LTR 160/200

Power Tig 160/200

Service manual

0740 800 104 040830 Valid for serial no. 704--xxx--xxxx to 011--xxx--xxxx
LIST OF CONTENTS Page
READ THIS FIRST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WIRING DIAGRAM LTR 160 Valid from ser.no. 842--xxx--xxxx . . . . . . . . . . . . . . . . . . . . . . . . . 8
WIRING DIAGRAM LTR 200 Valid for ser.no. 722--xxx--xxxx to 842--901--0271 . . . . . . . . . . . 10
WIRING DIAGRAM LTR 200 Valid from ser.no. 842--902--xxxx . . . . . . . . . . . . . . . . . . . . . . . . . 12
DESIGN CHANGES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
DESCRIPTION OF OPERATION CIRCUIT BOARD AP01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
1 +30 V +20 V ±10 V Power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2 Power supply to the fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3 Selection of welding method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4 Start / Stop, Reference input, Remote control input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
5 Slope up / Slope down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6 HF unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
7 Gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8a Shunt input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8b Shunt input with shunt signal amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9 Arc voltage sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10 Gate circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Checking the gate pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11 Thermal overload switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Component positions, circuit board AP01 0481 864 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Component positions, circuit board AP01 0481 818 880 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
TRANSISTOR BOARD AP02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
TRANSISTOR BOARD AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
MOS TESTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
SOFT STARTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
LTR 160, SUPPRESSION CIRCUIT BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
LTR 200, SUPPRESSION CIRCUIT BOARD AP08 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SUPPRESSION CIRCUIT BOARD AP09 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
DISASSEMBLY / REASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Assembling the diode modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Removal of transistor circuit boards AP02 and AP03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Refitting the transistor circuit board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Fitting the main transformer TC02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
LOAD CHARACTERISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

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
board is divided into numbered blocks, which are described individually in more detail in
the description 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
August 2004.

The manual is valid for LTR 160 and LTR 200 with serial numbers:
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.
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.

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

S Install and earth the welding unit in accordance with applicable standards.
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 stance 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.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

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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.
The conducting time and frequency are controlled by circuit board AP01.

WARNING !
STATIC ELECTRICITY can damage circuit
boards and electronic components.
S Observe precautions for handling electrostatic
sensitive devices.
ESD S Use proper static--proof bags and boxes.

AP01 The main circuit board with control electronics, see the description on
page 15 and DESIGN CHANGES on page 14.
AP02 Circuit board with power transistors for the positive pole,
see description on page 28.
WARNING! the transistors are connected to mains voltage potential.
AP03 Circuit board with power transistors for the negative pole,
see description on page 30.
WARNING! the transistors are connected to mains voltage potential.
AP08 Interference suppression circuit board. Prevents mains--borne interference,
see the circuit diagram on page 34.
AP09 Interference suppression circuit board, remote control connector, see the
circuit diagram on page 35.
AP10 Circuit board with shunt signal amplifier. See the description on page 20.
Included in the LTR 160 from serial number 842--xxx--xxxx. and in the
LTR 200 from serial number 842--902--xxxx.
AP11 HF generator. See the description on page 18.
C01 Transient protection.
C02 Capacitor, 1000µF, buffer/smoothing capacitor. Time to discharge after
turning off the unit: about two minutes.
C03 See C02. Only fitted in the LTR 200.
C04 -- C09 Decoupling capacitors.
C10 2 - capacitors, 12 nF. Protection against transient voltages. From serial
number 011--xxx--xxxx the capacitors are replaced by L04 and L05.
EV01 Fan, 24 VDC

