LKA 180 LKA 240
LKA 180
LKA 240
104
clka1p00
Instruction manual
0349 301 002
040928
Valid for serial no. 618−xxx−xxxx
ENGLISH
1
2
3
4
5
DIRECTIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
3
4
4
5
GAS CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
6
6
6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
6.1
Spot welding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
8
Selection table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
18
TOCe
−2−
GB
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).
−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−
Laxå 96−04−20
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN
2
Tel: + 46 584 81000
Fax: + 46 584 12336
SAFETY
WARNING
ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE PRECAUTIONS 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.
READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.
PROTECT YOURSELF AND OTHERS!
bc05d18e
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GB
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
bc05d18e
−4−
GB
LKA 180
LKA 240
LKA 180 1−phase
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
Wire sizes
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.
bc05d001
bc05d18e
−5−
GB
Lifting instructions
The power supply should be lifted by means of its lifting
eye. The handle is only intended for pulling it along the
ground.
5.1
Electrical connection
bc05d002
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.
400 V
5.2
bc05d008
230 V
Wire
bc05d004
TUBE WIRE
SOLID WIRE
When welding with tube wire the cables connected to the + and − terminals above
the wire feed unit must be switched.
bc05d18e
−6−
GB
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
S
S
S
S
S
S
Connect the return cable (E) to the work piece.
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.
Switch on the power source using the knob (L).
The white indicator lamp (K) should light up.
Press the trigger (D) on the welding torch until wire
is fed out of the contact tip (F).
Select suitable welding settings using the
woltage selector knob (L) and the wire feed
knod (H) as indicated by the table on page 9.
Start welding and adjust the settings if necessary.
Indication lamp (J) light up if the Power source
becomes to hot.
bc05d18e
−7−
bc05d005
GB
6.1
Spot welding
bc09
7
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.
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.
455 894−001
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.
466 074−001
367 556−001
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 designation and spare part number as shown in the spare parts list.
This will simplify dispatch and ensure you get the right part.
bc05d18e
−8−
Selection table
FIG 1 (LKA 180)
bc05t11a
−9−
FIG 2 (LKA 240)
bc05t11a
− 10 −
FIG 3 (LKA 180 1~)
bc05t11a
− 11 −
Diagram
bc05e001
bc05e11a
− 12 −
bc05e11a
− 13 −
bc05e005
bc05e11a
− 14 −
bc05e003
bc05e11a
− 15 −
bc05e004
bc05e11a
− 16 −
page
− 17 −
LKA 180 , LKA 240
Edition 040928
Spare parts list
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.
bc05s11a
− 18 −
LKA 180 , LKA 240
180 = LKA 180
240 = LKA 240
Item
no.
Qty
180
Qty
240
103
1
1
1
1
1
1
1
1
104
1
107
C = component designation in the circuit diagram
Denomination
Notes
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
1
0700 200 002
Welding gun MXL 200
1
−
−
1
0469 572 881
0469 443 880
Return cable
Return cable
109
1
1
469 361−001
Front panel
110
2
8
2
8
469 468−001
Link wheel
Screw
101
102
Ordering no.
Edition 040928
Complete
Complete
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
bc05s11a
− 19 −
C
LKA 180 , LKA 240
bc05s11a
Edition 040928
− 20 −
LKA 180 , LKA 240
Edition 040928
WIRE FEED UNIT
C = component designation in the circuit diagram
Item
no.
Qty
Ordering no.
−
−
455 890−890
Feed unit
Complete, contains items 301 − 333
300
301
302
1
2
1
367 529−001
455 906−001
455 907−001
466 262−001
Complete, contains items 301 − 305
303
304
305
1
1
1
Pressure arm
Spacer sleeve
Pressure roller
Pressure roller *
Nut
Holder
Shaft
306
1
455 896−001
Spring
308
309
310
1
1
1
469 397−001
2157 010−07
191 496−114
Drive unit
Locking washer
Key
311
1
466 074−001
Inlet nozzle
312
313
1
1
367 528−001
368 749−880
Pin bolt
Pressure transducer
314
2
368 750−001
Insulating sleeve
315
316
317
1
1
1
455 894−001
455 885−001
455 882−001
Insert tube
Outlet nozzle
Current sleeve
318
1
455 883−001
Spacer sleeve
Ĭ 16/8.2x0.9
319
1
Washer
320
1
Screw
Ĭ 16/8.4x1.5
M8x20
321
322
323
1
1
1
455 881−001
2152 012−02
455 898−001
Protection plate
O−ring
Screw
(M5x12)
324
326
1
1
Screw
Washer
M4x12
193 104−002
327
1
367 556−001
Feed roller
For Ĭ 0.6 − 0.8 mm Fe, Ss and cored wire
1
367 556−002
Feed roller *
For Ĭ 0.8 − 1.0 mm Fe, Ss and cored wire
1
367 556−006
Feed roller *
Knurled, for Ĭ 1.0 − 1.2 mm cored wire
1
367 556−004
Feed roller *
For Ĭ 1.0 − 1.2 mm Al wire
329
1
455 893−001
Shaft
330
331
332
333
1
3
1
1
455 884−001
2121 107−42
469 380−881
455 892−001
Gear housing
Screw
Capacitor
Spacer sleeve
Denomination
Notes
Knurled
SGA D8
M1
Included in item 308
Included in item 308
Ĭ 16/5x1
B12x16
PME 0.1 µF 400 V, with cable lugs
* = accessories
bc05s11a
C
− 21 −
C3
LKA 180 , LKA 240
Edition 040928
WIRE FEED UNIT
bc05s11a
− 22 −
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna−Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen−Valby
Tel: +45 36 30 01 11
Fax: +45 36 30 40 03
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel: +33 1 30 75 55 00
Fax: +33 1 30 75 55 24
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB Group (UK) Ltd
Waltham Cross
Tel: +44 1992 76 85 15
Fax: +44 1992 71 58 03
ESAB Automation Ltd
Andover
Tel: +44 1264 33 22 33
Fax: +44 1264 33 20 74
HUNGARY
ESAB Kft
Budapest
Tel: +36 1 20 44 182
Fax: +36 1 20 44 186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel: +39 02 97 96 81
Fax: +39 02 97 28 91 81
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel: +47 33 12 10 00
Fax: +47 33 11 52 03
POLAND
ESAB Sp. z o.o.
Katowice
Tel: +48 32 35 111 05
Fax: +48 32 35 111 20
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel: +421 7 44 88 24 26
Fax: +421 7 44 88 87 41
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel: +46 31 50 95 00
Fax: +46 31 50 92 22
ESAB International AB
Gothenburg
Tel: +46 31 50 90 00
Fax: +46 31 50 93 60
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki−Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA−CIS
ESAB Representative Office
Moscow
Tel: +7 095 937 98 20
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel: +7 812 325 43 62
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com
SOUTH KOREA
ESAB SeAH Corporation
Kyung−Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem−MG
Tel: +55 31 3369 4333
Fax: +55 31 3369 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
ESAB AB
SE−695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.com
031021
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