clka1p00
Valid for serial no. 618−xxx−xxxx0349 301 002 040928
LKA 180
LKA 240
104
Instruction manual
ENGLISH
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TOCe
1 DIRECTIVE 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 TECHNICAL DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GAS CONNECTION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Electrical connection 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Wire 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6 OPERATION 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.1 Spot welding 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 MAINTENANCE 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Selection table 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIAGRAM 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LKA 180 / 240 from serial number 618 complies with
standard EN 60974−1, in accordance with the requirements of directive (73/23/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 96−04−20
2 SAFETY
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 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 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!
GB
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3 INTRODUCTION
LKA 180/240 is a compact, step−switched Welding power sources, intended for
welding with solid wire with shielding gas and tube electrode without gas.
The complete package comprises a power source with integral wire feed unit,
(PSF 160 welding torch), mains lead, return cable with clamp, feed rollers for 0.6
and 0.8 mm wire and a gas hose. The assembly kit includes a handle, rear axle, 2
rear wheels and 2 castors.
Two control knobs provide adjustment of voltage and wire feed speed, which are
easily selected by referring to the table on page 9.
You can switch between solid wire with shielding gas and tube electrode without gas
by simply switching + and − connections on the terminal above the wire feed unit.
The spot welding function simplifies the task of making lap joints in sheet metal. A
thermal cut−out prevents the power source from overheating. The cut−out is reset
atomatically when the power source has cooled.
4 TECHNICAL DATA
LKA 180 LKA 240 LKA 180 1−phase
Mains supply 230/400 V,
3−phase 50 Hz
230/400 V,
3−phase 50 Hz
230 V, 1−phase
50 Hz
Mains lead 4x2,5 mm@ 4x2,5 mm@ 3x2,5 mm@
Fuse, slow 10 A 16 A 16 A
Maximum load
10% 165 A 160 A
20% 200 A
60% 65 A 120 A 75 A
100% 60 A 85 A 60 A
Mains supply 400 V, 3−phase 50 Hz 400 V,3−phase 50 Hz
Mains lead 4x1,5 mm@ 4x1,5 mm@
Fuse, slow 10 A 10 A
Maximum load
11% 170 A
18% 200 A
60% 75 A 110 A
100% 60 A 85 A
Voltage steps 7 10 7
Open circuit voltage 15−33 V 18−36 V 16−33 V
Wire feed speed 1−15 m/min 1−15 m/min 1−15 m/min
Spot welding time 250 ms−2,5 s 250 ms−2,5 s 250 ms−2,5 s
Wire reel 5−15 kg 5−15 kg 5−15 kg
GB
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LKA 180 1−phaseLKA 240LKA 180
Wire sizes
Unalloyed 0,6−0,8 mm 0,6−0,8 mm 0,6−0,8 mm
Stainless 0,6−0,8 mm 0,6−0,8 mm 0,6−0,8 mm
Aluminium 1,0 mm 1,0 mm 1,0 mm
Tube wire 0,8−0,9 mm 0,8−0,9 mm 0,8−0,9 mm
Dimensions 780x430x530 780x430x530 780x430x530
Weight 47 kg 50 kg 47 kg
Enclosure class IP 21 IP 21 IP 21
Application class
These welding rectifier conform to the requirements of IEC 974−1.
Enclosure class
The IP code indicates the enclosure class, i.e. the degree of protection against penetration by solid
objects or water. Equipment marked IP 21 is intended for indoor use.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
5 INSTALLATION
The installation 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.
GAS CONNECTION
Assembly of components Does not apply to tube electrode.
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The power supply should be lifted by means of its lifting
eye. The handle is only intended for pulling it along the
ground.
Lifting instructions
5.1 Electrical connection
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When delivered these power sources are wired for operation from a 400 V, 50 Hz,
three phase AC supply. The mains plug must conform to international standards and
be wired by a qual ified electrician. Check the mains voltage and fuses on all three
phases before connecting the machine.
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400 V
230 V
5.2 Wire
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TUBE WIRE SOLID WIRE
When welding with tube wire the cables connected to the + and − terminals above
the wire feed unit must be switched.
GB
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NOTE!
If the rollers slip or wire feed is unsatisfactory in any other way it may be necessary
to adjust the tension. This can be done using the tensioning screw on the pressure
arm.
WARNING!
Rotating parts can cause injury, take great care.
