ESAB LKB 400W Bedienungsanleitung

LKB 400W

WELDING RECTIFIER

Service manual

0349 300 020 01-01-24

1. CONNECTION DIAGRAM, LKB400W ................................................................................................ 4

2. COMPONENT POSITIONS, CIRCUIT BOARD LA07 (A1) ................................................................ 6

2.1 DESCRIPTION OF BOARD LA07.................................................................................................... 8

3. COMPONENT POSITIONS, CIRCUIT BOARD LKC31 (A2) ............................................................. 9

3.1 CONTROL CIRCUIT FUNCTION LKC31 ........................................................................................ 10

3.1.1 POWER SUPPLY ....... ............................................................................................................... 10

3.1.2 START/STOP ............................................................................................................................. 10

3.1.3 CONTROL MODES-2 STROKE/MOTOR-TEST/4-STROKE ................................................... 10

3.1.4 WIRE FEED SPEED ................................................................................................................... 11

3.1.5 MOTOR CONTROL/DYNAMIC BRAKING .............................................................................. 12

3.1.6 BURNBACK TIME, CONTACTOR, GAS VALVE ...................................................................... 13

3.2 V/A-METER OPTION (STANDARD CONTROL) ........................................................................... 13

4.TECHNICAL DATA ............................................................................................................................... 15

5. LOAD CHARACTERISTIC ................................................................................................................... 15

6. INSTALLATION .................................................................................................................................. 16

7. INSTRUCTION FOR USE .................................................................................................................... 16

8. COOLING CIRCUIT DIAGRAM ........................................................................................................... 17

9. MAINTENANCE ................................................................................................................................... 18

10. ACCESORIES .................................................................................................................................... 18

10.1 V/A METER ALLEMBLY INSTRUCTION .................................................................................... 18

11. SPARE PARTS LIST ...................................................................................................................... 19

! WARNING !

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUTIONS WHEN WELDING. ASK YOUR EMPLOYER FOR SAFETY PRACTICES THAT SHOULD

BE BASED ON MANUFACTURER’S HAZARD DATA.

ELECTRIC SHOCK - Can kill

- Install equipment in accordance with obligatory standards.

- Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothes.

- Insulate yourself from earth and workpiece.

- Ensure your work position is safe.

FUMES AND GASES - Can be dangerous to your health

- Keep your head away from fumes.

- Use ventilation and/or extraction to keep fumes and gases away from your breathing zone

and surroundings.

ARC RAYS - Can injure eyes and burn skin

- Protect your eyes and skin. Use correct welding screens, filter lens and wear protective clothes.

- Protect bystanders with suitable screens or curtains.

FIRE HAZARD

- Sparks (spatter) can cause fire. Make therefore sure there are no inflammable materials nearby.

NOISE - Excessive noise can damage your hearing.

- Protect your ears. Use ear defenders or other hearing protection.

- Warn bystanders of the risk.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING UNIT

PROTECT YOURSELF AND OTHERS !

1. CONNECTION DIAGRAM, LKB400W, 400V

Switch positions for switch Q3 Switch positions for switch Q4

COMPONENT DESCRIPTION

A1 Circuit board LA07 M1 Fan

A2 Circuit board LKC31 M2 Pump

A3 V/A - meter M3 Drive unit motor

T1 Transformer V2 Rectifier bridge

V1 Diode bridge B1,B2 Temperature switch

L1 Inductor B3 Flow switch

RI Shunt RV Wire speed reference potentiometer

K1 Contactor R2 Resistor

Q1 Rotary cam switch F1 Fuse 2A slow-blow

Q3 Rotary cam switch F2 Fuse 10A slow-blow

Q4 Rotary cam switch F3 Fuse 4A slow-blow

Q2 Circuit breaker H1 LED (green/yellow)

T2 Control transformer H2 LED (yellow)

C1,C2,C3 Capacitor 2uF 450V H3 LED (green)

C5,C6,C7 Capacitor 0,1uF/275V XGM Terminal block

R1 Resistor 3,3k 1W

LKB 400W, 400V

2. COMPONENT POSITIONS, CIRCUIT BOARD LA07 (A1)

DIAGRAM LA07 (A1)

DESCRIPTION OF BOARD LA07 (A1)

Power supply

The board is supplied 20V AC voltage (contacts 8,9 connector X1). Two step voltage regulation (elements

T9, U1) provide voltage 15 V ±5% required for control system power supply.

