ESAB LKB 400WS User manual

Brand: ESAB

Model: LKB 400WS

Category: Welding System

Type: User manual

This manual is also suitable for

ESAB LKB 400W, LKB 400WS is a step-switched welding power source for solid or cored wires with or without shielding gas. It allows welding with steel, stainless steel, and aluminum. The LKB 400W has a built-in cooling system for the welding torch, while the LKB 400WS does not. Both models feature adjustable burnback time, various welding voltage outputs, and overheating protection. An optional digital meter displays welding current and voltage.

Valid for serial no. 211--xxx--xxxx0349 301 038 020314

LKB 400W

LKB 400WS

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Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manuel d’instructions

Gebruiksaanwijzing

Instrucciones de uso

Istruzioni per l’uso

Manual de instruções

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Instrukcja obs³ugi

1. DECLARATION OF CONFORMITY ...................................................................................................44

2. SAFETY .............................................................................................................................................. 44

3. INTRODUCTION ................................................................................................................................. 45

3.1 TECHNICAL DATA ........................................................................................................................ 45

INSTALLATION .................................................................................................................................. 46

4.1 MAINS SUPPLY ............................................................................................................................. 46

4.2 UNPACKING ................................................................................................................................... 46

4.3 FILLING TANK WITH COOLING LIQUID ...................................................................................... 46

4.4 CONNECTING GAS HEATER ....................................................................................................... 46

5. OPERATION ....................................................................................................................................... 47

5.1 CONTROLS AND INDICATORS LKB 400W ................................................................................. 47

5.2 CONTROLS AND INDICATORS LKB 400WS ............................................................................... 49

6. MAINTENANCE .................................................................................................................................. 51

6.1 CLEANING ...................................................................................................................................... 51

7. SPARE PARTS ORDERING ............................................................................................................... 51

8. ACCESSORIES .................................................................................................................................. 51

8.1 METER ASSEMBLY INSTRUCTION ............................................................................................. 51

9. SCHEMATIC DIAGRAM ..................................................................................................................... 133

10. SPARE PARTS LIST ........................................................................................................................ 136

1 DECLARATION OF CONFORMITY

2SAFETY

WARNING !

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE

PRECAUSIONS WHEN WELDING. FOLLOW SAFETY INSTRUCTIONS OBLIGATORY IN A COMPANY,

PREPARED ACCORDING TO EQUIPMENT MANUFACTURER’S RECOMMENDATIONS.

ELECTRIC SHOCK – can kill

• Install equipment in accordance with obligatory standards.

• Do not touch live electrical parts with bare skin, wet gloves or wet clothes.

• Ensure your work position is safe.

FUMES AND GASES – can be dangerous to your health.

• Keep your head away from fumes.

• Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and

surroundings.

ARC RAYS – can injure eyes and skin.

• Protect your eyes and skin. Use suitable welding screens, filter lens and wear protective clothes.

• Protect bystanders with suitable screens or curtains.

FIRE HAZARD

• Sparks (spatter) can cause fire. Therefore make sure there are no inflammable materials nearby.

INAPPROPRIATE OPERATION OF EQUIPMENT – if unit operates in a faulty way, consult a trained

technician.

READ AND COMPREHEND THE INSTRUCTION MANUAL BEFORE

INSTALLING AND OPERATING UNIT

PROTECT YOURSELF AND OTHERS!

DECLARATION OF CONFORMITY

ESAB AB Arc Equipment, S-695 81 Laxå, Sweden, gives its unreserved guarantee that welding

rectifier LKB 400W/LKB 400WS from serial number 032 complies with standard IEN 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 requirements of directive (89/336/EEC) and addendum

(93/68/EEC).

----------------------------------------------------------------------------------------------------------------------------------

Laxå 2002-03-26

Henry Selenius

Managing Director

ESAB AB Arc Equipment

695 81 Laxå

Sweden Tel: +46 584 81 000 Fax: +46 584 411924

3 INTRODUCTION

The LKB 400W/LKB 400WS is step-switched welding power unit, intended for welding with solid filler

wires of steel, stainless steel or aluminium, and cored wires with or without shielding gas. The LKB 400W

is equipped with cooling liquid system of torch. The LKB 400 is not equipped with cooling liquid system of

torch and can operate only with torches cooled with shield gas.

3.1 TECHNICAL DATA

Standard delivery:

Power source equipped with adjustable burnback time.

Wire feed mechanism with feed roller for solid wire diameter 1,0 – 1,2.

Welding torch PSF 410W, 4,5m.

Return cable 5m.

Mains cable 5m and gas hose 1,5m.

Set includes: chain, cable strip for gas hose.

