Beruflich Dokumente
Kultur Dokumente
Service manual
0740 800 104 040830 Valid for serial no. 704--xxx--xxxx to 011--xxx--xxxx
LIST OF CONTENTS Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIRING DIAGRAM LTR 160 Valid from ser.no. 842--xxx--xxxx . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIRING DIAGRAM LTR 200 Valid for ser.no. 722--xxx--xxxx to 842--901--0271 . . . . . . . . . . . 10
WIRING DIAGRAM LTR 200 Valid from ser.no. 842--902--xxxx . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESIGN CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION OF OPERATION CIRCUIT BOARD AP01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 +30 V +20 V ±10 V Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Power supply to the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Selection of welding method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Start / Stop, Reference input, Remote control input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Slope up / Slope down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 HF unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8a Shunt input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8b Shunt input with shunt signal amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Arc voltage sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Gate circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking the gate pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Thermal overload switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Component positions, circuit board AP01 0481 864 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Component positions, circuit board AP01 0481 818 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSISTOR BOARD AP02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRANSISTOR BOARD AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MOS TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SOFT STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LTR 160, SUPPRESSION CIRCUIT BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LTR 200, SUPPRESSION CIRCUIT BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SUPPRESSION CIRCUIT BOARD AP09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Assembling the diode modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal of transistor circuit boards AP02 and AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Refitting the transistor circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fitting the main transformer TC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LOAD CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
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 wiring 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 wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and including
August 2004.
The manual is valid for LTR 160 and LTR 200 with serial numbers:
704--xxx--xxx, 722--xxx--xxxx, 726--xxx--xxxx, 842--xxx--xxxx, 011--xxx--xxxx.
The LTR 160 and LTR 200 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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COMPONENT DESCRIPTION
This component description refers to the wiring diagrams for LTR 160 and LTR 200.
The LTR 160/200 are a primary--switched power units, using parallel--connected
MOSFET--transistors as the switching elements. The switching frequency is 36.5 kHz. The
conducting interval varies between zero and 11 µs, depending on the welding current output.
The conducting time and frequency are controlled by circuit board AP01.
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.
AP01 The main circuit board with control electronics, see the description on
page 15 and DESIGN CHANGES on page 14.
AP02 Circuit board with power transistors for the positive pole,
see description on page 28.
WARNING! the transistors are connected to mains voltage potential.
AP03 Circuit board with power transistors for the negative pole,
see description on page 30.
WARNING! the transistors are connected to mains voltage potential.
AP08 Interference suppression circuit board. Prevents mains--borne interference,
see the circuit diagram on page 34.
AP09 Interference suppression circuit board, remote control connector, see the
circuit diagram on page 35.
AP10 Circuit board with shunt signal amplifier. See the description on page 20.
Included in the LTR 160 from serial number 842--xxx--xxxx. and in the
LTR 200 from serial number 842--902--xxxx.
AP11 HF generator. See the description on page 18.
C01 Transient protection.
C02 Capacitor, 1000µF, buffer/smoothing capacitor. Time to discharge after
turning off the unit: about two minutes.
C03 See C02. Only fitted in the LTR 200.
C04 -- C09 Decoupling capacitors.
C10 2 - capacitors, 12 nF. Protection against transient voltages. From serial
number 011--xxx--xxxx the capacitors are replaced by L04 and L05.
EV01 Fan, 24 VDC
cltr0de1 -- 4 --
FU01 - FU06 Fuses fitted to the control transformer. For fuse ratings: see item 212 in the
spare parts list. Early versions of the machines have no fuses.
HL01 Lamp, 28 V, white, lights when mains power is on.
L01 Secondary inductor.
L03 Primary inductor, improves the machine’s form factor, i.e. reduces the
mains load. Only included in the LTR 160.
L04, L05 Ferrite ring cores, transient voltage protection.
Replaces C10 from serial number 011--xxx--xxxx.
L06 Ferrite tube, transient protection for machines without shunt signal
amplifier. The shunt signal wires are twisted and wired three turns through
the tube. See DESIGN CHANGES on page 14.
