ESAB MECHTIG 160 User manual

LTO 160 valid for Serial NO 728 XXX--XXXX
LTO 250 valid for Serial NO 745 XXX--XXXX
0456 779 041 980902
MECHTIG 160
MECHTIG 250
LTO 160, LTO 250
105107106023104022041
Instruction manual
Betriebsanweisung Manual d’instructions Gebruiksaanwijzing

-- 2 --
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
ENGLISH 3..............................................
DEUTSCH 40.............................................
FRANÇAIS 78.............................................
NEDERLANDS 116.........................................

Diagram Schaltplan Schéma Schema
-- 1 5 4 --dpa6e11a
LTO 160

-- 1 5 5 --dpa6e11a

-- 1 5 6 --dpa6e11a
LTO 250

-- 1 5 7 --dpa6e11a

List of components Komponentenverzeichnis Liste des composants Lijst
van komponenten
-- 1 5 8 --dpa6c11a
LTO 160
C = Component designation in the circuit diagram
C Denomination C Denomination C Denomination
AP01 PC--board
AP02 PC--board
AP03 PC--board
AP07 PC--board
AP08 PC--board
AP10 PC--board
AP11 HF--unit
AP12 PC--board
AP13 PC--board
Motor--rotation
AP14 PC--board
Motor--rotation
AP15 PC--board
AP16 PC--board
AP17 PC--board
AP18 PC--board
C01 Capacitor
0,1 ←F, 1000 VDC
C02 Capacitor 1000 ←F
C04 Capacitor 0,1 ←F
C05 Caparcitor 4,7 ←F
C06 Capacitor 0,1 ←F
C07 Capacitor 0,1 ←F
C08 Capacitor 0,1 ←F
C09 Capacitor 0,1 ←F
C10 Capacitor 12 nF
C10 Capacitor
1 nF, 2000 V DC
EV01 Fan24VDC
EV02 Fan24VDC
FU06 Fuse 0,5 A
FU07 Fuse 0,5 A
FU08 Fuse 1,25 A
FU09 Fuse 1,25 A
HL01 Lamp WHITE
L01 Inductor
L02 Inductor
L03 Ferrite core
L04 Ferrite core
L05 Ferrite core
RS01 Shunt
ST01 Thermal switch
130/100 gr. C.
TC01 Control transformer
TC02 Transformer
TC03 Control transformer
TC04 Control transformer
V01 Rectifier bridge
V02 Rectifier bridge
V03 Diode module
V04 Diode module
V05 LED YELLOW
V06 Diode
QF01 Circuit breaker
YV01 Solenoid valve
X01 Connection block
3--POL
X02 Connectionblock
4--POL
X03 Connectionblock
2--POL
X04 Connectionblock
2--POL
TV01 HF--coil
R01 Resistor 3,9 kτ,5W
R02 Resistor 3,0 τΙ 10 W
R03 Resistor 3,0 τΙ 10 W
R04 Resistor 3,0 τΙ 10 W
R05 Resistor 3,0 τΙ 10 W
R06 Resistor 10 τΙ 10 W
R07 Resistor 10 τΙ 10 W
XS01 Connector 6--POL
XS02 Connector 4--POL
XS03 Connector 8--POL
XS04 Connector 26--POL
XS06 Connector 2--POL
XS07 Connector 2--POL
XS08 Connector 3--POL
XS09 Connector 5--POL
XS12 Connector 2--POL
XS13 Connector OKC 50
XS14 Connector OKC 50
XS15 Connector 2--POL
XS16 Connector 2--POL
XS17 Connector 2--POL
XS18 Connector 2--POL
XS19 Connector 4--POL
XS20 Connector 26--POL
XS22 Connector 7--POL
XS30 Connector 4--POL
XP31 Connector 4--POL
XS32 Outlet 2--POL
XS33 Connector
12--POL burndy
XS34 Connector
23--POL burndy
XS35 Connector
10--POL cannon
XS36 Connector
8--POL cannon
XS37 Connector 5--POL
XS38 Connector 2--POL
XS39 Connector 4--POL
XS40 Connector 6--POL
XS41 Connector 2--POL
XS42 Connector 2--POL
XS43 Connector 2--POL
XS44 Connector 2--POL
XS45 Connector 4--POL
XS46 Connector 4--POL
XS47 Connector
3--POL Twin con.
XS48 Connector
5--POL Twin con.
XP50 Pinplug2--POL
XS51 Sleeveplug2--POL
XS52 Connector 7--POL
XS53 Panel jack 2--POL

