Beruflich Dokumente
Kultur Dokumente
Service manual
0740 800 097 011019 Valid for serial no. 521--xxx--xxxx to serial no. 005--xxx--xxxx
LIST OF CONTENTS Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LOAD CHARACTERISTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
LKB 265, 400 -- 415 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Selector switch and suppressor board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
LKB 265, 230 -- 500 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Selector switch and primary--voltage connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
LKB 320, 400 -- 415 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Selector switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
LKB 320, 230 -- 500 V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Component description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Selector switches and primary--voltage connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
1 Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2 Start / Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 LKB 265 spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Wire feed speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
5 Motor drive / braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6 Burn--back time, contactor, gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Thermal overload cutout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Component positions, circuit board AP1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
DIGITAL INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Component positions on the display board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Connections to the display board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
SERVICE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Overheating of diode bridge V1--V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
New design of diode bridge V1--V6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
INSTRUCTIONS FOR USE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
SETTING THE WIRE FEED PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
ASSEMBLING INSTRUCTION FOR ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transformer set for CO2 heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Instrument set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
conte -- 2 --
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.
Use the connection diagram as a form of index for the description of operation. The circuit
board is divided into numbered blocks, which are described individually in more detail in
the description of operation. 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
September 2001.
The LKB 265 and LKB 320 are designed and tested in accordance with international
and European standard IEC/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 PRECAU-
TIONS WHEN WELDING. ASK FOR YOUR EMPLOYER’S SAFETY PRACTICES WHICH SHOULD BE
BASED ON MANUFACTURERS’ HAZARD DATA.
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TECHNICAL DATA
LKB 265 LKB 265 LKB 320 LKB 320
400 -- 415 V 230 -- 500 V 400 -- 415 V 230 -- 500 V
Mains voltage 400--415V 230/400--415/500V 400--415V 230/400--415/500V
3~ 50/60 Hz 3~ 50 Hz 3~ 50/60 Hz 3~ 50 Hz
230/440--460V 230/440--460V
3~ 60 Hz 3~ 60 Hz
Permissible load
100% duty cycle 150 A/22 V 150 A/22 V 195 A/24 V 195 A/24 V
60 % duty cycle 190 A/24 V 190 A/24 V 250 A/27 V 250 A/27 V
30 % duty cycle 265 A/27 V 265 A/27 V 320 A/30 V 320 A/30 V
Operating range 30A/15V--265A/27V 30A/15V--265A/27V 40A/16V--320A/30V 40A/16V--320A/30V
Open--circuit 15--38 V 15--38 V 16--40 V 16--40 V
voltage
Open--circuit power 50 W 50 W 52 W 52 W
Efficiency 0.69 0.69 0.71 0.71
Power factor 0.97 0.97 0.97 0.97
Control voltage 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz 42 V, 50/60 Hz
Dimensions, lxbxh 770x520x620 770x520x620 770x560x640 770x560x640
Weight 92 kg 92 kg 112 kg 112 kg
Enclosure class IP 23 IP 23 IP 23 IP 23
Application class S S S S
LKB 265 and LKB 320 comply with welding machine standard IEC/EN 60974--1 and EN 50199.
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.
The enclosure class indicates the degree of protection against penetration of solid objects and water.
Class IP 23 equipment is designed for indoor and outdoor use.
The symbol means that the power unit is designed for use in areas of elevated electrical hazard.
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LOAD CHARACTERISTIC
LKB 265
clkb0p20
LKB 320
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clkb0de0 -- 5 --
LKB 265, 400 -- 415 V
Component description
AP1 Circuit board, see description on page 14. SA1 10--way switch, for selecting welding
voltage
AP2 Suppressor board, see circuit diagram below ST1 Thermal oveload cutout, opens at 110 C.
Replacing terminal XT1 from serial no. The cutout is mounted on the cooling fins of
614--xxx--xxxx the diode bridge.
C1, C2 Capacitor ST2 Thermal overload cutout, opens at 110 C.
The cutout is mounted in the winding of
transformer TM1.
From serial no. xxx--640--xxxx
EV1 Fan TC1 Control power supply transformer
HL1 Lamp, white, On/Off TC2 Transformer for CO2 heater, accessory
KM1 Contactor TC3 Transformer for digital instrument,
accessory
L1 Inductor TM1 Main transformer
M1 Feed unit motor V1--V6 Diode bridge, see page 24 and 25.
P1 Digital instrument, accessory. V7 LED, yellow. Indication, thermal overload
See description on page 22.
QF1 Switch, On/Off XS1--2 Machine contact
R1 Resistor XS3--10 Sleeve contacts
R2 Varistor XT1--3 Terminal block
RS1 Shunt, accessory YV1 Solenoid valve
Switch positions for selector switch SA1 Circuit diagram and component positions for circuit
board AP2
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Connection diagram
clkb0de0 -- 7 --
LKB 265, 230 -- 500 V
Component description
AP1 Circuit board, see description on page 14. SA1 10--way switch, for selecting welding
voltage
AP2 Suppressor board, see circuit diagram on ST1 Thermal oveload cutout, opens at 110 C.
page 6. Replacing terminal XT1 from serial The cutout is mounted on the cooling fins of
no. 614--xxx--xxxx the diode bridge.
C1, C2 Capacitor ST2 Thermal overload cutout, opens at 110 C.
Mounted in the winding of transformer TM1.
From serial no. xxx--640--xxxx
EV1 Fan TC1 Control power supply transformer
HL1 Lamp, white, On/Off TC2 Transformer for CO2 heater, accessory
KM1 Contactor TC3 Transformer for digital instrument,
accessory
L1 Inductor TM1 Main transformer
M1 Feed unit motor V1--V6 Diode bridge, see page 24 and 25.
P1 Digital instrument, accessory. V7 LED, yellow. Indication, thermal overload
See description on page 22.
QF1 Switch, On/Off XS1--2 Machine contact
R1 Resistor XS3--10 Sleeve contacts
R2 Varistor XT1--3 Terminal block
RS1 Shunt, accessory YV1 Solenoid valve
Switch positions for selector Primary voltage connections for transformers TC1, TC2 and
switch SA1 terminal block XT2
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Connection diagram
clkb0de0 -- 9 --
LKB 320, 400 -- 415 V
Component description
AP1 Circuit board, see description on page 14. ST1 Thermal overload cutout, opens at 120 C
(110 C before serial no. 005--xxx--xxxx).
Mounted on the cooling fins of the diode
bridge.
C1, C2 Capacitor ST2 Thermal overload cutout, opens at 130 C.
Mounted in the winding of transformer TM1.
From serial no. xxx--640--xxxx
EV1 Fan
HL1 Lamp, white, On/Off TC1 Control power supply transformer
KM1 Contactor TC2 Transformer for CO2 heater, accessory
L1 Inductor TC3 Transformer for digital instrument,
accessory
M1 Feed unit motor TM1 Main transformer
P1 Digital instrument, accessory. V1--V6 Diode bridge, see page 24 and 25..
See description on page 22.
QF1 Switch, On/Off V7 LED, yellow. Indication, thermal overload
cutout
R1 Resistor XS1--2 Machine contact
R2 Varistor XS3--10 Sleeve contacts
RS1 Shunt, accessory XT1--3 Terminal block
SA1 4--way switch, for selection of welding YV1 Solenoid valve
voltage
SA2 10--way switch, for selection of welding
voltage
Selector switches
clkb0de0 -- 10 --
Connection diagram
clkb0de0 -- 11 --
LKB 320, 230 -- 500 V
Component description
AP1 Circuit board, see description on page 14. ST1 Thermal overload cutout, opens at 120 C
(110 C before serial no. 005--xxx--xxxx).
Mounted on the cooling fins of the diode
bridge.
C1, C2 Capacitor ST2 Thermal overload cutout, opens at 130 C.
Mounted in the winding of transformer TM1.
From serial no. xxx--640--xxxx
EV1 Fan
HL1 Lamp, white, On/Off TC1 Control power supply transformer
KM1 Contactor TC2 Transformer for CO2 heater, accessory
L1 Inductor TC3 Transformer for digital instrument,
accessory
M1 Feed unit motor TM1 Main transformer
P1 Digital instrument, accessory. V1--V6 Diode bridge, see page 24 and 25..
See description on page 22.
QF1 Switch, On/Off V7 LED, yellow. Indication, thermal overload
cutout
R1 Resistor XS1--2 Machine contact
R2 Varistor XS3--10 Sleeve contacts
RS1 Shunt, accessory XT1--3 Terminal block
SA1 4--way switch, for selection of welding YV1 Solenoid valve
voltage
SA2 10--way switch, for selection of welding
voltage
Switch positions for selector Primary voltage connections for transformers TC1, TC2 and
switches SA1 and SA2 terminal block XT2
clkb0de0 -- 12 --
Connection diagram
clkb0de0 -- 13 --
DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic
sensitive devices.
ESD S Use proper static--proof bags and boxes.
1 Power supply
The circuit board uses two different supply voltages: 16 V for the electronics and
42 V for power supply to the motor, contactor and gas valve.
clkb0e05
The 16 V power supply from transformer TC1 is rectified by diodes D3--D6 and
regulated to 15 V by voltage regulator VR1.
S 42 V power supply
A_42VAC and B_42VAC are used as control power supplies for the contactor and
gas valve. Indicating lamp HL1 is mounted on the front of the machine and shows
that the power is turned on.
The supply is rectified by diode bridge BR1. The output voltage (60 V) supplies the
wire feed unit motor.
clkb0de1 -- 14 --
2 Start / Stop
clkb0e07
Closing contact SB1 on the welding torch starts the welding process. The LKB 265
provides only two--stroke control mode: the LKB 320 provides a choice of
two--stroke or four--stroke control modes.
Welding gun 1
trigger switch
0
1
Gas valve T1
0
1
Wire feed 0
1
Contactor T1
0
T1 = Burn--back time
Start-- stop sequence, 2--stroke (LKB 265 and LKB 320)
LKB 320
Switch SW1 selects between 2--stroke and 4--stroke control mode.
clkb0e09
clkb0de1 -- 15 --
S Connection of pins 2 and 1 in switch SW1 selects 4--stroke control mode.
Welding gun 1
trigger switch
0
1
Gas valve 0
1
Wire feed 0
1
Contactor T1
0
T1 = Burn--back time
clkb0e08
The LKB 265 has a spot--welding capability, which the LKB 320 does not. It is
active when the switch in potentiometer RP2 is closed. Spot welding time is
adjustable between 0.2 and 2.5 seconds.
If the welding torch trigger switch is released while a spot weld is being made, the
welding sequence will be interrupted.. If the switch is held closed for longer than
the spot weld time, welding stops when the spot weld time is up. To restart, the
switch must be released and then operated again.
clkb0e06
The +5.1 V reference voltage (1 %) is derived from the PWM circuit, which
generates gate pulses for the motor drive transistor.
clkb0de1 -- 16 --
5 Motor drive / braking
black
red
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The motor is powered by the smoothed +60 V supply. Pulse width modulation of
transistor Q5 controls the motor voltage. The pulse frequency is about 9 kHz, and
maximum conduction time of the pulses is about 98 % of the pulse cycle time.
During the Off parts of the pulse cycle, the motor current freewheels through diode
D35.
At 24 V motor supply voltage, the wire feed roller speed is 160 r/min 5 %. At a
roller speed of 200 r/min, the wire feed speed is 19 m/min 5 %.
S Speed control
The gate pulses to transistor Q5 are generated by a PWM circuit. Resistors R84 and
R85 form a potential divider, providing a voltage signal that is proportional to the
wire speed. The PWM circuit compares the set speed with the actual speed.
S Current limit
The current limit is set at 5.5 A. The motor current is measured by resistor R68,
which produces a voltage drop proportional to the current (1 A = 100 mV). The
current limit restricts the conduction time of the gate pulses to transistor Q5.
S Braking
When the motor starts, capacitor C22 charges via diode D18. The voltage is limited
to 15 V by zener diode D13. The LED in optocoupler IC4 is activated when braking
is required, connecting C22 (15 V) to the gate of transistor Q3. The transistor
conducts and short--circuits the motor voltage via resistors R69 and R70, which limit
the braking current to about 20 A.
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6 Burn--back time, contactor, gas valve
clkb0e11
S Burn--back time
The burn--back time is the time from when motor braking starts until the main
contactor opens. When welding stops, capacitor C38 is discharged through
potentiometer R21. The time can be adjusted from 0 to 0.25 seconds.
S Gas valve
The gas valve is connected to board contacts A5 and A6.
S LKB 265
The valve receives its power supply from triac TC2 via resistor R20 (0τ).
S LKB 320
The valve receives its power supply from triac TC1.
clkb0de1 -- 18 --
7 Thermal overload cutout
The thermal overload cutout ST1 is mounted on the cooling fins of the diode bridge,
and operates at a temperature of 110 C in both machines.
The thermal overload cutout ST2 is mounted in the winding of transformer TM1,
and operates at a temperature of 110 C in LKB 265 and at 130 C in LKB 320.
The overload cutout ST2 is mounted from machine number XXX 640 XXXX.
A current normally flows through the cutouts from the +20 V supply via R2 and D2,
and from the +15 V supply via R8. The voltage at contact C1 is kept low by the
switch. If a cutout operates, C1 goes high and the output signals from the board are
disabled.
Operation of the cutout causes a current to flow from +20 V to 0 V via R2, D1 and
LED V7, which indicates operation of the cutout.
clkb0de1 -- 19 --
clkb0de1 -- 20 --
Component positions, circuit board AP1
clkb0e13
clkb0de1 -- 21 --
DIGITAL INSTRUMENT
Calibration
Note that any previously stored calibration corrections for voltage or current will be lost
when calibration is requested.
Equipment required
S Resistive load
S Reference shunt (10 mV / 100 A)
S Voltmeter
S Alternatively, the ESAB Checkmaster 9000 can be used instead of the above items.
Voltage calibration
S Connect the load resistance and the reference shunt to the power source.
S Press and hold the upper pushbutton (+) on the display board and turn on the power
source. Release the pushbutton.
S Calibration mode is indicated by the decimal point at the right--hand end of the voltage
display being visible. However, program version 1.1 does not display this decimal point
at this stage.
S Load the power source and compare the voltage as shown on the display with the actual
value indicated by the voltmeter. Press the plus or minus pushbuttons on the board until
the display shows the correct value.
S Turn the power source off and then turn it on again. Verify the results of the calibration.
Current calibration
S Connect the load resistance and the reference shunt to the power source.
S Press and hold the lower pushbutton (--) on the display board and turn on the power
source. Release the pushbutton.
S Calibration mode is indicated by the decimal point at the right--hand end of the current
display being visible. However, program version 1.1 does not display this decimal point
at this stage.
S Load the power source and compare the current as shown on the display with the actual
value as measured across the shunt. Press the plus or minus pushbuttons on the board
until the display shows the correct value.
S Turn the power source off and then turn it on again. Verify the results of the calibration.
clkb0de2 -- 22 --
Component positions on the display board
--
0V B1 A1
9V µ
Inductor voltage B2 A2
Bridge voltage B3
Shunt response B4
clkb0de2 -- 23 --
SERVICE INFORMATION
The overheating is depending on a voltage drop between the positive heatsink of the diode
bridge and the plus polarity screw, see B above.
This is caused by :
1. The connection resistance between the diode bridge heatsink of aluminium and the
polarity screw (B) is too high.
2. The nut (B) which is securing the diode bridge heatsink to the plus polarity screw is bad
tightened.
To eliminate the risk of overheating the connection is assembled according to the description
below. All machines delivered after August 19. 1996, from Esab Welding Equipment AB in
Laxå, are assembled as described below.
Service tips
When assembling the diode bridge:
Use one wrench at each side of the connection block when tightening the nuts. The torque
must be 18 Nm.
Take care so you don’t damage the insulator D and the connection block A, when tightening
the nuts.
clkb0de3 -- 24 --
New design of diode bridge V1--V6
Rectifier bridges V1--V6 in the LKB 265 and LKB 320 are redesigned from machine serial
number xxx--919--xxxx.
The bridge in the LKB 265 has article number 0455 815 880, the same number as before.
The bridge in the LKB 320 has article number 0455 815 881, the same number as before.
To fit a redesigned rectifier bridge in an old machine you must drill two new 9 mm holes in
the intermediate plate. Drill one hole 49 mm above and 8 mm behind the upper one of the
exixting holes. Drill the second hole 166 mm (c--c) directly below the new upper hole.
See the drawing below.
NOTE: The new rectifier bridge in the LKB 320 must have a thermal cut--out with 120 C
opening temperature, article number: 0321 229 004.
clkb0de3 -- 25 --
INSTRUCTIONS
This chapter contains an extract from the LKB 265/320 instruction manual.
INSTALLATION
Installation must be carried out by a qualified electrician.
Connect the power supply lead using the appropriate fuse in conformance with local
regulations. Cable areas below are according to Swedish regulations.
Make sure the welding rectifier is not covered or positioned so that cooling is obstructed.
LKB 320
Voltage 230 V 400--415 V 500 V 230 V 440--460 V
3~ 50 Hz 3~ 50/60 Hz 3~ 50 Hz 3~ 60 Hz 3~ 60 Hz
Primary current at:
100% duty cycle 16 A 9A 7A 16 A 8A
60% duty cycle 23 A 14 A 10 A 23 A 12 A
30% duty cycle 35 A 20 A 16 A 34 A 18 A
Conductor CSA, mm2 4x4 4 x 2.5 4 x 2.5 4x4 4 x 2.5
Fuse, slow--blow 20 A 16 A 16 A 20 A 16 A
clkb0de3 -- 26 --
A thermal overload cutout protects against overheating. The cutout resets automatically when
the unit has cooled.
B Switch, 10--position
C Switch, 4--position
D Main switch, On/Off
E Indicating lamp, On/Off
F Indicating lamp, thermal overload
G Welding torch connector
H Potentiometer, wire feed speed, 1.9 - 19 m/min
J Inductance terminals
K Potentiometer, spot welding time, 0.2 - 2.5 seconds
S A potentiometer is fitted on the centre plate, above the feed unit, for adjusting the
burn--back time over the range 0 - 0.25 seconds. The LKB 320 has also a switch in the
same position for selecting 2--stroke or 4--stroke control mode.
Brake hub
To prevent the wire bobbin from sliding off the brake hub,
secure it in position with the red knob.
The brake hub is adjusted in the factory before delivery. If it needs re--adjusting, proceed as
follows.
Braking power can be adjusted by the two screws (springs) in the centre of the hub.
Turn the screws clockwise to reduce braking effect.
Adjust the braking force so that the wire is slightly slack when wire feed stops.
S = Adjusting screws
MAINTENANCE
Regular maintenance is important for reliable, safe operation.
S Blow the power unit clean with dry compressed air at reduced pressure.
S For problem--free wire feed, clean and replace the wearing parts in the wire feed
mechanism at regular intervals. Note that an excessive pressure setting can cause
abnormal wear on the drive roller, feed roller and wire conduit.
See SETTING THE WIRE FEED PRESSURE on next page.
S Blow the wire conduit clean at regular intervals and clean the gas nozzle.
WARNING!
Rotating parts can cause injury, take great care
clkb0de3 -- 27 --
ACCESSORIES
Item Ordering no. Denomination
Figure 1 Figure 2
To check for correct feed pressure, feed the wire out against a piece of insulating material,
such as a piece of wood.
With the pistol held about 5 mm from the wood (Figure 1), the drive rollers should slip.
With the pistol held further away from the wood (about 50 mm, as shown in Figure 2), the
wire should continue to feed out, bending as it does so.
clkb0de3 -- 28 --
ASSEMBLING INSTRUCTION FOR ACCESSORIES
clkb0p11
clkb0de3 -- 29 --
Instrument set
clkb0de3 -- 30 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
Ordering numbers for LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD
0455 470 880 LKB 265 400--415V 3~ 50/60Hz
0455 470 881 LKB 265 230/400--415/500 3~ 50Hz: 230/440V 3~ 60Hz
0455 470 884 LKB 265 4WD 400--415V 3~ 50/60Hz
0455 480 880 LKB 320 400--415V 3~ 50/60 Hz
0455 480 881 LKB 320 230/400--415/500V 3~ 50Hz: 230/440--460V 3~ 60Hz
0455 480 884 LKB 320 4WD 400--415V 3~ 50/60 Hz
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.
bc14s11a -- 31 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
NOTE:
From machine serial number xxx--845--xxxx the cover is divided into two parts (items 103 and 114).
In older machines the cover (0456 031 003) is replaced by items 103 and 114.
bc14s11a -- 32 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
bc14s11a -- 33 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
265 = LKB 265 320 = LKB 320 C = component designation in the circuit diagram
Qty Qty
Item 265 320 Ordering no. Denomination Notes C
bc14s11a -- 34 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
bc14s11a -- 35 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
265 = LKB 265 320 = LKB 320 C = component designation in the circuit diagram
Qty Qty
Item 265 320 Ordering no. Denomination Notes C
bc14s11a -- 36 --
LKB 265, LKB 265 4WD, LKB 320, LKB 320 4WD Edition 010830
bc14s11a -- 37 --
LKB 265, LKB 265 4WD Edition 010830
bc14s11b -- 38 --
LKB 265, LKB 265 4WD Edition 010830
o
O
bc14s11b -- 39 --
LKB 265 Edition 010830
(W) = wear part (A) = accessory C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
-- -- 0455 890 892 Wire feed unit Complete, contains items 501 -- 531
500 1 0367 529 001 Pressure arm Complete, contains items 501 -- 505
501 1 0455 906 001 Spacer sleeve
502 1 0455 907 001 Pressure roller (W)
0466 262 001 Pressure roller (W)(A) Knurled
503 1 Nut SGA D8
504 1 Holder
505 1 Shaft
506 1 0455 896 001 Spring
508 1 0466 489 001 Drive unit M01
509 1 0215 701 007 Locking washer Included in item 508
510 1 0191 496 114 Key Included in item 508
511 1 0466 074 001 Inlet nozzle (W)
512 1 0367 528 001 Pin bolt
513 1 0368 749 880 Pressure transducer
514 2 0368 750 001 Insulating sleeve
515a 1 0455 894 001 Insert tube (W)(A) Plastic, must be used together with
item 516a. For welding with Al wire.
515b 1 0455 889 001 Insert tube (W) Steel, must be used together with item 516b
Delivered from serial no. xxx-- 640-- xxxx
516a 1 0455 885 001 Outlet nozzle (W)(A) Must be used together with item 515a
For welding with Al wire.
516b 1 0455 886 001 Outlet nozzle (W) Must be used together with item 515b
Delivered from serial no. xxx-- 640-- xxxx
517 1 0455 882 001 Current sleeve
518 1 0455 883 001 Spacer sleeve ⊘ 16/8.2x0.9
519 1 Washer ⊘ 16/8.4x1.5
520 1 Screw M8x20
bc14s11c -- 40 --
LKB 265 Edition 010830
bc14s11c -- 41 --
LKB 320, LKB 320 4WD Edition 010830
bc14s11d -- 42 --
LKB 320, LKB 320 4WD Edition 010830
bc14s11d -- 43 --
LKB 320 Edition 010830
(W) = wear part (A) = accessory C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
-- -- 0455 890 893 Wire feed unit Complete, contains items 701 -- 731
700 1 0469 833 880 Pressure arm Complete, contains items 701 -- 705
701 1 0367 907 013 Geared adapter
702 1 0369 728 001 Pressure roller (W)
0466 262 001 Pressure roller (W)(A) Knurled
703 1 Locking washer SGA D8
704 1 Holder
705 1 Shaft
706 1 0455 896 001 Spring
708 1 0466 489 001 Drive unit M01
709 1 0215 701 007 Locking washer Included in item 708
710 1 0191 496 114 Key Included in item 708
711 1 0466 074 001 Inlet nozzle (W)
712 1 0367 528 001 Pin bolt
713 1 0368 749 880 Pressure transducer
714 2 0368 750 001 Insulating sleeve
715a 1 0455 894 001 Insert tube (W)(A) Plastic, must be used together with
item 716a For welding with Al wire.
