clka1p00

Valid for serial no. 618−xxx−xxxx0349 301 002 040928

LKA 180LKA 240

104

Instruction manual

ENGLISH

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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 CONFORMITYEsab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guaranteethat welding power source LKA 180 / 240 from serial number 618 complies withstandard EN 60974−1, in accordance with the requirements of directive (73/23/EEA)and addendum (93/68/EEA).−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−−

Paul KarlssonManaging DirectorEsab Welding Equipment AB695 81 LAXÅSWEDEN 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 BEBASED ON MANUFACTURERS� HAZARD DATA.

ELECTRIC SHOCK − Can kill� Install and earth the welding unit in accordance with applicable standards.� Do not touch live electrical parts or electrodes with bare skin, wet gloves or wet clothing.� Insulate yourself from earth and the workpiece.� Ensure your working stance is safe.

FUMES AND GASES − Can be dangerous to health� Keep your head out of the fumes.� 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.� Protect your eyes and body. Use the correct welding screen and filter lens and wear protective

clothing.� Protect bystanders with suitable screens or curtains.

FIRE HAZARD� Sparks (spatter) can cause fire. Make sure therefore that there are no inflammable materials nearby.

NOISE − Excessive noise can damage hearing� Protect your ears. Use earmuffs or other hearing protection.� 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 forwelding 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 0.6and 0.8 mm wire and a gas hose. The assembly kit includes a handle, rear axle, 2rear wheels and 2 castors.

Two control knobs provide adjustment of voltage and wire feed speed, which areeasily selected by referring to the table on page 9.

You can switch between solid wire with shielding gas and tube electrode without gasby 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. Athermal cut−out prevents the power source from overheating. The cut−out is resetatomatically 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−phase50 Hz

Mains lead 4x2,5 mm� 4x2,5 mm� 3x2,5 mm�

Fuse, slow 10 A 16 A 16 A

Maximum load10% 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 load11% 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 classThe IP code indicates the enclosure class, i.e. the degree of protection against penetration by solidobjects 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 increasedelectrical 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 radiointerference. 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 liftingeye. The handle is only intended for pulling it along theground.

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 andbe wired by a qual ified electrician. Check the mains voltage and fuses on all threephases before connecting the machine.

bc05d008400 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 abovethe 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 necessaryto adjust the tension. This can be done using the tensioning screw on the pressurearm.

WARNING!

Rotating parts can cause injury, take great care.

6 OPERATION

General safety regulations for the handling of the equipment can be found onpage 3. Read through before you start using the equipment!

� 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.

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6.1 Spot welding

Select the spot welding time (G) on the scale marked 1−10. Spot weldingtime can be set anywhere between 0.2−2.5 sek.To set the welding voltage and wire feed speed see the recommendedtable on page 9. Press the torch trigger. When the set welding time has elapsed weldingwill 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 customerattempts 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

367 556−001466 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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− 17 −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

469 440−880469 565−880469 560−880

LKA 180LKA 180LKA 180

400 V 3 phase230/400 V reconnectable, 3 phase230 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

469 450−880469 570−880

LKA 240LKA 240

400 V 3 phase230/400 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 thecover. Kindly indicate type of unit, serial number, denominations and ordering numbers according tothe spare parts list.

Maintenance and repair work should be performed by an experienced person, and electrical work onlyby 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

Itemno.

Qty180

Qty240 Ordering no. Denomination Notes C

101102

103

1111

1111

469 368−001469 369−001469 664−001469 447−001

Cover plateRear panelRear panelSide panel

Only for the Australian marketWith text

104

107

1

1−

1

−1

0700 200 002

0469 572 8810469 443 880

Welding gun MXL 200

Return cableReturn cable

CompleteComplete

109 1 1 469 361−001 Front panel

110

28

28

469 468−001

Link wheelScrew M6 x 16 mm

111 1 1 368 265−001 Securing strap

120121122123124

21222

21222

469 453−001469 516−001

469 469−001192 859−126

Attachment ShaftWasherWheelLocking washer

D 21/36

125b 1 1 146 967−881 Brake hub From macine no. 547 612 ....

126

12

12

469 437−001

HandleScrew M6 x 16mm

LKA 180 , LKA 240 Edition 040928

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LKA 180 , LKA 240 Edition 040928

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WIRE FEED UNITC = component designation in the circuit diagram

Itemno. Qty Ordering no. Denomination Notes C

− − 455 890−890 Feed unit Complete, contains items 301 − 333

300 1 367 529−001 Pressure arm Complete, contains items 301 − 305301 2 455 906−001 Spacer sleeve302 1 455 907−001 Pressure roller

466 262−001 Pressure roller * Knurled303 1 Nut SGA D8304 1 Holder305 1 Shaft

306 1 455 896−001 Spring

308 1 469 397−001 Drive unit M1309 1 2157 010−07 Locking washer Included in item 308310 1 191 496−114 Key Included in item 308

311 1 466 074−001 Inlet nozzle

312 1 367 528−001 Pin bolt313 1 368 749−880 Pressure transducer

314 2 368 750−001 Insulating sleeve

315 1 455 894−001 Insert tube316 1 455 885−001 Outlet nozzle317 1 455 882−001 Current sleeve

318 1 455 883−001 Spacer sleeve � 16/8.2x0.9319 1 Washer � 16/8.4x1.5320 1 Screw M8x20

321 1 455 881−001 Protection plate322 1 2152 012−02 O−ring323 1 455 898−001 Screw (M5x12)