-- 1 5 9 --dpa6c11a
LTO 250
C = Component designation in the circuit diagram
C Denomination C Denomination C Denomination
AP01 PC--board
AP02 PC--board
AP03 PC--board
AP07 PC--board
AP08 PC--board
AP10 PC--board
AP11 HF--unit
AP12 PC--board
AP13 PC--board Motor--rota-
tion
AP14 PC--board Motor--rota-
tion
AP15 PC--board
AP16 PC--board
AP17 PC--board
AP18 PC--board
C01 Capacitor
0,1 ←F, 1000 VDC
C02 Capacitor 1000 ←F
C03 Capacitor 1000 ←F
C04 Capacitor
0,1 ←F, 400 V DC
C05 Caparcitor 4,7 ←F
C06 Capacitor
0,1 ←F, 275 V AC XZ
C07 Capacitor
0,1 ←F, 400 V DC
C08 Capacitor
0,1 ←F, 275 V AC XZ
C09 Capacitor
0,1 ←F, 275 V AC XZ
C10 Capacitor
1 nF, 2000 V DC
EV01 Fan24VDC
EV02 Fan24VDC
FU06 Fuse 0,5 A
FU07 Fuse 0,5 A
FU08 Fuse 1,25 A
FU09 Fuse 1,25 A
HL01 Lamp WHITE
L01 Inductor
L02 Inductor
L03 Ferrite core
L04 Ferrite core
L05 Ferrite core
RS01 Shunt 118 mV -- 250 V
ST01 Thermal switch
TC01 Control transformer
TC02 Transformer
TC03 Control transformer
TC04 Control transformer
V01 Rectifier bridge
V02 Rectifier bridge
V03 Diode module
V04 Diode module
V05 LED YELLOW
V06 Diode
QF01 Circuit breaker
YV01 Solenoid valve
X01 Connection block
3--POL
X02 Connectionblock
4--POL
X03 Connectionblock
2--POL
X04 Connectionblock
2--POL
TV01 HF--coil
R01 Resistor 3,9 kτ,5W
R02 Resistor 3,0 τΙ 10 W
R03 Resistor 3,0 τΙ 10 W
R04 Resistor 3,0 τΙ 10 W
R05 Resistor 3,0 τΙ 10 W
R06 Resistor 10 τΙ 10 W
R07 Resistor 10 τΙ 10 W
XS01 Connector 6--POL
XS02 Connector 4--POL
XS03 Connector 8--POL
XS04 Connector 26--POL
XS06 Connector 2--POL
XS07 Connector 2--POL
XS08 Connector 3--POL
XS09 Connector 5--POL
XS12 Connector 2--POL
XS13 Connector OKC 50
XS14 Connector OKC 50
XS15 Connector 2--POL
XS16 Connector 2--POL
XS17 Connector 2--POL
XS18 Connector 2--POL
XS19 Connector 4--POL
XS20 Connector 26--POL
XS22 Connector 7--POL
XS30 Connector 4--POL
XP31 Connector 4--POL
XS32 Outlet 2--POL
XS33 Connector
12--POL burndy
XS34 Connector
23--POL burndy
XS35 Connector
10--POL cannon
XS36 Connector
8--POL cannon
XS37 Connector 5--POL
XS38 Connector 2--POL
XS39 Connector 4--POL
XS40 Connector 6--POL
XS41 Connector 2--POL
XS42 Connector 2--POL
XS43 Connector 2--POL
XS44 Connector 2--POL
XS45 Connector 4--POL
XS46 Connector 4--POL
XS47 Connector
3--POL Twin con.
XS48 Connector
5--POL Twin con.
XP50 Pinplug2--POL
XS51 Sleeveplug2--POL
XS52 Connector 7--POL
XS53 Panel jack 2--POL

-- 1 6 0 --Sida

Spare parts list Ersatzteilliste Liste de pièces détachées
Reserveonderdelenlijst
-- 1 6 1 --dpa6r11a
Edition 980709
Ordering no. Denomination Notes
0456 770 880 LTO 160 (MECHTIG 160) 230 V, 1 µ
0457 220 880 LTO 250 (MECHTIG 250) 400 V, 3 µ