715b 1 0455 889 001 Insert tube (W) Steel, must be used together with item 716b
Delivered from serial no. xxx-- 640-- xxxx
716a 1 0455 885 001 Outlet nozzle (W)(A) Must be used together with item 715a
For welding with Al wire.
716b 1 0455 886 001 Outlet nozzle (W) Must be used together with item 715b
Delivered from serial no. xxx-- 640-- xxxx
717 1 0455 882 001 Current sleeve
718 1 0455 883 001 Spacer sleeve ⊘ 16/8.2x0.9
719 1 Washer ⊘ 16/8.4x1.5
720 1 Screw M8x20
721 1 0455 881 001 Protection plate
722 1 0215 201 202 O--ring
723 1 0455 898 001 Screw (M5x12)
bc14s11e -- 44 --
LKB 320 Edition 010830
bc14s11e -- 45 --
LKB 265 4WD, LKB 320 4WD Edition 010830
(W) = wear part (A) = accessory C = component designation in the circuit diagram
Qty Qty
Item Ordering no. Denomination Notes C
265 320
1 -- 0456 316 880 Wire feed unit Complete, contains items 801 - 834
1 0456 316 881 Wire feed unit Complete, contains items 801 - 834
801 1 1 0469 833 880 Pressure arm complete
802 2 2 0455 071 001 Axle
4 4 0215 702 706 Locking washer D4
803 1 1 0469 833 881 Pressure arm complete
804 1 1 0469 837 880 Outlet nozzle 2.0
805 2 2 0367 528 001 Pin bolt
806 1 1 0455 047 002 Front flange
807 2 2 0458 721 001 Locking nut M6
808 1 1 0469 838 001 Cover
809 1 1 0455 046 001 Gear housing
810 1 1 Screw M4x12
1 1 Rivet washer D16/5x1
811 1 1 0455 052 001 Motor gear
812 1 1 0193 260 152 Connector 4 pole
4 4 0040 953 601 Pasnduit strip
813 1 1 0455 623 885 Cable set
814 1 1 0469 380 882 Capacitor 0.1 µF 400 V
815 1 1 Screw M8X25
1 1 Nut M8
2 2 Washer D16/8.4 x 1.5
816 1 1 0455 044 001 Current connection
817 1 1 0455 048 001 Insulating tube
3 3 Nut M6
1 1 Screw M6x40
3 3 Washer D12/6.4x1.5
818 1 1 0455 045 001 Insulating sleeve
819 3 3 Screw M6x16
820 2 2 0455 070 001 Sleeve
821 1 1 0455 050 001 Spring
822 1 1 0455 049 001 Inlet nozzle
823 1 1 0456 093 880 Cable set
824 2 2 Screw M6x28
825 1 1 Screw M6x12
826 4 4 0153 043 002 Insulating washer
827 1 1 0455 072 001 Intermediate nozzle Di3
828 2 -- 0369 557 002 Feed roller 0.8 / 1.0 V--groove
2 0369 557 003 Feed roller 1.0 / 1.2 V--groove
2 2 0455 053 880 Gear adapter
829 2 2 0458 722 001 Axel feed roller
830 1 1 0466 489 001 Wire feed motor
831 2 2 0368 749 880 Pressure device
832 2 2 0368 750 001 Insulating sleeve
833 1 1 0455 816 001 Bracket
834 1 1 Washer D12/6.4X1.5
bc14s11f -- 46 --
LKB 265 4WD, LKB 320 4WD Edition 010830
bc14s11f -- 47 --
NOTES
notes -- 48 --
notes -- 49 --
ESAB subsidiaries and representative offices
www.esab.net
011004