0740 800 106
Valid for serial no. 716--xxx--xxxx to 852--xxx--xxxx030314
LUD 320
LUD 450
Service manual
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LIST OF CONTENTS Page
READ THIS FIRST 3...............................
WARNING 4......................................
COMPONENT DESCRIPTION 5.....................
WIRING DIAGRAM LUD 320/450 8..................
AP1 DESCRIPTION OF OPERATION 10..............
AP1 CIRCUIT DIAGRAM 11.........................
AP1 COMPONENT POSITIONS 14..................
FITTING COMPONENTS ON THE HEAT SINK 15......
AP2 COMPONENT POSITIONS 16...................
AP2 DESCRIPTION OF OPERATION 18..............
SOFT STARTING 32................................
AP5 DIAGRAM AND COMPONENT POSITIONS 33....
AP6 COMPONENT POSITIONS 34...................
AP6 DESCRIPTION OF OPERATION 35..............
SETTING UNIT 40..................................
WIRING DIAGRAM, SETTING UNIT 41................
AP1B, COMPONENT POSITIONS 43.................
AP3B, DIAGRAM AND COMPONENT POSITIONS 44..
REPLACING THE BATTERY 45......................
FAULT LOG 46.....................................
FAULT CODES 48..................................
SERVICE FUNCTIONS 54...........................
LOAD CHARACTERISTICS 70.......................
TECHNICAL DATA 71...............................
INSTALLATION 72..................................
CONTROL PANEL AND CONNECTIONS 75...........
MAINTENANCE 76.................................
SPARE PARTS LIST 77..............................
ACCESSORIES 92..................................
NOTES 94.........................................
Rights reserved to alter specifications without notice.
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READ THIS FIRST
Maintenance and repair work should be performed by an experienced person, and electrical
work only by a trained electrician. Use only recommended replacement parts.
This service manual is intended for use by technicians with electrical/electronic training for
help in connection with fault--tracing and repair.
Use the wiring diagram as a form of index for the description of operation. The circuit
boards ar e divided into numbered blocks, which are described individually in more detail in
the descriptions of operation. All component names in the wiring diagram are listed in the
component description.
This manual contains details of all design changes that have been made up to and including
February 2003.
The LUD 320 and LUD 450 are designed and tested in accordance with international
and European standard IEC/EN 60974--1 and EN 50199.
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.
INTRODUCTION
The LUD 320 and LUD 450 are transistor--controlled welding rectifier power units, intended
for MMA, MIG/MAG, TIG welding and CAG (Carbon Arc Gouging). They are used
together with a setting unit and MEK 4C, MEK 44C, MEK 20C or MLC 30C wire feed unit.
The wire feed units have their own service manuals.
The design features, construction and method of operation of the setting unit are described in
this manual. A description of its use, however, is in a separate programming manual.
The programming manual is available in t he following languages: Swedish, Danish,
Norwegian, Finnish, English, German, French, Dutch, Spanish, Italian, Portuguese, Greek
and Czech.
The ordering no. of the manual is different depending on language and software version.
Please contact ESAB for a list of available manuals.
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WARNING
Many parts of the power unit are at mains voltage.
WARNING
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
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
S Install and earth the welding unit in accordance with applicable s tandards.
S Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.
S Insulate yourself from earth and the workpiece.
S Ensure your working s tance is safe.
FUMES AND GASES -- Can be dangerous to health
S Keep your head out of the fumes.
S Use ventilation, extraction at the arc, or both, to keep fumes and gases from your breathing zone and
the general area.
ARC RAYS -- Can injure eyes and burn skin.
S Protect your eyes and body. Use the correct welding screen and filter lens and wear protective
clothing.
S Protect bystanders with suitable screens or curtains.
FIRE HAZARD
S Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.
NOISE -- Excessive noise can damage hearing
S Protect your ears. Use ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
INSTRUCTIONS
Straps must be used when lifting the power source.
The handle is solely intended for pulling the power
source.
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COMPONENT DESCRIPTION
WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S
SS
S Observe precautions for handling electrostatic
sensitive devices.
S
SS
S Use proper static--proof bags and boxes.
ESD
This component description refers to the diagram on page 8.
AP1 Power board; see the f unction description on page 10.
AP2 Control circuit board; see the function description on page 18.
AP3 Connection board, for communication with the setting unit, wire feed unit
and remote control device.
