muUrReKs> a Transtig DC 160i/200i SERVICE MANUAL Note: For information on DC 160i refer to LTN 160 For information on DC 200i refer to LTN 200LIST OF CONTENTS Page INTRODUCTION seuss : : . 2 RATING PLATE. errr tee 4 COMPONENT DESCRIPTION, LTN 160/200 o . 6 CONNECTION DIAGRAM, LTN 160 40 CONNECTION DIAGRAM, LTN 200 : 1 BLOCK DIAGRAM, CIRCUIT BOARD APOt 12 COMPONENT POSITIONS, CIRCUIT BOARD APOI |: 15 DESCRIPTION OF OPERATION, CIRCUIT BOARD APOt 16 CHECKING THE GATE PULSES ..... : : : 26 CIRCUIT DIAGRAM, CIRCUIT BOARD APO2 28 CIRCUIT DIAGRAM, CIRCUIT BOARD APO3 . : + 30 MOS TESTER fo Fans ¥ 7" 32 SOFT STARTING ooo eee een ees 33 CIRCUIT DIAGRAM, CONTROL PANEL APOS | 34 CIRCUIT DIAGRAM, DISPLAY BOARD APO6 36 CIRCUIT DIAGRAM, CIRCUIT BOARD APO? .. 2... ose eee eee e cece eee 1 38 CIRCUIT DIAGRAM, CIRCUIT BOARD APOS .. . 40 DISASSEMBLY / REASSEMBLY : 41 FAULT CODES . 45 LOAD CHARACTERISTICS feces eee : cect testes sees AT TECHNICAL DATA .....-..- 0020220 c eee veces 4B INSTALLATION soos € 0 ne 49 OPERATION .. a win a teen es 50 MAINTENANCE, on nee a am we : 2. 55 ACCESSORIES . ‘ feces 56 SPARE PARTS LIST LTN 160/200 59 INTRODUCTION This service manual is intended for use by technicians with electrical training for fault-tracing and repair. To help you understand how the machine is intended to be used, a brief guide to the machine is included at the end of the manual. The manual contains details of all design modifications up to and including February 1994. Trace faults with the help of the diagrams in the manual. The machine components are listed and described in alphanumerical order in conjunction with the connection diagrams. The components shown and numbered in the block diagram are described on the pages after the block diagram. | The Aristotig 160 and 200 are designed and tested in accordance with interna- tional standard EN 60 974-1 (IEC 974-1). 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. Rights reserved to alter specifications without notice comme. soa2eA WARNING A ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF ‘AND OTHERS. TAKE PRECAUTIONS WHEN WELDING. ‘ASK FOR YOUR EMPLOYER'S SAFETY PRACTICES WHICH SHOULD BE BASED ON MANUFACTURER'S 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. Insulate yourself from earth and the workpiece. * Ensure your working stance is safe. FUMES AND GASES - Can be dangerous to health * Keep your head out of the fumes. © Use ventilation, extraction at the are, or both, to keep fumes and gases from your breathing zone and the general area. ARC RAYS - Can injure eyes and burn skin. * Protect your eyes and body. Use the correct welding screen and filter lens and wear protective clothing. ‘* Protect bystanders with suitable screens or curtains. FIRE HAZARD © Sparks (spatter) can cause fire. Make sure therefore that there are no flammable materials nearby. MALFUNCTION * Call for expert assistance in the event of malfunction. READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING THE EQUIPMENT PROTECT YOURSELF AND OTHERS! ctinoget 940228 A cisioleRATING PLATE ‘The rating plate is secured to the back of the machine. The example shown below is the rating plate for an Aristotig 200 with an explanation of how the plate should be read and interpreted. Esob Welding Equipment AB cd S-g9581 Loxe Steden ESAB ‘| |LTN 200 worry zzz | | 7 = 2| | =A CD B= ec 97-1 || oh 24/20 V = 200 4728 V “ x x] 60 %[ 100 % A[160 AT 115 A v[ 26 vi 25 v 200 A718 V 4 x] 60 %[100 % A[150 Al TIS A vi 16 v[ 15 Vv ~ [Uy 400¥ 3 5 pos Show) Ir | (7 A] 12 Al 10 A 6 COOLING AF. IP 23 is] eta 4 LTN 200 is the type designation for the Aristotig 200. The first letter, L, indicates that Aristotig is a rectifier, while T indicates TIG welding and N indicates the design generation. The 200 indicates the maximum welding current. 2 These symbols indicate that Aristotig incorporates an inverter transformer and rectifier. 3 This section indicates the voltage/current characteristic for MMA welding and a current range of 4 - 200 A. ‘The voltage values of 20 and 28 V in the heading indicates that we comply with the international arc characteristic as defined in IEC 974-1. cetmoder so2294 This section indicates the voltage/current characteristic for TIG welding and a current range of 3 - 200 A. The voltage values of 10 and 18 V in the heading indicates that we comply with the international are characteristic as defined in IEC 974-1. X = The duty cycle, which indicates for how long a time welding can be carried out at the specified welding data, expressed as a percentage of a 10-minute period. Iz = The current at the respective duty cycle. Up = The arc line characteristic voltage. Ug = The open-circuit voltage. 5 Indicates that the unit is intended for connection to a 400 V three-phase supply at 50 or 60 Hz. 1, = primary currents at the various load points. 6 AF indicates that the rectifier is fan-cooled. 1P23 indicates the enclosure class in respect of protettion against penetrat- ing objects and water. ‘The © symbol indicates that the rectifier is designed for use in areas of el- evated electrical risk. 7 The machine’s serial number, in the form of three groups of figures (xxx yyy z22). The first group (xxx) indicates the version. The figures represent the year and week of approval of the version. ‘The second group (yyy) shows the year and week of final testing of the machine. For example, 344 indicates Week 44, 1993. ‘The final group (zzz) consists of three or four figures, and is a serial number in the range 0001 to 9999. 8 Shows that ESAB complies with the international standard, IEC 974-1.COMPONENT DESCRIPTION, LTN 160/200 This component description refers to the connection diagram for the LTN 160 on page 10 and to that for the LTN 200 on page 11. Components that are used only in the LTN 200 are indicated by a "2" in front of the component designation. Those components that are used only in the LTN 160 are indicated by a “1” in front of the component designation. The LTN 160/200 are 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 us, depending on the welding current output. The conducting time and frequency are controlled by circuit board APOL. APO1 The main circuit board with control electronics. See block diagram on page 12 and description on page 16. APO2 Circuit board with power transistors for the positive pole, see description on page 28 . WARNING! the transistors are connected to mains voltage potential. APO3 Circuit board with power transistors for the negative pole, see description on page 30 . WARNING: the transistors are connected to mains voltage potential. APO4 Interference suppression circuit board, transient protection, protect- ing the secondary diodes against transients. APOS Circuit board control panel. The circuit diagram is shown on page 34. APOS Display driver board with pulse generator. The circuit diagram is shown’on page 36. APO? Interference suppression circuit board: see the circuit diagram on page 38 . Apo Interference suppression circuit board. Prevents mains-porne inter- ference.APOg AP10 AP11 cot co2 cos co4 cos c06-Co9 EVvot HLO1 Lot Lo2 Los QFO1 RO1 RSO1 STO1 TCO1 TCO2 TV01 vot vo2 Interference