ESAB LKB 220S User manual

Valid for serial no. xxx--xxx--xxxx0349 301 033 GB

LKB 220

LKB 220S

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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

Ïäçãßåò ÷ñÞóåùò

Instrukcja obs³ugi

1. DECLARATION OF CONFORMITY .................................................................................................... 40

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

3. INTORDUCTION .................................................................................................................................. 41

3.1 TECHNICAL DATA .......................................................................................................................... 41

INSTALLATION ................................................................................................................................... 42

4.1 MAINS SUPPLY ............................................................................................................................... 42

4.2 UNPACKING .................................................................................................................................... 42

4.3 ASSEMBLY OF UNIT ...................................................................................................................... 42

5. OPERATION ....................................................................................................................................... 43

5.1 CONTROLS AND INDICATORS ...................................................................................................... 43

5.1.1 LKB 220 ...................................................................................................................................... 43

5.1.2 LKB 220S .................................................................................................................................... 44

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

6.1 CLEANING ....................................................................................................................................... 46

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

8. ACCESORIES ..................................................................................................................................... 46

8.1 TRANSFORMER FOR CO

ASSEMBLY INSTRUCTION ............................................................... 46

8.2 METER ASSEMBLY INSTRUCTION .............................................................................................. 47

9. SCHEMATIC DIAGRAM ..................................................................................................................... 120

10. SPARE PARTS LIST ......................................................................................................................... 124

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

rectifier LKB 220/220S 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 2000-11-07

Anders Birgersson

Managing Director

Esab Welding Equipment AB

695 81 Laxå

Sweden Tel: +46 584 81 000 Fax: +46 584 123 06

3 INTRODUCTION

The LKB 220 and LKB 220S are step-switched welding power units, intended for welding with solid filler

wires of steel, stainless steel or aluminium, and cored wires with or without shielding gas.

3.1 TECHNICAL DATA

Standard delivery

Power source equipped with spot welding function, adjustable burnback time and soft-start function.

Wire feed mechanism with feed roller for solid wire, diameter 0,8 – 1,0.

Welding torch PSF 250 4,5m

Return cable 4,5m with return clamp

Mains cable 3m and gas hose 1,5m

Set includes: handle (with screws), shelf for gas cylinder (with screws), chain, bracket (with screw), cable

strip.

400-415V, 3~50/60 Hz 230V 3~50/60 Hz

Mains voltage 3x400V, 50-60 Hz 3x230V, 50/60 Hz

Mains fuse 10A delayed 20A delayed

Rated power consumption 9,7 kVA

Rated welding current Duty cycle* 30% 220 A

Duty cycle* 60% 155 A

Duty cycle* 100% 120 A

Welding current range

20A/15V÷220A/25V

Open circuit voltage 14-32 V

Enclosure class IP 23

Application class

Dimensions Length

Width

Height

770

520

620

Weight 90 kg

*Duty cycle is based on 10-minute period. Duty cycle 30% means that after 3 minutes of unit operation, 7

minutes brake is required. Duty cycle 100% means that the unit can work continuously.

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 elevated 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 220/220S and other obstacles that may block air-flow through the unit.

4.1 MAINS SUPPLY

Voltage 400- 415V

3~ 50 Hz

230V

3~ 50 Hz

Rated primary current:

P100% 5A 8,6A

P60% 7A 12A

P30% 12A 21A

Mains cable cross-section 4x1,5 mm

4x2,5mm

Fuse, slow-blow 10A 20A

4.2 UNPACKING

A. Unpack the equipment and check that there is no obvious damage. Notify 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 ASSEMBLY OF UNIT

5 OPERATION

5.1 CONTROLS AND INDICATORS

5.1.1 LKB 220

Fig.5.1 LKB220 front panel view.

Fig.5.2 View of control panel in wire feeder compartment of LKB220

A. POWER ON/OFF SWITCH - Turning this switch to the ‘I’ position applies power to the unit. The green

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

also be switched on.

B. OVERHEATING The orange signal LED diode 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. Do not switch the power source off as this

will remove the power from the cooling fans. The unit will be ready to resume welding when the orange

indicator has tuned off.