324 1 Screw M4x12326 1 193 104−002 Washer � 16/5x1

327 1 367 556−001 Feed roller For � 0.6 − 0.8 mm Fe, Ss and cored wire 1 367 556−002 Feed roller * For � 0.8 − 1.0 mm Fe, Ss and cored wire 1 367 556−006 Feed roller * Knurled, for � 1.0 − 1.2 mm cored wire 1 367 556−004 Feed roller * For � 1.0 − 1.2 mm Al wire

329 1 455 893−001 Shaft

330 1 455 884−001 Gear housing331 3 2121 107−42 Screw B12x16332 1 469 380−881 Capacitor PME 0.1 µF 400 V, with cable lugs C3333 1 455 892−001 Spacer sleeve

* = accessories

LKA 180 , LKA 240 Edition 040928

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WIRE FEED UNIT

ESAB ABSE−695 81 LAXÅSWEDENPhone +46 584 81 000

www.esab.com

031021

ESAB subsidiaries and representative offices

EuropeAUSTRIAESAB Ges.m.b.H Vienna−Liesing Tel: +43 1 888 25 11 Fax: +43 1 888 25 11 85

BELGIUMS.A. ESAB N.V. Brussels Tel: +32 2 745 11 00 Fax: +32 2 726 80 05

THE CZECH REPUBLICESAB VAMBERK s.r.o. PragueTel: +420 2 819 40 885 Fax: +420 2 819 40 120

DENMARKAktieselskabet ESAB Copenhagen−Valby Tel: +45 36 30 01 11 Fax: +45 36 30 40 03

FINLANDESAB Oy Helsinki Tel: +358 9 547 761 Fax: +358 9 547 77 71

FRANCEESAB France S.A. Cergy Pontoise Tel: +33 1 30 75 55 00 Fax: +33 1 30 75 55 24

GERMANYESAB GmbH Solingen Tel: +49 212 298 0 Fax: +49 212 298 204

GREAT BRITAINESAB 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

HUNGARYESAB Kft Budapest Tel: +36 1 20 44 182 Fax: +36 1 20 44 186

ITALYESAB Saldatura S.p.A. Mesero (Mi) Tel: +39 02 97 96 81 Fax: +39 02 97 28 91 81

THE NETHERLANDSESAB Nederland B.V. Utrecht Tel: +31 30 248 59 22 Fax: +31 30 248 52 60

NORWAYAS ESAB Larvik Tel: +47 33 12 10 00 Fax: +47 33 11 52 03

POLANDESAB Sp. z o.o.KatowiceTel: +48 32 35 111 05Fax: +48 32 35 111 20

PORTUGALESAB Lda Lisbon Tel: +351 1 837 1527 Fax: +351 1 859 1277

SLOVAKIAESAB Slovakia s.r.o. Bratislava Tel: +421 7 44 88 24 26 Fax: +421 7 44 88 87 41

SPAINESAB Ibérica S.A. Alcobendas (Madrid) Tel: +34 91 623 11 00 Fax: +34 91 661 51 83

SWEDENESAB 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

SWITZERLANDESAB AG Dietikon Tel: +41 1 741 25 25 Fax: +41 1 740 30 55

North and South AmericaARGENTINACONARCO Buenos Aires Tel: +54 11 4 753 4039 Fax: +54 11 4 753 6313

BRAZILESAB S.A. Contagem−MG Tel: +55 31 3369 4333 Fax: +55 31 3369 4440

CANADAESAB Group Canada Inc.Missisauga, Ontario Tel: +1 905 670 02 20 Fax: +1 905 670 48 79

MEXICOESAB Mexico S.A. Monterrey Tel: +52 8 350 5959 Fax: +52 8 350 7554

USAESAB Welding & Cutting Products Florence, SC Tel: +1 843 669 44 11 Fax: +1 843 664 44 58

Asia/PacificCHINAShanghai ESAB A/PShanghaiTel: +86 21 6539 7124Fax: +86 21 6543 6622

INDIAESAB India Ltd CalcuttaTel: +91 33 478 45 17 Fax: +91 33 468 18 80

INDONESIAP.T. Esabindo Pratama Jakarta Tel: +62 21 460 01 88 Fax: +62 21 461 29 29

MALAYSIAESAB (Malaysia) Snd Bhd Selangor Tel: +60 3 703 36 15 Fax: +60 3 703 35 52

SINGAPOREESAB Singapore Pte Ltd Singapore Tel: +65 861 43 22 Fax: +65 861 31 95

ESAB Asia/Pacific Pte LtdSingaporeTel: +65 861 74 42Fax: +65 863 08 39

SOUTH KOREAESAB SeAH Corporation Kyung−Nam Tel: +82 551 289 81 11 Fax: +82 551 289 88 63

UNITED ARAB EMIRATESESAB Middle East Dubai Tel: +971 4 338 88 29 Fax: +971 4 338 87 29

Representative officesBULGARIAESAB Representative OfficeSofiaTel/Fax: +359 2 974 42 88

EGYPTESAB Egypt Dokki−CairoTel: +20 2 390 96 69 Fax: +20 2 393 32 13

ROMANIAESAB Representative Office BucharestTel/Fax: +40 1 322 36 74

RUSSIA−CISESAB Representative Office MoscowTel: +7 095 937 98 20 Fax: +7 095 937 95 80

ESAB Representative Office St PetersburgTel: +7 812 325 43 62 Fax: +7 812 325 66 85

DistributorsFor addresses and phonenumbers to our distributors inother countries, please visit ourhome page

www.esab.com