ESAB LTR 200 User manual

Valid for serial no. 011--xxx--xxxx0457 305 201 GB 041101

Power Tig 160

Power Tig 200

LTR 160, LTR 200

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 6....................................................

5.1 Lifting instructions 6.........................................................

6 OPERATION 7.......................................................

6.1 LIFTARC 8.................................................................

7 MAINTENANCE 9....................................................

8 ORDERING OF SPARE PARTS 9......................................

DIAGRAM 10............................................................

ORDERING NUMBER 12.................................................

SPARE PARTS LIST 13...................................................

ACCESSORIES 14.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guaran -

tee that welding power source LTR 160/200 from serial number 842 complies with

standard EN 60974--1, in accordance with the requirements of directive (73/23/EEC)

and addendum (93/68/EEC) and with standard EN 50199 in accordance with the re-

quirements of directive (89/336/EEC) and addendum (93/68/EEC).

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Laxå 1997--06--10

Paul Karlsson

Managing Director

Esab Welding Equipment AB

695 81 LAXÅ

SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336

2SAFETY

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 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 take fumes and gases away from your breathing zone

and the general area.

ARC RAYS -- Can injure eyes and burn skin.

S Protect y our 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 y our ears. Use earmuffs or other hearing protection.

S Warn bystanders of the risk.

MALFUNCTION -- Call for expert assistance in the event of malfunction.

PROTECT YOURSELF AND OTHERS!

ESAB can provide yo u with all necessary welding protection an d accessories.

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WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

3 INTRODUCTION

LTR 160/200 is a rectifier based on inverter technology and designed for TIG

welding and welding with coated electrodes.

Inverter technology contributes to low energy consumption, low weight and compact

dimensions.

The advanced electronic design permits rapid regulation and first class welding

characteristics.

LTR 160/200 is available in two versions, one with a central socket and one with an

OKC socket for connecting a TIG torch.

LTR 160/200 is 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 cover to protect

connections from slag.

An optional handle bracket 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 bottle and cooling

unit.

ESAB’s accessories for the product can be found on page 14.

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4 TECHNICAL DATA

LTR 160 LTR 200

Permittedloadat

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 110A/24V 150 A/26 V

100 % duty cycle 80 A/23 V 115A/25V

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

MMA 4--160 A 5--200 A

Slope up, adjustable on circuit board 0-- 5 s 0-- 5 s

Slope down 0,1--10 s 0,1--10 s

Gas pre --flow ,adjustable on

circuit board

0-- 5 s 0-- 5 s

Gas post--flow 5-- 20 s 5-- 20 s

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

Fuse, slow rupture 16 A 10 A

Mains cable,cross section 3x2,5 mm

4X1,5 mm

Dimension lxbxh 515x285x415 mm 515x285x415mm

Weight 23 kg 24.5 kg

Application class

Class of enclosures IP 23 IP 23

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

Cable areas acc. to Swedish regulations.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Enclosure class

The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

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bt16d12e

5 INSTALLATION

The installatio n must be executed by a professional.

WARNING!

This product is intended for industrial use. In a domestic environment this product may cause radio

interference. It is the user’ s responsibility to take adequate precautions.

LTR 160 LTR 200

Mains voltage 230 V ¦ 10 %, 1--phase 400 V ¦ 10 %, 3--phase

Mains frequency 50--60 Hz 50--60 Hz

Fuse, slow rupture 16 A*) 10 A

Mains cable, cross section 3x2.5 mm

4X1,5 mm

Welding cable, cross section 25 mm

25 mm

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

LTR 160/200 are equipped with m ains 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 rectifier is not cov-

ered 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 T IG torch and the return cable or the MMA welding cables.

The machine is now ready for welding.

5.1 Lifting instructions

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6OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

1 Mains power switch on/off 8 Remote control connection

2 Yellow indicating lamp 9 Dust filter

3 White indicating lamp 10 Gas nipple (connection of gas cylinder)

4 Slope--down time 11 Connection for TIG torch

5 Lift--Arc/HF--unit/MMA 12 Connection for return cable when TIG welding

6 Current setting 13 2/4--stroke

7 Gas post--flow 14 Remote control switch

The welding cable and return cable should be connected to 12 and 15 with MMA--welding.

S Using the remote control socket on the machine the current can be remotely

regulated in TIG and MMA modes.

S Selector switch is used to select remote control operation.

S PHA5 remote control unit allows use of pulsed current in TIG mode.

When the main power switch is switched on the white indicating lamp, on the front,

comes on.

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. T he 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.

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bt16d12e

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.

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.

6.1 LIFTARC

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.

Place the electrode against Press in the torch trigger..

the workpiece.

Tilt the torch a little, lift and To stop--reease the

an arc is produced. torch trigger.

bt07d109

Dismantling the filter

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bt16d12e

7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates to connect or carry out service,

maintenance or repair work on welding equipment.

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. .

8 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.

LTR 160, LTR 200 is designed and tested in accordance with the international and Eu-

ropean standards IEC/EN 60974--1 and EN 50199. It is the obligation of the service unit

which has carried out the service or repair work to make sure that the product still

conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

Edition 041 101

Diagram

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bt16e11a

LTR 160

Edition 041 101

-- 1 1 --

bt16e11a

LTR 200

LTR 160, LT R 200

Edition 041 101

Ordering number

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bt16o11a

Ordering no. Denomination Type Notes

0456 840 800 Welding power source LTR 160 with central connection for TIG welding

0456 840 881 Welding power source LTR 160 with OKC connection for TIG welding

0456 840 882 Welding power source LTR 200 with central connection for TIG welding

0456 840 883 Welding power source LTR 200 with OKC connection for TIG welding

0457 305 990 Spare parts list LTR 160,

LTR 200

LTR 160, LT R 200

Edition 041 101

Spare parts list

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bt19s11a

Item

Qty Ordering no. Denomination

1 2 0441 819 001 Screw

2 1 0468 275 001 Grill

3 1 0468 519 001 Filter

LTR 160, LT R 200

Edition 041 101

Accessories

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cltr0sa1

Trolleyfor5lgascylinder ......... 0468 530 880

T rolley for 10--50 l gas cylinder 0456 804 880

bt07t003

Protective handle for connections . .

.......

0458 31 1 001

LTR 160, LT R 200

Edition 041 101

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cltr0sa1

bt07t004

Tophandle ....................... 0468 305 880

For LTR 200 & LTR 255

CoolingunitOCF2L ..............

For LTR 160

CoolingunitOCF2A ..............

0457 216 880

0457 216 883

Remote control MMA 1 (10 m cable) .

MMA and TIG: current

0349 501 024

Remote control unit AT1 ...........

MMA and TIG: current

0459 491 896

Remote control unit AT1 CF .......

MMA and TIG: rough and fine setting

of current.

0459 491 897

LTR 160, LT R 200

Edition 041 101

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cltr0sa1

Remote cable 12 pole -- 8 pole

5m...............................

10m..............................

15m..............................

25m..............................

0459 552 880

0459 552 881

0459 552 882

0459 552 883

Foot control FS002,

includingcable ...................

0349 090 886

LTR 255: Return cable, 35 mm

(state the length when ordering) 0262 613 602...............

LTR 160 & LTR 200: Return cable, 25 mm

(state the length when ordering) 0262 613 601.....

Return current clip 0367 558 880........................................................

Welding current cable and return current cable, complete for MMA welding:

LTR 255 LTR 160 & 200

Welding current cable, 5 metre 0468 539 882 0468 539 880

Return current cable, 5 metre 0468 539 883 0468 539 881

Information on TIG torches can be found in separate brochures.

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ESAB AB

SE--695 81 LAXÅ

SWEDEN

Phone +46 584 81 000

www.esab.co m

031021

ESAB subsidiaries and representative offices

Europe

AUSTRIA

ESAB Ges.m.b.H

Vienna--Liesing

Tel: +43 1 888 25 11

Fax: +43 1 888 25 11 85

BELGIUM

S.A. ESAB N.V.

Brussels

Tel: +32 2 745 11 00

Fax: +32 2 726 80 05

THE CZECH REPUBLIC

ESAB VAMBERK s.r.o.

Prague

Tel: +420 2 819 40 885

Fax: +420 2 819 40 120

DENMARK

Aktieselskabet ESAB

Copenhagen--Valby

Tel:+4536300111

Fax:+4536304003

FINLAND

ESAB Oy

Helsinki

Tel: +358 9 547 761

Fax: +358 9 547 77 71

FRANCE

ESAB France S.A.

Cergy Pontoise

Tel:+33130755500

Fax:+33130755524

GERMANY

ESAB GmbH

Solingen

Tel: +49 212 298 0

Fax: +49 212 298 204

GREAT BRITAIN

ESAB Group (UK) Ltd

Waltham Cross

Tel: +44 1992 76 85 15

Fax: +44 1992 71 58 03

ESAB Automation Ltd

Andover

Tel: +44 1264 33 22 33

Fax: +44 1264 33 20 74

HUNGARY

ESAB Kft

Budapest

Tel:+3612044182

Fax:+3612044186

ITALY

ESAB Saldatura S.p.A.

Mesero (Mi)

Tel:+3902979681

Fax:+390297289181

THE NETHERLANDS

ESAB Nederland B.V.

Utrecht

Tel: +31 30 248 59 22

Fax: +31 30 248 52 60

NORWAY

AS ESAB

Larvik

Tel:+4733121000

Fax:+4733115203

POLAND

ESAB Sp.z.o.o

Warszaw

Tel: +48 22 813 99 63

Fax: +48 22 813 98 81

PORTUGAL

ESAB Lda

Lisbon

Tel: +351 1 837 1527

Fax: +351 1 859 1277

SLOVAKIA

ESAB Slovakia s.r.o.

Bratislava

Tel:+421744882426

Fax:+421744888741

SPAIN

ESAB Ibérica S.A.

Alcobendas (Madrid)

Tel: +34 91 623 11 00

Fax: +34 91 661 51 83

SWEDEN

ESAB Sverige AB

Gothenburg

Tel:+4631509500

Fax:+4631509222

ESAB International AB

Gothenburg

Tel:+4631509000

Fax:+4631509360

SWITZERLAND

ESAB AG

Dietikon

Tel: +41 1 741 25 25

Fax: +41 1 740 30 55

North and South America

ARGENTINA

CONARCO

Buenos Aires

Tel: +54 11 4 753 4039

Fax: +54 11 4 753 6313

BRAZIL

ESAB S.A.

Contagem--MG

Tel: +55 31 3369 4333

Fax: +55 31 3369 4440

CANADA

ESAB Group Canada Inc.

Missisauga, Ontario

Tel: +1 905 670 02 20

Fax: +1 905 670 48 79

MEXICO

ESAB Mexico S.A.

Monterrey

Tel: +52 8 350 5959

Fax: +52 8 350 7554

USA

ESAB Welding & Cutting Products

Florence, SC

Tel: +1 843 669 44 11

Fax: +1 843 664 44 58

Asia/Pacific

CHINA

Shanghai ESAB A/P

Shanghai

Tel: +86 21 6539 7124

Fax: +86 21 6543 6622

INDIA

ESAB India Ltd

Calcutta

Tel: +91 33 478 45 17

Fax: +91 33 468 18 80

INDONESIA

P.T. Esabindo Pratama

Jakarta

Tel: +62 21 460 01 88

Fax: +62 21 461 29 29

MALAYSIA

ESAB (Malaysia) Snd Bhd

Selangor

Tel: +60 3 703 36 15

Fax: +60 3 703 35 52

SINGAPORE

ESAB Singapore Pte Ltd

Singapore

Tel: +65 861 43 22

Fax: +65 861 31 95

ESAB Asia/Pacific Pte Ltd

Singapore

Tel: +65 861 74 42

Fax: +65 863 08 39

SOUTH KOREA

ESAB SeAH Corporation

Kyung--Nam

Tel: +82 551 289 81 11

Fax: +82 551 289 88 63

UNITED ARAB EMIRATES

ESAB Middle East

Dubai

Tel: +971 4 338 88 29

Fax: +971 4 338 87 29

Representative offices

BULGARIA

ESAB Representative Office

Sofia

Tel/Fax: +359 2 974 42 88

EGYPT

ESAB Egypt

Dokki--Cairo

Tel: +20 2 390 96 69

Fax: +20 2 393 32 13

ROMANIA

ESAB Representative Office

Bucharest

Tel/Fax: +40 1 322 36 74

RUSSIA--CIS

ESAB Representative Office

Moscow

Tel:+70959379820

Fax: +7 095 937 95 80

ESAB Representative Office

St Petersburg

Tel:+78123254362

Fax: +7 812 325 66 85

Distributors

For addresses and phone

numbers to our distributors in

other countries, please visit our

home page

ESAB LTR 200, LTR 160, LTR 160, LTR 200 User manual

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