ESAB LTR 160 User manual

Valid for serial no. 011--xxx--xxxx0457 305 201 GB 041101

Power Tig 160

Power Tig 200

LTR 160, LTR 200

Instruction manual

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TOCe

Rights reserved to alter specifications without notice.

1 DIRECTIVE 3........................................................

2SAFETY 3...........................................................

3 INTRODUCTION 4...................................................

4 TECHNICAL DATA 5.................................................

5 INSTALLATION 6....................................................

5.1 Lifting instructions 6.........................................................

6 OPERATION 7.......................................................

6.1 LIFTARC 8.................................................................

7 MAINTENANCE 9....................................................

8 ORDERING OF SPARE PARTS 9......................................

DIAGRAM 10............................................................

ORDERING NUMBER 12.................................................

SPARE PARTS LIST 13...................................................

ACCESSORIES 14.......................................................

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1DIRECTIVE

DECLARATION OF CONFORMITY

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

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!

ESAB can provide you with all necessary welding protection and accessories.

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WARNING!

Read and understand the instruction manual before installing

or operating.

Do not use the power source for thawing frozen pipes.

WARNING!

This product is solely intended for arc welding.

3 INTRODUCTION

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.

ESAB’s accessories for the product can be found on page 14.

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4 TECHNICAL DATA

LTR 160 LTR 200

Permittedloadat

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 110A/24V 150 A/26 V

100 % duty cycle 80 A/23 V 115A/25V

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

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 10,6 kVa

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 mm24X1,5 mm2

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.

Application class

The symbol indicates that the power source is designed for use in areas with increased

electrical hazard.

Duty cycle

The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a cer-

tain load without overloading.

Enclosure class

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

objects or water. Equipment marked IP23 is designed for indoor and outdoor use.

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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.

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 mm24X1,5 mm2

Welding cable, cross section 25 mm225 mm2

*) When welding with max 100 A a 10 A slow rupture fuse is sufficient.

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

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

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.

Earth according to applicable directives.

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.

5.1 Lifting instructions

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6OPERATION

General safety regulations for the handling of the equipment can be found on

page 3. Read through before you start using the equipment!

1Mains power switch on/off 8Remote control connection

2Yellow indicating lamp 9Dust filter

3White indicating lamp 10 Gas nipple (connection of gas cylinder)

4Slope--down time 11 Connection for TIG torch

5Lift--Arc/HF--unit/MMA 12 Connection for return cable when TIG welding

6Current setting 13 2/4--stroke

7Gas post--flow 14 Remote control switch

The welding cable and return cable should be connected to 12 and 15 with MMA--welding.

SUsing the remote control socket on the machine the current can be remotely

regulated in TIG and MMA modes.

SSelector switch is used to select remote control operation.

SPHA5 remote control unit allows use of pulsed current in TIG mode.

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.

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.

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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.

6.1 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.

bt07d109

Dismantling the filter

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7 MAINTENANCE

Regular maintenance is important for safe, reliable operation.

Note!

All guarantee undertakings from the supplier cease to apply if the customer himself

attempts any work in the product during the guarantee period in order to rectify any

faults.

Only those persons who have appropriate electrical knowledge (authorized

personnel) may remove the safety plates to connect or carry out service,

maintenance or repair work on welding equipment.

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. .

8 ORDERING OF SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.

LTR 160, LTR 200 is designed and tested in accordance with the international and Eu-

ropean standards IEC/EN 60974--1 and EN 50199. It is the obligation of the service unit

which has carried out the service or repair work to make sure that the product still

conforms to the said standard.

Spare parts may be ordered through your nearest ESAB dealer, see the last page of

this publication.

Edition 041101

Diagram

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LTR 160

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