-- 1 6 2 --dpa6r11a
LTO 160, LTO 250 C = component designation in the circuit diagram
Item Qty. Ordering no. Denomination Notes C
201 10468 543 880 Handle complete
202 10468 529 001 Rubber cloth
203 10468 278 001 Cover When the cover is replaced, items 204
and 209 must also be replaced
204 10 0192 859 006 Plate Must be pressed with 50 kg pressure,
when fitted
205 0468 532 001 Screw eco--fix
206 20193 392 119 Insulating bushing
207 10456 765 880 Bracket
208 10456 743 880 Front panel
209 10469 402 880 Seal. strip w. washer 12 pcs of item 104 included
210 10193 759 001 Indicator lamp White, 28 V HL01
211 10193 759 002 Indicator Yellow V05
212 10366 296 002 Knob
213 10456 769 001 Cover plate Left
214 20441 819 001 Handwheel
215 10468 275 001 Grating
216 10468 519 001 Filter
217 0192 562 103
0192 562 104
0192 562 106
Nut
Nut
Nut
M5
M5
M6
218 10456 725 001
0457 223 001
Frontplate
Frontplate
LTO 160
LTO 250
219 10212 602 208 Nut IN6
220 10193 307 104 Cable clamp
221 10369 761 001 Mains cable 3x2,5mm
2with plug
222 10456 767 001 Cover plate Right
223 10456 768 001 Rear plate
224 10192 784 006 Sleeve plug XS30
225 10192 784 005 Pin plug XP31
226 10366 295 004 Sleeve plug QF01
227 20193 701 002 Fuse holder
228 20567 900 136 Fuse 1,25 A FU08, FU09
229 20193 701 001 Fuse holder
-- 10193 260 154 Connector 6--pole for 0,75 mm2conductor XS01
-- 10193 260 003 Connector 4--pole for 0,35 mm2conductor XS02
-- 10193 260 156 Connector 8--pole for 0,75 mm2conductor XS03
-- 10193 260 001 Connector 2--pole for 0,35 mm2conductor XS06,XS07,
XS15, XS16,
XS18
-- 10193 260 151 Connector 3--pole for 0,75 mm2conductor XS08
-- 10193 260 153 Connector 5--pole for 0,75 mm2conductor XS09
-- 10193 669 002 Connector 2--pole for 0,75 mm2conductor XS17
-- 10193 590 302 Sleeve For connector XS 17
-- 10193 260 152 Connector 4--pole for 0,75 mm2conductor XS19, XS22

-- 1 6 3 --dpa6r11a
LTO 160, LTO 250

-- 1 6 4 --dpa6r11a
LTO 160 C = component designation in the circuit diagram
Item Qty Ordering no. Denomination Notes C
301 10367 268 002 HF Module AP11
302 50365 534 001 Space washer Rubber washer
303 20193 312 101 Ferrite core
304 10455 043 880 HF--coil TV01
305 20192 859 006 Locking washer
306 10468 527 001 Bracket
307 20365 584 002 Nail
308 2Busbar ”601
309 0320 029 002 Grond link
310 0192 547 001 Nut type F
311 10468 295 001 Control transformer TC01
312 10193 045 011 Connection block Delivered as 12 pole, to be cut to
4--pole X02
313 10193 054 004 Solenoid valve YV01
314 10190 315 102 Gas hose To be ordered per meter
0,3 meter as delevered
315 10365 803 002 Water connection female
316 10193 045 011 Connection block Delivered as 12 pole, to be cur to
3--pole X01
317 10455 861 880 Bracket
318 10468 545 001 Sign
319 10486 343 880 Circuit board Suppression board AP08
322 20156 868 880 Welding Cable Con. OKC 50 XS13, XS14
324 20466 325 001 Gasket
325 10538 500 902 Sleeve terminal 2--pole XS12
326 10443 693 003 Cap
329 10467 809 880 Primary inductor L03
330 10468 521 001 Insulation
331 10367 269 880 Capacitor 0,1 ←F 400 V, with cable lugs C06
332 10468 534 881 Filter 0,1 ←F 400 V, with cable lugs C07
333 10468 534 880 Filter 3,9 kτ5W, withcablelugs R01
334 10457 230 001 Panel jack 1/4” XS53
335 10457 228 880 Cover
336 10457 229 880 Support

-- 1 6 5 --dpa6r11a
LTO 160

-- 1 6 6 --dpa6r11a
LTO 250 C = component designation in the circuit diagram
Item Qty. Ordering no. Denomination Notes C
301 10367 268 002 HF Module AP11
302 50365 534 001 Space washer Rubber washer
303 20193 312 101 Ferrite core
304 10455 043 880 HF--coil TV01
305 20192 859 006 Locking washer
306 10468 527 001 Bracket
307 20365 584 002 Nail
308 2Busbar 601
309 0320 029 002 Grond link
310 0192 547 001 Nut type F
311 10468 295 001 Control transformer TC01
312 10193 045 011 Connection block Delivered as 12 pole, to be cut to
4--pole X02
313 10193 054 004 Solenoid valve YV01
314 10190 315 102 Gas hose To be ordered per meter
0,3 meter as delevered
315 10365 803 002 Water connection female
316 10193 045 011 Connection block Delivered as 12 pole, to be cur to
3--pole X01
317 10455 861 880 Bracket
318 10468 545 001 Sign
319 10486 356 880 Circuit board Suppression board AP08
322 20156 868 880 Welding Cable Con. OKC 50 XS13, XS14
324 20466 325 001 Gasket
325 10538 500 902 Sleeve terminal 2--pole XS12
326 10443 693 003 Cap
329 10455 569 001 Primary inductor L03
330 10468 521 001 Insulation
331 10194 066 007 Capacitor 0,1 ←F 400 V, with cable lugs C06
332 10194 053 236 Filter 0,1 ←F 400 V, with cable lugs C07
333 10468 534 880 Filter 3,9 kτ5W, withcablelugs R01
334 10457 230 001 Panel jack 1/4” XS53
335 10457 228 880 Cover
336 10457 229 880 Support
337 10457 252 001 Control Transformer TC04
338 10457 519 001 Fan EV02