QF01 Mains power supply switch.
R01 Resistor, 3.9 kΩ 5 W.
R02 Resistor, 4.7 kΩ.
RP01 Potentiometer 500 kΩ. For gas post flow time 5 - 20 seconds.
RP02 Potentiometer 500 kΩ. For slope down time 0.1 - 10 seconds.
RP03 Potentiometer 10 kΩ 2 W, for setting of the welding current.
RS01 Shunt, 137 mV at 160 A respektively 200 A. The wires B1 and B2 must be
twisted in machines without shunt signal amplifier, AP10.
SA01 Switch, 2/4--stroke changeover.
SA02 Selector switch: TIG Lift Arc / TIG HF / MMA
SA03 Switch, activation of remote control.
ST01 Thermal overload cutout, for overload protection, mounted on the main
transformer (TC02) winding. See: Thermal overload switch on page 24.
TC01 Control power transformer. Secondary output voltages of 26, 2x18, 19, 23
and 42 V.
TC02 Main transformer. For fitting instructions, see page 38.
TV01 HF coil.
V01, V02 Mains rectifier bridge, 35 A, 1200 V. V02 is only fitted in the LTR 200.
After replacing the rectifier bridges, the machine must be soft--started: see
instructions on page 33.
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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 in the LTR 160 is one diode module mounted and in the
LTR 200 there are two. Each diode module has two diodes. For
installation instructions, see page 36.
V05 LED, yellow. Lights when thermal switch ST01 operates (breaks) as a
result of high temperature.
X01 -- X02 Terminal block.
XP01 Pin connector with jumper. Connected when the machine is used without
water cooler.
XS . . Sleeve connectors.
Note: the connectors XS01, XS02, XS03, XS05 and XS06 has changed
design. Valid for LTR 160 from serial number 842--xxx--xxxx and for
LTR 200 from serial number 842--902--xxxx.
The sleeve numbering is reversed compared to the earlier version. The
wire numbering and the numbering of the contact pins of the circuit board
is not changed, compare the diagrams on page 10 and 12.
The ordering numbers for the connectors are listed under item 303 in the
spare parts list.
XS10 12--pole Burndy contact, for connection of remote control unit.
XS11 TIG central connector: only LTR model - 880 and - 882.
XS12 2--pole Cannon connector, only LTR model - 881 and - 883.
XS13 Welding current connector, OKC, only LTR model - 881 and - 883.
XS14 Welding current terminals, (two), OKC type.
XS24 Connection for 400V to water cooler. (The water cooler is an accessory,
which is mounted under the machine.)
XS25 Connection for water flow guard.
YV01 Solenoid valve
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WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726
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WIRING DIAGRAM LTR 160 Valid from ser.no. 842--xxx--xxxx
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WIRING DIAGRAM LTR 200
Valid for ser.no. 722--xxx--xxxx to 842--901--0271
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cltr0de1 -- 11 --
WIRING DIAGRAM LTR 200 Valid from ser.no. 842--902--xxxx
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DESIGN CHANGES
1. Replace the AP01 control card and the AP09 interference suppression card.
2. Cut wire B1. BE CAREFUL! Do not mix up the wires. If you mix up B1 and B2, you
will get a current surge that will destroy the machine.
3. Slide a 40 mm insulating sleeve over each end of the wire.
4. Solder the red wire of the ferrite tube between the two cut ends of B1.
5. Cut wire B2. BE CAREFUL! Do not mix up the wires.
6. Slide a 40 mm insulating sleeve over each end of the wire.
7. Solder the black wire of the ferrite tube between the two cut ends of B2.
8. Slide the insulation sleeves over the joints and secure the whole with cable ties.
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LTR 160/200, new HF generator and recifier unit
New HF generator from ser. no. xxx--006--xxxx. See the description on page 18.
New design of the rectifier unit from ser. no. 011--xxx--xxxx. See C10, L04 and L05 in the
component description and items 430 and 530 in the spare parts list.
+30 V
Power supply to the gas and HF relays.
±10 V
Voltage tolerance ±5%. The power supply from transformer TC01 is protected by
two 1.25 A slow--blow fuses.
+20 V
Power supply to the control amplifier, the pulse width modulator and the gate
circuits.
Voltage tolerance ±5%. The power supply from transformer TC01 is protected by an
800 mA slow--blow fuse.
Capacitor C93 slows the rise time of the 20 V supply at power--on, which delays the
gate pulses to the MOSFET transistors.
HL01 is an indicating lamp on the front of the machine, lighting to indicate that the
main power switch is On.
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2 Power supply to the fan
The LTR is fitted with a DC--powered fan. It is supplied at 28 V ±5% from voltage
regulator VR5. The power supply from transformer TC01 is protected by a 630 mA
slow--blow fuse.
MMA, LiftArc, HF
Switch SA02 selects the welding method by disabling, through a diode network, the
functions that are not to be active for a particular welding method.
2--stroke/4--stroke
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4 Start / Stop, Reference input, Remote control input
Start/Stop
When operating in TIG welding mode, the machine is started from the welding torch
switch, which is connected to the machine via contacts XS11/XS12. Alternatively,
welding can be started from a remote control device and connectors J and K in
remote control unit contact XS10. Relay RE1 is used only during TIG starts. See
also the description of arc voltage sensing on page 21.
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5 Slope up / Slope down
Potentiometer RP02 on the front of the machine is used for setting the Slope Down
time (the decay time for the welding current when TIG--welding). The time is
adjustable between 0.1 and 10 seconds.
Potentiometer R58 on the circuit board controls the Slope Up time (the rise time for
the welding current when TIG--welding). It is adjustable between 0 and 5 seconds.
On delivery, the Slope Up time has been set at 0.
6 HF unit
When the torch switch is closed and the open--circuit voltage exceeds about 45 V,
relay RE3 closes and activates HF unit AP11. The relay drops off when the arc
voltage is less than 45 V or if the arc has not struck within 0.5 seconds.
In the MMA welding mode, transistor Q7 is held off by --10 V from diode D18. In
the Lift Arc mode, Q7 is held off by - 10 V from diode D17.
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,
0367 268 001. 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 as spare part for older machines. The
colour of the new type is grey, the old is black. The new has screw connections for
the connection cables and different hole pattern for the mounting.
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When fitting the new generator to older machines: three new mounting holes for the
generator must be drilled and the cable shoes must be removed from the connection
cables. Fit the generator with the connection terminal turned towards the base plate.
7 Gas valve
Gas valve YV1 is controlled by relay RE2. Potentiometer RP01, on the front panel
of the machine, is used for adjusting the gas post--flow time in the range 5--20
seconds.
Potentiometer R30, on the circuit board, controls the gas pre--flow time between 0
and 5 seconds. When delivered, it is set at 0 seconds.
The gas valve is activated briefly when the machine is energised.
8a Shunt input
Shunt input for the LTR 160 with serial number 704--xxx--xxxx and 726--xxx--xxxx and
for the LTR 200 with serial number 722--xxx--xxxx up to 842--901--0271
LTR 160: The shunt provides a signal of 137 mV at a welding current of 160A.
LTR 200: The shunt provides a signal of 137 mV at a welding current of 200A.
The cables (B1 and B2) between the shunt and the circuit board must be twisted in
order to prevent any interference reaching the circuit board.
Do not mix up cables B1 and B2, it will cause over current which destroys the
output transistors.
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8b Shunt input with shunt signal amplifier
Shunt input for the LTR 160 from serial number 842--xxx--xxxx and for the LTR 200
from serial number 842--902--xxxx
The shunt signal amplifier board AP10 is voltage supplied from circuit board AP01.
Resistor R16 adjusts the offset voltage of amplifier IC1. This resistor is adjusted
during manufacture of the circuit board, and should not subsequently be adjusted.
The signal amplification is set by fixed resistors and it is not adjustable.
The shunt voltage is 137 mV at maximal welding current, 160 respectively 200 A.
The voltage between the contacts B1 and B2 on circuit board AP01 must be 5.7 V
±2% at maximal welding current.