suppression circuit board, remote control connector, see the diagram on page 40 Circuit board shunt amplifier, see description on page 19. HF generator. Capacitor, 0.1uF, 1000 VDC, transient protection. Capacitor, 1000uF, buffer/smoothing capacitor. Time to discharge after turning off the unit: about two minutes. See C02. Decoupling capacitor, 0.1uF, 1000 VDC, protects against HF. 2- capacitors, 4.7uF, see LO2. Capacitor, 0.1nF, 400 VDC Fan, 24 VDC . Lamp, 28 V, white, lights when mains power is on. Secondary inductor. Inductor, forms an LC circuit with COS and V06 to reduce the risk of arc extinction at low welding currents. ‘When VO03 conducts, the LC circuit charges up. The circuit is capa~ ble of temporarily maintaining a high arc voltage at low current, thus reducing the risk of arc extinction. Diode V06 prevents capacitor C05 from going negative. Primary inductor, improves the machine’s form factor, i.e. reduces the mains load. Mains power supply switch, 2-pole in the LTN 160 and 3-pole in the LTN 200. Resistor, 3.9 kQ5 W. Shunt, 120 mV at 140 A (LTN 160) or 200 A (LTN 200). Thermal overload cutout, for overload protection, mounted on the main transformer (TCO2) winding. LTN 160: breaks at 130 °C and resets at 100 °C. LTN 200: breaks at 150 °C and resets at 130 °C. Control power transformer. The primary is supplied at 230 V (LTN 160) or 400 V (LTN 200), with secondary output voltages of 9, 20, 26 and 42 V. Main transformer. For fitting instructions, see on page 44. HF coil. Mains rectifier bridge, 35 A, 1200 V. For fitting instructions, see on page 43 . Mains rectifier bridge, 35 A, 1200 V. For fitting instructions, see on page 43 .V03,vo04 Vos vos x01 x02 XSO1 XxS02 XS03 xs04 xS05 XS06-XS07 xs08 XS09 XS10 XS11 XS12 XS13. XS14 XS15-XS16 XS17 XS18 xs19 XS20 XS21 XS22 XS23 YVO1 etnoaet 940228 & Rectifier and freewheel diodes. V03, which consists of six parallel- connected diodes, rectifies the welding current, V04 consists of eight parallel-connected diodes. During the time in- terval between two voltage pulses from transformer TC02, the welding current is maintained through the freewheel diodes by inductor LO!. ‘V03 and V04 are fitted on the same heat sink. If the diodes are faulty, it is necessary to replace the entire heat sink, as the diodes are soldered to it. For installation instructions, see on page 41 . LED, yellow. Lights when thermal cutout STOI operates (breaks) as a result of high temperature. Diode, see L02. Mains terminal connection block, 3-pole Terminal block, 4-pole 6-pole connector. 4-pole connector. 8-pole connector. 26-pole ribbon cable connector . T-pole connector. 2-pole connector. 3-pole connector. S-pole connector. 12-pole Burndy contact, for connection of remote control unit, TIG central connector: only LTN models -880 and -882. 2-pole Cannon connector, only LTN models -881 and -883. Welding current connector, OKC, only LTN models -881 and -883. Welding current terminals, (two), OKC type 2-pole connector. 2-pole connector. 2-pole connector. 4-pole connector. 26-pole connector for ribbon cable. 7-pole connector. 4-pole connector. 2-pole connector. Solenoid vaiveDISPLAY BOARD - APOS‘erode! 940228 ACONNECTION DIAGRAM, LTN 160 ARAL —ULILLLIL ELIDA titi TOOT I ALL Cm + ppd Le EE ELE -10-CONNECTION DIAGRAM, LTN 200 MOCLECLE PEELE LLL Lt) “COE PERCE) “POLE 8 job ebddbbd eb} Jb | | ctinodes 840228 A antesBLOCK DIAGRAM, CIRCUIT BOARD APO01 wi weLpine Process CONTROL, POWER SUPPLY POWER SUPPLY MONITORING START/STOP INPUT. REMOTE CONTROL INPUT SHUNT INPUT WITH AMPLIFIER ARC VOLTAGE SENSING -12- nagar 940228 A cca,|GEROUS VOLTAGE 410 aa 12 43 44 ciinadas 940228 A inte HF UNIT GAS VALVE MACHINE TYPE SELECTION THERMAL OVERLOAD SWITCH WELDING PROCESS CONTROL INTERFACE CIRCUITS FOR CONTROL PANEL PULSE WIDTH MODULATOR GATE CIRCUIT -13-catnoder o4az78 A -14-COMPONENT POSITIONS, CIRCUIT BOARD APO1 ST oe ST] ok 8 add /\a\8 WARNING: High voltage within the shaded area. Terminals X1 to X6 are tied to|'— 0 Von the circuit board, and must have good electrical con- tact with the screen enclosure. ncaa! 940228 AustDESCRIPTION OF OPERATION, CIRCUIT BOARD APO1 This description refers to the block diagram on page 12 and to the components posi- tion diagram on page 15 Only those parts connected to the board’s inputs and outputs are described here. If the circuit board is faulty, it must be replaced. After replacing the circuit board, the machine must be soft-started. See the in- structions on on page 33 . 4 POWER SUPPLY ‘The power supply to the board can be divided into three parts; a, b and, Transformer TCO! supplies 9 V AC via connectors AS and A6 to rectifier diodes D28 - D31. Voltage regulator VR2 stabilises the supply to +5 £0.25 V DC. Resistors R126 and R127, capacitor C104 and diode D27 form a voltage monitoring circuit for the unregulated supply to voltage regulator VR2. The voltage from potential divider R126/R127 is connected to pin 9 of IC7: see 2) below. The voltage is about 2.5 V. wakek oy rk ms Connections Al and A2 supply rectifier diodes D36 - D39 from the 26 V secondary on transformer TCOl. Voltage regulator VR4 stabilises the voltage to +28 V, and this is used to power fan EVO1 via connections G7 and G8. Voltage regulator VR3 produces a stabilised +15 V supply, which is used to supply the remote control unit. This supply is referred to'as +15 VB, and its neutral point, OVB, is separated from the electronic neutral (0 V). Potentiometer R122 is used to adjust the voltage. See also 4) on page 18. -16- cetnoces 940z28 Atnoges 940228 - an | WV Connections A3 and Ad supply rectifier diodes D32 - D35 with 20 V from conneeter TCOL. Voltage regulator VRIL produces an output voltage of Sa rT) V, which supplies the pulse width modulator output stage (Block 13). Perential divider R100/R101 supplies 2.6 V to the computer in Block 11. This provides a signal that the power supply is available. TS PTY unregulated DC power supply to VRI also supplies relay REL in Block 7 and indicating lamp HLOI via resistor R120. eso k ade D22 drops the voltage to +15 V, and this, together with the -15 V supply, powers the analogue circuits. Te eeettive 15 V supply is provided by a circuit consisting of D24, D23, C97 and C98, Resistors R123 and R115 limit the current through Zener Sfode D25, which in turn produces a stabilised -15 V output, The computer so tors the -15 V supply by a signal from the right-hand side of resistor R54 POWER SUPPLY MONITORING 1C7 and 1C9 monitor the voltage of > battery BAI. The nominal battery | voltage is 3 V. If it falls below 2.5 V, 1~ the display shows error message E06. | Battery life is about five years. \ A voltage of about 2.5 V is supplied to IC7, pin 9, from power supply cir- cuit 1a. If this voltage drops below the threshold voltage of 1.3 V, pin 10 of ICT goes low, providing the computer with a low power supply voltage sig- nal. The computer then generates 2" __" warning signal in the display and stores current data. If the +5 V supply to pin 3 of IC7 drops below 4.65 V, pin 15 goes low and Jnnibits the pulse width modulator in block 3. The computer receives 2 iaeet signal and data in the RAM memory is protected by the