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FU01 - FU06 Fuses fitted to the control transformer. For fuse ratings: see item 212 in the
spare parts list. Early versions of the machines have no fuses.
HL01 Lamp, 28 V, white, lights when mains power is on.
L01 Secondary inductor.
L03 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.
L06 Ferrite tube, transient protection for machines without shunt signal
amplifier. The shunt signal wires are twisted and wired three turns through
the tube. See DESIGN CHANGES on page 14.
QF01 Mains power supply switch.
R01 Resistor, 3.9 kΩ 5 W.
R02 Resistor, 4.7 kΩ.
RP01 Potentiometer 500 kΩ. For gas post flow time 5 - 20 seconds.
RP02 Potentiometer 500 kΩ. For slope down time 0.1 - 10 seconds.
RP03 Potentiometer 10 kΩ 2 W, for setting of the welding current.
RS01 Shunt, 137 mV at 160 A respektively 200 A. The wires B1 and B2 must be
twisted in machines without shunt signal amplifier, AP10.
SA01 Switch, 2/4--stroke changeover.
SA02 Selector switch: TIG Lift Arc / TIG HF / MMA
SA03 Switch, activation of remote control.
ST01 Thermal overload cutout, for overload protection, mounted on the main
transformer (TC02) winding. See: Thermal overload switch on page 24.
TC01 Control power transformer. Secondary output voltages of 26, 2x18, 19, 23
and 42 V.
TC02 Main transformer. For fitting instructions, see page 38.
TV01 HF coil.
V01, V02 Mains rectifier bridge, 35 A, 1200 V. V02 is only fitted in the LTR 200.
After replacing the rectifier bridges, the machine must be soft--started: see
instructions on page 33.

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V03,V04 Rectifier and freewheel diodes.
V03 rectifies the welding current. During the time interval between two
voltage pulses from transformer 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.
V05 LED, yellow. Lights when thermal switch ST01 operates (breaks) as a
result of high temperature.
X01 -- X02 Terminal block.
XP01 Pin connector with jumper. Connected when the machine is used without
water cooler.
XS . . Sleeve connectors.
Note: the connectors XS01, XS02, XS03, XS05 and XS06 has changed
design. Valid for LTR 160 from serial number 842--xxx--xxxx and for
LTR 200 from serial number 842--902--xxxx.
The sleeve numbering is reversed compared to the earlier version. The
wire numbering and the numbering of the contact pins of the circuit board
is not changed, compare the diagrams on page 10 and 12.
The ordering numbers for the connectors are listed under item 303 in the
spare parts list.
XS10 12--pole Burndy contact, for connection of remote control unit.
XS11 TIG central connector: only LTR model - 880 and - 882.
XS12 2--pole Cannon connector, only LTR model - 881 and - 883.
XS13 Welding current connector, OKC, only LTR model - 881 and - 883.
XS14 Welding current terminals, (two), OKC type.
XS24 Connection for 400V to water cooler. (The water cooler is an accessory,
which is mounted under the machine.)
XS25 Connection for water flow guard.
YV01 Solenoid valve

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WIRING DIAGRAM LTR 160 Valid for ser.no. 704 -- 726

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WIRING DIAGRAM LTR 160 Valid from ser.no. 842--xxx--xxxx

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cltr0de1 -- 9 --
WIRING DIAGRAM LTR 200
Valid for ser.no. 722--xxx--xxxx to 842--901--0271

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cltr0de1 -- 11 --
WIRING DIAGRAM LTR 200 Valid from ser.no. 842--902--xxxx

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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.
Most of the machines that have suffered from interference problems have been put right by
fitting the conversion set described below. The ordering number for the set is 0458 024 880,
and it is suitable for all LTR 160/200 with serial numbers as listed above. It comprises a
modified control card (E481 864 880), an interference suppression card (0486 187 883) and a
ferrite tube with connections for soldering it into the shunt cables.
The above control card and interference suppression card are also suitable for use with
LTR160/200 machines that have not been converted by fitting the entire set.