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9 Arc voltage sensing
Machines with shunt signal amplifier: The arc voltage from RS01 is connected to
AP01 through AP10. The resistors R172 and R177, with the value 0 Ω, are
mounted. The capacitors C52 and C95 are not mounted on the board.
Machines without shunt signal amplifier: The arc voltage from RS01 is
connected directly to AP01. The resistors R172 and R177 are not mounted. The
capacitors C52 and C95 are mounted on the board.
The arc voltage signal limits the open--circuit voltage and is also used to sense the
start of welding. During TIG welding, the arc voltage can vary between 5 and 45 V.
The following description describes the starting sequence for the various welding
modes:
MMA
1. Open--circuit voltage control.
Open--circuit voltage LTR 160: 65--80 V; LTR 200: 72--82 V.
2. A voltage less than 45 V is interpreted as a welding start. The control amplifier
generates an elevated starting current for about 300 ms.
The starting current is 75% higher than the set value of current when the set
value is 25 A. The starting current is 25% higher than the set value of current
when the set value is 160 A.
3. Welding is performed at the set value of current.
TIG, HF START
1. Gas pre--flow.
2. The starting voltage is about 100 V, and HF ignition is provided for a maximum
of 0.5 seconds.
3. A voltage less than 45 V is interpreted as a welding start. The control amplifier
generates an elevated starting current for about 50 ms.
The starting current is 20 A higher than the set value of current.
4. Welding is performed at the set value of current.
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1. Gas pre--flow.
2. Open--circuit voltage LTR 160: 65--80 V; LTR 200: 72--82 V.
Contact with the workpiece causes the control amplifier to generate a sensing
current, which is limited to 8 A.
3. When the electrode is lifted from the workpiece and the arc voltage exceeds
5 V, the control amplifier generates an elevated starting current for about 50 ms.
The starting current is 20 A higher than the set value of current.
4. Welding is performed at the set value of current.
10 Gate circuit
The pulse width modulator IC13 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. The pulse frequency is 36.5 ¦0.5 kHz and the maximum pulse time is
41% ¦1.5% of the cycle time.
Maximum pulse time results in maximum current and voltage.
IMPORTANT
The frequency and pulse time are very important parameters. If they are
incorrect, they can result in transistor failure in the main circuit.
See also CHECKING THE GATE PULSES on next page.
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.
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The two gate circuits are identical, and so only one is described here.
When Q17 conducts, a voltage pulse is produced on the transformer’s secondary
winding. This pulse is conducted via D40, D43 and output J1 to the gate on the
MOSFET transistors. The pulse returns via the source, connection J2, D42 and C79.
The peak gate - source voltage is 14 V.
The gate pulse between J1 and J2 charges C79 to 3.3 V. When Q17 turns off, the
voltage from the secondary of the pulse transformer changes polarity, causing Q18
and Q19 to start to conduct. The gate voltage becomes - 3.3 V, turning off the
MOSFET transistors.
When checking the gate pulses, connect a dummy gate load to the circuit board, see
instructions on next page.
If circuit board AP02 or AP03 has failed, the gate pulses must always be checked.
Remove connections XS07 and XS08 (gate pulses). Connect a dummy gate load to
outputs J1 and J2 and to K1 and K2.
IMPORTANT: never check the gate pulses when AP02 and AP03 are
connected: use a dummy gate load.
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
41% ¦1.5% 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.
After replacing AP01, check the gate pulses again and soft--start the machine, as
described on page 33.
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5V
0V
cmha2p25
Gate pulses as measured across a dummy gate load on circuit board AP01,
between terminals J1 and J2.
Thermal overload sensor ST01 is fitted in the main transformer (TC02) winding.
LTR 160: opens at 130 _C and resets (closes) at 100 _C.
LTR 200: opens at 150 _C and resets (closes) at 130 _C.