backup bat- tery power supply. Bay PoP To aupplies the RAM memory in Block 11 with power, both when the machine is energised and when it is shut down. When power to the machine is turned off, the display also shows * to confirm that the computer has stored the current data. -17-Pressing the torch contact switch applies 42 V across connections CI and C2. Resistors R78 and R79 limit the current, while zener diodes D20 and Da2I prevent optocoupler IC14 from being activated too early. The output signal from IC14, pin 4, goes high (+5 V) when the torch contact switch is not activated, and low (0 V) when it is activated. REMOTE CONTROL INPUT te The remote control unit is powered by the +15 VB supply through con- nections C3 and 0 VB via connection C5. The reference signal is connected to C4. If the remote control input is activated, but there is no reference signal, resistor R72 holds the reference input low. This results in a welding current of 3 A for TIG welding and 4 A for MMA welding. The remote control unit plug must incorporate a link between pins L and M. When the remote control unit is connected, the voltage at the cathode of diode D19 is 0 V. With the remote control unit removed, the voltage at the cathode of the diode is +5 V. When pins L and M in XS10 are con- nected, the remote control input is activated. When adjusting the +15 VB voltage, link connections C3 and C4 and measure the voitage at the cathode of diode D12. The voltage there must be 5.1 £0.05 V. Adjust the voltage by means of resistor R122: see circuit diagram 1b on page 16. -18- enoaes 240228tina 940228. Shunt amplifier circuit board AP10 is supplied with #15 V via connections DI and D3 on circuit board APOI. ‘The signal from the shunt amplifier is connected to inputs D4 and Ds. with OV teDS. At no-load voltage, the circuit board’s neutral voltage (0 V) is at the same potential as the Welding circuit negative connection. In the LTN 160, 120 mV shunt voltage corresponds to 140 A welding cur- ree ik the LTN 200, 120 mV shunt voltage corresponds to 200 A welding cereont. In order to be able to use the same programs in both machines, @ simple resistor network interface circuit (see 9) on page 21) tells the com puter which type the machine is. In the 200 machine, the signal from the shunt is amplified by the shunt amplifier, so that a_120 mV input signal from the shunt produces a 6.66 V output signal. Resistors R10, R6 and R7 on circuit board APO1 divide this voltage to 2.12 V, which is then supplied to pin 3 of 1C2. In the 160 machine, transistor Ql is turned on by IC8. This connects resis- Lar RO to 0 V. connecting resistors R8 and R9 in parallel with R6 and RZ {Shek R10, these resistors form a potential divider which divides the 6.66 V to 1.48 V, which is then supplied to pin 3 of 1C2. 1C2 is a buffer circuit. The computer receives @ signal representing the Welding current from output pin 6 of 1C2 via filter R20 and C17. Resistor 4 connects the shunt signal to the control amplifier. The Aristotig has different current setting resolutions in the TIG and MMA modes, in the TIG mode, the welding current can be set in I A steps. while Inthe MMA mode, the current can be set in 2 A steps. This means that the lowest current in the MMA mode is 4 A, while in the TIG mode it is3 A. [ cel Cea Be wins ews Se o| el Component positions, APIO -19-6 ARC VOLTAGE MONITORING This circuit measures and scales the arc voltage to a suitable level for the computer. 64 V arc voltage produces a voltage signal of 5.1 V at the cathode of diode D3. The open-circuit voltage is controlled in order to prevent too high an open- circuit voltage. The arc voltage is connected to input D2 and supplied to potential divider R29 and R30, the output from which is supplied to the Voltage control circuit. The open-circuit voltage must be about 70 V. 7 HF GENERATOR WARNING: Dangerous voltages in this circuit, When the welding torch switch is operated, and the open-circuit arc voltage is over 50 V, relay REI closes and turns on HF generator API1. It remains activated for 0.75 seconds. If the arc has not struck within this time, the relay drops off. a Filter RC1 is not fitted to machines with serial numbers of 313 351 . and above. Where the filter is fitted (i.e. to earlier machines), it can happen that the welding torch produces weak HF sparks even when the torch trigger switch contact is not activated. This is not dangerous to the operator, but the filter should be removed when the machine is next being serviced. 8 GAS VALVE oa ic Operating the torch trigger switch causes semiconductor relay RE2 to con- duct and energise solenoid valve YVO1. C82 and R111 form an HF filter. = 20- cermoder saz A,10 MACHINE TYPE INDICATOR =f ‘As the same circuit boards are used in the Aristotig 160 and 200, it is nec- essary for the computer to know what type of machine it is controlling. A link is therefore provided connector G to short out pull-up resistors R113 and R14, When it connects Gi - G4, it indicates that the machine is an LTN 160, while when it connects Gi - G3 it indicates that the machine is an LTN 200. The relevant input line to the computer (G3 or G4) goes low to indicate which type the machine is. THERMAL OVERLOAD CUTOUT The thermal overload switch, STOL, is connected to inputs K1 and K2. The contact is normally closed, which means that input K2 is at 10 V. This voltage is dropped by the potential divider formed by resistors R31 and R32 to 4.8 V, and used as an input voltage to the computer. LED V05, which indicates excessive temperature, is connected to J1 and J2. ‘When the thermal overload cutout operates, the input to R118 goes low, al- lowing QI5 to conduct and lighting LED VO0S. -24-11 WELDING PROCESS CONTROL The processor inputs are the set values of welding data and the arc voltage. The processor also calculates a set value signal for welding current and supplies this to the current control amplifier. ese The process regulator control principle. HOT START, MMA In the MMA normal welding mode, the welding current is briefly elevated at the start of welding. The higher current setting is engaged for 150 milli- seconds. ‘The starting current is twice the normal welding current (i.e. twice the set Yalue), subject to a maximum of 210 A for the LTN 160 and 300 A for the LTN 200. int Welding start, normal welding, MMA J. Contact between the electrode and the workpiece. 2. Starting current for 150 ms. In the MMA spray welding mode, the starting current is three times the set value, but the duration is shorter at only 50 ms. The maximum starting currents are the same as for normal welding. ct? Welding start, spray welding, MMA J. Contact between the electrode and workpiece. 