ESAB LKA 150 Service Manual
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ESAB LKA 150 Service Manual

ESAB LKA 150 Service Manual

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LKA 150
clka0p00
Service manual
0349 300 001
040928
Valid for serial no. 923−xxx−xxxx

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Summary of Contents for ESAB LKA 150

  • Page 1 LKA 150 clka0p00 Service manual 0349 300 001 040928 Valid for serial no. 923−xxx−xxxx...

  • Page 2: Table Of Contents

    ......SPARE PARTS LIST, LKA 150 ......

  • 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 150 is designed and tested in accordance with international standard EN 60974−1, EN 50199.

  • Page 4: Rating Plate

    1. LKA 150 is the type designation for this power source. The first letter, L, indicates that the LKA 150 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 − clka0de1...

  • Page 6: Component Description, Lka 150

    COMPONENT DESCRIPTION, LKA 150 Circuit board with control electronics: see the diagram on page 6 and description on page 7. Capacitor 0.1µF, 400 VDC, transient protection. Capacitor 0.1µF, 400 VDC, transient protection. Inductor. Wire feeder motor. Switch, 8−way, for 7−step and Off (main On/Off switch) adjustment of the welding current.

  • Page 7: Connection Diagram, Lka 150

    CONNECTION DIAGRAM, LKA 150 clka0e01 − 5 − clka0de1...

  • Page 8: Circuit Diagram, Circuit Board Ap1

    CIRCUIT DIAGRAM, CIRCUIT BOARD AP1 clka0e02 − 6 − clka0de1...

  • Page 9: Component Positions, Circuit Board Ap1

    COMPONENT POSITIONS, CIRCUIT BOARD AP1 clka0e03 DESCRIPTION OF OPERATION, CIRCUIT BOARD AP1 This description relates to the circuit diagram and the component positions diagram. If the circuit board is faulty, it must be replaced. CONTROL CIRCUIT Pressing trigger switch SB1 on the welding torch energises relay RE1 from control power transformer TR1.
  • Page 10 RFI SUPPRESSION AND BASE LOAD RESISTORS Capacitors C4 − C6 protect against RFI. Resistors R12 and R15 provide a minimum base load for the rectifier bridge: in addition, they act as discharge resistors for the capacitors. MOTOR DRIVE CIRCUIT The wire feed motor is powered by the rectified secondary voltage from main transformer TM1.
  • Page 11 CIRCUIT DIAGRAM, CIRCUIT BOARD AP1 clka0e02 − 9 − clka0de1...

  • Page 12: Motor Diagrams

    MOTOR DIAGRAMS clka0p04 Motor voltage and current when R13 is at its minimum position and QF1 is in position 3. The motor is unloaded. clka0p05 Motor voltage and current when R13 is in its maximum position and QF1 is in position 3. The motor is unloaded.

  • Page 13: Load Characteristic, Lka 150

    LOAD CHARACTERISTIC, LKA 150 clka0p06 − 11 − clka0de1...

  • Page 14: Technical Data

    TECHNICAL DATA Load capacity At 8% duty cycle 150 A / 16 V At 60% duty cycle 55 A / 17 V At 100% duty cycle 40 A / 16 V No−load voltage 16 − 28 V Wire feed speed 2,5 −...

  • Page 15: Installation

    INSTALLATION To be able to operate the LKA 150 at maximum power (position 7), it must be supplied via a 16 A slow−blow fuse. However, a 10 A slow−blow fuse is sufficient for welding at currents up to about 100 A.

  • Page 16: Operation

    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). The gas flow must be 8 − 12 litres per minute. Turn on the power unit and set a suitable voltage with knob (H).

  • Page 17: Welding Data Selection

    WELDING DATA SELECTION clka0p13 − 15 − clka0de1...

  • Page 19: Spare Parts List, Lka 150

    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 20 C = component designation in the circuit diagram Item Ordering no. Denomination Notes 469 358−001 Cover plate 469 356−001 Rear panel 469 821−001 Rear panel Only for the Australian market 469 386−001 Side panel With text 0700 200 001 Welding gun MXL 150v Complete 469 571−880 Return cable...
  • Page 21 clka0p02 − 18 − clka0se1...
  • Page 22 Spare parts list − Reservdelsförteckning − Ersatzteilverzeichnis − Liste de détachées C = component designation in the circuit diagram Item Ordering no. Denomination Notes 469 471−001 Switch 469 668−001 Switch Only for the Australian market 192 562−801 Cage nut 469 300−880 Inductor 469 280−880 Transformer...
  • Page 23 clka0p03 − 20 − clka0se1...
  • Page 24 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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