Inputs

1. Auxiliary contact of main contactor type NO - 11,12 X1,

2. Contact of temperature sensor type NC - 4,3 X1,

3. Contact of liquid pressure sensor type NO - 2,1 X1,

4. Reserved input - 6,7 X1,

5. Reserved input - 5,10 X1.

Outputs

1. Fan switch contact NO, MOV 275V - 1,6 X2, (6- common phase contact)

2. Pump switch contact NO, MOV275V - 3,6 X2, (6- common phased contact)

3. Power supply switch for feeder

type NO , MOV 75V - 1,2 X4,

4. Power supply for LED diode green-yellow (H1) - 1,2,3 X3 (2-common cathode)

5. Power supply for LED diode yellow (H2) - 6,7 X3 (6-cathode)

6. Power supply for LED diode green (H3) - 4,5 X3 (5-cathode)

LED diodes– external

1. H1 – two colours: green - unit on signal,

yellow – unit off signal,

2. H2 - yellow: on when unit overheated,

3. H3 – green: on when cooling liquid flow correct.

Operation

After switching the unit, feeding unit is powered (relay PK1) and fan (relay PK2) and pump (relay PK3) are

switched on. If within 5s the signal from liquid pressure sensor (NO contact ) is not supplied, wire feeding

unit power supply shall be disconnected. Power supply shall be restored on signal from pressure sensor.

Proper pressure (liquid flow) is indicated by green diode placed on the front panel of the unit (H3).

Wire feeder power supply is disconnected as well by means of signal from external thermal NC-type

switches. Overheating is indicated by yellow diode (H2) placed on the front panel of the unit. Wire feeder

power supply shall be restored on absence of overheating.

Oscillator-counter U2 is reset during main contactor operation and during overheating. After 5 minutes from

the last switch-off of contactor and end of overheating period, pump is switched off (relay PK3) and after 10

minutes – fan is switched off (relay PK2). On the fan switch-off unit goes into the idle mode indicated by

yellow lighting of diode H1 placed on the front panel of the unit. Wire feeder remains powered (relay PK1).

In the idle mode, with switched off pump, it is possible to start welding by means of button on torch.

Then, contactor is switched on again, counter U2 is reset, fan and pump are activated. Within 5s signal from

liquid pressure sensor should appear. If not, wire feeder power supply circuit (relay PK1) is disconnected.

Power supply shall be restored on signal from pressure sensor.

3. COMPONENT POSITIONS, CIRCUIT BOARD LKC31 (A2)

3.1 CONTROL CIRCUIT FUNCTION LKC31

Sections 3.1.1-3.1.6 below refer to the diagrams in chapter 1.

3.1.1 POWER SUPPLY

The circuit board uses one supply voltage: 42VAC – rectified by the bridge V2 for power supply to the motor

and control circuitry.

•Power supply to the electronic circuitry

-the +26V power supply from V3 through R3 – is regulated to 15V by voltage regulator A1,

-+15V is used for powering of motor control electronic

•+60V power supply is used for motor control,

This voltage may vary (with load/mains voltage deviation) – from –15% to +10%.

•+26V (intermediate voltage for A1) – is also used for powering of relays K1 and K2 (on PCB) and for input

control circuit (“START/STOP”).

3. 1.2 START/STOP

Closing contact S1 on the welding torch starts the welding process – or only motor M3 depending on control

mode selection (see – section 3.1.3)

3. 1.3 CONTROL MODES – 2-STROKE/MOTOR-TEST/4-STROKE

By the switch S3 on the PCB (pos. M) – in the motor compartment – welder may select the following control

modes:

A) 2-STROKE CONTROL

When the trigger switch (welding gun-S1) is depressed – welding process starts (wire feed motor, gas

valve and power unit contactor).

When trigger switch is released – welding process stops (motor and gas valve – immediately, contactor –

when burnback time is elapsed).

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