Operation of the thermal overload switch interrupts the gate pulses to the transistor
boards, and is indicated by LED V05.
cltr0de2 -- 24 --
Component positions, circuit board AP01 0481 864 880
R58 Slope up
WARNING:
High voltage within
the shaded area
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Component positions, circuit board AP01 0481 818 880
R58 Slope up
WARNING:
High voltage within
the shaded area
cltr0de2 -- 26 --
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TRANSISTOR BOARD AP02
cmha2e06
Simpified circuit diagram for transistor board AP02 (positive)
The --880 variant is used in the LTR 160 and the - 882 variant is used in the LTR 200..
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 37.
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 32 for testing.
Due to a change to transistors with higher current rating, the circuit board
may have one transistor less than specified in the diagram above.
cltr0de3 -- 28 --
Component positions, circuit board AP02
cmha2e07
cltr0de3 -- 29 --
TRANSISTOR BOARD AP03
cmha2e08
Simpified circuit diagram for transistor board AP03 (negative)
The --880 variant is used in the LTR 160 and the - 882 variant is used in the LTR 200..
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 37 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.
Q1 -- Q8 MOSFET transistors. These require a special instrument.
See MOS TESTER on page 32 for testing.
Due to a change to transistors with higher current rating, the circuit board
may have one transistor less than specified in the diagram above.
cltr0de3 -- 30 --
R21 Charging resistor, 12Ω, 10W, for buffer capacitor C02 (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. This capacitor is only fitted in
LTR 200. After turning off the mains power supply, the discharge time for
the capacitor is about two minutes.
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.
cmha2e09
cltr0de3 -- 31 --
MOS TESTER
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.
Testing:
S Press the pushbutton marked TEST.
S If the board is healthy, both the red and green LEDs should flash alternately, about once
a second.
S 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.)
S 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 on page 23.
After replacement of the boards, the machine must be soft--started.
cltr0de3 -- 32 --
SOFT STARTING
S Remove and insulate wires 07 and 08 from rectifier bridge V01: see the circuit diagram
on page 7.
In the LTR 200, also remove and insulate wire 09 to rectifier bridge V02: see the circuit
diagram on page 10.
S Connect an external power supply, having a current limit of 1 A, to the positive and
negative connections on V01.
S Adjust the power supply voltage to 30 V.
S Power the remaining parts of the unit from the normal power supply.
S Select MMA mode.
S Measure the output voltage from the machine. On the LTR 160 this must be 10V ¦1V,
and on the LTR 200 it must be 6V ¦1V.
S 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 for 30 V across the buffer capacitor
cltr0de3 -- 33 --
LTR 160, SUPPRESSION CIRCUIT BOARD AP08
cltn0e35
cltn0e34
Diagram and component positions for the old version (0486 356 880) of circuit board AP08
Most of the machines produced before October 1998 are deliverd with circuit board 0486 356
880. As spare part for those machines circuit board 0486 356 880 or 0486 577 880 may be
used. 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.
cltr0de3 -- 34 --
Diagram and component positions for the new version (0486 577 880) of circuit board AP08
cltn0e29
cltn0e27
Circuit diagram Component positions
cltr0de3 -- 35 --
DISASSEMBLY / REASSEMBLY
1. Clean the contact surface of the heat sink with extremely fine abrasive paper.
2. Apply a thin film of contact oil (see items 454 and 555 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 picture above is valid for the LTR 160, which has one diode module. Assemble the two
diode modules in the LTR 200 in a similar way.
From serial number 011--xxx--xxxx the diode modules are different connected compared to
the picture above: see the spare parts list. The fitting procedure for the modules is however
the same as described above.
cltr0de3 -- 36 --
Removal of transistor circuit boards AP02 and AP03
cltr0de3 -- 37 --
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 428 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
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
cltr0de3 -- 38 --
LOAD CHARACTERISTICS
LTR 160
LTR 200
cltr0de3 -- 39 --
TECHNICAL DATA
Slope up,
adjustable on the circuit board 0 -- 5 sec. 0 -- 5 sec.
Slope down 0.1 -- 10 sec. 0.1 -- 10 sec.
Open--circuit voltage 65 -- 80 V 72 -- 82 V
Open--circuit power 30 W 47 W
Useful power, P
at max current MMA 4.8 kW 6.8 kW
Apparent power, S
at max current MMA 6.9 kVA 10.6 kVA
Application class
Class of enclosure IP 23 IP 23
The welding power sources comply with the requirements set out in IEC 974--1
The symbol indicates that this power source is designed for use in areas where there is an
increased electrical hazard.