Location of the L06 ferrite tube

1. Replace the AP01 control card and the AP09 interference suppression card.
2. Cut wire B1. BE CAREFUL! Do not mix up the wires. If you mix up B1 and B2, you
will get a current surge that will destroy the machine.
3. Slide a 40 mm insulating sleeve over each end of the wire.
4. Solder the red wire of the ferrite tube between the two cut ends of B1.
5. Cut wire B2. BE CAREFUL! Do not mix up the wires.
6. Slide a 40 mm insulating sleeve over each end of the wire.
7. Solder the black wire of the ferrite tube between the two cut ends of B2.
8. Slide the insulation sleeves over the joints and secure the whole with cable ties.

LTR 160/200 with shunt signal amplifier

LTR 160 machines with effect from serial number 842--xxx--xxxx, and LTR 200 machines
with effect from serial number 842--902--xxxx, have a new AP01 control card and an
amplifier card (AP10) mounted on the shunt. The L06 ferrite tube is not fitted to these
machines, and the new control card is not suitable for use in older machines.

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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.

DESCRIPTION OF OPERATION CIRCUIT BOARD AP01

This description refers to the wiring diagrams and to the components layout diagrams.
Only those items that are connected to the inputs and outputs of the circuit board are
described here.
If there is a fault on the circuit board, the whole circuit board must be replaced.
After replacing the board, the machine must be soft--started, as described on page 33.

1 +30 V +20 V ±10 V Power supply

+30 V
Power supply to the gas and HF relays.

±10 V
Voltage tolerance ±5%. The power supply from transformer TC01 is protected by
two 1.25 A slow--blow fuses.

+20 V
Power supply to the control amplifier, the pulse width modulator and the gate
circuits.
Voltage tolerance ±5%. The power supply from transformer TC01 is protected by an
800 mA slow--blow fuse.
Capacitor C93 slows the rise time of the 20 V supply at power--on, which delays the
gate pulses to the MOSFET transistors.
HL01 is an indicating lamp on the front of the machine, lighting to indicate that the
main power switch is On.

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2 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.

3 Selection of welding method

MMA, LiftArc, HF

Switch SA02 selects the welding method by disabling, through a diode network, the
functions that are not to be active for a particular welding method.

2--stroke/4--stroke

Closing switch SA01 selects 2--stroke control mode.

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4 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.
Voltage regulator VR1 incorporates internal thermal protection against overload.
At the lowest current reference, the voltage at circuit board contact C9 is 0 V. At the
maximum current reference, the voltage is about 14 - 15 V.
Resistor R74 adjusts the output voltage from VR1 so that the reference voltage and
the control amplifier provide the correct maximum current. This resistor is adjusted
during manufacture of the circuit board, and should not subsequently be adjusted.
Switch SA03 selects adjustment of the welding current from the remote control
device or from the front panel of the machine.
If it is the Remote position, but no remote control device is connected, resistor R75
holds the current reference at the minimum level.

Start/Stop
When operating in TIG welding mode, the machine is started from the welding torch
switch, which is connected to the machine via contacts XS11/XS12. Alternatively,
welding can be started from a remote control device and connectors J and K in
remote control unit contact XS10. Relay RE1 is used only during TIG starts. See
also the description of arc voltage sensing on page 21.

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5 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). It is adjustable between 0 and 5 seconds.
On delivery, the Slope Up time has been set at 0.

6 HF unit

WARNING! dangerous voltage.

When the torch switch is closed and the open--circuit voltage exceeds about 45 V,
relay RE3 closes and activates HF unit AP11. The relay drops off when the arc
voltage is less than 45 V or if the arc has not struck within 0.5 seconds.
In the MMA welding mode, transistor Q7 is held off by --10 V from diode D18. In
the Lift Arc mode, Q7 is held off by - 10 V from diode D17.
The voltage on the primary side of HF transformer TV01 is about 400 V, and the
secondary voltage is about 8 kV.
From serial number xxx--006--xxxx a new type of HF generator is used,
0367 268 001. This generator produces about 500 V on the primary side of the HF
transformer and about 10 kV on the secondary side.
The new HF generator replaces the old type as spare part for older machines. The
colour of the new type is grey, the old is black. The new has screw connections for
the connection cables and different hole pattern for the mounting.

