ESAB LTS 160 is a fan-cooled welding power source that is designed for mechanized TIG welding. It features a user-friendly programming box for setting welding parameters, executing welding processes, storing welding procedures, and communicating with an external PC. The LTS 160 offers high welding quality, precise control over welding parameters, and the ability to save and recall welding procedures.
This welding power source is commonly used in industrial applications such as shipbuilding, automotive manufacturing, and construction.
ESAB LTS 160 is a fan-cooled welding power source that is designed for mechanized TIG welding. It features a user-friendly programming box for setting welding parameters, executing welding processes, storing welding procedures, and communicating with an external PC. The LTS 160 offers high welding quality, precise control over welding parameters, and the ability to save and recall welding procedures.
This welding power source is commonly used in industrial applications such as shipbuilding, automotive manufacturing, and construction.
Valid for serial no. 008, 3060458 343 001 030324
PROWELDER 160
PROWELDER 250
LTS 160, LTS 250
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
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Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
SVENSKA 3..............................................
DANSK 14................................................
NORSK 25................................................
SUOMI 36................................................
ENGLISH 47..............................................
DEUTSCH 58.............................................
FRANÇAIS 69.............................................
NEDERLANDS 80.........................................
ESPAÑOL 91..............................................
ITALIANO 102..............................................
PORTUGUÊS 113..........................................
ÅËËÇÍÉÊÁ 124.............................................
ENGLISH
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TOCe
1DIREKTIV 48.........................................................
2SAFETY 48...........................................................
3 INTRODUCTION 49...................................................
3.1 Equipment 49................................................................
3.2 Programming box 50.........................................................
3.3 Applications 50..............................................................
4 TECHNICAL DATA 51.................................................
5 INSTALLATION 52....................................................
5.1 Lifting instructions 52.........................................................
5.2 Mains voltage connection 53...................................................
5.3 Termination resistans 53......................................................
5.4 Connection of complete welding system 54......................................
6 OPERATION 55.......................................................
6.1 Controls and connections 55...................................................
6.2 Cooling unit 56...............................................................
6.3 Overheating protection 56.....................................................
6.4 Flow guard, water 56.........................................................
6.5 Flow guard, gas 56...........................................................
6.6 Error messages 56...........................................................
7 MAINTENANCE 57....................................................
7.1 Check--up and cleaning 57....................................................
8 ORDERING OF SPARE PARTS 57......................................
DIAGRAM 136............................................................
SPARE PARTS LIST 141...................................................
ACCESSORIES 157.......................................................
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1DIREKTIV
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source LTS 160, LTS 250 from serial number 008 complies with standard EN 60974--1, in ac-
cordance with the requirements of directive (73/23/EEC) and addendum (93/68/EEC) and with stan-
dard EN 50199 in accordance with the requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
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Anders Birgersson
Managing Director
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 411924
Laxå 2000--04--17
2SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommen-
dations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3. The workplace must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
GB
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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 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 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!
3 INTRODUCTION
LT S 160, LTS 250 are welding power sources of the rectifier type designed for
mechanised TIG welding.
They are fan--cooled and also includes a cooling system for water--cooling of the
welding tool.
They is prepared for connection to an external PC.
3.1 Equipment
LT S 160 and LTS 250 are supplied with:
S Programming box with connection cable (10 m)
S Return cable (5 m) with r eturn cable clamp
S Gashose(2m)withhoseclamp.
S End resistor.
S Programming manual in swedish, english, german och french.
S PC card.
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3.2 Programming box
The welding power source is provided with a programming box for:
S Programming of welding procedures when welding with a welding tool.
S Executing a welding process.
S Storing welding program in an internal or external memory unit (PC card).
S Transferring welding programs between programming units.
S Setting of different parameter values when welding with a TIG hand torch.
For the handling, see Programming manual.
The programming manual is available in the following languages:
Language Article no. Language Article no.
English 0457 706 X74 French 0457 706 X76
German 0457 706 X75 Swedish 0457 706 X70
Italian 0457 706 X79 Finnish 0457 706 X73
Norwegian 0457 706 X72 Danish 0457 706 X71
Dutch 0457 706 X77 Spanish 0457 706 X78
Portuguese 0457 706 X80 Russian 0457 706 X86
3.3 Applications
Welding power source LTS can be used for welding with:
S Tube welding tools for joining tubes
S Tube--to--plate welding tools for welding of tube diameters 12--60 m m
S Automatic welding machine A25 STB with floating head.
S TIG hand torch
A wire feed unit for filler wire can be connected to the welding power source.
Motors for external units (roller beds, turntables, etc.) can be controlled by way of the
PAL 3 motor control unit.
ESAB accessories for mechanised and manual TIG welding are found on
page 157.
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4 TECHNICAL DATA
LTS 160 LTS 250
Mains voltage 230 V ±10%, 1∼ 50/60 Hz 400 V ±10%, 3∼ 50/60 Hz
Permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
160 A / 16 V
110A/15V
80 A / 13 V
250 A / 20 V
180 A / 17 V
140 A / 16 V
No--load power 50 W 55 W
Power factor 0,68 0,61
Efficiency ≥0,75 ≥0,75
No--load voltage 70 V 70 V
Primary current:
100% duty cycle
9A 9A
Arc strike HF HF
Dimensions l x w x h
without cooling unit
with cooling unit
515 x 285 x 620 mm
515 x 285 x 835 mm
515 x 285 x 620 mm
515 x 285 x 835 mm
Weight without cooling unit
with cooling unit
37 kg
56,5 kg
38 kg
57,5 kg
Temperature class F (155 _C) F (155 _C)
Enclosure type IP 23 IP 23
Application class
Setting range
LTS 160 LTS 250
Operating range, current 5 A / 10 V -- 160 A / 16 V 5 A / 10 V -- 250 A / 20 V
Steps of adjustment, current 1A 1A
Wire feed speed 0.10--2.50 m/min 0.10--2.50 m/min
Pulse and background time 0.01 -- 25.0 s 0.01 -- 25.0 s
Pre--heat time 0 -- 600 s 0 -- 600 s
Gas pre-- and post--flow 0 -- 6000 s 0 -- 6000 s
Slope--up and slope down 0,1 -- 25 s 0,1 -- 25 s
Sector 0--10r 0--10r
Steps of adjustment, sector
break point
0,001 r 0,001 r
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 the welding power source.
Enclosure class
The IP code indicates the enclosure class, i. e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 23 is designed for indoor and outdoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
GB
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5 INSTALLATION
The in stallatio 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.
Place the welding power source so as not to prevent the cooling air from circulating
through the m achine.
5.1 Lifting instructions
GB
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5.2 Mains voltage connection
S Make sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to the regulations valid.
The rating plate with connection data.
Recommend ed cable areas and fuse sizes
LTS 160 LTS 250
Mains voltage 230 V 400 V
Mains frequence 50--60 Hz 50--60 Hz
Fuse, slow--blow 16 A 16 A
Cable area
3x2,5mm
2
4x1,5mm
2
5.3 Termination resistans
To avoid communication trouble the two end points of
the CAN--bus should be fitted with an termination
resistans. One of the CAN--bus end points is in the
programming box which has a built--in resistor. T he
other one is in the power source and should be fitted
with an termination resistans if the output in question is
not used. F or the location of the resistor, see the
following figure.
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5.4 Connection of complete welding system
A--A Connection cable -- programming box
B--B, Z --Z Motor cable --wire feed
C--C, S --S Motor cable -- rotation
D--D Signal cable -- external PC
G--G Cooling--water hose in
H--H Cooling--water hose out
J--J Welding cable
L--L Torch contact
M--M Gas hose out
N--N Gas hose in
P--P Signal cable -- external PC
Q--Q Return cable +
R--R Connection cable -- pulsetransmitter
VEC
T--T,V--V Connection cable -- CAN 42 V
X Connection cable -- external motor
U--U Connection cable -- rotor VEC
GB
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6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 48. Read through before you start using the equipment!
6.1 Controls and connections
1 Connection for programming box 11 Fuse, slow rupture 1.25 A
(connection 230 V)
2 Connection CAN 42 V for motor control unit
PAL3 and A25 VEC motor
12 Connection for cooling unit 230 V, 1.25 A
3 White indicating lamp, mains voltage ON 13 Connection for flow--guard, (water)
4 Orange indicating lamp, overheating 14 Connection for welding and start gas out
5 Switch for mains voltage ON/OFF 15 Connection for torch contact, TIG hand torch
6 Connection for root gas in 16 Connection for return cable (+)
7 Connection for welding gas in 17 Connection for welding cable (--)
8 Connection for start gas in 18 Connection for rotation
9 Connection for root gas out 19 Connection for wire feed
10 Fuse, slow rupture 1.25 A
(connection 230 V)
20 Connection for PC/printer
GB
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6.2 Cooling unit
N.B. To give room for the cooling unit under the welding
power source, the tool box on the carriage must be
dismounted.
Screw the cooling unit and the welding power source
together.
6.3 Overheating protection
The LTS is provided with a thermal cut--out which trips in case of too high
temperature. The welding current is interrupted and an orange indicating lamp on the
front of the power source lights up. The programming box also shows an error
message. The thermal cut--out is reset automatically when the unit has cooled down.
6.4 Flow guard, water
If there is no cooling water flowing, the flow guard will block the welding power
source. The welding current is then interrupted and an error message is displayed in
the character window of the programming unit.
6.5 Flow guard, gas
The flow guard interrupts the ongoing welding process if the gas flow falls below 6
l/min. An error message is displayed by the programming box.
6.6 Error messages
The welding power source has a built--in function for handling error messages. All
error messages are presented in the programming box, and in some cases
measures will be taken automatically. See also programming manual 0457 706 xxx.
GB
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7 MAINTENANCE
Note:
All warranty undertakings given b y the supplier cease to apply if the customer
attempts to rectify any faults on the machine during the warranty period.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
7.1 Check--up and cleaning
Generally LTS 160 and LTS 250 does not require any
maintenance. Normally, it is sufficient to blow out the
machine using clean, compressed air (reduced pres-
sure) annually, and the dust filter should be cleaned
regularly. If the machine is set up in dusty or dirty
environment the machine and the dust filter should
be cleaned more often.
Dismounting the filter
8 ORDERING OF SPARE PARTS
LTS 160, L TS 250 is designed and tested in accordance with the EN 60974--1 (IEC
50199) international standard.
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 are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list.
This will simplify dispatch and ensure you get the right part.
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ESAB LTS 160 is a fan-cooled welding power source that is designed for mechanized TIG welding. It features a user-friendly programming box for setting welding parameters, executing welding processes, storing welding procedures, and communicating with an external PC. The LTS 160 offers high welding quality, precise control over welding parameters, and the ability to save and recall welding procedures.
This welding power source is commonly used in industrial applications such as shipbuilding, automotive manufacturing, and construction.
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