Mains voltage 400V-415V 3~

50/60Hz

230V 3~ 50Hz

Mains fuse 25 A delayed 35 A delayed

Rated power consumption 18,8 kVA

Rated primary current for P35% 26 A 45 A

Rated welding current Duty cycle* 35% 400 A

Duty cycle* 100% 237 A

Welding current range

30÷400A

Open circuit voltage

14÷47V

Dimensions Length

Width

Height

1100

630

845

Weight 215 kg

Working flow of cooling liquid at pressure of 2,5 bar 1 dm

/min (60l/h)

Selection of cooling liquid depending on ambient

temperature

- Distilled water

- Solution of 30% Antifreeze Coolant + 70% distilled

water

from 0°C to +40°C

from -10°C to 0

Tank capacity 6 dm

Warning:

The unit is characterised by the following:

- Enclosure class IP 23 indicates that the unit is designed for indoor and outdoor use.

- Application class S means that the unit is designed for use in areas of increased electric hazard.

4 INSTALLATION

Installation shall be executed by competent and authorised person.

Connect the mains cable and protect it with appropriate fuse in conformance with local regulations.

Unit must be protected from dust, dirt and overheating. A distance of minimum 300 mm must be kept

between the LKB 400W/LKB 400WS and other obstacles that may block air-flow through the unit.

4.1 MAINS SUPPLY

Voltage 400V-415V

3~ 50/60 Hz

230V

3~ 50 Hz

Rated primary current:

100% Duty cycle 16A 28A

35% Duty cycle 26A 45A

Mains cable cross-section 4x4mm² 4x10mm²

Fuse, slow-blow 25A 35A

4.2 UNPACKING

A. Unpack the equipment and check that there is no obvious damage. Notify the supplier (distributor) if

any faults or damage are apparent.

B. Check if no parts are left in packing before disposal.

C. Check if all ventilation openings are opened and unblocked.

4.3 FILLING TANK WITH COOLING LIQUID

Fill cooling system tank with cooling liquid. Correct level of cooling liquid is marked with a symbol

, on

the back panel of the unit.

Depending on ambient temperature cooling liquid shall be:

- Distilled water at temperature 0°C to +40°C

- solution 30% Antifreeze Coolant (glycol based) and 70% distilled water at temperature from -10°C to

4.4 GAS HEATER CONNECTING

If CO

gas heater applied:

- insert cable of gas heater through opening on back panel of the unit

- connect cable to terminals 5,6 of terminal block XGM assembled to back panel inside the unit (symbol

GAS HEATER)

5 OPERATION

5.1 CONTROLS AND INDICATORS LKB 400W.

Fig. 5-1. LKB 400W front panel view.

A. POWER ON/OFF SWITCH Turning this switch to “I” position applies power to the unit. The green

LED diode (pos. B) will illuminate indicating that power is supplied to the equipment. The cooling fan

and pump engine will also be switched on. The green LED diode (pos. C) illuminates indicating

correct liquid circulation in installation. Pump is switched off 5 minutes after welding process has been

stopped. After another 5-minute period cooling fan is switched off and unit turns into stand-by mode.

It will be indicated by illuminating of the yellow LED diode (pos. B). After welding process has been

resumed, fan and pump will be activated automatically.

WARNING: If pump emits irregular noises, it signifies presence of air inside. In such a case unit

must be switched off and immediately switched on again.

B. OPERATION INDICATOR - diode indicating that unit is on (green colour) or in stand-by mode (yellow

colour)

C. COOLING INDICATOR - diode indicating correct circulation of cooling liquid (green colour)

D. WELDING VOLTAGE ADJUSTMENT is carried out by means of 5 position switch of coarse control

and a fine control 7 position switch. It is therefor possible to select 35 different welding voltage

outputs.

WARNING: Operating these voltage switches during the welding process (loaded power source) can

cause damage to unit!

E. OVERHEATING The orange signal LED diode (E) will illuminate in the event of overheating. The

welding output is then automatically disabled until the LKB reaches normal temperature. Should this

indicator illuminate leave the power source a few minutes to cool down. The unit will be ready to

resume welding when the orange indicator has turned off.

F. DIGITAL METER indicates actual values of welding current and voltage. The toggle switch allows

you to select either voltage or current display. The LKB 400W is supplied without a meter. The meter

kit is supplied as an optional extra and has a last reading hold facility.

G. POTENTIOMETER to set wire feeding speed (in the range of 1,6 ÷ 25 m/min)

H. CONNECTION (Euro connection) to connect welding torch

I. CURRENT SOCKETS to connect current cable with clamp

J. CONNECTION PIPE for cooling liquid outlet (cold liquid)

K. CONNECTION PIPE for cooling liquid inlet (hot liquid)

Fig.5-2. View of control panel in wire feeder compartment of LKB 400W.

L. POTENTIOMETER of burnback time regulation

M. MODE SELECTOR 2-stroke – motor test – 4-stroke

5.2 CONTROLS AND INDICATORS LKB 400WS.

Fig. 5-3. LKB 400WS front panel view.

