Lka 180

LKA 180
LKA 240
104
clka1p00
Instruction manual
0349 301 002 040928 Valid for serial no. 618−xxx−xxxx

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ENGLISH
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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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 Tel: + 46 584 81000 Fax: + 46 584 12336
2 SAFETY
WARNING
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

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!
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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, 230/400 V, 230 V, 1−phase
3−phase 50 Hz 3−phase 50 Hz 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
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LKA 180 LKA 240 LKA 180 1−phase

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 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.
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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
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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 and
be wired by a qual ified electrician. Check the mains voltage and fuses on all three
phases before connecting the machine.
400 V 230 V
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5.2 Wire
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TUBE WIRE SOLID WIRE

When welding with tube wire the cables connected to the + and − terminals above
the wire feed unit must be switched.
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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 Connect the return cable (E) to the work piece.
S 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.
S Switch on the power source using the knob (L).
The white indicator lamp (K) should light up.
S Press the trigger (D) on the welding torch until wire
is fed out of the contact tip (F).
S Select suitable welding settings using the
woltage selector knob (L) and the wire feed
knod (H) as indicated by the table on page 9.
S Start welding and adjust the settings if necessary.
S Indication lamp (J) light up if the Power source
becomes to hot. bc05d005
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6.1 Spot welding
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.
bc09
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.
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 455 894−001
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, 466 074−001 367 556−001
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.
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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~)
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Diagram

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− 13 −
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page

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 LKA 180 400 V 3 phase

469 565−880 LKA 180 230/400 V reconnectable, 3 phase
469 560−880 LKA 180 230 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 LKA 240 400 V 3 phase

469 570−880 LKA 240 230/400 V reconnectable, 3 phase
469 560−881 LKA 180 230 V single−phase, only for the Australian market.
469 450−882 LKA 240 400 V 3 phase, only for the Australian market.
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.
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180 = LKA 180 240 = LKA 240 C = component designation in the circuit diagram
Item Qty Qty

Ordering no. Denomination Notes C
no. 180 240
101 1 1 469 368−001 Cover plate

102 1 1 469 369−001 Rear panel
1 1 469 664−001 Rear panel Only for the Australian market
103 1 1 469 447−001 Side panel With text
104 1 1 0700 200 002 Welding gun MXL 200
107 1 − 0469 572 881 Return cable Complete

− 1 0469 443 880 Return cable Complete
109 1 1 469 361−001 Front panel
110 2 2 469 468−001 Link wheel
8 8 Screw M6 x 16 mm
111 1 1 368 265−001 Securing strap
120 2 2 469 453−001 Attachment
121 1 1 469 516−001 Shaft
122 2 2 Washer D 21/36
123 2 2 469 469−001 Wheel
124 2 2 192 859−126 Locking washer
125b 1 1 146 967−881 Brake hub From macine no. 547 612 ....
126 1 1 469 437−001 Handle
2 2 Screw M6 x 16mm
− 19 −
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− 20 −
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WIRE FEED UNIT

C = component designation in the circuit diagram
Item
Qty Ordering no. Denomination Notes C
no.
− − 455 890−890 Feed unit Complete, contains items 301 − 333
300 1 367 529−001 Pressure arm Complete, contains items 301 − 305
301 2 455 906−001 Spacer sleeve
302 1 455 907−001 Pressure roller
466 262−001 Pressure roller * Knurled
303 1 Nut SGA D8
304 1 Holder
305 1 Shaft
306 1 455 896−001 Spring
308 1 469 397−001 Drive unit M1

309 1 2157 010−07 Locking washer Included in item 308
310 1 191 496−114 Key Included in item 308
311 1 466 074−001 Inlet nozzle
312 1 367 528−001 Pin bolt

313 1 368 749−880 Pressure transducer
314 2 368 750−001 Insulating sleeve
315 1 455 894−001 Insert tube

316 1 455 885−001 Outlet nozzle
317 1 455 882−001 Current sleeve
318 1 455 883−001 Spacer sleeve Ĭ 16/8.2x0.9

319 1 Washer Ĭ 16/8.4x1.5
320 1 Screw M8x20
321 1 455 881−001 Protection plate

322 1 2152 012−02 O−ring
323 1 455 898−001 Screw (M5x12)
324 1 Screw M4x12

326 1 193 104−002 Washer Ĭ 16/5x1
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 1 455 884−001 Gear housing

331 3 2121 107−42 Screw B12x16
332 1 469 380−881 Capacitor PME 0.1 µF 400 V, with cable lugs C3
333 1 455 892−001 Spacer sleeve
* = accessories
− 21 −
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WIRE FEED UNIT
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ESAB subsidiaries and representative offices
Europe NORWAY Asia/Pacific Representative offices

