ESAB LTR 160 User manual

Valid for serial no. 842--xxx--xxxx

0457 305 101 991005

Power Tig 160/200

LTR 160/200

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Bruksanvisning

Brugsanvisning

Bruksanvisning

Käyttöohjeet

Instruction manual

Betriebsanweisung

Manual 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 12................................................

NORSK 21................................................

SUOMI 30................................................

ENGLISH 39..............................................

DEUTSCH 48.............................................

FRANÇAIS 57.............................................

NEDERLANDS 66.........................................

ESPAÑOL 75..............................................

ITALIANO 84..............................................

PORTUGUÊS 93..........................................

ÅËËÇÍÉÊÁ 102.............................................

ENGLISH

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TOCe

1 DIRECTIVE 40........................................................

2SAFETY 40...........................................................

3 INTRODUCTION 41...................................................

3.1 TECHNICAL DATA 42........................................................

4 INSTALLATION 43....................................................

5 OPERATION 44.......................................................

5.1 LIFTARC 45.................................................................

6 MAINTENANCE 46....................................................

7 ORDERING OF SPARE PARTS 46......................................

8 ACCESSORIES 46....................................................

DIAGRAM 111............................................................

SPARE PARTS LIST 113...................................................

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1 DIRECTIVE

DECLARATION OF CONF ORMITY

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 keep fumes and gases 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 ear defenders or other hearing protection.

S Warn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

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3 INTRODUCTION

Note!

This product is solely intended for arc welding.

NOTE! All warranty undertakings given by the supplier cease to apply if the

customer attempts to rectify any faults on the machine during the warranty

period.

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.

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3.1 TECHNICAL DATA

LTR 160 LTR 200

Permitted load at

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 110 A/24 V 150 A/26 V

100 % duty cycle 80 A/23 V 11 5 A/25 V

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

Setting range, 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 10,6kVa

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.

The symbol indicates that this power source is designed for use in areas where

there is an increased electrical hazard.

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

penetration by solid objects and water.

Equipment marked IP 23 is designed for in-- and outdoor use.

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4 INSTALLATION

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.

LT R 160/200 are equipped with mains voltage compensation, which means that a

¦10 % variation in the mains voltage only results in a ¦0,2%variationinthe

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.

Earthaccordingtoapplicabledirectives.

3. Connect the shielding gas.

4. Connect the TIG torch and the return cable or the MMA welding cables.

The machine is now ready for welding.

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5OPERATION

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 T IG 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 m ode.

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.

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Mode = HF

When the torch trigger is pressed the gas starts flowing. The 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.

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.

5.1 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.

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Dismantling the filter

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6 MAINTENANCE

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. .

7 ORDERING OF SPARE PARTS

A service manual and list of spare parts can be ordered from your nearest ESAB

representative, see the last page of this publication.

When ordering parts please state the machine model, serial number, and the name

and spare part number as shown in the list of spare parts.

This will simplify dispatch and ensure you get the right parts.

8 ACCESSORIES

Order number

Carriage for 5 l gas cylinder 0468 530 880.......................

Carriage for 10--50 l gas cylinder 0456 804 880..................

Protective guard for connections 0468 311 001...................

Handle loop 0468 305 880....................................

Return cable, 25 mm

(state the length when ordering) 02626 136 01....... ..........

Return cable clamp 0367 558 880..............................

Foot pedal F S002, incl. cable 0349 090 886.....................

Welding cable, 5 meter 0468 539 880...........................

Return cable, 5 meter 0468 539 881............................

Cooling unit OCF 2L ( to LTR 200) 0457 216 880..................

TIG torch:

HW17R, 4 meter with central connector 0588 000 724.........

HW17R, 4 meter with OKC connector 0588 000 722...........

Information on additional TIG torches and remote control units can be found in

separate brochures.

The following remote controls can be connected:

PHA1,PHA2,PHA5,PHB1,PHB2,PHC2 och F S002.

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Carriage for 10--50 l gas cylinder

Carriage for 5 l gas cylinder

Protective guard

bt07t003

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Handle loop

LIFTING

INSTRUCTIONS

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

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