A. POWER ON/OFF SWITCH Turning this switch to “I” position applies power to the unit. The green

LED diode (pos. B) will illuminate indicating that power is supplied to the equipment. The cooling fan

and pump engine will also be switched on. The green LED diode (pos. C) illuminates indicating

correct liquid circulation in installation. Pump is switched off 5 minutes after welding process has been

stopped. After another 5-minute period cooling fan is switched off and unit turns into stand-by mode.

It will be indicated by illuminating of the yellow LED diode (pos. B). After welding process has been

resumed, fan and pump will be activated automatically.

WARNING: If pump emits irregular noises, it signifies presence of air inside. In such a case unit

must be switched off and immediately switched on again.

B. OPERATION INDICATOR - diode indicating that unit is on (green colour) or in stand-by mode (yellow

colour)

C. COOLING INDICATOR - diode indicating correct circulation of cooling liquid (green colour)

D. WELDING VOLTAGE ADJUSTMENT is carried out by means of 5 position switch of coarse control

and a fine control 7 position switch. It is therefor possible to select 35 different welding voltage

outputs.

WARNING: Operating these voltage switches during the welding process (loaded power source) can

cause damage to unit!

E. OVERHEATING The orange signal LED diode (E) will illuminate in the event of overheating. The

welding output is then automatically disabled until the LKB reaches normal temperature. Should this

indicator illuminate leave the power source a few minutes to cool down. The unit will be ready to

resume welding when the orange indicator has turned off.

F. DIGITAL METER displays thickness of workpiece for voltage selected by means of switches D. Unit

adjusts suitable welding parameters for selected voltage. It also displays wire feed speed and

prospective or actual value of current/voltage (actual values of U/I are displayed during welding

process!) Toggle switches allow you to select required value. The meter has a last reading hold

facility.

G. POTENTIOMETER to set wire feeding speed (in the range of 1,6 ÷ 25 m/min)

H. CONNECTION (Euro connection) to connect welding torch

I. CURRENT SOCKETS to connect current cable with clamp

J. CONNECTION PIPE for cooling liquid outlet (cold liquid)

K. CONNECTION PIPE for cooling liquid inlet (hot liquid)

L. INDICATORS ( 3 x LED) for proper selection of the current outlet inductance

M. INDICATOR of the synergy control status:

- red light when operation prohibited (control function disabled),

- green light continuous – correct parameters for work,

Fig.5-4. View of control panel in wire feeder compartment of LKB 400WS.

N. MODE SELECTOR 2-stroke – motor test – 4-stroke

O. POTENTIOMETER of burnback time regulation

P. POTENTIOMETER for presetting of the filler wire diameter

R. CONTROL MODE SELECTOR - “standard” – (i.e. SYNERGY OFF) or “Synergy” control; for

“synergy” – allows to select data of the filler wire material and shielding gas.

6 MAINTENANCE

WARNING: All guarantee obligations of producer are nullified if customer attempts to repair any

faults by himself.

6.1 CLEANING

The LKB 400W/LKB 400WS should be regularly blown down with dry, compressed air at a low pressure.

If unit is used in dirty or dusty environment it shall be cleaned more often. Otherwise ventilation openings

can be blocked which can result in overheating.

7 SPARE PARTS ORDERING

When ordering spare parts, please state machine type, serial number, designation and spare part number

as shown in spare parts list. It will simplify dispatch and ensure you get the right part

8 ACCESORIES

V/A meter kit: 0349 302 118

8.1 V/A METER ALLEMBLY INSTRUCTION

1. Take off side panels of unit.

2. Put plastic sleeve on the axle of switch on meter’s board.

3. Fasten meter’s board and sleeve to front panel of unit.

4. Assemble cover of meter to partition of unit.

5. Disconnect current cable (+) from the bridge.

6. Connect shunt with reducing sleeve and rectifier bridge, and next connect current cable (+) to free

end of shunt.

7. Connect wiring of meter according to schematic diagram of LKB 400W

1. Meter A3

2. Shunt

3. Wiring for transformer T2

4. Wiring for PCB A2

5. Wiring for shunt and socket (

)

6. Rectifier bridge

7. PCB A3

8. Current cable (+)

9. Transformer T2

10. Socket (

)

The brake hub

The hub is adjusted when delivered, if readjustment is required, follow the instructions below. Adjust the

brake hub so that wire is slightly slack when wire feed stops.

Adjusting the braking torque:

WARNING!

Rotating parts can cause injury, take great care.

ESAB LKB 400WS User manual

Brand: ESAB

Model: LKB 400WS

Category: Welding System

Type: User manual

This manual is also suitable for

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ESAB LKB 400WS User manual

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