6 OPERATION
General safety regulations for the handling of the equipment can be found on
page 3. Read through before you start using the equipment!
S Connect the return cable (E) to the work piece.
S When welding with solid wire, open the gas valve (A)
and adjust the gas flow with the reduction valve (B).
The flow should be between 8−12 l/min.
S Switch on the power source using the knob (L).
The white indicator lamp (K) should light up.
S Press the trigger (D) on the welding torch until wire
is fed out of the contact tip (F).
S Select suitable welding settings using the
woltage selector knob (L) and the wire feed
knod (H) as indicated by the table on page 9.
S Start welding and adjust the settings if necessary.
S Indication lamp (J) light up if the Power source
becomes to hot.
GB
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6.1 Spot welding
Select the spot welding time (G) on the scale marked 1−10. Spot welding
time can be set anywhere between 0.2−2.5 sek.
To set the welding voltage and wire feed speed see the recommended
table on page 9.
Press the torch trigger. When the set welding time has elapsed welding
will stop automatically. There is no need to release the trigger.
A new welding cycle will start when you press the trigger again.
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7 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.
IMPORTANT
This welding equipment has been designed, tested and manufactured to give long,
trouble−free service.
Regular maintenance is essential for safe and reliable operation.
Removal of dust
Blow away dust that has gathered in the power source
using dry compressed air at low pressure.
Wire feed unit
Components that are subject to wear must be
regularly cleaned and replaced to ensure reliable
wire feed. Note that if the tension is too high it may
cause excessive wear on the pressure roller,
feed roller and wire liner.
Torch
Regularly blow the wire liner clean and clean the gas shroud
8 ORDERING OF SPARE PARTS
Spare parts are ordered through your nearest ESAB representative, see back cover.
When ordering spare parts, please state machine type and number as well as desig-
nation and spare part number as shown in the spare parts list.
This will simplify dispatch and ensure you get the right part.
GB
455 894−001
367 556−001
466 074−001
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Selection table
FIG 1 (LKA 180)
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FIG 2 (LKA 240)
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FIG 3 (LKA 180 1~)
Diagram
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page
LKA 180 , LKA 240 Edition 040928
Spare parts list
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clka1p00
Valid for serial no. 618−xxx−xxxx
Ordering numbers for LKA 180 , LKA 240
Ordering no. Denomination Notes
469 440−880
469 565−880
469 560−880
LKA 180
LKA 180
LKA 180
400 V 3 phase
230/400 V reconnectable, 3 phase
230 V single−phase
469 560−881 LKA 180 230 V single−phase, only for the Australian market.
Position 102 deviates from version 469 560−880
469 450−880
469 570−880
LKA 240
LKA 240
400 V 3 phase
230/400 V reconnectable, 3 phase
469 560−881 LKA 180 230 V single−phase, only for the Australian market.
Position 102 deviates from version 469 560−880
469 450−882 LKA 240 400 V 3 phase, only for the Australian market.
Position 102 deviates from version 469 560−880
Spare parts are to be ordered through the nearest ESAB agency as per the list on the back of the
cover. Kindly indicate type of unit, serial number, denominations and ordering numbers according to
the spare parts list.
Maintenance and repair work should be performed by an experienced person, and electrical work only
by a trained electrician. Use only recommended spare parts.
LKA 180 , LKA 240 Edition 040928
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180 = LKA 180 240 = LKA 240
C = component designation in the circuit diagram
Item
no.
Qty
180
Qty
240
Ordering no. Denomination Notes C
101
102
103
1
1
1
1
1
1
1
1
469 368−001
469 369−001
469 664−001
469 447−001
Cover plate
Rear panel
Rear panel
Side panel
Only for the Australian market
With text
104
107
1
1
−
1
−
1
0700 200 002
0469 572 881
0469 443 880
Welding gun MXL 200
Return cable
Return cable
Complete
Complete
109 1 1 469 361−001 Front panel
110
2
8
2
8
469 468−001
Link wheel
Screw M6 x 16 mm
111 1 1 368 265−001 Securing strap
120
121
122
123
124
2
1
2
2
2
2
1
2
2
2
469 453−001
469 516−001
469 469−001
192 859−126
Attachment
Shaft
Washer
Wheel
Locking washer
D 21/36
125b 1 1 146 967−881 Brake hub From macine no. 547 612 ....
126
1
2
1
2
469 437−001
Handle
Screw M6 x 16mm
LKA 180 , LKA 240 Edition 040928
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