Valid for serial no. 906--xxx--xxxx0456 312 101 020514
LTG 250
LTG 400
101103105107109111102021110025108024042106023061104022041100020040060001
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 10................................................
NORSK 17................................................
SUOMI 24................................................
ENGLISH 31..............................................
DEUTSCH 38.............................................
FRANÇAIS 45.............................................
NEDERLANDS 52.........................................
ESPAÑOL 59..............................................
ITALIANO 66..............................................
PORTUGUÊS 73..........................................
ÅËËÇÍÉÊÁ 80.............................................
ENGLISH
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TOCe
1 DIRECTIVE 32........................................................
2SAFETY 32...........................................................
3 INTRODUCTION 33...................................................
3.1 TECHNICAL DATA 33........................................................
4 INSTALLATION 34....................................................
4.1 Connecting to electrical supply LTG 250 34......................................
4.2 Connecting to electrical supply LTG 400 34......................................
4.3 TIG welding 35...............................................................
5 OPERATION 36.......................................................
6 MAINTENANCE 37....................................................
7 ORDERING OF SPARE PARTS 37......................................
ASSEMBLY INSTRUCTIONS 87...........................................
DIAGRAM 88............................................................
SPARE PARTS LIST 90...................................................
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bt08d1e1
1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guaran-
tee that welding power source LTG 250/400 from serial number 622 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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Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 1996--05--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 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!
GB
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3 INTRODUCTION
LTG 250/400 are thyristor--controlled welding rectifiers intended solely for TIG
welding and welding with coated electrodes.
Two versions of the LTG 250/400 are available; with central socket or with
OKC couplings.
The welding rectifier is supplied with rear wheels and front castors, plus a gas bottle
stand and one OKC coupling.
3.1 TECHNICAL DATA
LTG 250 LTG 400
Max. permissible load
at 35% duty cycle 250 A 400 A
at 60% duty cycle 190 A 315 A
at 100% duty cycle 150 A 250 A
Open circuit voltage 68 V 65--75 V
Open circuit power 0.22 kW 0.49 kW
Efficiency (h)
35% duty cycle MMA 67%, TIG 55% MMA 88%, TIG 82%
Slope --up
(not LiftArc mode) 0.1--15 s 0.1--15 s
Slope --down 0.1--15 s 0.1--15 s
Gas post--flow 1--25 s 1--25 s
Enclosure class IP 21 IP 21
Application class
Weight 195 kg 205 kg
Dimensions lxbxh 1250x745x780 1250x745x780
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The welding power source complies with the requirements of IEC 974--1 and
EN 60974--1.
The symbol
indicates that the 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 21 is intended for indoor use.
GB
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4 INSTALLATION
WARNING
This product is intended for industrial use. In a domestic environment this
product may cause radio interfer ence. It is the user’s responsibility to take
adequate precautions.
4.1 Connecting to electrical supply LTG 250
50/60 Hz 50 Hz 50 Hz 60 Hz 50 Hz 60 Hz
Voltage (V) 3x230 3x400 3x415 3x440 3x500 3x550
Primary current (A)
33 18 18 17 14 15
Fuse, slow (A) 25 16 16 16 16 16
Cable (mm
2
) 4x4 4x2.5 4x2.5 4x2.5 4x2.5 4x2.5
4.2 Connecting to electrical supply LTG 400
50/60 Hz 50 Hz 50 Hz 60 Hz 50 Hz 60 Hz
Voltage (V) 3x230 3x400 3x415 3x440 3x500 3x550
Primary current (A)
57 31 31 31 26 26
Fuse, slow (A) 63 25 25 25 20 20
Cable (mm
2
) 4x10 4x4 4x4 4x4 4x2,5 4x2,5
Power cable rating complies with Swedish regulations.
LTG 250/400 can be configured for the following m ains supply voltages:
230/400/415 and 500 V, 50 Hz -- 230/440 and 550 V, 60 Hz
1. Make sure the welding rectifier is configured for the available mains supply. See
the connection instructions and wiring diagram. The rectifier can be reconfigured
at terminal block XT4 on the m ain transformer.
2. See Technical data for power cable and fuse ratings.
3. Connect the TIG torch to the central socket.
4. Connect the return cable to the OKC socket m arked +. Minimum cable
cross--section is
25 mm
2
for LTG 250 and 50mm
2
for LTG 400.