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 When fitting the new generator to older machines: three new mounting holes for the
generator must be drilled and the cable shoes must be removed from the connection
cables. Fit the generator with the connection terminal turned towards the base plate.

7 Gas valve

Gas valve YV1 is controlled by relay RE2. Potentiometer RP01, on the front panel
of the machine, is used for adjusting the gas post--flow time in the range 5--20
seconds.
Potentiometer R30, on the circuit board, controls the gas pre--flow time between 0
and 5 seconds. When delivered, it is set at 0 seconds.
The gas valve is activated briefly when the machine is energised.

8a 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.
LTR 200: The shunt provides a signal of 137 mV at a welding current of 200A.
The cables (B1 and B2) between the shunt and the circuit board must be twisted in
order to prevent any interference reaching the circuit board.
Do not mix up cables B1 and B2, it will cause over current which destroys the
output transistors.

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8b 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.
Resistor R16 adjusts the offset voltage of amplifier IC1. This resistor is adjusted
during manufacture of the circuit board, and should not subsequently be adjusted.
The signal amplification is set by fixed resistors and it is not adjustable.
The shunt voltage is 137 mV at maximal welding current, 160 respectively 200 A.
The voltage between the contacts B1 and B2 on circuit board AP01 must be 5.7 V
±2% at maximal welding current.

Component positions, circuit board AP10

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9 Arc voltage sensing

Machines with shunt signal amplifier: The arc voltage from RS01 is connected to
AP01 through AP10. The resistors R172 and R177, with the value 0 Ω, are
mounted. The capacitors C52 and C95 are not mounted on the board.
Machines without shunt signal amplifier: The arc voltage from RS01 is
connected directly to AP01. The resistors R172 and R177 are not mounted. The
capacitors C52 and C95 are mounted on the board.
The arc voltage signal limits the open--circuit voltage and is also used to sense the
start of welding. During TIG welding, the arc voltage can vary between 5 and 45 V.
The following description describes the starting sequence for the various welding
modes:
MMA
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.
The starting current is 75% higher than the set value of current when the set
value is 25 A. The starting current is 25% higher than the set value of current
when the set value is 160 A.
3. Welding is performed at the set value of current.

TIG, HF START
1. Gas pre--flow.
2. The starting voltage is about 100 V, and HF ignition is provided for a maximum
of 0.5 seconds.
3. A voltage less than 45 V is interpreted as a welding start. The control amplifier
generates an elevated starting current for about 50 ms.
The starting current is 20 A higher than the set value of current.
4. Welding is performed at the set value of current.

TIG, LIFTARC START

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 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.
The starting current is 20 A higher than the set value of current.
4. Welding is performed at the set value of current.

10 Gate circuit

The pulse width modulator IC13 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 maximum pulse time is
41% ¦1.5% of the cycle time.
Maximum pulse time results in maximum current and voltage.

IMPORTANT
The frequency and pulse time are very important parameters. If they are
incorrect, they can result in transistor failure in the main circuit.
See also CHECKING THE GATE PULSES on next page.

The MOSFET transistors’ drive stage produces control pulses for the gate--source 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. The
insulation voltage between the pulse width modulator and the gate circuits is 4 kV.

WARNING! The gate circuits are at mains voltage.

cltr0de2 -- 22 --
 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. The pulse returns via the source, connection J2, D42 and C79.
The peak gate - source voltage is 14 V.
The gate pulse between J1 and J2 charges C79 to 3.3 V. When Q17 turns off, the
voltage from the secondary of the pulse transformer changes polarity, causing Q18
and Q19 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 AP02 or AP03 has failed, the gate pulses must always be checked.
Remove connections XS07 and XS08 (gate pulses). Connect a dummy gate load to
outputs J1 and J2 and to K1 and K2.

