ESAB | LTS 160 | Instruction manual | ESAB LTS 160 User manual

ESAB LTS 160 User manual
PROWELDER 160
PROWELDER 250
LTS 160, LTS 250
Bruksanvisning
Brugsanvisning
Bruksanvisning
Käyttöohjeet
Instruction manual
Betriebsanweisung
0458 343 001
030324
Manuel d’instructions
Gebruiksaanwijzing
Instrucciones de uso
Istruzioni per l’uso
Manual de instruções
Ïäçãßåò ÷ñÞóåùò
Valid for serial no. 008, 306
SVENSKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
DANSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
NORSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
SUOMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ENGLISH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
DEUTSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
FRANÇAIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
NEDERLANDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
ESPAÑOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
ITALIANO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
PORTUGUÊS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
ÅËËÇÍÉÊÁ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Rätt till ändring av specifikationer utan avisering förbehålles.
Ret til ændring af specifikationer uden varsel forbeholdes.
Rett til å endre spesifikasjoner uten varsel forbeholdes.
Oikeudet muutoksiin pidätetään.
Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
Reservado el derecho de cambiar las especificaciones sin previo aviso.
Ci riserviamo il diritto di variare le specifiche senza preavviso.
Reservamo--nos o direito de alterar as especificações sem aviso prévio.
Äéáôçñåßôáé ôï äéêáßùìá ôñïðïðïßçóçò ðñïäéáãñáöþí ×ùñßò ðñïåéäïðïßçóç.
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ENGLISH
1 DIREKTIV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 SAFETY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
48
48
49
3.1 Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2 Programming box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.3 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49
50
50
4 TECHNICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
52
5.1
5.2
5.3
5.4
Lifting instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mains voltage connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Termination resistans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection of complete welding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
52
53
53
54
6 OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
6.1
6.2
6.3
6.4
6.5
6.6
Controls and connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overheating protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow guard, water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flow guard, gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
55
56
56
56
56
56
7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
7.1 Check--up and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
57
8 ORDERING OF SPARE PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
SPARE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
TOCe
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GB
1
DIREKTIV
DECLARATION OF CONFORMITY
ESAB Welding Equipment AB, S--695 81 Laxå, Sweden, gives its unreserved guarantee that welding
power source LTS 160, LTS 250 from serial number 008 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 requirements of directive (89/336/EEC) and addendum
(93/68/EEC).
--------------------------------------------------------------------------------------------------------------------------------------
Laxå 2000--04--17
Anders Birgersson
Managing Director
ESAB Welding Equipment AB
695 81 LAXÅ
SWEDEN
2
Tel: + 46 584 81000
Fax: + 46 584 411924
SAFETY
Users of ESAB welding equipment have the ultimate responsibility for ensuring that anyone who
works on or near the equipment observes all the relevant safety precautions. Safety precautions
must meet the requirements that apply to this type of welding equipment. The following recommendations should be observed in addition to the standard regulations that apply to the workplace.
All work must be carried out by trained personnel well--acquainted with the operation of the welding
equipment. Incorrect operation of the equipment may lead to hazardous situations which can result
in injury to the operator and damage to the equipment.
1.
Anyone who uses the welding equipment must be familiar with:
S its operation
S location of emergency stops
S its function
S relevant safety precautions
S welding
2.
The operator must ensure that:
S no unauthorised person is stationed within the working area of the equipment when it is
started up.
S no--one is unprotected when the arc is struck
3.
The workplace must:
S be suitable for the purpose
S be free from draughts
4.
Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5.
General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during operation.
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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!
3
INTRODUCTION
LTS 160, LTS 250 are welding power sources of the rectifier type designed for
mechanised TIG welding.
They are fan--cooled and also includes a cooling system for water--cooling of the
welding tool.
They is prepared for connection to an external PC.
3.1
Equipment
LTS 160 and LTS 250 are supplied with:
S
Programming box with connection cable (10 m)
S
Return cable (5 m) with return cable clamp
S
Gas hose (2 m) with hose clamp.
S
End resistor.
S
Programming manual in swedish, english, german och french.
S
PC card.
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3.2
Programming box
The welding power source is provided with a programming box for:
S
Programming of welding procedures when welding with a welding tool.
S
Executing a welding process.
S
Storing welding program in an internal or external memory unit (PC card).
S
Transferring welding programs between programming units.
S Setting of different parameter values when welding with a TIG hand torch.
For the handling, see Programming manual.
The programming manual is available in the following languages:
Language
Article no.
Language
Article no.
English
0457 706 X74
French
0457 706 X76
German
0457 706 X75
Swedish
0457 706 X70
Italian
0457 706 X79
Finnish
0457 706 X73
Norwegian
0457 706 X72
Danish
0457 706 X71
Dutch
0457 706 X77
Spanish
0457 706 X78
Portuguese
0457 706 X80
Russian
0457 706 X86
3.3
Applications
Welding power source LTS can be used for welding with:
S
Tube welding tools for joining tubes
S
Tube--to--plate welding tools for welding of tube diameters 12--60 mm
S
Automatic welding machine A25 STB with floating head.
S TIG hand torch
A wire feed unit for filler wire can be connected to the welding power source.
Motors for external units (roller beds, turntables, etc.) can be controlled by way of the
PAL 3 motor control unit.
ESAB accessories for mechanised and manual TIG welding are found on
page 157.