2. Starting current for 50 ms. -22- tnoder 40220 &12 CONTROL PANEL INTERFACE CIRCUITS a a) ace} ‘All machine functions are controlled from the panel on the front of the machine. The display window and the LEDs are driven by IC21 and connected by a ribbon cable to board contact B, pins 3-18. The pulse generator is supplied at +5 V via inputs B25 and B26. Pulses are supplied from the pulse generator to connections B23 and B24 with a 90° mutual phase displacement. Resistors R97 and R98 are pull-up resistors. ICI1 squares up the pulse flanks. The two red @@_ and the two green pushbuttons are connected to 0. Pressing any of them pulls down the corresponding input (B19 - B22) to 0 V, and the signal is filtered by an RC filter network formed by capacitors C72 - C75 and resistors R93 - R96 before being applied to the computer. -23- csinoder 840228 A13 The pulse width modulator 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 maxi- mum pulse time is 40.5 +1% of the cycle time. Maximum pulse time results in maximum current and voltage. ICS controls the pulse frequency, the pulse time and inhibition of pulses. Transistor Q12 supplies the pulse transformer’s primary winding. Diodes Di7 and D18 are squelch diodes that protect Q12 against back-emf from the transformer. IMPORTANT ‘The frequency and pulse time are very important parameters. If they are in- correct, they can result in transistor failure in the main circuit. See also CHECKING THE GATE PULSES on page 26 . -24- etnoaet 240228 444 cstnodes sare A GATE CIRCUIT The MOSFET transistors’ drive stage produces control pulses for the gate- couroe 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. Fhe insulation voltage between the pulse width modulator and the gate cir- cuits is 4 kV. WARNING! The gate circuits are at mains voltage. The two gate circuits are identical, and so only one is described here. When QI2 conducts, a voltage pulse is produced on the transformer's sec Sudary winding. ‘This pulse is conducted via D13, D14 and output El to the gate on the MOSFET transistors. ‘The pulse returns via the sousee, con- eection E2, D16 and C36. The peak gate - source voltage is 14 V. The gate pulse between El and E2 charges C36 to 3.3 V. When Q12 wens Off, the voltage from the secondary of the pulse transformer changes po!ar- tty, causing Ql4 and QI3 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.CHECKING THE GATE PULSES If circuit board APO2 or APO3 has failed, the gate pulses must always be checked. Remove connections XS06 and XSO7 (gate pulses). Connect a dummy gate load to outputs El and E2 and to Fl and F2. John a Sn L__< Dummy gate load - IMPORTANT: never check the gate pulses when APO2 and APO3 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 40.5 1% of the cycle time, measured at a level of +5 V. If the gate pulse does not lie within these tolerances, replace circuit board APOI. After replacing APO1, check the gate pulses again and soft-start the machine, as de- scribed on page 33 . Bvidiv | Vows | es Gate pulses as measured across a dummy gate load on circuit board APOI, between terminals FI and F2. = 26 -CIRCUIT DIAGRAM, CIRCUIT BOARD APO2 ne APO2 (POSITIVE) CIRCUIT BOARD, 481 803 -880/-882 ‘The -880 variant is used in the LTN 160 and the -882 variant in the LTN 200. Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced in its entirety. In addition, circuit board APO3 must also be replaced. Instructions for removing and fitting the circuit board are to be found on page 42. ‘A01,A02 Connections AOI - A02 are for the gate pulses from circuit board APOI. D4-D3__ Transient voltage protection. Ds Back-emf protection diode (squelch diode), for main transformer TCO2 when the transistors turn off. FA Fuse, for protection of circuit board APO1 if circuit board APO2 fails. Q1-Q8 MOSFET transistors. These require a special instrument (see ‘MOS TESTER’ on page 32) for testing. = 28 - etnaget 90228 4COMPONENT POSITIONS, CIRCUIT BOARD AP02 CIRCUIT BOARD 401 803.8807 - 862 mans | oz 03 Ic C= cy mounted a 882 -29- cena! 940228. &CIRCUIT DIAGRAM, CIRCUIT BOARD APO3 APO3 (NEGATIVE) CIRCUIT BOARD 481 848 -880/-882 ‘The -880 variant is used in the LTN 160 and the -882 variant in the LTN 200. Individual transistors must not be replaced: if the circuit board is faulty, it must be replaced in its entirety. In addition, circuit board APO2 must also be replaced. See on page 42 for instructions for removing and fitting the circuit board. A01,A02 Connections AOI - A02 are for the gate pulses from circuit board APO1. B01,B02 When the machine is loaded, pulses from a trigger pulse winding on main transformer TC02 are supplied to connections B01 and BO2, for use as gate pulses in controlling thyristor TY 1. D1-D3_ Transient voltage protection. DS Back-emf protection diode (squelch diode), for main transformer TCO2 when the transistors turn off. ‘ -30-Q1-Q8 R21 R26 R27 TY1 MOSFET transistors. These require a special instrument (see ‘MOS TESTER’ on page 32) for testing. Charging resistor, 12, 10W, for buffer capacitor C02 (C03). ‘When energising the power unit, pulses from control circuit board APO! are delayed by 300 ms to allow the buffer capacitor to charge. Discharge resistor for buffer capacitor C03. This capacitor is fitted only in the LTN 200. Discharge time for the capacitor, after the mains power supply has been turned off, is about two minutes. Discharge resistor for buffer capacitor C02. After turning off the mains power supply, the discharge time for the capacitor is about two minutes. ‘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. COMPONENT POSITIONS, CIRCUIT BOARD AP03 se 08-5 [ le} TTT Oa} » p| «mio (lee | | \ 08 os only outed t= 822 --MOS TESTER The MOS tester is a special instrument, and can be ordered only from ESAB’s service department in Laxd. 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 LTN 200). Remove the gate connections from APO1. Connect the clip on the red wire of the instrument to the red wire (the gate wire) on the transistor board. Connect the clip on the yellow wire of the instrument to the yellow wire (the source) on the transistor board. Connect the biack wire to the cooling fins (drain). Testing: . Press the pushbutton marked TEST. If the board is healthy, both the red and green LEDs should flash alternately, about once a second. 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.) 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 APO1 before commissioning the new transistor boards. After replacement of the boards, the machine must be soft-started. | -32-SOFT STARTING «Remove and insulate wires 07 and 08 from rectifier bridge VOl: see the circuit diagram on page 10 - tn the LTN 200, also remove and insulate wire 09 to rectifier bridge VO2: see the circuit diagram on page 11 © Connect an external power supply, having a current limit of 1 A, to the positive ‘ad negative connections on VO1. «Adjust the power supply voltage to 30 V- «power the remaining parts of the unit from the normal power supply. © Select MMA mode. © Measure the output voltage from the machine, On tbe LTN 160 this must be 10 V x1 V, and on the LTN 200 it must be 6 V 21. Measure the primary voltage to transformer C02. With a voltage of 30 V across ine buffer capacitor, the waveform must appear aS shown below. Lt [ || E\y ro we || Primary voltage at TC02 for 30 V across the buffer capacitor coment -33- cetnades 40228CIRCUIT DIAGRAM, CONTROL PANEL APOS a ar * Che -34- cemoget 90220Ne COMPONENT POSITIONS ON CONTROL PANEL © ceneeneco Om 0 0 0 Re) a3 8 5 2° 3 0 3 2 . § ,O 0 zB 3 {© ,O © ,O ,0 ° 0 ,0 epee gg & g eo 0 ° 10 5 $4 oO 9 0 5 