-- 1 6 7 --dpa6r11a
LTO 250

-- 1 6 8 --dpa6r11a
LTO 160, LTO 250 C = component designation in the circuit diagram
Item Qty.
160 Qty. 250 Ordering no. Denomination Notes C
401 1 1 0468 542 001 Cover
402 1 1 0468 544 001 Insulation
403 1-- 0486 112 881 PC--board AP01
-- 10486 112 882 PC--board AP01
404 1 1 0468 541 001 Screen box
405 1 1 0468 302 001 Insulation
406 1 1 0486 192 880 Circuit board Suppression board AP07
407 1 1 0468 310 001 Insulation
408 2 2 0468 279 001 Insulation
409 1 1 0468 280 001 Insulation
410 1 1 Busbar ”601
411 1 1 Busbar ”601
412 1 1 0486 166 880 Circuit board Shunt amplifier AP10
413 4 4 0366 588 001 Nut IN4
414 1 1 0468 274 001 Bracket
415 2 2 0468 520 001 Grating
416 4 4 0162 532 001 Bushing
417 4 4 0158 619 001 Insulating washer
418 2-- 0468 547 880 Capacitor 0,1 ←F with cable lugs C08, C09
-- 20194 066 007 Capacitor 0,1 ←F with cable lugs C08, C09
419 Battery Not used in LTO 160 and LTO
250
420 1 1 Busbar ”600
421 1 1 Busbar ”600
423 1 1 Busbar ”600
424 1 1 Busbar ”600
426 1 1 0192 903 506 Capacitor 1000 ←FC02

-- 1 6 9 --dpa6r11a
LTO 160, LTO 250

-- 1 7 0 --dpa6r11a
LTO 160 C = component designation in the circuit diagram
Item Qty. Ordering no. Denomination Notes C
501 10467 801 001 Fan 24 V DC EV01
502 1Circuit board Transistor board, positive pole.
”602 AP02
503 10192 883 150 Capacitor 0,1 ←F, 1000 V DC C01
504 10193 316 208 Recifier bridge V01
505 10467 800 001 Insulation
508 20467 797 001 Guide
509 20467 793 180 Heat sink
510 1Circuit board Transistor board, negative pole
”602 AP03
511 15 Spring ”602
512 10468 016 880 Inductor Secondary L01
513 10192 716 004 Diode 6A, 400W V06
514 20193 529 017 Capacitor 160V 4,7 ←FC05
515 10468 496 001 Holder
516 10468 215 880 Inductor Complete L02
517 1Winding 516
518 1Bobbin 516
519 2Core 516
520 2Clip 516
521 10468 961 880 Shunt 120 mV at 140 A RS01
522 10192 883 017 Capacitor 0,1 ←F , 1000 V DC C04
523 20212 913 108 Distance Nut M8
524 1Busbar ”601
525 10320 655 009 Thermal cutout Opens at 130˚C, closed at 100˚C,
526 ST01
526 10467 792 880 Transformer coil Includes item 525 TC02
10466 602 001 Conductor To be ordered per meter 0,6 m / trans-
former 020
527 10467 799 001 Clamp
528 40193 312 101 Ferrite core
0365 652 002 Tape For air gap
0191 124 021 Glue For ferrite core
529 10193 669 002 Connector 2--pole XS17
0193 590 302 Sleeve 2 per connector
530 1Rectifier unit Complete, includes items 531 -- 535
531 10455 648 001 Heat sink mashined
532 10193 948 001 Diode module V03 / V04
533 10455 650 002 Busbar
534 10455 650 001 Busbar With insulation
535 20467 648 883 Capacitor Complete with cable lugs C10
Spare parts sets
600 x0468 881 880 Busbars, primary 420 + 421 + 423 + 424
601 x0468 881 885 Busbars, secondary. 308 + 410 + 411 + 524
602 x0468 881 882 Transistor board 502 + 510 + 511
604 x0192 058 106 Contact oil To be used when mounting item 602