Related Manuals for ESAB Caddy 130
Summary of Contents for ESAB Caddy 130
- Page 1 LHN 130/140/200 Caddy 130/140/200 cmha2p00 Service manual 0740 800 043 040906 Valid for serial no. 301- -xxx- -xxxx to 220- -xxx- -xxxx...
- Page 2 LIST OF CONTENTS Page READ THIS FIRST ............COMPONENT DESCRIPTION, LHN 130/140/200 .
- Page 3 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. ELECTRIC SHOCK - - Can kill Install and earth the welding unit in accordance with applicable standards. Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
- Page 4 COMPONENT DESCRIPTION, LHN 130/140/200 This component description relates to the wiring diagrams on pages 7 - - 11. The LHN 130/140/200 rectifier power units are primary switched type, using parallel- - connected MOSFET transistors as switching devices. Switching frequency is 36 kHz. The conduction interval ranges between zero and 11 µs, depending on the welding current being supplied.
- Page 5 Capacitor, 0.1 µF, 1000 VDC, protects the equipment against RFI. 2 - - capacitors, 4.7 µF: see L02. Not mounted in LHN 130. 2 - - capacitors, 12 nF. Protection against transient voltages. Replacing AP04 from serial number 628- - xxx- - xxxx. See “transient protection, rectifer unit V03, V04”...
- Page 6 V01, V02 Mains rectifier diode bridge, 35 A, 1200 V. After replacing the rectifier bridges, the machine must be soft- - started: see instructions on page 25. Rectifier bridge V02 is only mounted in LHN 200. V03, V04 Rectifier and freewheel diodes. V03 rectifies the welding current.
- Page 7 WIRING DIAGRAM LHN 130 cmha2e20 - - 7 - - cmha2de1...
- Page 8 WIRING DIAGRAM LHN 140 valid before ser.no. 011- -xxx- -xxxx cmha2e01 - - 8 - - cmha2de1...
- Page 9 WIRING DIAGRAM LHN 140 valid for ser.no. 011- -xxx- -xxxx and 220- -xxx- -xxxx - - 9 - - cmha2de1...
- Page 10 WIRING DIAGRAM LHN 200 valid before ser.no. 011- -xxx- -xxxx cmha2e02 - - 10 - - cmha2de1...
- Page 11 WIRING DIAGRAM LHN 200 valid for ser. no. 011- -xxx- -xxxx and 220- -xxx- -xxxx - - 11 - - cmha2de1...
- Page 12 COMPONENT POSITIONS, CIRCUIT BOARD AP01 cmha2e05 Circuit board AP01 0481 870 880, fitted before serial number 220- -xxx- -xxxx Circuit board AP01 0481 870 885, fitted before serial number 220- -xxx- -xxxx - - 12 - - cmha2de1...
- Page 13 Circuit board AP01 0486 886 880, fitted from serial number 220- -xxx- -xxxx WARNING: high voltage in the shaded areas From serial number 220- - xxx- - xxxx circuit board 0486 886 880 is fitted in the machines. The circuit board versions are fully interchangeable and can be used in any of the machines. - - 13 - - cmha2de1...
- Page 14 DESCRIPTION OF OPERATION, CIRCUIT BOARD AP01 This description refers to the wiring diagrams on pages 7- - 11 and to the component position diagrams on pages 12 and 13. Only those items connected to the circuit board inputs and outputs are described here. If the circuit board is faulty, it must be replaced. There are three versions of the circuit board, this description applies to all versions.
- Page 15 Under voltage detector This circuit senses if the mains power supply voltage is too low. Loss of mains power supply for more than 10 ms, or low voltage, results in the pulse width modulator (8) blocking the gate pulses. The reference voltage to IC1, +ref.
- Page 16 Current reference This circuit supplies a signal voltage to the current setting potentiometer and remote control unit. It also modifies the current reference signal to a suitable level for the control amplifier (7). Connections A01 and A02 are supplied at 17 V from transformer TC01. This supply is rectified and smoothed for supply to voltage regulator VR2.
- Page 17 Control amplifier The control amplifier sets a suitable welding current in relation to the current setting and arc voltage. The circuit can be divided up into three main parts: Average current control Starting current control Short- - circuit current limit Pulse Width Modulator The pulse width modulator determines the frequency and pulse time of the control pulses to the MOSFET transistors.