Dummy gate load

IMPORTANT: never check the gate pulses when AP02 and AP03 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
41% ¦1.5% of the cycle time, measured at a level of +5 V.
If the gate pulse does not lie within these tolerances, replace circuit board AP01.
After replacing AP01, check the gate pulses again and soft--start the machine, as
described on page 33.

cltr0de2 -- 23 --
 5V

0V

cmha2p25

Gate pulses as measured across a dummy gate load on circuit board AP01,
between terminals J1 and J2.

11 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.

cltr0de2 -- 24 --
Component positions, circuit board AP01 0481 864 880

R58 Slope up

R30 Gas pre flow

WARNING:
High voltage within
the shaded area

cltr0de2 -- 25 --
Component positions, circuit board AP01 0481 818 880

R58 Slope up

R30 Gas pre flow

WARNING:
High voltage within
the shaded area

cltr0de2 -- 26 --
cltr0de2 -- 27 --
TRANSISTOR BOARD AP02

cmha2e06
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. In addition, circuit board AP03 must also be replaced.
Instructions for removing and fitting the circuit board are to be found on page 37.

A01, A02 Connections A01 - A02 are for the gate pulses from circuit board AP01.
D1 -- D3 Transient voltage protection.
D5 Back--emf protection diode (squelch diode), for main transformer TC02
when the transistors turn off.
F1 Fuse, for protection of circuit board AP01 if circuit board AP02 fails.
Q1 -- Q8 MOSFET transistors. These require a special instrument.
See MOS TESTER on page 32 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.

cltr0de3 -- 28 --
Component positions, circuit board AP02

cmha2e07

cltr0de3 -- 29 --
TRANSISTOR BOARD AP03

cmha2e08
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. In addition, circuit board AP02 must also be replaced.
See page 37 for instructions for removing and fitting the circuit board.

A01, A02 Connections A01 - A02 are for the gate pulses from circuit board AP01.
B01, B02 When the machine is loaded, pulses from a trigger pulse winding on main
transformer TC02 are supplied to connections B01 and B02, for use as gate
pulses in controlling thyristor TY1.
D1 -- D3 Transient voltage protection.
D5 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 32 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.

cltr0de3 -- 30 --
R21 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.
R26 Discharge resistor for buffer capacitor C03. This capacitor is only fitted in
LTR 200. After turning off the mains power supply, the discharge time for
the capacitor is about two minutes.
R27 Discharge resistor for buffer capacitor C02. After turning off the mains
power supply, the discharge time for the capacitor is about two minutes.
TY1 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

cmha2e09

cltr0de3 -- 31 --
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:

S Disconnect the power unit from the mains.
S Disconnect capacitor C02 (and C03 in LTR 200).
S Remove the gate connections from AP01.
S Connect the clip on the red wire of the instrument to the red wire (the gate wire) on the
transistor board.
S Connect the clip on the yellow wire of the instrument to the yellow wire (the source) on
the transistor board.
S Connect the black wire to the cooling fins (drain).

Testing:
S Press the pushbutton marked TEST.
S If the board is healthy, both the red and green LEDs should flash alternately, about once
a second.
S 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.)
S 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 AP01 before commissioning the new transistor boards.
See instruction on page 23.
After replacement of the boards, the machine must be soft--started.

cltr0de3 -- 32 --
SOFT STARTING
S Remove and insulate wires 07 and 08 from rectifier bridge V01: see the circuit diagram
on page 7.
In the LTR 200, also remove and insulate wire 09 to rectifier bridge V02: see the circuit
diagram on page 10.
S Connect an external power supply, having a current limit of 1 A, to the positive and
negative connections on V01.
S Adjust the power supply voltage to 30 V.
S Power the remaining parts of the unit from the normal power supply.
S Select MMA mode.
S 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.
S Measure the primary voltage to transformer TC02. With a voltage of 30 V across the
buffer capacitor, the waveform must appear as shown below.

