ESAB LKA 180 Service Manual
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ESAB LKA 180 Service Manual

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LKA 180/240
clka1p00
Service manual
0349 300 002
040928
Valid for serial no. 618−xxx−xxxx

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Summary of Contents for ESAB LKA 180

  • Page 1 LKA 180/240 clka1p00 Service manual 0349 300 002 040928 Valid for serial no. 618−xxx−xxxx...

  • Page 2: Table Of Contents

    ........COMPONENT DESCRIPTION, LKA 180/240 ....CONNECTION DIAGRAM, LKA 180 Single−phase, 230 V CONNECTION DIAGRAM, LKA 180 3−phase, 400 V ..

  • Page 3: Introduction

    Use the diagrams in the manual when tracing faults. The machine components are described in alphabetical order on the pages foregoing the connection diagram. The LKA 180 and 240 are designed and tested in accordance with international standard EN 60974−1, EN 50199.

  • Page 4: Rating Plate

    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. 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 indi- cates the design generation.
  • Page 5 341 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. − 3 − clka1de1...

  • Page 6: Component Description, Lka 180/240

    Switch, 7−way in the LKA 180 and 10−way in the LKA 240. Resistor, 1 Ω, only fitted in the single−phase version of LKA 180. Resistor, 5.6 kΩ 5 W, only fitted in the single−phase version of LKA 180. Welding torch trigger switch Thermal overload cutout, for protection against overload, fitted in the winding of main transformer TM1.

  • Page 7: Connection Diagram, Lka 180 Single−Phase, 230 V

    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.

  • Page 8: Connection Diagram, Lka 180 3−Phase, 400 V

    CONNECTION DIAGRAM, LKA 180 3−phase, 400 V When checking the no−load voltages, load the machine with a dummy load of 5.6 kΩ 5 W, connecting it between plus and minus on the rectifier bridge. clka1e01 − 6 − clka1de1...

  • Page 9: Connection Diagram, Lka 180 3−Phase, 230/400 V

    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 kΩ 5 W, connecting it between plus and minus on the rectifier bridge. clka1e12 − 7 − clka1de1...

  • Page 10: Connection Diagram, Lka 240 3−Phase, 400 V

    CONNECTION DIAGRAM, LKA 240 3−phase, 400 V When checking the no−load voltages, load the machine with a dummy load of 5.6 kΩ 5 W, connecting it between plus and minus on the rectifier bridge. clka1e02 − 8 − clka1de1...

  • Page 11: Connection Diagram, Lka 240 3−Phase, 230/400 V

    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 kΩ 5 W, connecting it between plus and minus on the rectifier bridge. clka1e13 − 9 − clka1de1...

  • Page 12: Circuit Diagram, Circuit Board Ap1

    CIRCUIT DIAGRAM, CIRCUIT BOARD AP1 − 10 − clka1de1 clka1e03...
  • Page 13 − 11 − clka1de1 clka1e04...

  • Page 14: Component Positions, Circuit Board Ap1

    COMPONENT POSITIONS, CIRCUIT BOARD AP1 clka1e05 − 12 − clka1de1...

  • Page 15: Description Of Operation, Circuit Board Ap1

    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.
  • Page 16 START/STOP CIRCUIT, THERMAL OVERLOAD CIRCUIT AND SPOT WELDING CIRCUIT clka1e08 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.
  • Page 17 BURN−BACK TIME clka1e09 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.
  • Page 18 MOTOR DRIVE AND BRAKING clka1e10 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.

  • Page 19: Load Characteristics

    LOAD CHARACTERISTICS LKA 180 single phase clka1p04 LKA 180 3−phase clka1p06 LKA 240 clka1p05 − 17 − clka1de1...

  • Page 20: Technical Data

    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 − 18 −...

  • Page 21: Installation

    INSTALLATION Place the machine in a suitable position and check that cooling is not obstructed. 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.

  • Page 22: Operation

    GASLESS WIRE SOLID WIRE clka0p10 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 Connect the return current conductor clamp (E) to the workpiece. When welding with solid wire, open the gas valve (A) on the gas bottle and adjust the gas flow by reducer valve (B).

  • Page 23: Maintenance

    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. Welding torch. Blow the wire guide clean and clean the gas nozzle at regular intervals. WELDING DATA SELECTION MACHINE SETTINGS, LKA 180 single−phase clka1p15 − 21 − clka1de1...
  • Page 24 MACHINE SETTINGS, LKA 180 3−phase clka1p16 − 22 − clka1de1...
  • Page 25 MACHINE SETTINGS, LKA 240 clka1p17 − 23 − clka1de1...

  • Page 27: Spare Parts List Lka 180/240

    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.
  • Page 28 C = component designation in the circuit diagram 180 = LKA 180 240 = LKA 240 Item Ordering no. Denomination Notes 469 368−001 Cover plate 469 369−001 Rear panel 469 664−001 Rear panel Only for the Australian market 469 447−001...
  • Page 29 − 26 − clka1se1...
  • Page 30 WIRE FEED UNIT C = component designation in the circuit diagram Item Ordering no. Denomination Notes − − 455 890−890 Feed unit Complete, contains items 301 − 333 367 529−001 Pressure arm Complete, contains items 301 − 305 455 906−001 Spacer sleeve 455 907−001 Pressure roller...
  • Page 31 WIRE FEED UNIT − 28 − clka1se1...
  • Page 32 180= 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 Ordering no. Denomination Notes 193 054−002 Gas valve − − − − 469 659−001 Switch With knob (item 227) −...
  • Page 33 clka1p03 − 30 − clka1se1...
  • Page 34 ESAB subsidiaries and representative offices Europe NORWAY Asia/Pacific Representative offices AS ESAB AUSTRIA BULGARIA CHINA Larvik ESAB Ges.m.b.H ESAB Representative Office Shanghai ESAB A/P Tel: +47 33 12 10 00 Vienna−Liesing Sofia Shanghai Fax: +47 33 11 52 03 Tel: +43 1 888 25 11...

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Lka 240

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