L) and the wire feed control knob (H),
as shown in the tables on page 23 -- 25.
S
Start welding. Adjust the settings if necessary.
S
The yellow LED (J) on the front panel will light if the thermal overload cutout operates
as a result of overload.
The overload cutout resets automatically when the machine has cooled to a safe temperature.
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Spot welding
Set potentiometer (G) to a suitable spot welding time: the time range is steplessly adjustable
from 0.2 to 2.5 seconds. The scale is graduated from 1 to 10.
Press the torch trigger switch. When the preset welding time is up, welding will be stopped
without the operator having to release the trigger switch.
Release the trigger switch and press it again to start a new welding sequence.
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-- 22 --
MAINTENANCE
S
Cleaning away dust
Blow the unit clean with compressed air at reduced pressure.
S
Wire feed mechanism.
The wire feed mechanism should be cleaned, and wearing parts replaced, at regular intervals in order to ensure smooth, reliable wire feed.
Do not tension the pressure roller too hard, as this will result in abnormal wear to the
pressure roller, the feed roller and the wire guide.
S
Welding torch.
Blow the wire guide clean and clean the gas nozzle at regular intervals.
WELDING DATA SELECTION
MACHINE SETTINGS, LKA 180 single-- phase
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-- 23 --
MACHINE SETTINGS, LKA 180 3-- phase
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-- 24 --
MACHINE SETTINGS, LKA 240
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-- 25 --
REPLACING THE WIRE GUIDE
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REMOVING / REFITTING THE GAS NOZZLE
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REMOVING / REFITTING THE GAS DIFFUSER
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The instructions on this page are only valid for machines with PSG 14 welding guns.
For machines with PSF 160 guns, please see the instruction manual which is delivered with
the gun.
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-- 26 --
SPARE PARTS LIST LKA 180/240
Edition 9606
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Ordering no.
Denomination
Notes
469 440--880
469 565--880
469 560--880
LKA 180
LKA 180
LKA 180
400 V 3 phase
230/400 V reconnectable, 3 phase
230 V single--phase
469 560--881
LKA 180
230 V single--phase, only for the Australian market.
Position 102 deviates from version 469 560--880
469 450--880
469 570--880
LKA 240
LKA 240
400 V 3 phase
230/400 V reconnectable, 3 phase
469 560--881
LKA 180
230 V single--phase, only for the Australian market.
Position 102 deviates from version 469 560--880
469 450--882
LKA 240
400 V 3 phase, only for the Australian market.
Position 102 deviates from version 469 560--880
Spare parts list - Reservdelsförteckning - Ersatzteilverzeichnis - Liste de pièces détachées
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the cover. Kindly indicate type of unit, serial number,
denominations and ordering numbers according to the spare parts list.
Reservdelar beställs genom närmaste ESAB--representant, se sista sidan. Vid beställning var vänlig uppge typ och tillverkningsnummer samt
benämningar och beställningsnummer enligt reservdelsförteckningen.
Die Ersatzteile können bei der nächsten ESAB--Vertretung bestellt werden, siehe letzte Seite. Bitte geben Sie Typenbezeichnung und
Herstellungsnummer sowie Bezeichnungen und Bestellnummern laut Ersatzteilverzeichnis an.
Au dos de la brochure, vous trouverez l’adresse du représentant ESAB le plus proche. Prière de lui adresser votre commande, après avoir pris le
soin de mentionner le type et le numéro de série de l’unité ainsi que le numéro de commande et la désignation conformément á la liste de pièces
détachées.
clka1se1
-- 24 --
C = component designation in the circuit diagram
180 = LKA 180
240 = LKA 240
Item
no.
Qty
180
Qty
240
101
1
1
469 368--001
Cover plate
102
1
1
1
1
469 369--001
469 664--001
Rear panel
Rear panel
Only for the Australian market
103
1
--
-1
469 447--001
469 456--001
Side panel
Side panel
With text
With text
104
1
1
469 409--880
Welding gun PSG 14
1) Complete
105
1
1
1
1
469 518--881
469 518--886
Gas nozzle
Gas nozzle
1) Standard
1) For spot welding, option
106
1
1
Contact tip
1) See item 152, 153 and 154
107
1
--
-1
469 572--880
469 443--880
Return cable
Return cable
Complete
Complete
108
1
1
469 518--885
Wire liner
1) Wire liner of steel spiral
see also item 154
109
1
1
469 361--001
Front panel
110
2
8
2
8
469 468--001
Link wheel
Screw
111
1
1
368 265--001
Securing strap
112
1
1
193 498--104
Connector
2)
113
1
1
Inlet nozzle
2) See item 150 and 151
114
1
1
Capacitor
2) PME 0.1 ←F 400 V, with cable lug
115
1
1
Feed roller
2) See item 150 and 151
116
1
1
469 573--880
Wire feeder
Ordering no.
