ESAB LTR 160 User manual

GB
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.
GB

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.
GB

Edition 041101
Diagram
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LTR 160

Edition 041101
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LTR 200

LTR 160, LTR 200
Edition 041101
Ordering number
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Ordering no. Denomination Type Notes
0456 840 800 Welding power source LTR 160 with central connection for TIG welding
0456 840 881 Welding power source LTR 160 with OKC connection for TIG welding
0456 840 882 Welding power source LTR 200 with central connection for TIG welding
0456 840 883 Welding power source LTR 200 with OKC connection for TIG welding
0457 305 990 Spare parts list LTR 160,
LTR 200

LTR 160, LTR 200
Edition 041101
Spare parts list
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bt19s11a
Item Qty Ordering no. Denomination
1 2 0441 819 001 Screw
2 1 0468 275 001 Grill
3 1 0468 519 001 Filter

LTR 160, LTR 200
Edition 041101
Accessories
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cltr0sa1
Trolleyfor5lgascylinder ......... 0468 530 880
Trolley for 10--50 l gas cylinder 0456 804 880
bt07t003
Protective handle for connections . .
....... 0458 311 001

LTR 160, LTR 200
Edition 041101
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cltr0sa1
bt07t004
Tophandle ....................... 0468 305 880
For LTR 200 & LTR 255
CoolingunitOCF2L ..............
For LTR 160
CoolingunitOCF2A ..............
0457 216 880
0457 216 883
Remote control MMA 1 (10 m cable) .
MMA and TIG: current 0349 501 024
Remote control unit AT1 ...........
MMA and TIG: current
0459 491 896
Remote control unit AT1 CF .......
MMA and TIG: rough and fine setting
of current.
0459 491 897

LTR 160, LTR 200
Edition 041101
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cltr0sa1
Remote cable 12 pole -- 8 pole
5m...............................
10m..............................
15m..............................
25m..............................
0459 552 880
0459 552 881
0459 552 882
0459 552 883
Foot control FS002,
includingcable ................... 0349 090 886
LTR 255: Return cable, 35 mm2(state the length when ordering) 0262 613 602...............
LTR 160 &LTR 200: Return cable, 25 mm2(state the length when ordering) 0262 613 601.....
Return current clip 0367 558 880........................................................
Welding current cable and return current cable, complete for MMA welding:
LTR 255 LTR 160 & 200
Welding current cable, 5 metre 0468 539 882 0468 539 880
Return current cable, 5 metre 0468 539 883 0468 539 881
Information on TIG torches can be found in separate brochures.

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ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone [phone]
www.esab.com
031021
ESAB subsidiaries and representative offices
Europe
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Tel: [phone]
Fax: [phone]
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Copenhagen--Valby
Tel:[phone]
Fax:[phone]
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Tel: [phone]
Fax: [phone]
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Fax:[phone]
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Tel/Fax: [phone]
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Tel:[phone]
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Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.com