C. WELDING VOLTAGE ADJUSTMENT is carried out by means of coarse control 3 position switch, and

fine control 7position switch. It is therefore possible to select 21 different welding voltage outputs.

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

cause damage to unit!

D. DIGITAL METER indicates actual values of current or welding voltage. The toggle switch allows you to

select either voltage or current display. The LKB 220 is supplied without a meter. The meter kit is

supplied as option extra and has a last reading hold facility.

E. POTENTIOMETER with switch – to switch on spot welding and impulse time (for spot welding) in the

range of 0,5 ÷ 4 s.

F. POTENTIOMETER to set wire feed speed – in the range of 1,4 ÷ 19 m/min.

G. POTENTIOMETER of burnback time regulation (0÷0.35 s)

H. CONNECTION (Euro connection) to connect welding torch

I. OUTPUT SOCKETS to connect work return cable with clamp

J. MODE SELECTOR: CREEP START 50% - 100% - 70%

5.1.2 LKB 220S

Fig. 5.3 LKB220S front panel view

A. POWER ON/OFF SWITCH - Turning this switch to the ‘I’ position applies power to the unit. The green

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

be switched on.

B. OVERHEATING The orange LED diode 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 for a few minutes to cool down. Do not switch the power source off as this will

remove the power from the cooling fans. The unit will be ready to resume welding when the orange

indicator has turned off.

C. INDICATOR of the synergy control status:

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

- green light continuous – correct parameters for work,

- green light flashing - possible operation in synergy mode – but not recommended (“mixed” arc).

D. WELDING VOLTAGE ADJUSTMENT is carried out by means of a coarse control 3 position switch, and

a fine control 7 position switch. It is therefore possible to select 21 different welding voltage outputs.

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

cause damage to unit!

E. 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.

F. POTENTIOMETER with switch – to switch on spot welding mode and impulse time (for spot welding) in

the range of 0,5 ÷ 4 s.

G. POTENTIOMETER to set wire feed speed – in the range of ±10% value of the speed - preset by the

program.

H. INDICATORS ( 2 x LED) for proper selection of the current outlet inductance

I. OUTPUT SOCKETS to connect work return cable with clamp

J. CONNECTION (Euro connection) to connect welding torch

Fig.5.4 View of the control panel in the wire feeder compartment for LKB220S

K. 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.

L. POTENTIOMETER for presetting of the filler wire diameter

M. POTENTIOMETER of burnback time regulation.

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

6 MAINTENANCE

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

faults by himself.

6.1 CLEANING

The LKB 220/220S 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 is spare parts list. It will simplify dispatch and ensure you get the right part.

8 ACCESORIES

Transformer for CO

kit 0349 302 080

V/A meter kit: 0349 302 079

8.1 ASSEMBLY INSTRUCTION OF GAS HEATER TRANSFORMER FOR CO

− Take off side panels of unit.

− Fasten transformer T3 and terminal block XG in places marked with arrows.

− Connect wiring of transformers T3 with components according to schematic diagram of unit.

1- Transformer T2

2- Transformer T3

3- Terminal block XG

4- Wiring for Q1 and T2

8.2 V/A METER ASSEMBLY INSTRUCTION

− Take off side panels of unit.

− Fasten meter’s board to front panel of unit.

− Assemble cover of meter to partition of unit.

− Disassemble inductor.

− Disassemble bridge rectifier.

− Disconnect current cable (+) from the bridge.

− Connect shunt and bus

− Connect shunt and bus (+) end of bridge rectifier and next connect current cable (+) to free end of shunt.

− Assemble bridge rectifier in unit.

− Assemble inductor.

− Connect wiring of meter according to schematic diagram of LKB 220.

1- V/A-Meter A2

2- Shunt RI

3- Bus

4- Wiring for circuit board A1

5- Wiring for transformer T2

6- Wiring for shunt and current socket cable (

)

7- Current cable (+)

8- Rectifier bridge

9- Inductor

10- Current socket cable ( )

ESAB LKB 220S, LKB 220, LKB 220, LKB 220S User manual

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