AP4 Hall effect sensor, 1 V / 100 A
AP5 Circuit board, suppression (EMC). See circuit diagram on page 33.
AP6 Circuit board for TIG welding; see the function description on page 35.
AP7 HF device, output voltage: 500V peak. Only on machines with TIG
welding capability.
C1 -- C2 Capacitor, decoupling.
C3 Start and run capacitor for pump motor M1.
C4 Start and run capacitor for fan EV2.
C5 Capacitor, decoupling.
C6 Capacitor, for speed reduction of cooling fan EV2.
C7 Capacitor, C7 and R3 smooth the no--load voltage for MMA welding.
C8 Capacitor, decoupling.
EV1 Fan, 24 V DC. Cools circuit board AP1.
EV2 Fan, 230 V AC.
FU1 MCB, 10 A, protects the 42 V supply to the wire feed unit.
FU2 Fuse, 2A, slow--blow. Protects fan EV2, pump motor M1 and HF
generator AP7.
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HL1 Indicating lamp on the front of the machine. Lights when the main
On/Off switch QF1 is on.
L1 Primary inductor. Filters the mains voltage and improves the power
factor.
L2 Secondary inductor. Its inductance exceeds 10 µH at high currents and
about 60 µH at low currents.
L3 2+4+4 ferrite rings. Reduce transients to/from transfor mer TM1. See also
V1 below and AP1:3 on page 10.
L4 Ferrite ring. Suppresses interference in the signal fr o m Hall effect sensor
AP4. The wires from AP4 must be wound four turns around the ring.
M1 Pump motor. Only on the LUD 320W/450W.
Q1 -- Q2 IGBT modules. See AP1:4 on page 12 and the instructions on page 15.
QF1 Main power supply switch.
QF2 Cooling water pump switch. Only on 320W/450W.
R2 Resistor. Discharges capacitor C7 when the no--load voltage is turned off.
R3 Resistor. With C7, it smooths the no--l oad voltage for MMA welding.
SL1 Flow switch for cooling water (accessory). See AP2:11 on page 31.
ST1 Thermal switch: see AP2:9 on page 30, and the fitting instructions
on page 15.
ST2 Thermal switch: controls the fan speed. See AP2:10 on page 30.
ST3 Thermal switch; see AP2:9 on page 30.
TA1 Current transformer, 400:1. Note that it must never be run with open--
circuited secondary. See also AP2:4 on page 24.
TC1 Control power supply tr ansformer.
TM1 Main transformer. See AP1:3 on page 10.
TV1 HF transformer. The primary winding has one turn, and the secondary
winding has 26 turns. The unloaded secondary winding is about 13 kV
peak.
When fitting the transformer it is important that the air gaps in the trans-
former cores are correct. See item 621 in the spare parts list.
Fitted only to machines with TIG welding capability.
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V1 Diode modules with secondary diodes. There are five diode modules in
the LUD 450 and four in the LUD 320.
Each module consists of two diodes. The transient voltages produced
when the diodes turn off are suppressed by eight ferrite rings, i.e. four in
each diode leg.
If one diode module is faulty, replace all diode modules.
See page 15 for fitting instructions for V1.
V2 (TY1) Thyristor module. See AP2:8 on page 29 and the instructions on page 15.
V3 LED, yellow. Indicates overtemperature. See AP2:9 on page 30.
VC1 (BR1) Rectifier bridge. See fitting instructions on page 15.
XP1 -- XP3 Connectors (male).
XP36 Connector (male).
XS1 -- XS17 Connector (female).
XS18 -- XS20 Connector, OKC 50
XS21, XS22 Connector (female).
XS25 -- XS28 Connector (female).
XS29 Central connector for TIG welding.
XS30 Connector, OKC 50 HF, for TIG welding.
XS31 -- XS35 Connector (female).
XT1 -- XT4 Terminal block.
YV1 Solenoid valve. Only on machines with TIG welding capability.
WIRING DIAGRAM LUD 320/450
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AP1 DESCRIPTION OF OPERATION
Circuit board AP1 is the mother board in the power section of the power unit. The
components of the power section are mounted on a cast heat sink.
If the IGBT modules, circuit board AP1 and/or circuit board AP2 are replaced, the gate
pulses must be checked and the machine must be soft--started: see pages 26 and 32.