cmha2p24
Primary voltage at TC02 for 30 V across the buffer capacitor

cltr0de3 -- 33 --
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. As spare part for those machines circuit board 0486 356 880 or 0486 577 880 may be
used. The new circuit board suppresses noise better than the old board. To fit the new board
in older machines a new mounting hole must be drilled in the mounting plate.

cltr0de3 -- 34 --
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

cltr0de3 -- 35 --
DISASSEMBLY / REASSEMBLY

Assembling the diode modules

Heat sink with diode module

1. Clean the contact surface of the heat sink with extremely fine abrasive paper.
2. Apply a thin film of contact oil (see items 454 and 555 in the spare parts list) to the
contact surfaces.
3. Fit the diode modules and tighten the screws A (M6) to a torque of 6 Nm. Tighten the
screws B (M4) to a torque of 1 Nm.
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.

From serial number 011--xxx--xxxx the diode modules are different connected compared to
the picture above: see the spare parts list. The fitting procedure for the modules is however
the same as described above.

cltr0de3 -- 36 --
Removal of transistor circuit boards AP02 and AP03

1. Remove all wires and busbars connected to the board.

2. 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

1. When replacing the transistor circuit board, both boards must always be replaced and
new springs must be fitted.
2. Clean the contact surface (3) of the heat sink with extremely fine abrasive paper.
3. Apply a thin film of contact oil (see items 454 and 555 in the spare parts list) to the
contact surfaces.
4. 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 where there are components that are to be in contact
with the heath sink. Due to a change to transistors with higher current rating, there might
be less transistors on the spare part board than on the original board.
5. When fitting cable lugs and busbars to the boards, it is important that the washers 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.

Connections to circuit board AP03

a 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
LTR 200: wire 013 from negative of V02
e Gate connection from circuit board AP01
f Connector XS17 from transformer TC02

cltr0de3 -- 37 --
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. Part numbers for the requisite adhesive and tape are shown as Item 428 in the spare
parts list.

1. 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)

cmha2p32

Fitting wire 020

2. 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.
3. 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.

cmha2p33
Airgap (t) in the transformer core

cltr0de3 -- 38 --
LOAD CHARACTERISTICS

LTR 160

LTR 200

cltr0de3 -- 39 --
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
60 % duty cycle 110 A / 24 V 150 A / 26 V
100 % duty cycle 80 A / 23 V 115 A / 25 V

Setting range, TIG 4 -- 160 A 5 -- 200 A

Setting range, MMA 4 -- 160 A 5 -- 200 A

Slope up,
adjustable on the circuit board 0 -- 5 sec. 0 -- 5 sec.
Slope down 0.1 -- 10 sec. 0.1 -- 10 sec.

Gas pre flow,

adjustable on the circuit board 0 -- 5 sec. 0 -- 5 sec.
Gas post flow 5 -- 20 sec. 5 -- 20 sec.

Open--circuit voltage 65 -- 80 V 72 -- 82 V
Open--circuit power 30 W 47 W
Useful power, P
at max current MMA 4.8 kW 6.8 kW
Apparent power, S
at max current MMA 6.9 kVA 10.6 kVA

Power factor, at max current MMA 0.69 0.64

Efficiency, at max current MMA 0.75 0.82

Mains connection 230 V ±10% 3~ 400 V ±10%

Mains frequency 50 -- 60 Hz 50 -- 60 Hz
Fuse, slow rupture 16 A *) 10 A
Mains cable, cross section 3x2.5 mm2 4x1.5 mm2

Dimension lxbxh 515x285x415 mm 515x285x415 mm

Weight 23 kg 24.5 kg

Application class
Class of enclosure IP 23 IP 23

The welding power sources comply with the requirements set out in IEC 974--1

The symbol indicates that this power source is designed for use in areas where there is an
increased electrical hazard.
The enclosure class indicates the degree of protection against penetration by solid objects and
water. Equipment marked IP 23 is designed for in-- and outdoor use.