yg -35-NN E'S C~é~*~S CIRCUIT DIAGRAM, DISPLAY BOARD AP06 -36- citmoges 640220COMPONENT POSITIONS ON THE DISPLAY BOARD J TOUUVOUTTOUTUOOUUUUT | citnoget 90228CIRCUIT DIAGRAM, CIRCUIT BOARD APO7 an aie a as ar A -38- enader 040220 &COMPONENT POSITIONS ON CIRCUIT BOARD APO7CIRCUIT DIAGRAM, CIRCUIT BOARD AP09 COMPONENT POSITIONS, CIRCUIT BOARD APOS cetnaget 940226 A eal cl 2 C4 GHD "6 -40-DISASSEMBLY / REASSEMBLY REMOVING THE RECTIFIER UNIT (V03, VO4) «Note which wires are connected to the respective terminals (4). * Remove the screws (4). Pull out the rectifier unit. REFITTING THE RECTIFIER UNIT «Press the insulation (f) against transformer TC02, and slide the rectifier unit in on the guides (e). © Reconnect the wires to screws (4). ccnbant 940228 ateREMOVAL OF TRANSISTOR CIRCUIT BOARDS APO2 AND APO3 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. Removaljrefitting of transistor circuit board REFITTING THE TRANSISTOR CIRCUIT BOARD ‘When replacing the transistor circuit board, both boards must always be replaced and new springs must be fitted. Clean the contact surface (3) of the heat sink with extremely fine abrasive paper. Apply a thin film of contact oil (see item 504 in the spare parts list) to the contact surfaces. Place the circuit board (2) on the cooling fins. Secure first one spring on each side of the board by pressing the spring down with a screwdriver (4). Then secure the remaining springs. NOTE: The springs must be fitted over the components that are to be in contact with the heat sink. When fitting cable lugs and busbars to the boards, it is important that the wash- ers are fitted in the correct order. Start by placing the lug on the foil, and then fit a flat washer, a spring washer and finally the screw. -42-Connections to circuit board APO3 UH ena a LTN 160: not connected. LTN 200: wire 045 to the connection between C02 and C03. b LTN 160: busbar connected to positive on C02. LN 200; busbar connected to positive on C03. Busbar connected to negative on C02. LTN 160: wire 024 from primary inductor L03. LTN 200: wire 013 from negative of rectifier VO2. e Gate connection from circuit board APOI. Connector XS17 from transformer TCO2 FITTING THE RECTIFIER BRIDGE For reliable cooling, rectifier bridges VOL and VO2 must be fitted as shown in the drawing. ‘After replacing the rectifier bridges, the machine must be soft-started: see instructions on page 33. -43- cstnodet 940220FITTING THE MAIN TRANSFORMER TCo2 When repiacing 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. * 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) 2tums — T “| ennaps Fitting wire 020. * 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. * 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. Airgap (t) in the transformer core -44- citmocet 040228 AFAULT CODES If the integral fault monitoring system detects a fault, the display shows Ex, where xx is a two-digit number identifying the fault. Faults E01 - £06 can be detected during the automatic self-test routine that is run when the unit is switched on. Other faults can be detected as and when they occur. E01 Memory error in internal RAM (in the computer). If this code occurs, turn the machine off and then on again. If it persists, replace circuit board APOL. £02 Memory error in external RAM (outside the computer). If this code occurs, turn the machine off and then on again. If it persists, replace circuit board APO!. E03 Memory error, program memory (EPROM). Tf this code occurs, turn the machine off and then on again. If it persists, replace circuit board APO!. E04 Memory error, RAM memory contents test. Cheek that the battery voltage is at least 2.5 V. If it less than this, replace the battery. If the voltage is correct, turn the machine off and then on again: if the fault persists, replace circuit board APO!. E05 Memory error, variable values outside limits in battery-backed RAM. Perform the same checks as for error code E04. E06 _Battery voltage below 2.5 V. Measure the battery voltage: if itis less than 2.5 V, replace the battery. If the battery voltage is over 2.5 V, replace cir- cuit board APO! . This error code can be acknowledged/reset by pressing one of the arrow pushbuttons. This will have no effect other than to clear the error code display. The display will return next time the machine is turned on, and can again be cleared by pressing one of the arrow pushbuttons. IPthe battery is not replaced before its voltage has fallen below 2.0 Y, error code E04 or EOS will be displayed. These displays cannot be cleared. E10 _ Incorrect power supply voltage (should be 20 V), tolerance +1 V. Use 2 voltmeter to verify this fault. Measure the voltage from transformer Teol, If the transformer output voltage is correct, but the 20 V supply voltage is wrong, replace circuit board APOI. E14 Incorrect power supply voltage (should be -15 V), tolerance +2/-1 V. Use a voltmeter to verify this fault. Measure the voltage from transformer TOOL. If the transformer output voltage is correct, but the -15 V supply voltage is wrong, replace circuit board APO1. E13 High heat sink temperature. The thermal cutout has operated and indicat- ing lamp VOS lights. The machine has been overloaded. ‘Check that the cooling fan is running, and that the air filter is not blocked. -45- stages 240220 &E14 Current servo fault: excessive difference between the actual value and the set value of welding current. The power clectronics circuitry is not capable of maintaining the welding current that the process regulator is demanding, Tolerances : £5 A in TIG mode and +10 A in MMA mode. _ The process regulator servo compares the actual value signal and the set value signal, as shown above. The set value signal is the current control signal from the process regulator. The actual value signal is provided by the shunt signal, supplied to the processor analogue inputs. These two signals are put through low-pass filters, each with the same time constant, and are then compared with each other. The time constant is about two seconds. This fault code is reset when the welding current returns to within the tol- erance values, when welding is restarted or when the machine is turned off. It is also possible to reset the display by pressing any of the pushbuttons. Doing this has no effect other than to reset the display. ‘This fault code can sometimes occur during abnormal welding conditions, e.g. as a result of a failed start. When starting and finishing welding, the current is briefly outside the toler- ance limits. However, the above-mentioned filtering prevents these brief excursions from triggering the fault code display. Too low a power supply voltage to the. +..5 V voltage regulator. The dis- play briefly shows this symbol when the machine is turned off. If the voltage drops below the permissible value when the machine is in use, the display will show this symboi briefly and the machine will then stop. See also POWER SUPPLY MONITORING on page 17. ‘The display shows this symbol if the machine's program has crashed. This can be caused, for example, by extreme external interference If this error code occurs, find and rectify the source of the interference, turn off the machine, wait five seconds, and start it again. -46-LOAD CHARACTERISTICS LTN 160 oye 20 30 40 60 G0 70 80 90 100 110 120 160 110 150 — Loan CHARACTERISTIC 12 (A) TE StaNDAROIZED LOAD VOLTAGE AT TIG (20.4 +10) TES TANDARDIZED LOAD VOLTAGE AT MMA (120.04 « 20) 0 10 20 30 40 50 60 70 80 {90 100110 120180140150160170180190200710 = Loap CHARACTERISTIC. 