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4
TECHNICAL DATA
LTS 160
230 V ±10%, 1∼ 50/60 Hz
LTS 250
400 V ±10%, 3∼ 50/60 Hz
160 A / 16 V
110 A / 15 V
80 A / 13 V
50 W
250 A / 20 V
180 A / 17 V
140 A / 16 V
55 W
Power factor
Efficiency
No--load voltage
Primary current:
100% duty cycle
0,68
≥0,75
70 V
9A
0,61
≥0,75
70 V
9A
Arc strike
HF
HF
Dimensions l x w x h
without cooling unit
with cooling unit
Weight without cooling unit
with cooling unit
Temperature class
515 x 285 x 620 mm
515 x 285 x 835 mm
37 kg
56,5 kg
F (155 _C)
515 x 285 x 620 mm
515 x 285 x 835 mm
38 kg
57,5 kg
F (155 _C)
Enclosure type
IP 23
IP 23
Operating range, current
Steps of adjustment, current
Wire feed speed
Setting range
LTS 160
5 A / 10 V -- 160 A / 16 V
1A
0.10--2.50 m/min
LTS 250
5 A / 10 V -- 250 A / 20 V
1A
0.10--2.50 m/min
Pulse and background time
Pre--heat time
0.01 -- 25.0 s
0 -- 600 s
0.01 -- 25.0 s
0 -- 600 s
Gas pre-- and post--flow
0 -- 6000 s
0 -- 6000 s
Slope--up and slope down
Sector
Steps of adjustment, sector
break point
0,1 -- 25 s
0 -- 10 r
0,001 r
0,1 -- 25 s
0 -- 10 r
0,001 r
Mains voltage
Permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
No--load power
Application class
Duty cycle
The duty cycle refers to the time as a percentage of a ten--minute period that you can weld at a certain load without overloading the welding power source.
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 23 is designed for indoor and outdoor use.
Application class
The symbol
indicates that the power source is designed for use in areas with increased
electrical hazard.
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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.
Place the welding power source so as not to prevent the cooling air from circulating
through the machine.
5.1
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Lifting instructions
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GB
5.2
S
Mains voltage connection
Make sure the welding power source is connected to the right mains voltage and
that it is properly fused. Connect to earth according to the regulations valid.
The rating plate with connection data.
Recommended cable areas and fuse sizes
LTS 160
LTS 250
Mains voltage
230 V
400 V
Mains frequence
50--60 Hz
50--60 Hz
Fuse, slow--blow
16 A
3 x 2,5 mm 2
16 A
4 x 1,5 mm 2
Cable area
5.3
Termination resistans
To avoid communication trouble the two end points of
the CAN--bus should be fitted with an termination
resistans. One of the CAN--bus end points is in the
programming box which has a built--in resistor. The
other one is in the power source and should be fitted
with an termination resistans if the output in question is
not used. For the location of the resistor, see the
following figure.
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5.4
Connection of complete welding system
A--A
B--B, Z--Z
C--C, S--S
D--D
G--G
H--H
J--J
L--L
M--M
N--N
P--P
Q--Q
R--R
T--T,V--V
X
U--U
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Connection cable -- programming box
Motor cable --wire feed
Motor cable -- rotation
Signal cable -- external PC
Cooling--water hose in
Cooling--water hose out
Welding cable
Torch contact
Gas hose out
Gas hose in
Signal cable -- external PC
Return cable +
Connection cable -- pulsetransmitter
VEC
Connection cable -- CAN 42 V
Connection cable -- external motor
Connection cable -- rotor VEC
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GB
6
OPERATION
General safety regulations for the handling of the equipment can be found on
page 48. Read through before you start using the equipment!
6.1
Controls and connections
1 Connection for programming box
11 Fuse, slow rupture 1.25 A
(connection 230 V)
2 Connection CAN 42 V for motor control unit 12 Connection for cooling unit 230 V, 1.25 A
PAL3 and A25 VEC motor
3 White indicating lamp, mains voltage ON
13 Connection for flow--guard, (water)
4 Orange indicating lamp, overheating
14 Connection for welding and start gas out
5 Switch for mains voltage ON/OFF
15 Connection for torch contact, TIG hand torch
6 Connection for root gas in
16 Connection for return cable (+)
7 Connection for welding gas in
17 Connection for welding cable (--)
8 Connection for start gas in
18 Connection for rotation
9 Connection for root gas out
19 Connection for wire feed
10 Fuse, slow rupture 1.25 A
(connection 230 V)
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20 Connection for PC/printer
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GB
6.2
Cooling unit
N.B. To give room for the cooling unit under the welding
power source, the tool box on the carriage must be
dismounted.
Screw the cooling unit and the welding power source
together.
6.3
Overheating protection
The LTS is provided with a thermal cut--out which trips in case of too high
temperature. The welding current is interrupted and an orange indicating lamp on the
front of the power source lights up. The programming box also shows an error
message. The thermal cut--out is reset automatically when the unit has cooled down.
6.4
Flow guard, water
If there is no cooling water flowing, the flow guard will block the welding power
source. The welding current is then interrupted and an error message is displayed in
the character window of the programming unit.
6.5
Flow guard, gas
The flow guard interrupts the ongoing welding process if the gas flow falls below 6
l/min. An error message is displayed by the programming box.
6.6
Error messages
The welding power source has a built--in function for handling error messages. All
error messages are presented in the programming box, and in some cases
measures will be taken automatically. See also programming manual 0457 706 xxx.
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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.
Only those persons who have appropriate electrical knowledge (authorised
personnel) may remove the safety plates to connect or carry out service,
maintenance or repair work on welding equipment.
7.1
Check--up and cleaning
Generally LTS 160 and LTS 250 does not require any
maintenance. Normally, it is sufficient to blow out the
machine using clean, compressed air (reduced pressure) annually, and the dust filter should be cleaned
regularly. If the machine is set up in dusty or dirty
environment the machine and the dust filter should
be cleaned more often.
Dismounting the filter
8
ORDERING OF SPARE PARTS
LTS 160, LTS 250 is designed and tested in accordance with the EN 60974--1 (IEC
50199) international standard.
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 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.
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