5. Connect the gas supply and adjust the flow rate, 5--10 l/min.
6. If required, connect the water--cooling unit. T he cable should be connected to
terminal block XT2.
To minimise the voltage drop when using very long welding cables it may be necess-
ary to use cables with a larger cross--section. Make sure that all connections are se-
cure.
GB
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bt08d1e2
4.3 TIG welding
S Make sure the TIG torch, gas hose and return cable are securely connected.
S Make sure a correctly ground thoriated tungsten electrode is fitted to the torch.
S Set the power switch to the ”I” setting and make sure the air flow is not
obstructed.
S Select the start method: HF or LiftArc.
S Select local or remote control.
S Set the required current, slope--down time and gas post--flow.
S The machine is now set up for welding.
Water--cooled TIG--torch Self--cooled TIG--torch
Place the electrode against the workpiece.
Press in the torch switch.
T ilt the torch a little, lift and an arc is produced.
To stop-release the torch trigger.
LIFTARC
GB
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bt08d1e2
5OPERATION
Power switch QO1: switches power on or off. Indicator lamp (HL1) lights up and fan
starts when set to ”I”.
Potentiometer RPO4: for adjusting welding current in range 4--250 or 5--400A.
Potentiometer RPO2: for adjusting slope--up time, 0.1--15 seconds, during which
the current is gradually increased from the minimum value to the set value. Does not
apply to LiftArc mode.
Potentiometer RPO3: for adjusting slope--down time, 0.1--15 s, during which the
current is gradually decreased from the set value to the minimum value.
Potentiometer RPO1: for adjusting gas post--flow, 1--25 s, i.e. the period for which
the gas continues to flow after the arc is extinguished.
Switch SA1: for selecting TIG start method.
LiftArc mode: 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.
HF mode: when the torch trigger is pressed the gas starts flowing. The high fre-
quency 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.
Switch SA7: for connecting water--cooling unit.
Indicator lamp HL2 lights up when connected.
Switch SA2: for selecting 2 stroke or 4 stroke operation.
2--stroke means that the arc ignites when you press the torch trigger and is extin -
guished when you r elease it.
4--stroke means that there is no need to hold the torch trigger during welding. You
press the trigger and release it to ignite the arc, then press it and release it again to
extinguish the arc.
Switch SA5: for local or remote control.
Local control means that the current set at the machine is used.
Remote control means that the current set on the pulse unit or remote control is
used.
Remote socket XS1 and XS2: for connecting remote control and/or pulse unit.
TIG socket XS3: quick connector for TIG torch, gas and control unit.
OKC coupling XS4: for return cable or for electrode holder when MMA welding.
Indicator lamp HL3: the yellow indicator lamp lights up when the thermal cut--out is
tripped.
The cut--out is automatically reset when the welding rectifier has cooled down.
GB
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bt08d1e2
1. Switch with indicator lamp (HL1).
2. Current range from 4 A to 250 A and
5 A to 400 A.
3. Gas post--flow, 1--25s.
4. Slope--down function, 0.1--15 s.
5. Option to connect ammeter and
voltmeter, analogue or digital.
6. On/off switch for external cooling unit,
with indicator lamp (HL2).
7. Slope--up function, 0.1--15s.
8. Socket for remote control or pulse unit.
9. Socket for pedal control.
10. Selection of starting method: LiftArc or HF.
11. 2/4 str o ke control gives operator ability to weld without keeping the torch trigger
depressed.
12. Choice of welding m ethod -- TIG welding or welding with coated electrodes.
13. Hot start produces a current surge for a short period at the moment of starting.
Used when welding with coated electrodes.
14. Central socket designed for TIG torch with combined current, gas and switch in
same unit.
15. Sockets for return cable and electrode holder.
16. Indicator lamp, thermal cut--out.
6 MAINTENANCE
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.
LTG 250/400 normally requires no maintenance.
Blow the inside of the welding rectifier clean once a year using dry compressed air at
reduced pressure.
If the machine is set up in a dusty or dirty environment it should be cleaned more
regularly.
7 ORDERING OF SPARE PARTS
Ordering spare parts
When ordering spare parts, please state the model, serial number and the descrip-
tion and order number of the spare parts as shown in the list of spare parts.
This simplifies despatch and ensures correct delivery.
GB
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