AUSTRIA AS ESAB BULGARIA
Larvik CHINA
ESAB Ges.m.b.H Shanghai ESAB A/P ESAB Representative Office
Vienna−Liesing Tel: +47 33 12 10 00 Sofia
Fax: +47 33 11 52 03 Shanghai
Tel: +43 1 888 25 11 Tel: +86 21 6539 7124 Tel/Fax: +359 2 974 42 88
Fax: +43 1 888 25 11 85 Fax: +86 21 6543 6622
POLAND EGYPT
BELGIUM ESAB Sp. z o.o. INDIA ESAB Egypt
S.A. ESAB N.V. Katowice ESAB India Ltd Dokki−Cairo
Brussels Tel: +48 32 35 111 05 Calcutta Tel: +20 2 390 96 69
Tel: +32 2 745 11 00 Fax: +48 32 35 111 20 Tel: +91 33 478 45 17 Fax: +20 2 393 32 13
Fax: +32 2 726 80 05 Fax: +91 33 468 18 80
PORTUGAL ROMANIA
THE CZECH REPUBLIC ESAB Lda INDONESIA ESAB Representative Office
ESAB VAMBERK s.r.o. Lisbon P.T. Esabindo Pratama Bucharest
Prague Tel: +351 1 837 1527 Jakarta Tel/Fax: +40 1 322 36 74
Tel: +420 2 819 40 885 Fax: +351 1 859 1277 Tel: +62 21 460 01 88
Fax: +420 2 819 40 120 Fax: +62 21 461 29 29 RUSSIA−CIS
SLOVAKIA ESAB Representative Office
DENMARK ESAB Slovakia s.r.o. MALAYSIA Moscow
Aktieselskabet ESAB Bratislava ESAB (Malaysia) Snd Bhd Tel: +7 095 937 98 20
Copenhagen−Valby Tel: +421 7 44 88 24 26 Selangor Fax: +7 095 937 95 80
Tel: +45 36 30 01 11 Fax: +421 7 44 88 87 41 Tel: +60 3 703 36 15
Fax: +45 36 30 40 03 Fax: +60 3 703 35 52 ESAB Representative Office
SPAIN St Petersburg
FINLAND ESAB Ibérica S.A. Tel: +7 812 325 43 62
Alcobendas (Madrid) SINGAPORE
ESAB Oy ESAB Singapore Pte Ltd Fax: +7 812 325 66 85
Helsinki Tel: +34 91 623 11 00
Fax: +34 91 661 51 83 Singapore
Tel: +358 9 547 761 Tel: +65 861 43 22
Fax: +358 9 547 77 71 Distributors
SWEDEN Fax: +65 861 31 95
For addresses and phone
FRANCE ESAB Sverige AB ESAB Asia/Pacific Pte Ltd numbers to our distributors in
ESAB France S.A. Gothenburg Singapore other countries, please visit our
Cergy Pontoise Tel: +46 31 50 95 00 Tel: +65 861 74 42 home page
Tel: +33 1 30 75 55 00 Fax: +46 31 50 92 22 Fax: +65 863 08 39
www.esab.com
Fax: +33 1 30 75 55 24 ESAB International AB
Gothenburg SOUTH KOREA
GERMANY Tel: +46 31 50 90 00 ESAB SeAH Corporation
ESAB GmbH Fax: +46 31 50 93 60 Kyung−Nam
Solingen Tel: +82 551 289 81 11
Tel: +49 212 298 0 SWITZERLAND Fax: +82 551 289 88 63
Fax: +49 212 298 204 ESAB AG
Dietikon UNITED ARAB EMIRATES
GREAT BRITAIN Tel: +41 1 741 25 25 ESAB Middle East
ESAB Group (UK) Ltd Fax: +41 1 740 30 55 Dubai
Waltham Cross Tel: +971 4 338 88 29
Tel: +44 1992 76 85 15 North and South America Fax: +971 4 338 87 29
Fax: +44 1992 71 58 03
ARGENTINA
ESAB Automation Ltd CONARCO
Andover Buenos Aires
Tel: +44 1264 33 22 33 Tel: +54 11 4 753 4039
Fax: +44 1264 33 20 74 Fax: +54 11 4 753 6313
BRAZIL
HUNGARY
ESAB S.A.
ESAB Kft
Contagem−MG
Budapest
Tel: +55 31 3369 4333
Tel: +36 1 20 44 182
Fax: +55 31 3369 4440
Fax: +36 1 20 44 186
CANADA
ITALY ESAB Group Canada Inc.
ESAB Saldatura S.p.A. Missisauga, Ontario
Mesero (Mi) Tel: +1 905 670 02 20
Tel: +39 02 97 96 81 Fax: +1 905 670 48 79
Fax: +39 02 97 28 91 81
MEXICO
THE NETHERLANDS ESAB Mexico S.A.
ESAB Nederland B.V. Monterrey
Utrecht Tel: +52 8 350 5959
Tel: +31 30 248 59 22 Fax: +52 8 350 7554
Fax: +31 30 248 52 60
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
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LKA 180

0349 301 002 040928 Valid for serial no. 618−xxx−xxxx

Downloaded from www.Manualslib.com manuals search engine

ELECTRIC SHOCK − Can kill

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

Downloaded from www.Manualslib.com manuals search engine

LKA 180 LKA 240 LKA 180 1−phase

Downloaded from www.Manualslib.com manuals search engine

LKA 180 LKA 240 LKA 180 1−phase

These welding rectifier conform to the requirements of IEC 974−1.

Downloaded from www.Manualslib.com manuals search engine

5.1 Electrical connection

TUBE WIRE SOLID WIRE

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Downloaded from www.Manualslib.com manuals search engine

6.1 Spot welding

8 ORDERING OF SPARE PARTS

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Spare parts list

Valid for serial no. 618−xxx−xxxx

Ordering numbers for LKA 180 , LKA 240

Ordering no. Denomination Notes

469 440−880 LKA 180 400 V 3 phase

469 450−880 LKA 240 400 V 3 phase

Downloaded from www.Manualslib.com manuals search engine

Item Qty Qty

101 1 1 469 368−001 Cover plate

107 1 − 0469 572 881 Return cable Complete

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WIRE FEED UNIT

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

306 1 455 896−001 Spring

308 1 469 397−001 Drive unit M1

311 1 466 074−001 Inlet nozzle

312 1 367 528−001 Pin bolt

314 2 368 750−001 Insulating sleeve

315 1 455 894−001 Insert tube

318 1 455 883−001 Spacer sleeve Ĭ 16/8.2x0.9

321 1 455 881−001 Protection plate

324 1 Screw M4x12

329 1 455 893−001 Shaft

330 1 455 884−001 Gear housing

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WIRE FEED UNIT

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Europe NORWAY Asia/Pacific Representative offices