AP1:1 THE MAINS POWER UNIT
The mains voltage is rectified by rectifier VC1. Primary inductor L1
improves the power factor and increases resistance to mains--borne
transients.
Smoothing condensers C12 -- C15 charge up through r esistors R3 and R4
when the power is turned on. The two resistors are short--circuited by
thyristor TY1 (V2) about 1.2 seconds after starting. If the thyristor fails to
do this, the two resistors could be burnt out when load was applied to the
machine. Their ratings are 12Ω 10 W each and their ordering number is:
0193 775 114.
Resistors R5 and R9 form a potential divider / discharge resistor for
capacitors C12 -- C15.
See page 15 for instructions on fitting VC1 and TY1 (V2).
AP1:2 CAPACITIVE POTENTIAL DIVIDER
Capacitors C1 and C2 f orm a capacitive potential divider for the centre
point to which the main transformer is connected. Resistors R1 and R2 are
discharge / potential divider resistors.
AP1:3 MAIN TRANSFORMER
The transformer is strip--wound, with four primary tur ns and 1 + 1
secondary turns.
Its core has an air gap of about 0.13 mm, which is of key importance for
operation of the entire inverter. It must not be reduced or eliminated.
Two ferrite ri ngs, L3, are fitted to the conductors connected to the primary
winding. Their purpose is to attenuate current transients arising from
operation of the IGBT transistors.
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AP1 CIRCUIT DIAGRAM
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AP1:4 IGBT
The switching components in the power section consist of two IGBT
modules, Q1 and Q2, operating at a fixed switching frequency of 20 kHz.
The IGBT modules must never be energised when the gate conductors are
disconnected.
Fitting instructions are given on page 15.
If the IGBT modules have failed, we recommend that the mains rectifier,
VC1, should also be replaced.
AP1:5 TRANSIENT PROTECTION
An RCD filter protects against transients produced by turn--off of the IGBT
modules. It consists of components R18, R19, C10, C11, D1 and D2.
AP1:6 THEGATECIRCUIT
The IGBT transistors are each driven by their own gate circuits. These
circuits are galvanically isolated from control circuit board AP2 by
transformers TR1 and TR2.
Fuses F1 and F2 protect the gate drive circuits if the power unit should fail.
Instructions for checking the gate pulses can be found on page 26.
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AP1 CIRCUIT DIAGRAM
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AP1 COMPONENT POSITIONS
The drawing above shows the positions of the contacts on the first and second versions of
circuit board AP1.
On the first version, all the contacts on the board are 10 mm high. On the later versions,
contacts B, C and N are 14 mm high, while contact B has also changed places with contact
PE. The arrows, on the diagram above, are pointing out the contacts.
When fitting this board in machines that have been originally supplied with the first version,
fit the connectors to the following board contacts: XS1 on PE, XS2 on PF and XS4 on PB.
See the circuit diagram on page 11.
Contacts XS1 and XS2 must be secured to the board by means of a cable tie.
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FITTING COMPONENTS ON THE HEAT SINK
Thermally conducting grease
A layer of thermally conducting grease must be applied to the components described below
before they are fitted.
Start by cleaning the heat sink, and then apply a thin, even layer of grease to the contact
surface of the component. The purpose of this grease is to fill any hollows in the surface of
the component and the heat sink: those parts of the component and the heat sink that are in
true metallic contact may have such contact.
Fit the components as described below.
The order ing number for the thermally conducting grease is given on page 84 of the spare
parts list. Only the grease recommended by us may be used.
Fitting instructions
Q1, Q2 IGBT MODULES
The IGBT modules are extr emely sensitive to ESD. Never touch a module
having an open gate input. Apply appropriate ESD protection measures
when fitting the modules.
Clean the heat sink and apply thermally conducting grease as described
above. Fit the module and tighten the screws to a torque of 1 Nm. Further
tighten the screws to a torque of 4.5 Nm, tightening them alternately.
Warning: An incorrectly fitted IGBT module can lead to failure. Do not
tighten the screws harder than 4.5 Nm.
V1 DIODE MODULES
Clean the heat sink and apply thermally conducting grease as described
above. Fit the module and tighten the screws to a torque of 1 Nm. Further
tighten the screws to a torque of 4.5 Nm.
V2 (TY1) THYRISTOR MODULE
Clean the heat sink and apply thermally conducting grease as described
above. Fit the module and tighten the screws to a torque of 1.2 Nm.