The enclosure class indicates the degree of protection against penetration by solid objects and
water. Equipment marked IP 23 is designed for in-- and outdoor use.
cltr0de3 -- 40 --
INSTRUCTIONS
This chapter is an extract from the instruction manual for the LTR 160/200.
INTRODUCTION
Note!
This product is solely intended for arc welding.
LTR 160/200 are rectifiers based on inverter technology and designed for TIG welding and
welding with coated electrodes. They are available in two versions, one with a central socket
and one with an OKC socket for connecting a TIG torch.
The machines are supplied complete with 5 metre mains cable, 5 metre return cable, gas hose
and hose clamps.
Versions with a central socket are also supplied with a protective handle to protect the
connections from strokes.
An optional top handle can be fitted to the machine for winding up cables and to protect the
control panel.
Two different trolleys are available to facilitate transport with a gas cylinder and cooling unit.
INSTALLATION
WARNING
This product is intended for industrial use. In a domestic environment it may cause
radio interference. It is the user’s responsibility to take adequate precautions.
LTR 160/200 are equipped with mains voltage compensation, which means that a ¦10 %
variation in the mains voltage only results in a ¦0.2 % variation in the welding current.
To reduce the voltage drop when using a long cable it can be advisable to select a heavier
cable cross section.
1. Place the equipment in a suitable place and make sure the machine is not covered or
set--up so that cooling is prevented.
2. Make sure the machine is connected to the correct mains voltage.
Earth according to applicable directives.
3. Connect the shielding gas.
4. Connect the TIG torch and the return cable or the MMA welding cables.
cltr0de4 -- 41 --
OPERATION
S Using the remote control socket on the machine the current can be remotely regulated in
TIG and MMA modes.
S PHA5 remote control unit allows use of pulsed current in TIG mode.
To take your mind off the risk of overloading the machine it 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.
Mode = HF
When the torch trigger is pressed the gas starts flowing. The high frequency unit is switched
on and produces a spark between the electrode and the work piece, which ionises the gas and
ignites the arc. Once the arc is stable the HF unit is automatically switched off. It is also
switched off if the arc has not struck after 0.5 seconds.
Mode = MMA
In this mode the machine is set up for welding with coated electrodes. The HF unit and
Lift--Arc are disabled and the Hot--start unit is now activated to give a higher current during
striking.
cltr0de4 -- 42 --
Mode 2/4--stroke
2 stroke: arc is struck when the torch trigger is depressed and extinguished when the trigger
is released.
4 stroke: there is no need to keep the torch trigger depressed during the welding sequence.
Press and release the trigger to strike the arc. Press and release the trigger again to extinguish
the arc.
Mode = Lift--Arc
The torch electrode is positioned at the point where you want to start welding, when you
press the trigger and raise the torch the arc is struck.
Using the built--in slope--up function the current rises to the preset value. When you want to
stop welding you release the switch and the current slowly decreases in accordance with the
preset slope--down time.
bt07t001
Place the electrode against the workpiece . Press the torch switch
bt07t002
Tilt the torch a little, lift and an arc is produced To stop -- release the torch trigger
cltr0de4 -- 43 --
MAINTENANCE
Generally, LTR 160/200 do not require any
maintenance. Normally, it is sufficient to blow
out the machine using clean, compressed air
annually, and the dust filter should be cleaned
regularly.
If the machine is set up in dusty or dirty
environments the machine and dust filter should
be cleaned more often.
NOTE: All warranty undertakings given by the
supplier cease to apply if the customer attempts
to rectify any faults on the machine during the
warranty period. Dismantling the filter bt07d10
SPARE PARTS
The spare parts list for the LTR 160 and LTR 200 is published in a separate document with
filename / ordering no. 0457 305 990
cltr0de4 -- 44 --
NOTES
notes -- 45 --
ESAB subsidiaries and representative offices
ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
031021