- Page 18 Gate circuit The driver stage for the MOSFET transistors provides control pulses to the gate- - source of the power transistors. There is a separate output for each switching 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.
- Page 19 CHECKING THE GATE PULSES If circuit board AP02 or AP03 has failed, the gate pulses must always be checked. Remove connections XS04 and XS05 (gate pulses), and connect a gate load to connections E01 and E02 and to F01 and F02. Gate load IMPORTANT: never check the gate pulses when AP02 and AP03 are connected: always use a dummy gate load.
- Page 20 CIRCUIT DIAGRAM, CIRCUIT BOARD AP02 cmha2e06 AP02 (POSITIVE) CIRCUIT BOARD 481 803 - -880 / - - 882 / - -889 The - -880 variant is used in the LHN 140, the - - 882 variant in the LHN 200 and the - - 889 variant in LHN 130.
- Page 21 COMPONENT POSITIONS, CIRCUIT BOARD AP02 cmha2e07 - - 21 - - cmha2de1...
- Page 22 CIRCUIT DIAGRAM, CIRCUIT BOARD AP03 cmha2e08 AP03 (NEGATIVE) CIRCUIT BOARD 481 848 - - 880 / - - 882 / - -889 The - -880 variant is used in the LHN 140, the - - 882 variant in the LHN 200 and the - - 889 variant in LHN 130.
- Page 23 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 24 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.
- Page 24 MOS TESTER The MOS tester is a special instrument, and can be ordered only from ESAB’s service department in Laxå. Order number is 468 469- - 001. Connect the instrument as follows: Disconnect the power unit from the mains. Disconnect capacitor C02 (and C03 in the LHN 200).
- Page 25 SOFT STARTING Remove and insulate wires 007 and 008 from rectifier bridge V01: see the circuit diagram on page 7 and 8 for LHN 130/140. In the LHN 200, also remove and insulate wire 009 to rectifier bridge V02: see circuit diagram on page 10.
- Page 26 Remove the strap from the rear panel (1). Remove the cable bushing (2) and slide it back along the cable. Remove the two screws (3). Caddy 130/140: Remove the rear panel from the casing (7) and disconnect the wires to the switch (4). Caddy 200: Remove switch knob (6) and screws (5).
- Page 27 REMOVAL OF FRONT PANEL Remove the rear panel and casing. Remove screws (a). Remove the positive busbar from the rectifier unit. Screw (b) is accessible from beneath the machine. Remove nut (c) and remove the negative busbar from the shunt. Remove connectors XS10 and XS03 from circuit board AP01.
- Page 28 REMOVAL OF TRANSISTOR CIRCUIT BOARDS AP02 AND AP03 Remove the rear panel and casing. Remove all wires and busbars connected to the board. Remove the springs that hold the board (2) in position by prising them off with a screwdriver (1) between the cooling flange and the spring. Removal/refitting of transistor circuit board REFITTING THE TRANSISTOR CIRCUIT BOARD When replacing the transistor circuit board, both boards must always be replaced and...
- Page 29 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 30 LOAD CHARACTERISTICS Caddy 140 Caddy 200 cmha2p19 cmha2p21 Caddy 130 - - 30 - - cmha2de1...
- Page 31 TECHNICAL DATA Caddy 130 Caddy 140 Caddy 200 Load capacity At 35% intermittence 130 A / 25 V 140 A / 26 V 200 A / 28 V At 60% intermittence 100 A / 24 V 110 A / 24 V...
- Page 32 230 - - 240 V, 50- - 60 Hz. To use Caddy 130/140 at its full rating, it must be protected by a 16 A slow- -blow fuse. If, however, it will be used only for welding currents of up to about 100 A, a 10 A slow- - blow fuse is sufficient.
- Page 33 The Caddy 130/140 is suitable for use with the majority of coated electrodes from 1.6 mm to 3.25 mm diameter, while the Caddy 200 can be used with electrodes up to 4.0 mm diameter.
- Page 34 MAINTENANCE Clean the air filter in the front panel of LHN 140/200 regularly, and replace it if damaged. Remove the filter by inserting a screwdriver in the slit in the grille and prising out the lower part of the grille, as shown on the right.
- Page 35 SPARE PARTS The spare parts lists for the LHN 130 and LHN 140/200 are published in separate documents with filename / ordering no: LHN 130: 0455 996 990 LHN 140/200: 0468 964 990 NOTES - - 35 - - notes...
- Page 36 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...