ESAB LKB 160 Instruction manual

LKB 160

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Valid for serial no. --xxx--xxxx0349 301 023 GB

1. DECLARATION OF CONFORMITY .................................................................................................... 32

2. SAFETY ............................................................................................................................................... 32

3. INTRODUCTION................................................................................................................................... 33

3.1 TECHNICAL DATA .......................................................................................................................... 33

INSTALLATION ................................................................................................................................... 34

4.

4.1 MAINS SUPPLY ............................................................................................................................... 34

4.2 UNPACKING .................................................................................................................................... 34

4.3 ASSEMBLY OF UNIT ...................................................................................................................... 34

5. OPERATION ........................................................................................................................................ 35

5.1 CONTROLS AND INDICATORS ..................................................................................................... 35

6. MAINTENANCE ................................................................................................................................... 36

6.1 CLEANING ....................................................................................................................................... 36

7. SPARE PARTS ORDERING ................................................................................................................ 36

8. ACCESORIES ...................................................................................................................................... 36

8.1 TRANSFORMER FOR CO

ASSEMBLY INSTRUCTION .............................................................. 36

2

8.2 METER ASSEMBLY INSTRUCTION .............................................................................................. 37

9. SCHEMATIC DIAGRAM ...................................................................................................................... 94

10. SPARE PARTS LIST ......................................................................................................................... 95

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1 DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

Esab Welding Equipment AB, S-695 81 Laxå, Sweden, gives its unreserved guarantee that welding
rectifier LKB 160 from serial number 032 complies with standard IEN 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 2000-11-07

Anders Birgersson
Managing Director
Esab Welding Equipment AB
695 81 Laxå
Sweden Tel: [phone] Fax: [phone]

2SAFETY

WARNING !

ARC WELDING AND CUTTING CAN BE INJURIOUS TO YOURSELF AND OTHERS. TAKE
PRECAUSIONS WHEN WELDING. FOLLOW SAFETY INSTRUCTIONS OBLIGATORY IN A COMPANY,
PREPARED ACCORDING TO EQUIPMENT MANUFACTURER’S RECOMMENDATIONS.

ELECTRIC SHOCK – can kill

• Install equipment in accordance with obligatory standards.

• Do not touch live electrical parts with bare skin, wet gloves or wet clothes.

• Ensure your work position is safe.

FUMES AND GASES – can be dangerous to your health.

• Keep your head away from fumes.

• Use ventilation and/or extraction to keep fumes and gases away from your breathing zone and

surroundings.

ARC RAYS – can injure eyes and skin.

• Protect your eyes and skin. Use suitable welding screens, filter lens and wear protective clothes.

• Protect bystanders with suitable screens or curtains.

FIRE HAZARD

• Sparks (spatter) can cause fire. Therefore make sure there are no inflammable materials nereby.

INAPPROPRIATE OPERATION OF EQUIPMENT – if unit operates in a faulty way, consult a trained
technician.

READ AND COMPREHEND THE INSTRUCTION MANUAL BEFORE

INSTALLING AND OPERATING UNIT

PROTECT YOURSELF AND OTHERS!

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3 INTORDUCTION

The LKB 160 is step-switched welding power unit, intended for welding with solid filler wires of steel,
stainless steel or aluminium, and cored wires with or without shielding gas.

3.1 TECHNICAL DATA

Standard delivery:

Power source equipped with spot welding function, adjustable burnback time and creep start function.
Wire feed mechanism with feed roller for solid wire, diameter 0,6 – 0,8.
Welding torch PSF 160 3m
Return cable 4,5m with return clamp
Mains cable 3m and gas hose 1,5m

Set includes: handle (with screws), shelf for gas cylinder (with screws), chain, bracket (with screw), cable
strip.

Mains voltage 1x230 V, 50/60Hz
Mains fuse 16 A delayed
Rated power consumption 5,7 kVA
Rated welding current Duty cycle* 45% 130 A

Duty cycle* 60% 112 A

Duty cycle* 100% 87 A
Welding current range
Open circuit voltage 18÷28 V
Enclosure class IP 23
Application class

28A/15,4V÷130A/20,5V

Dimensions Length

Width
Height

Weight 73,5 kg

*Duty cycle is based on 10-minute period. Duty cycle 45% means that after 4,5 minutes of unit operation, 5,5
minutes brake is required. Duty cycle 100% means that the unit can work continuously.

Warning:

The unit is characterised by the following:

- Enclosure class IP 23 indicates that the unit is designed for indoor and outdoor use.