*) When welding with max 100 A a 10 A slow--blow fuse is sufficient.

With 16 A slow fuse, max. 150 A, 20% duty cycle for MMA welding.

cltr0de3 -- 40 --
INSTRUCTIONS
This chapter is an extract from the instruction manual for the LTR 160/200.

INTRODUCTION

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.
The machines are supplied complete with 5 metre mains cable, 5 metre return cable, gas hose
and hose clamps.
Versions with a central socket are also supplied with a protective handle to protect the
connections from strokes.
An optional top handle can be fitted to the machine for winding up cables and to protect the
control panel.
Two different trolleys are available to facilitate transport with a gas cylinder and cooling unit.

INSTALLATION

WARNING
This product is intended for industrial use. In a domestic environment it may cause
radio interference. It is the user’s responsibility to take adequate precautions.

LTR 160/200 are equipped with mains voltage compensation, which means that a ¦10 %
variation in the mains voltage only results in a ¦0.2 % variation in the welding current.
To reduce the voltage drop when using a long cable it can be advisable to select a heavier
cable cross section.

1. Place the equipment in a suitable place and make sure the machine is not covered or
set--up so that cooling is prevented.
2. Make sure the machine is connected to the correct mains voltage.
Earth according to applicable directives.
3. Connect the shielding gas.
4. Connect the TIG torch and the return cable or the MMA welding cables.

The machine is now ready for welding.

cltr0de4 -- 41 --
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. Remote control connection
9. Dust filter
10. Gas nipple
11. Connection for TIG torch
12. Connection for return current cable when TIG welding and for welding current cable
when MMA welding
13. 2/4--stroke selector switch
14. Remote control switch
15. Connection for return current cable when MMA welding

S Using the remote control socket on the machine the current can be remotely regulated in
TIG and MMA modes.
S PHA5 remote control unit allows use of pulsed current in TIG mode.

To take your mind off the risk of overloading the machine it has been equipped with an
integrated thermostat that trips if the temperature becomes too high.
When this occurs the welding current is cut out and the yellow indicating lamp comes on.
When the temperature has dropped the thermostat automatically resets.

Mode = HF
When the torch trigger is pressed the gas starts flowing. The high frequency unit is switched
on and produces a spark between the electrode and the work piece, which ionises the gas and
ignites the arc. Once the arc is stable the HF unit is automatically switched off. It is also
switched off if the arc has not struck after 0.5 seconds.

Mode = MMA
In this mode the machine is set up for welding with coated electrodes. The HF unit and
Lift--Arc are disabled and the Hot--start unit is now activated to give a higher current during
striking.

cltr0de4 -- 42 --
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.

Mode = Lift--Arc
The torch electrode is positioned at the point where you want to start welding, when you
press the trigger and raise the torch the arc is struck.
Using the built--in slope--up function the current rises to the preset value. When you want to
stop welding you release the switch and the current slowly decreases in accordance with the
preset slope--down time.

bt07t001
Place the electrode against the workpiece . Press the torch switch

bt07t002
Tilt the torch a little, lift and an arc is produced To stop -- release the torch trigger

cltr0de4 -- 43 --
MAINTENANCE
Generally, LTR 160/200 do not require any
maintenance. Normally, it is sufficient to blow
out the machine using clean, compressed air
annually, and the dust filter should be cleaned
regularly.
If the machine is set up in dusty or dirty
environments the machine and dust filter should
be cleaned more often.
NOTE: All warranty undertakings given by the
supplier cease to apply if the customer attempts
to rectify any faults on the machine during the
warranty period. 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