VC1 RECTIFIER BRIDGE
Clean the heat sink and apply thermally conducting grease as described
above. Fit the bridge and tighten the screws to a torque of 1 Nm. Further
tighten the screws to a torque of 4.5 Nm.
ST1 THERMAL OVERLOAD SWITCH
Clean the heat sink and apply thermally conducting grease as described
above. Fit the switch and tighten it to a torque of 1.2 Nm.
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AP2 COMPONENT POSITIONS
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The following points are marked on the component positions diagram:
A= Connection points to 0V for the circuit board’s screen box.
B= CAN_0, connected to the screen of the CAN connectors.
SeeCANBUSonpage28.
C= Connection point between the circuit board and the machine chassis (Gnd).
This point has no galvanic connection to 0V on the circuit board
LED1, LED2 and LED3 fitted on circuit board AP01 can be used to check if the machine
starts correctly when switching on the mains power.
The LED’s are lit in the following order: LED1 -- LED2 -- LED3.
After LED3 is lit any combination of lit LED’s may occur.
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AP2 DESCRIPTION OF OPERATION
Sections AP2:1 -- AP2:11 r efer to the wiring diagr am on page 8 and the components position
diagram on page 16.
If circuit boards AP1 and/or AP2 are replaced, the gate pulses must be checked and the
machine must be soft--started: see pages 26 and 32.
If circuit board AP2 is replaced, the input for the current sensor must be adjusted:
seepage20.
AP2:1 POWER SUPPLY
+5V The +5V supply is regulated by voltage regulator VR5/VR6. IC16
forms a reset circuit that monitors both the regulated 5V supply after
the regulator and the unregulated.
If the voltage after the regulator drops below 4.65V, I C16 generates a
reset signal to the processor, the CAN controller and the PWM circuit.
When the voltage rises through 4.65V on starting, IC16 maintains the
reset signal for 200 ms to ensure that the machine program starts
correctly.
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IC16 monitors the voltage to the regulator input in order to make a
controlled shutdown in the event of low mains voltage, loss of power
supply or turning off the machine.
If the voltage across C110 drops below 6V, the gate pulses to the IGBT
transistors are cut off immediately and the processor receives an ’early
warning’ signal that enables it to shut down the process in a controlled
manner.
+15V There are four different 15V supplies on the board: 15V, 15VB, 15VC
and 15VD. The processor monitors all these voltages except 15VD.
15VB
supplies the pulse transformers that drive the IGBT transistors.
The voltage must be between 13.9V and 15.6V. If it is not, the gate
pulses to the IGBT transistors are interrupted, and the setting unit
displays error code 10.
15VC
If the 15VC supply is outside its tolerance of 13. 9 -- 15.6V, the setting
unit displays error code 8.
15VD
See OVERVOLTAGE AND UNDERVOLTAGE PROTECTION
on page 24.
--15V If this voltage varies outside its tolerance of 14. 0 -- 16.1V, the setting
unit will display error code 9.
POWER SUPPLY TO THE CAN BUS
SeeCANBUSonpage28.
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AP2:2 CURRENT SENSOR
Input S4 is intended for use with a current sensor that produces a signal of
1V/100A, linearly proportional to the current.
If AP2 or AP4 are replaced, the machine must be recalibrated to ensure that it
delivers the correct current. Apply a resistive load to the machine and adjust the
current by means o f potentiometer R21.
Adjust the LUD 320 to give 300 A±1% at 32 V.
Adjust the LUD 450 to give 400 A ±1% at 34 V.
Use an accurately calibrated external shunt and multimeter when making
the adjustments.
Use the service functions on page 62 to set the current when adjusting the
machine.
Remember also to check the current at low values: 12 A / 14 V, for which the
tolerance is ±2 A. If the current is outside this tolerance, adjust it by means of
offset potentiometer R201. If this is incapable of bringing the current within its
tolerance, replace current sensor AP4.
At no--load, current sensor AP4 must produce an output signal of 0V ±20mV at
input S4. It must be replaced if it produces the wrong value signal at no--load.
From October 2001 there are two different types of current sensors. Either of
them might be fitted to the machine. As the connection cable is different for the
two types, spare part sensors are delivered with connection cable and ferrite
ring. See item 431a in the spare parts list. It is important to use correct
connection cable to the sensor.
Connection cables for the current sensor
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