Related Manuals for ESAB LTR 160
Summary of Contents for ESAB LTR 160
- Page 1 LTR 160/200 Power Tig 160/200 Service manual 0740 800 104 040830 Valid for serial no. 704- -xxx- -xxxx to 011- -xxx- -xxxx...
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Page 2: Table Of Contents
............WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726 . -
Page 3: Read This First
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. -
Page 4: Component Description
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. - Page 5 Lamp, 28 V, white, lights when mains power is on. Secondary inductor. 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.
- Page 6 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.
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Page 7: Wiring Diagram Ltr 160 Valid For Ser.no. 704 -- 726
WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726 - - 7 - - cltr0de1... -
Page 8: Wiring Diagram Ltr 160 Valid From Ser.no. 842--Xxx--Xxxx
WIRING DIAGRAM LTR 160 Valid from ser.no. 842--xxx--xxxx - - 8 - - cltr0de1... - Page 9 - - 9 - - cltr0de1...
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Page 10: Wiring Diagram Ltr 200 Valid For Ser.no. 722--Xxx--Xxxx To 842--901--0271
WIRING DIAGRAM LTR 200 Valid for ser.no. 722--xxx--xxxx to 842--901--0271 - - 10 - - cltr0de1... - Page 11 - - 11 - - cltr0de1...
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Page 12: Wiring Diagram Ltr 200 Valid From Ser.no. 842--902--Xxxx
WIRING DIAGRAM LTR 200 Valid from ser.no. 842--902--xxxx - - 12 - - cltr0de1... - Page 13 - - 13 - - cltr0de1...
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Page 14: Design Changes
LTR 160/200 without shunt signal amplifier LTR 160 units having serial numbers 704- - xxx- - xxxx and 726- - xxx- - xxxx, and LTR 200 units having serial numbers 722- -xxx- -xxxx, have sometimes suffered from problems. The gas valve can open as a result of interference from other machines working on the same workpiece, and there is sometimes also noise from the TIG arc on the machines. -
Page 15: Description Of Operation Circuit Board Ap01
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. -
Page 16: Power Supply To The Fan
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. Selection of welding method MMA, LiftArc, HF Switch SA02 selects the welding method by disabling, through a diode network, the... -
Page 17: Start / Stop, Reference Input, Remote Control Input
Start / Stop, Reference input, Remote control input Reference input/Remote control input This input has its own power supply and a high- - impedance input to the control amplifier. This protects it against short circuits between the remote control cable and the welding circuit. -
Page 18: Slope Up / Slope Down
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). -
Page 19: Gas Valve
The gas valve is activated briefly when the machine is energised. 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. -
Page 20: Shunt Input With Shunt Signal Amplifier
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. -
Page 21: Arc Voltage Sensing
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. -
Page 22: Gate Circuit
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. -
Page 23: Checking The Gate Pulses
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. -
Page 24: Thermal Overload Switch
Thermal overload switch 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. -
Page 25: Component Positions, Circuit Board Ap01 0481 864 880
Component positions, circuit board AP01 0481 864 880 R58 Slope up R30 Gas pre flow WARNING: High voltage within the shaded area - - 25 - - cltr0de2... -
Page 26: Component Positions, Circuit Board Ap01 0481 818 880
Component positions, circuit board AP01 0481 818 880 R58 Slope up R30 Gas pre flow WARNING: High voltage within the shaded area - - 26 - - cltr0de2... - Page 27 - - 27 - - cltr0de2...
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Page 28: Transistor Board Ap02
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. - Page 29 Component positions, circuit board AP02 cmha2e07 - - 29 - - cltr0de3...
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Page 30: Transistor Board Ap03
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. - Page 31 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. Discharge resistor for buffer capacitor C03. This capacitor is only fitted in LTR 200.
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Page 32: Mos Tester
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. Connect the instrument as follows: Disconnect the power unit from the mains. Disconnect capacitor C02 (and C03 in LTR 200). -
Page 33: Soft Starting
Power the remaining parts of the unit from the normal power supply. Select MMA mode. 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. -
Page 34: Ltr 160, Suppression Circuit Board Ap08
LTR 160, SUPPRESSION CIRCUIT BOARD AP08 Circuit diagram Component positions LTR 200, 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. -
Page 35: Suppression Circuit Board Ap09
Diagram and component positions for the new version (0486 577 880) of circuit board AP08 SUPPRESSION CIRCUIT BOARD AP09 cltn0e29 cltn0e27 Circuit diagram Component positions - - 35 - - cltr0de3... -
Page 36: Disassembly / Reassembly
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. -
Page 37: Removal Of Transistor Circuit Boards Ap02 And Ap03
LTR 160: not connected LTR 200: wire 045 to the connection between C02 and C03 b LTR 160: busbar to positive on C02 LTR 200: busbar to positve on C03 c Busbar connected to negative on C02 d LTR 160: wire 024 from inductor L03... -
Page 38: Fitting The Main Transformer Tc02
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. -
Page 39: Load Characteristics
LOAD CHARACTERISTICS LTR 160 LTR 200 - - 39 - - cltr0de3... -
Page 40: Technical Data
TECHNICAL DATA LTR 160 LTR 200 Permitted load at: 20 % duty cycle, MMA 160 A / 26 V 35 % duty cycle, TIG 160 A / 16 V 200 A / 18 V 35 % duty cycle, MMA 200 A / 28 V... -
Page 41: Instructions
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. -
Page 42: Operation
OPERATION 1. Mains power switch on/off 2. Yellow LED, indicates overload 3. White indicating lamp, lights when mains power is on 4. Slope down 0.1 - - 10 seconds 5. Welding methode selector switch 6. Current setting 7. Gas post- -flow, 5 - - 20 seconds 8. - Page 43 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.
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Page 44: Maintenance
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 - - 44 - - cltr0de4... -
Page 45: Notes
NOTES - - 45 - - notes... - Page 46 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...