469 380--881
Denomination
Notes
C
MRX M6 x 16 mm
1
1
469 400--880
Feed unit
2) Complete, includes item 113, 114, 115,
118 and 119
2) Includes item 113, 114, 115 and 118
117
4
4
153 043--002
Insulating washer
2)
118
1
1
Outlet nozzle
2) See item 150 and 151
119
1
1
469 397--001
Drive unit
2) Motor and gear box
120
2
2
469 453--001
Attachment
121
1
1
469 516--001
Shaft
122
2
2
123
2
2
469 469--001
Wheel
Washer
XS4
C3
M1
D 21/36
124
2
2
192 859--126
Locking washer
125a
1
1
469 474--001
Brake hub
Before machine no. 547 612 ....
125b
1
1
146 967--881
Brake hub
From macine no. 547 612 ....
126
1
2
1
2
469 437--001
Handle
Screw
MRX M6 x 16mm
127
1
1
469 518--887
Gas diffuser
1) With spring coil
128
1
1
469 518--894
O--ring
1)
129
1
1
469 518--891
Swan neck
1)
130
1
1
469 518--892
Handle
1)
131
1
1
469 518--893
Switch
1) Complete
SB1
SPARE PARTS SETS
Item
Ordering no.
Denomination
Notes
150
469 520--880
Spare parts set
2) Contains items 115 feed roller 0.6/0.8,
113 inlet nozzle and 118 outlet nozzle
151
469 520--881
Spare parts set
2) Contains items 115 feed roller 1.0/1.2,
113 inlet nozzle and 118 outlet nozzle
152
469 518--882
469 518--896
469 518--895
Contact tip
Contact tip
Contact tip
1) Contains item 106, 5 contact tip ø 0.6 and 5 contact tip ø 0.8
1) Contains item 106, 10 contact tip ø 0.6
1) Contains item 106, 10 contact tip ø 0.8
153
469 518--883
Contact tip
1) Contains item 106, 5 contact tip ø 1.0
154
469 518--884
Spare parts set
1) Contains item 106 5 contact tip ø 1.0
and item 108 wire liner of teflon, for aluminium welding
155
155 716--880
Gas flow gauge
1) For protection gas
1) Only for machines supplied with the PSG 14 welding gun
2) Only for machines with serial numbers prior to 618 ... ....
clka1se1
-- 25 --
clka1p02
clka1se1
-- 26 --
WIRE FEED UNIT
Valid from serial number 618 ... ....
C = component designation in the circuit diagram
Item
no.
Qty
Ordering no.
--
--
455 890--890
Feed unit
Complete, contains items 301 -- 331
300
301
302
1
1
1
367 529--001
455 906--001
455 907--001
466 262--001
Complete, contains items 301 -- 305
303
304
305
1
1
1
Pressure arm
Spacer sleeve
Pressure roller
Pressure roller *
Nut
Holder
Shaft
306
1
455 896--001
Spring
308
309
310
1
1
1
455 887--880
2157 010--07
191 496--114
Drive unit
Locking washer
Key
311
1
466 074--001
Inlet nozzle
312
313
1
1
367 528--001
368 749--880
Pin bolt
Pressure transducer
314
2
368 750--001
Insulating sleeve
315
316
317
1
1
1
455 894--001
455 885--001
455 882--001
Insert tube
Outlet nozzle
Current sleeve
318
319
320
1
1
1
455 883--001
Spacer sleeve
Washer
Screw
⊘ 16/8.2x0.9
⊘ 16/8.4x1.5
M8x20
321
322
323
1
1
1
455 881--001
2152 012--02
455 898--001
Protection plate
O--ring
Screw
(M5x12)
324
326
1
1
193 104--002
Screw
Washer
M4x12
⊘ 16/5x1
327
1
1
1
1
367 556--001
367 556--002
367 556--006
367 556--004
Feed roller
Feed roller *
Feed roller *
Feed roller *
For ⊘ 0.6 -- 0.8 mm Fe, Ss and cored wire
For ⊘ 0.8 -- 1.0 mm Fe, Ss and cored wire
Knurled rollers for ⊘ 1.0 -- 1.2 mm cored wire
For ⊘ 1.0 -- 1.2 mm Al wire
329
1
455 893--001
Shaft
330
331
332
1
3
1
455 884--001
2121 107--42
469 380--881
Gear housing
Screw
Capacitor
Denomination
Notes
Knurled
SGA D8
M1
Included in item 308
Included in item 308
B12x16
PME 0.1 ←F 400 V, with cable lugs
* = accessories
clka1se1
C
-- 27 --
C3
WIRE FEED UNIT
Valid from serial number 618 ... ....