- Application class S means that the unit is designed for use in areas of elevated electric hazard.

770
520
620

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4 INSTALLTION

Installation shall be executed by competent and authorised person.
Connect the mains cable and protect it with appropriate fuse in conformance with local regulations.
Unit must be protected from dust, dirt and overheating. A distance of minimum 300 mm must be kept
between the LKB 160 and other obstacles that may block air-flow through the unit.

4.1 MAINS SUPPLY

Voltage 230V

1~ 50/60 Hz

Rated primary current:

P100% 8A

P60% 10A

P45% 22A

Mains cable cross-section 3x1,5mm

Fuse, slow-blow 16A

4.2 UNPACKING

2

A. Unpack the equipment and check that there is no obvious damage. Notify supplier (distributor) if any

faults or damage are apparent.

B. Check if no parts are left in packing before disposal.

C. Check if all ventilation openings are opened and unblocked.

4.3 ASSEMBLY OF UNIT

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5 OPERATION

5.1 CONTROLS AND INDICATORS

Fig.5.1 LKB160 front panel view

Fig.5.2 View of control panel in wire feed unit compartment for LKB.

A. POWER ON/OFF SWITCH AND WELDING VOLTAGE ADJUSTMENT – Turning this switch to one of

seven positions ‘1÷7’ applies power to the unit. The green LED diode (B) will illuminate indicating that
power is supplied to the equipment. Cooling fan will also be switched on. Welding voltage adjustment is
carried out by means of turning this switch.

WARNING: Operating this switch during the welding process (loaded power source) can cause

damage to unit!

B. OVERHEATING The orange signal LED diode will illuminate in the event of overheating. The welding

output is automatically disabled until the LKB reaches normal temperature. Should this indicator
illuminate leave the power source a few minutes to cool down. Do not switch the power source off as
this will remove the power from the cooling fans. The unit will be ready to resume welding when the
orange indicator has turned off.

C. DIGITAL METER indicates actual values of current or welding voltage. The toggle switch allows you to

select either voltage or current display. The LKB160 is supplied without a meter. The meter kit is supplied
as an optional extra and has a last reading hold facility.

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D. POTENTIOMETER with switch – to switch on spot welding and impulse time (for spot welding) – in the

range of 0,5 ÷ 4 s.

E. POTENTIOMETER to set wire feed speed (in the range of 1,4 ÷ 19 m/min).

F. POTENTIOMETER of burnback time regulation .

G. CONNECTION (Euro connection) to connect welding torch

H. OUTPUT SOCKET to connect return cable with clamp

I. MODE SELECTOR: CREEP START 50% - 100% - 70%

6 MAINTENANCE

WARNING: All guarantee obligations of producer are nullified if customer attempts to repair any

faults by himself.

6.1 CLEANING

The LKB 160 should be regularly blown down with dry, compressed air at a low pressure. If unit is used in
dirty or dusty environment it shall be cleaned more often. Otherwise ventilation openings can be blocked
which can result in overheating.

7 SPARE PARTS ORDERING

When ordering spare parts, please state machine type, serial number, designation and spare part number as
shown is spare parts list. It will simplify dispatch and ensure you get the right part.

8 ACCESSORIES

Transformer kit for CO2 0349 302 080
V/A meter kit 0349 302 078

8.1 ASSEMBLY INSTRUCTION OF GAS HEATER TRANSFORMER FOR CO

− Take off side panels of unit.

− Fasten transformer T3 and terminal block XG in places marked with arrows.

− Connect wiring of transformers T3 with components according to schematic diagram of unit.

2

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1- Transformer T2
2- Transformer T3
3- Terminal block XG
4- W iring for Q1 and T2

8.2 V/A METER ASSEMBLY INSTRUCTION

− Take off side panels of unit.

− Fasten meter’s board to front panel of unit.

− Assemble cover of meter to partition of unit.

− Disassemble rectifier bridge.

− Disconnect current cable (+) from the bridge.

− Connect shunt and bus according to diagram.

− Connect shunt and bus to (+) end of rectifier bridge and next connect current cable (+) to free end of

shunt.

− Assemble rectifier bridge in unit.

− Connect wiring of meter according to schematic diagram of LKB 160.

1- V/A-Meter A2
2- Shunt RI
3- Bus
4- W iring for board A1
5- W iring for transformer T2
6- W iring for shunt and current socket (-)
7- Current cable (+)
8- Current socket (-)
9- Rectifier bridge V1

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