12 ( STANDARDIZED LOAD VOLTAGE AT TIG (220.04 +10) TRE StaNDAAOIZED LOAD VOLTAGE AT MMA (2 0.04 + 20) -aT- inode 90228 exesTECHNICAL DATA Load capacity At 35% duty cycle, TIG At 35% duty cycle, MMA. At 60% duty cycle At 100% duty cycle Operating range, TIG Operating range, MMA. Slope up Slope down Gas pre-flow Gas post-flow Pulse time Pause time Open-circuit voltage Power factor at max. current, MMA Efficiency at max. current, MMA. Power supply Primary current Mains fuse rating Mains cable, area Weight Dimensions, I x b xh ‘etnaget s4o228 A Aristotig 160 Aristotig 200 160 A/16V 200A / 18 V 140 A/ 26 V 200 A/ 28 V 110A /24V 150 A /26V 80/23 V NS A/25V 3-160 3-200 4 4-140 4-200 0- 10sec 0- 10 sec 0 - 10sec 0- 10 sec 0 - 25 sec 0- 25 sec 0 - 25 sec 0- 25 sec 0.02 - 5.0 sec 0.02 - 5.0 sec (0.001 - 5.0 sec 0.001 - 5.0 sec) 0.02 - 5.0 sec 0.02 - 5.0 sec (0.001 - 5.0 sec 0.001 - 5.0 sec) 70V 70V 0.69 0.63 0.75 0.78 230 V 50-60 Hz 400 V 50-60 Hz 220A 10A 16 A* 16 A* 3x 2.5mm? 4x L.Smm? *See also ‘INSTALLATION’ on the next page. Approx. 23 kg Approx. 23 kg SISK 285x415 515 x 285x415 -48-INSTALLATION Aristotig 160 The Aristotig 160 is intended for use with a 230 V single-phase power supply, and sae asi ith supply voltages from 230 V to 240 V, 50 - 60 Hz. ‘To make full use of the Aristotig 160, it must be protected by # 16 A anti-surge fuse. For welding up to about 100 A, a 10 A anti-surge fuse will suffice. Aristotig 200 The Aristotig 200 is intended for use with a 400 V, 3-phase 50 Hz or 60 Hz supply. ‘A 10 A anti-surge fuse is sufficient to allow full use to be made of the Aristotig 200. (Normally, 400 V supplies are protected by 16 A fuses.) Aristotig 160/200 “The necessary welding current cable size is 16mm? for the Aristotle 160 and 25mm* Fan he mistotig 200. Cables longer than 3 m are seldom requirec If you are going ror anti at come distance from an electrical power supply socket) i is better to have 10 wields extension cable than long welding current cables, as the voltage drop is less in mains cables than in welding cables. in mains vind, however, that t00 long mains cables can affect the welding voltage. If possible, use a cable with a larger cross-sectional area if long cables must be used. ‘The Azistotig 160 and 200 incorporate mains voltage compensation circuitry, which The Atthat £10% variation in power supply voltage results in only £0.2% variation in welding voltage. «Place the machine in a suitable position, and check that cooling air flow is not obstructed. «Check that the machine is connected to the correct mains voltage supply. Nate the necessary earth continuity connections as required by safety reat lations. © Connect the supply of shielding gas. © Connect the TIG welding torch and return current cable or cables for MMA welding. © The machine is now ready for use. 49 - nodes 90208OPERATION The main On/Off switch on the Aristotig is on the right-hand side of the front panel, The white indicating lamp, (3), above the main switch, lights when power is turned on. A thermal cutout protects the machine against overload. It operates before the tem- perature rise in the machine becomes excessive, lighting the yellow LED (2) on the front panel and interrupting the welding process. The display also shows error code E13. The thermal overload cutout resets automatically when the temperature in the unit has fallen to a safe level. Main On| Off switch Yellow LED, high temperature White indicating lamp, Power On Display Adjustment knob Pushbuttons Remote control unit connector Dust filter Gas nipple Se NALA WN -50-Control panel The front of the unit incorporates 2 control panel for selecting operating modes and functions and for setting welding parameters. The panel incorporates a display, an adjustment knob, LEDs and pushbuttons. The pushbuttons are used to select and voatrol the various functions. Selection is indicated by a lit LED. Set/select the function(s) required on one row at a time. ‘A red LED shows which row retest use the red GIS) arrow pushbuttons to move between Fos: Use the green I} arrow pushbuttons to move within Tove, Having selected a mode or function, adjust the valve required by means of the rotary djustment knod. The LEDs to the right of the display ‘window show the units (ampere/volt/second) being set. In the rows in ‘which only a function is being set, the display shows” -"- Description of the functions : . Row | (° . Row 2 | © . Row 3 ° . Row 4 ° . Row 5 ° . Row 6 | CO} . Row7 eo ot o2 or2 OMA Row 1 T1G-welding or MMA-welding oof of Tryou select MMA, set the current here and then ignore rows 2-5. If you select TIG, pass on to Row 2. MMA Are Force Wher the current is being set, you can also set the required Are Force. This Wher the aynamic response of the machine, to produce a softer or harder arc. ‘To activate the Arc Force setting mode, press the two red GD arrows si- multaneously for two seconds. The display shows a value between 0 and 100. Higher values give 2 harder are, The standard Arc Force setting is 10. Press any of the buttons to return the power unit to the Normal mode. Set values of Arc Force remain in memory. Different settings can be stored in the machine’s two welding data memories. -81-Row 2 MMaA Spray welding Spray welding can be used when welding ‘with stainless steel electrodes. This means that the arc is alternately struck and extinguished, in order to provide better control of the heat input. The electrode need be lifted only slightly from the workpiece to extinguish it. The machine must be in the current setting mode in order to be able to ac- tivate this function. To do so, press the two green arrows at the same time for two seconds. The —_ -* symbol indicates that the function has been activated. Note that the symbol is displayed only briefly. The spray welding mode remains stored in memory when the machine is switched off. To reset the machine to the normal welding mode, press the two green arrows. The display responds by showing the * ———” symbol briefiy. WARNING If the machine is in the Spray Welding mode when using ordi- nary electrodes, the electrodes can easily weld themselves to the workpiece. The are will also appear to be pulsing. TIG/HF ignition or TIG/Liftare ignition OO 1% 0 Ft If HF ignition has been selected, the HF generator will be activated when the torch trigger switch is operated. The HF generator is activated for 0.75 seconds: if the arc has not struck during this time, the machine turns off the HF generator. Operate the LIFTARC ignition feature as shown below. Place the electrode against the workpiece Press in the torch switch Bs Tilt the torch a litle, lif and an arc is produced To stop - release the torch trigger -52- cron 940228 &Row 3 Row 4 Row 5 Row 6 Continuous or pulsed current O O- O JUL 2-stroke or 4-stroke © Tt on Zistroke control means that the arc is struck when the torch switch is pressed and extinguished when it is released. sequence for 4-stroke welding. , + 1. First depression of the torch switch starts the machine on pilot current. 2. When the switch is released, the curre 7 increases to the set value. Pressing the switch again reduces the current to pilot current. Releasing the switch extinguishes the arc. ‘The diagram to the right shows the control © @ ® © 1 4 BY ‘Adjusting welding parameters LTN 160 LTN 200 1. Gas pre-flow 0- 25 sec 0 - 25 sec 2. Slope up 0 - 10 sec 0- 25 sec 3, Pulsed/continuous current 3-160 3-200 A 4, Pulse time 0.02-5.0sec 0.02. - 5.0 see 5. Pause current 3- 160A 3-200 A 6. Pause time 0.02-5.0sec 0.02 - 5.0 sec T. Slope down 0- 10 sec 0- 10 sec 8. Gas post-flow 0 - 25 sec 0 - 25 sec £ oo Pulse time/Pause time The setting range for these parameters is normally 0.02 - 5.0 seconds. However, by pressing the two green arrows together for two seconds, times down to 0.001 second can be set. This extended setting range remains available until the two green arrows are again pressed. When activating or de-activating this feature, the machine must be in the pulse or pause time setting mode. “Times shorter than 0.25 seconds are displayed without a decimal point. ‘Using the display for parameter measurement °° ® °o® ‘The display can be made to show arc voltage or current while welding is in progress. The current value displayed is a mean value of the process regulator signal to the summing point. The voltage is 2 mean value of the measured arc voltage. Voltages are displayed with a resolution of 0.25 V, while currents are displayed with a resolution of 2 A in MMA mode and IA in TIG mode. The display has a sample-and-hold characteristic, i.e. the value last being displayed before slope-down continues to be displayed when welding stops. -53- cetnade) 940228. &Row 7 Welding data memory O O1 O02 01-200 A Four different sets of welding data parameters can be stored in the ma chine’s memory: two for TIG welding and two for MMA welding. The following parameters can be stored: MMA: Welding current, Arc Force, spray welding/normal welding. TIG: The alternative selected on Row 3 (Continuous or pulsed current). Alll settings on Row 5. Change welding data memory with the green 8} arrow pushbuttons. In the TIG control mode, the data memory can also be changed by briefly pressing the torch contact, irrespective of whether welding is in progress or not. Press the two green arrows together to activate the program switch mode. The O 1-2 indicating lamp is lit when the program switch mode is activated. If four-stroke control mode has been selected, a brief depression of the torch switch will change welding data memory. The same applies for two-stroke control mode if welding is not in progress. ‘When welding with two-stroke control, welding data memory can be changed by briefly releasing the welding torch contact. ‘The welding data memory is battery-backed, so that data is retained even if the machine is turned off or disconnected from the mains. Remote control unit TIG and MMA welding current can be remotely controlled via the remote control input. If pulsed current is selected in the TIG mode, it is the pulsed current that is remotely controlled. Stepping the machine forward to the position for setting welding current without the remote control unit causes the display to show the value that has been set on the remote control unit. ‘The remote control unit is activated automatically when the plug is inserted into the contact, with indication of this being provided by the OZ A LED. Note that pins L and M in the remote control unit plug must be strapped for the automatic engagement feature to work. The following remote control units can be connected: PHAL, PHA2, PHBI, PHB2, PHC2, PHE2 and FS002. ‘When using the FSO02 remote control unit, the slope-up and slope-down times must be set to 0 seconds. -54-MAINTENANCE The Aristotig 160 and 200 normally need only @ minimum of maintenance. It is usually sufficient to blow them clean with compressed air once a year and to clean the fan air filter regularly, If the machine is used in a dusty or dirty environment, it should be blown clean more often. Il} : oF | SSS SI oe Ss = he SS s Removing the filter. The machine’s memory is battery-backed. If the display shows the E06 error code, battery voltage is low. See Error Codes on page 45 - . Note that all guarantee obligations will be void if the customer carries out any work on the machine during the guarantee period to rectify any faults. -55- ctnoder 90228- >ACCESSORIES Order number 5 | gas bottle trolley, see picture on page 58 468 530-880 10 - 50 I gas bottle trolley, see picture on page 58 468 320-880 Protective handle for input/output contacts 468 311-001 Top handle 468 305-880 Return current cable, 25 mm? (state length when ordering) 2626 136-01 Return current clip 367 558-880 FS002 foot control, inciuding cable 349 090-886 ‘Welding current cable, 5 meter 468 539-880 Return current cable, 5 meter 468 539-881 TIG torches: BTD 153, 4 meter with central connector 368 347-886 BTD 153, 4 meter with OKC connector 368 347-881 BTD 203, 4 meter with central connector 368 347-883 BTD 203, 4 meter with OKC connector 368 347-883 See separate brochure for details of other TIG torches and remote control units. -56- citnodes suons8 AAccessories Protective handle Top handle -57- cnoget 940258 ASPARE PARTS LIST LTN 160/200 Spare pars list - Reservdelst8rteckning - Ersatzteilverzelchnis - Liste de pléces détachées tne back of he cover, Kinty tneate ype ol wn, sits are o be ordered trough th nearest ESAB og0nc var villa uopge fp och tivereningsnummer samt ite geben Sie Typanbezsiennong und ‘manlonnee fe ype ae a Sotignaton contormement laste mee -59- etnodet 840228 A eraenSpare parts list - Reservdelsférteckning - Ersatzteilverzeichnis - Liste de détachées 160 = LIN 160. 700 = LTH 200 ¢ = component designation in the circuit ciagram tem lary [ary ‘i P er | BY | 22 | ordering no Denomination Notes e lass 200-800 |urw 160 [Aristotig 160 with central connector lass 500-883 |LTN 460 ‘Aristotig 160 with OKC connection lass 300-882 |uTw 200 Axistotig 200 with central connector [ase 300-663 | |LTN 200 ‘Aristotig 200 with OKC connector tor] 1 | + |esssts-260 | Hancte (Complete soz} + | + [458520001 — |Rupoer mat sos] 1 | 1 lass a7e-cor [cover when the cover is replaces, items 104 /and 108 must algo be replaced 104 | 10 | 10 [192 950-008 | Lecking washer Must be pressed with £0 Kg pressure, jwnen fites 105 | 23 | 23 |aes ssz-cor | screw ros | 2 | 2 |tesas2-119 [insulating bushing tor] + | + [4a r02-880 — /oisplay beara ap05 sos} + | + [46s 208-880 [control pane! tem 108 inetuced AOS too| 1 | + |fe9402:680 | Ruboer seat 12 pes of tem 104 inctudes sto} 1 | + [ser a7se09 [knoe ait] 1 | [193750001 |inaiesting amo wiite, 28.V Huot 12] 1 | + {19s 758002 | Ugnt-emiting cioae Yellow vos via} 1 | 1 [2ee20002 [knoe aa] 2 | 2 |atarsoor [screw ss] 1 | 1 |468275-001 [protection grt se] + | 4 [ass sioco1 fener s17| 1 | 4 [66 205.001 [Protection cap se] + | 4 |set 220002 [Grommet