300
304
303
306
302
305
315
314
301
308
313
316
317
318
332
312
309
329
310
321
319
311
320
331
327
330
326
322
324
clka1se1
-- 28 --
323
180= LKA180 240= LKA240
1ph= 1 phase 230V rec= reconnectable 230/400V 400= 400 V mains supply voltage
C = component designation in the circuit diagram
Item
no
Qty
180
1ph
Qty
180
400
Qty
180
rec
Qty
240
400
Qty
240
rec
Ordering no.
Denomination
Notes
C
201
1
1
1
1
1
193 054--002
Gas valve
202
1
-----
-1
----
--1
---
---1
--
----1
469 659--001
469 472--001
469 564--001
469 473--001
469 566--001
Switch
Switch
Switch
Switch
Switch
203
1
--
-1
-1
-1
-1
193 297--101
193 296--104
Contactor
Contactor
KM1
KM1
204
1
--
-1
-1
-1
-1
469 300--880
469 295--880
Inductor
Inductor
L1
L1
205
1
--
-1
1
--
-1
1
--
469 563--001
469 470--001
Control transformer
Control transformer
Primary voltage 230/400 V
Primary voltage 400 V
TC1
TC1
206
1
---
-1
--
-1
--
--1
--1
469 660--880
469 285--880
469 290--880
Main transformer
Main transformer
Main transformer
Thermal cutout ST1 included
Thermal cutout ST1 included
Thermal cutout ST1 included
TM1
TM1
TM1
207
1
---
-1
--
--1
-1
--
--1
2626 133--14
2626 134--05
192 106--117
Mains cable
Mains cable
Mains cable
3 x 2.5 mm2 2.5 meter
4 x 1.5 mm2 2.5 meter
4 x 2.5 mm2 2.5 meter
to be ordered per meter
208
1
1
1
1
1
190 315--102
Gas hose
To be ordered per meter
1.5 meter as delivered
209
1
---
-1
--
-1
--
--1
--1
469 662--880
469 318--880
469 346--880
Diode bridge
Diode bridge
Diode bridge
210
1
1
1
1
1
469 380--880
Capacitor
Set of 2 capacitors, PME 0.1ìF
400V, with cable lugs
C1 +C2
211
---
---
1
1
---
1
1
466 884--006
469 569--001
Terminal
Insulation
6--pole
With text
XT3
212
1
1
1
1
1
193 260--006
Connector
7--pole
XS3
213
214
1
1
1
1
1
1
1
1
1
1
193 260--151
193 260--157
Connector
Connector
3--pole, to R49 on AP1
9--pole
XS1
215
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
193 260--153
193 260--150
193 260--151
Connector
5--pole, before ser.no. 618 ...
2--pole, from ser.no. 618 ...
3--pole, from ser.no. 618 ...
YV1
With knob (item 227)
Without knob (item 227)
With knob (item 227)
With knob (item 227)
With knob (item 227)
QF1
QF1
QF1
QF1
QF1
V1 -- V6
V1 -- V6
V1 -- V6
XS2
216
1
1
1
1
1
193 260--153
Connector
5--pole, to R50 on AP1
217a
-1
1
--
1
--
1
--
1
--
469 477--002
469 477--001
Cable inlet
Cable inlet
With mains terminal
XT1
217b
1
--
--
--
--
162 781--011
Mains terminal
XT1
1
--
--
--
--
468 882--005
Insulation
Delivered as 12--pole,
to be cut to 2--pole
With text
218
6
6
6
6
6
192 562--105
Cage nut
M6
219
3
3
3
3
3
469 381--001
Speednut
220
1
--
-1
-1
-1
-1
321 229--003
320 918--001
Thermal cutout
Thermal cutout
221
1
1
1
1
1
469 377--001
Connection block
222
223
1
1
1
1
1
1
1
1
1
1
469 378--001
469 379--001
Insulation
Bus bar
224
1
1
1
1
1
1
1
1
1
1
486 159--880
486 159--882
Circuit board
Circuit board
Before ser.no. 618 ... ....
From ser.no. 618 ... ....
AP1
AP1
225
1
1
1
1
1
193 759--002
Light--emitting diode
Yellow
V7
226
1
1
1
1
1
193 759--001
Indicating lamp
White, 28 V
HL1
227
-1
1
--
-1
-1
-1
366 296--001
Knob
Knob
Included in item 202
228
2
2
2
2
2
191 510--104
Knob
229
1
--
1
--
1
--
-1
-1
469 365--001
469 366--001
Panel
Panel
With text
With text
230
1
--
--
1
1
469 479--001
Fan
24 V DC
231
1
--
--
--
--
467 169--001
Resistor
232
1
--
--
--
--
369 864--881
Resistor
clka1se1
-- 29 --
Opens at 110C
Opens at 130C
ST2
ST2
XT2
EV1
R1
5.6 kΩ 5 W
R2
clka1p03
clka1se1
-- 30 --
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
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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