ESAB LKA 180 User manual

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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).

−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−

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

SInstall and earth the welding unit in accordance with applicable standards.

SDo not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.

SInsulate yourself from earth and the workpiece.

SEnsure your working stance is safe.

FUMES AND GASES −Can be dangerous to health

SKeep your head out of the fumes.

SUse 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.

SProtect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.

SProtect bystanders with suitable screens or curtains.

FIRE HAZARD

SSparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE −Excessive noise can damage hearing

SProtect your ears. Use earmuffs or other hearing protection.

SWarn bystanders of the risk.

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

PROTECT YOURSELF AND OTHERS!

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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

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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.

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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!

SConnect the return cable (E) to the work piece.

SWhen 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.

SSwitch on the power source using the knob (L).

The white indicator lamp (K) should light up.

SPress the trigger (D) on the welding torch until wire

is fed out of the contact tip (F).

SSelect suitable welding settings using the

woltage selector knob (L) and the wire feed

knod (H) as indicated by the table on page 9.

SStart welding and adjust the settings if necessary.

SIndication lamp (J) light up if the Power source

becomes to hot.

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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.

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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