GB
Valid for serial no. 011--xxx--xxxx0457 328 101 GB 041101
Aristotig 255
LTN 255
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 Control panel 8.............................................................
6.2 Other functions 10............................................................
6.3 Fault tracing 11..............................................................
7 MAINTENANCE 12....................................................
8 ORDERING OF SPARE PARTS 12......................................
DIAGRAM 13............................................................
ORDERING NUMBER 14.................................................
SPARE PARTS LIST 15...................................................
ACCESSORIES 16.......................................................
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1DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTN 255 from serial number 745 complies with standard
EN 60974--1, in accordance with the requirements of directive (73/23/EEA) and ad-
dendum (93/68/EEA) and standard EN 50199 in accordance with the requirements
of directive (89/336/EEA) and addendum (93/68/EEA).
-- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- -- --------
Paul Karlsson
Managing Director
Esab Welding Equipment AB
695 81 LAXÅ
SWEDEN Tel: + 46 584 81000 Fax: + 46 584 12336
Laxå 97--10--30
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
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 y our 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 y our ears. Use earmuffs or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
ESAB can p rovide 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
LTN 255 are rectifiers designed using inverter technology and are intended for TIG --
welding and welding using coated electrodes.
Inverter technology contributes towards low power consumption, a low weight and
compact dimensions.
The advanced electronics with microprocessor control provides, amongst others,
quick regulation and top class welding characteristics.
LTN 255 is equipped with ARC PLUS, a new type of control that with MMA welding
provides a more intensive, more concentrated and smoother arc. It reacts quicker
after a short circuiting drop transfer, which r educes the risk of the electrode sticking.
In addition, the machine is equipped with Arc F orce, which means that the power
source’s dynamics can be adjusted, softer or harder depending on the type of elec-
trode and the welder’s preference.
ARC PLUS -- because of the regulator’s good characteristics it is only necessary to
change the Arc Force settings in exceptional circumstances.
When drop welding using stainless steel electrodes a special feature on the machine
can be activated to facilitate welding.
LTN 255 is available in two designs, one with a central connector and one with an
OKC connector for a TIG torch.
LTN 255 issuppliedcompletewitha5metremainscable,5metrereturncable, gas
hose and hose clips. Machines with a central connector are also fitted with a safety
bar to protect the connectors from impact.
As an accessory there is a loop handle to fit on the machines which acts as a cable
reel as well protecting the control panel. There are also two carriages available for
transportation with a gas cylinder and cooling unit.
ESAB’s accessories for the product can be found on page 16.
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4 TECHNICAL DATA
Permittedloadat
35 % duty cycle, TIG 250 A/20 V
35 % duty cycle, MMA 250 A/30 V
60 % duty cycle 180 A/27 V
100 % duty cycle 140 A/26 V
Setting range, TIG 3--250 A
Setting range, MMA 4--250 A
Slope up 0-- 10 s
Slope down 0-- 10 s
Gas pre --flow 0-- 25 s
Gas post--flow 0-- 25 s
Pulse time 0,02--5,0 s
(0,001--5,0 s)
Pause time 0,02--5,0 s
(0,001--5,0 s)
Open --circuit voltage 70--80 V
Open--circuit power 40 W
Useful Power, P
at max current MMA 8,78 kW
Apparent Power, S
at max current MMA 13,3 kVa
Power factor, at max current MMA 0,65
Efficiency, at max current MMA 0,85
Fuse, slow rupture 16 A
Mains cable,cross section 4x1,5 mm
2
Dimensions lxwxh 515x285x415 mm
Weight 25 kg
Application class
Class of enclosures IP 23
The welding power sources comply with the requirements set out in IEC 974--1
Cable areas acc. to Swedish regulations.
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.
Application class
The symbol indicates that the power source is designed for use in areas with increased
electrical hazard.
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 b e executed by a profession al.
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.
Mains voltage 400 V ¦ 10 % , 3--phase
Mains frequency 50--60 Hz
Fuse, slow rupture 16 A
Mains cable, cross section 4x1.5 mm
2
Welding cable, cross section 35 mm
2
LTN 255 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 cur-
rent.
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!
8
45 32
1
9
610 11 12 7
1. Mains power switch 9. Gas nipple (connection of gas cylinder)
2. Yellow indicating lamp 10. Connection for TIG torch
3. White indicating lamp 12. Connection for return cable when TIG welding
4. