GB
Valid for serial no. 745--xxx--xxxx, 842--xxx--xxxx,
011--xxx--xxxx
0457 326 201 GB 041101
Power Tig 255
LTR 255
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 11.................................................
SPARE PARTS LIST 12...................................................
ACCESSORIES 13.......................................................
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1DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTR 255 from serial number 745 complies with standard
EN 60974--1, in accordance with the requirements of directive (73/23/EEA) and ad-
dendum (93/68/EEA) and standard EN 50199 in accordance with the requirements
of directive (89/336/EEA) and addendum (93/68/EEA).
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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 97--10--30
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 255 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 255 is available in two versions, one with a central socket and one with a n OKC
socket for connecting a TIG torch.
LTR 255 is supplied complete with 5 m etre 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 13.
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4 TECHNICAL DATA
LTR 255
Permittedloadat
35 % duty cycle, TIG 250 A/20 V
35 % duty cycle, MMA 250 A/30 V
60 % duty cycle 180 A/27 V
100 % duty cycle 140 A/26 V
Setting range, TIG 5--250 A
MMA 5--250 A
Slope up, adjustable on circuit board 0-- 5 s
Slope down 0,1--10 s
Gas pre --flow ,adjustable on
circuit board
0-- 5 s
Gas post--flow 5-- 20 s
Open --circuit voltage 70--90 V
Open--circuit power 50 W
Useful Power, P
at max current MMA 9,3 kW
Apparent Power, S
at max current MMA 14,67 kVa
Power factor, at max current MMA 0,63
Efficiency, at max current MMA 0,80
Fuse, slow rupture 16 A
Mains cable,cross section 4x1,5 mm
2
Dimension lxbxh 515x285x415mm
Weight 24 kg
Application class
Class of enclosures IP 23
The welding power sources comply with the requirements set out in IEC 974-- 1
Cable areas acc. to Swedish regulations.
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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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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bt18d12e
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.
Mains voltage 400 V ¦10 %, 3--phase
Mains frequency 50--60 Hz
Fuse, slow rupture 16 A
Mains cable, cross section 4X1,5 mm
2
Welding cable, cross section 35mm
2
LTR 255 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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bt18d12e
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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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.
GB
Dismantling the filter
bt07d109
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bt18d12e
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, LT R 255 do not require
any maintenance. Normally, it is
sufficient to blow out the m achine
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 255 is designed and tested in accordance with the international and European
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.
GB
Edition 041 101
Diagram
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bt18e11a
LTR 255
Edition 041 101
Ordering number
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bt18o11a
Ordering no. Denomination Type Notes
0456 840 884 Welding power source LTR 255 with central connection for TIG welding
0456 840 885 Welding power source LTR 255 with OKC connection for TIG welding
0457 326 990 Spare parts list LTR 255
LTR 255
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 255
Edition 041 101
Accessories
-- 1 3 --
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 255
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 255
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
2
(state the length when ordering) 0262 613 602...............
LTR 160 & LTR 200: Return cable, 25 mm
2
(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.
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
www.esab.co m
/