cltr0de4 -- 44 --
NOTES

notes -- 45 --
ESAB subsidiaries and representative offices

Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
CHINA
ESAB Ges.m.b.H Larvik ESAB Representative Office
Tel: +47 33 12 10 00 Shanghai ESAB A/P
Vienna--Liesing Shanghai Sofia
Tel: +43 1 888 25 11 Fax: +47 33 11 52 03 Tel/Fax: +359 2 974 42 88
Tel: +86 21 6539 7124
Fax: +43 1 888 25 11 85 Fax: +86 21 6543 6622
POLAND EGYPT
BELGIUM ESAB Sp.z.o.o INDIA ESAB Egypt
S.A. ESAB N.V. Warszaw ESAB India Ltd Dokki--Cairo
Brussels Tel: +48 22 813 99 63 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 22 813 98 81 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 726 80 05 Fax: +91 33 468 18 80
PORTUGAL ROMANIA
THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
ESAB VAMBERK s.r.o. Lisbon P.T. Esabindo Pratama Bucharest
Prague Tel: +351 1 837 1527 Jakarta Tel/Fax: +40 1 322 36 74
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 01 88
Fax: +420 2 819 40 120 Fax: +62 21 461 29 29 RUSSIA-- CIS
SLOVAKIA ESAB Representative Office
DENMARK ESAB Slovakia s.r.o. MALAYSIA Moscow
Aktieselskabet ESAB Bratislava ESAB (Malaysia) Snd Bhd Tel: +7 095 937 98 20
Copenhagen--Valby Tel: +421 7 44 88 24 26 Selangor Fax: +7 095 937 95 80
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +60 3 703 36 15
Fax: +45 36 30 40 03 Fax: +60 3 703 35 52 ESAB Representative Office
SPAIN St Petersburg
FINLAND ESAB Ibérica S.A. Tel: +7 812 325 43 62
SINGAPORE
ESAB Oy Alcobendas (Madrid) Fax: +7 812 325 66 85
Tel: +34 91 623 11 00 ESAB Singapore Pte Ltd
Helsinki Singapore
Tel: +358 9 547 761 Fax: +34 91 661 51 83
Tel: +65 861 43 22 Distributors
Fax: +358 9 547 77 71 Fax: +65 861 31 95
SWEDEN For addresses and phone
FRANCE ESAB Sverige AB ESAB Asia/Pacific Pte Ltd numbers to our distributors in
ESAB France S.A. Gothenburg Singapore other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Tel: +65 861 74 42 home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Fax: +65 863 08 39
www.esab.com
Fax: +33 1 30 75 55 24 ESAB International AB
SOUTH KOREA
Gothenburg
GERMANY Tel: +46 31 50 90 00 ESAB SeAH Corporation
ESAB GmbH Fax: +46 31 50 93 60 Kyung--Nam
Solingen Tel: +82 551 289 81 11
Tel: +49 212 298 0 SWITZERLAND Fax: +82 551 289 88 63
Fax: +49 212 298 204 ESAB AG
Dietikon UNITED ARAB EMIRATES
GREAT BRITAIN Tel: +41 1 741 25 25 ESAB Middle East
ESAB Group (UK) Ltd Fax: +41 1 740 30 55 Dubai
Waltham Cross Tel: +971 4 338 88 29
Tel: +44 1992 76 85 15 North and South America Fax: +971 4 338 87 29
Fax: +44 1992 71 58 03
ARGENTINA
ESAB Automation Ltd CONARCO
Andover Buenos Aires
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313
BRAZIL
HUNGARY
ESAB S.A.
ESAB Kft
Contagem--MG
Budapest
Tel: +55 31 3369 4333
Tel: +36 1 20 44 182
Fax: +55 31 3369 4440
Fax: +36 1 20 44 186
CANADA
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20
Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
MEXICO
THE NETHERLANDS ESAB Mexico S.A.
ESAB Nederland B.V. Monterrey
Utrecht Tel: +52 8 350 5959
Tel: +31 30 248 59 22 Fax: +52 8 350 7554
Fax: +31 30 248 52 60
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58

ESAB AB
SE-- 695 81 LAXÅ
SWEDEN
Phone +46 584 81 000

www.esab.com

031021