inter st9/ 1 | - [sep 761-001 [Mains cable 13x25 mm? with plug + | 4 [eee ste-se2 [Mains cate 4348 mm? rao} ¢ | 4 |067 605-001 | Rubber foot rar] 1 | + [268-205-006 — |switen larot yaa | 29 | 29 [192 552-403 |Cage aut “iow” Ms 3 | 3 |ie2 82-101 |Cage nut “high M5: 2 | 2 |rezsez-tos |Cage nut Me va + | - 468 206-001 |eront cover [LT 160 with contrat connector + | + [asa Sor-cor | Front cover [ETN 200 with central connector | rae] 1 | ~ [483 206-002 — |eront cover LTW 100 with Oke connector | + | 4 [ase Sor-cc2 | Front cover [ETN 200 witn OKC connector = | 1 | + |re9260-154 — |connector E-pote for 0.75 mm? conductor xsot 3 | 1 [193-280-003 | connector ‘pote for 0.38 mm? eonctuctor |xso2 + | 4 | 4 |isaaso%56 — |Eonnector e-pote for 0.75 mm* conductor xS03 2 | 2 |193260185 [connector pote for 0.75 mm? conductor xS05, xs21 = | 5 | 5 [toa asc001 [Connector 2-pate for 0:35 mm? conductor X08, xs07, XS15, XS16, xsi = | 1) + |10az60151 [connector S-pate for 0.75 mm? conductor xso8 Do] a) 4 |tea 260-482 [ESnnector S-pote for 0.75 mm? conductor xs03 I] a | 4 |tsa6es:002 — [Eannector 2-pote XSI + | 2 | 2 |19850002 — [Sieeve For connector XS17, = | 2 | 2 |re0260152 [connector pole for 0.75 mm* conductor xSt9, xS22 2 | 4 | 4 |se5260%80 | Connector ‘pote for 0.75 mm? conductor xs23 -60-60 = LW 160. 200 = LIN 200 = component designation nthe cet ingame tem | ary || orcerna ne. | denomination Woes c tot | + | + fseraenace [we wnt pees ce} s | & foes soeaot [spacer wosner user washer nea} 2 | 2 frmssiaor rere core roe] i | + faseszeaso |r cot rot nos] 2 | 2 |recessaoe —|Lecing washer noe] + | + |eesszra01 {psig pate aor| 2 | 2 |aessncooe fat mela la pussar Inca in tem 01 woe] 1 | + |rovsistoe — frose robe ordered per meter ae weer 2s astverss x10 | 5 | 5 |seoczaone leer cont washer au] 2 | 2 [tecsircor —|soeeanut aia s | 1 [tes ansa01 [coral vansoomer reat ara] s | + frosowors — {rermina! nek Devered a6 12. tobe cit to pce x02 ais] 1 | + |rercstoce —|scenad waive bros ais] 1 | + froroisorr [termina ce Detvere as t-te, obec ope x01 air] a | + fase zaeto [rotting ate aie] 1 | ~ [as susc0r on rw 10 i ese Se ler 3 no 1 | + last ssee00 — lcrcut noare ‘suppression boars 4708 zo] | connecior, socket, ‘2, nce in tam 221 |xsto 4] fuse tro (Sreuttos Segoslon Sore come, tem 20 [ASOD incoed | zaa| 2 | 2 |ieosmess: Wetting current comector love sa xsi maa] i | 1 [esraseato {rie cena comecor sit za 2| 2 lugs azeaor [cancer iacrines win cena connector 3/3 (teeageo; (Sse pene Wik Sie toons tas] 1 | + |ssesconce — |conector, secet Jony OKC variant, 2508 sta ei |} freee |secetcos. ay SCE variant Br | 1 | { ileseencst [Rete cbinecor On Oke vores Ba] 1 | 1 fsbteaio [Weg trent comecor Sry Oxe vere st9 aaa] 1 | - |asracoaso —|rrmary nauctor ws z0| 1 | - [zen set01 |nsuiaion zai] 1 | + fosraeoeso — [capsctor as we sco con maa] | + [acess — [capsctor as wr scov cor mas] 1 | + [ase scsase [renter sox sw ot cetnose) 40220 -62-Urn 160 1200 = LIN200 © = component designation inthe eiruit diagram nem | ary [a | orsering no nomination notes < }no. |160 | 200 | Oréenng oe aor |i | + fase seacer uc ser| 1 | + lass seccor lineation S| 1 | 3 lage ttaaeo [Grout boars aro 1 | 1 [fesoseser [Baten For memory backup en APO! soe] {| 1 lige Seracr —|[Screering vox 31 | 1 \éss soacet — finouaton oe | 1 | + lass asco [crew noare suppression boars noo? sor| 1 | + [ase stoco —linsuaton | Son 2 | 2 [isearsco —insuaton ge| ¢ | 3 (fsezeoam [insulation ao] 1 | 4 usar Inchuced in tem sot Sh | Susvar "Rete in tom Sot 32 | 1 | 1 [ess tees [rout soars ‘Shunt apie aero a) 4 | 4 fooesascor fru Hi) 4 | 4 [les stecor —|Hoting pte us| 2 | 2 tseseon [Gn aie | «| « |ro2 e201 [eusning a | 4 | & |isseteoot— [eushing wol 1 | usar Incudes in tem $00 iyi | user Ince nem 800 ge |) | [Connection bar Ireded nfem $00 ae] i Susser luged nem SoD el) | 3 Busoar inetd i tem $00 BB) | i Busoer eludes in tem 380 as | + | 2 |ro2-scosce — |canaator cour c02, co Sr | 1 | 2 losgessert [Es5tete ove Hoa esata -64-LIN 160 200 = LIN 200 = component designation inthe circuit dlagram We” |ay | SY | ordering no. Denomination Notes c sot] t | [467 eot-001 fan 24 vor evo: vals |. circuit boara ‘Transistor board, postive pole lao Included in item 502 1 Jctreuit noare ‘Transistor board, postive pole apo | nctased item 582 403} 1 | 1 |s92009-150 {capacitor Jost uF 1000 vor cot aoe| i | 2 fies atezos [Rect onage or, vor 405} 1 | + |4s7 800001 {insulation aoe} 1 | + |as9 015-960 |pectiner unit Heat sink with siodes vos, vos 407) - | 4 Jeet seo-se0 [Creu voare Suppression boars pos a | + [eet aaoses — [Circut beara Suppression b08r0 neo aoa} 2 | 2 esr 77-001 |ouce 40s | 2 | 2 |4sr 700-100 |eat sink ao} a |: Cireut board Transistor board, negative pole Pos Included in item 802 1 (Circuit boar Transistor board, negative pole ;APos Incuded in item 503 anfas [se Spring Incudes in item 502 ane 503 412 t | + [asa ot6-s60 —|insuetor Seconsary Lot \ 43 | 1 | 2 |se2 716-004 vos aa 2 |te3 S20017 lar ue os a | 4 | + [ase 496-001 aie | 1 | 5 [ass 2ts.880 — |incuctor Icomotete Loa ar} t | \anaing Tncluses in ier 418 Gali | t Bobbin Included in item 418, | ao} 2 | 2 Core Ineluae in item 416 | 20} 2/2 a Ineluced in item 416 eat} + | = |4s0 961-280 |smunt 120 my at 140 sot = | 4 [ess 030.280 | Shunt 120 mv st 200 A RSOt az] i | 1 [ie2eas-150 Capacitor Joan 1000 vO cos 423] 2 | 2 [2ia9%3i.08 — |Spscer Ma aala fa Busbor Include in tem 50% fas) 4 |? Thermal cutout ‘Opens at 130°C, closes at 100°C stot Ineluced In em 426 4 Thermal cutout ‘Opens at 150°C, closes at 130°C stot Ineluced in tem 426 aas| + | - |4s7 752-800 | rranstormer cot Inctuges item 425 roe + | i |as7 06-880 | transtocmer cot inetuges tem 425 roa 4 | 1 {aes c02001 — |conauetor ‘To.be ordered per m, OSmvtranstorm, [020 aar| 1 | 4 [esr 7o0-00: {cin ala | 4 [ies atzt0: — |Fermte core 1365 652.002 [Tape For air gap rst 126021 |ctue For ferrite core ‘SPARE PARTS SETS Item | ordering ne, | Denomination Notes 500 |488 861-280 | Busbars, primary (Contains items 314, 15, 316, 317, 318 and 319 sor |4s8 881-285 | susbers, seconcary [Contains items 208, 311, 312 end 424 502 |468 261-882 [Transistor boards LTN 160. [contains items 402, 410 and 15 springs (Item 411) 503 |468 281-883 [Transistor boards LTN 200. |Contains items 402, 410 and 19 springs (tem 414) sot |192 058.108 [contact at ‘To be used when mounting tems 502 and $02 ‘atmoret ston28 A - 66 -Uin160 enoset 40228 Atte VIEW FROM THE REAR anonGroup H.Q. International directory of subsidiary and associated companies. Agency network, by countries. Group Headquarters SWEDEN ean AB Gorienoug Fok n46-31-$0 90 00 ax +45-31-50 9281 SAB Intaratonal AB. Gorenoug Tak 46-31-50 90 00 Fax +46-31-50 93 60 Nordie countries Eeab Sverige AB Garrenburg i 48-44-50 95 00 Fax 6-31-50 92 22 DENMARK ESAB AIS Képennavn-Valoy ‘at 245-96-00 04 14 Fax 48-36-30 40 03 FINLAND sa Oy ‘ont ak 350-0-557 781 Fax! +356-0-547 77 70 honwar Europe excl. Nordie Countries AUSTRIA Eran Geeim.b.x Vienna-Liesing je 28-222-88 28 11 Fane 989-222-08 25 11 85 BELGIUM SA Era NY. Brussels Tel +32-2-726 34 00 Fasc o32-2-726 00 05 CZECH REPUBLIC ESAB S10. 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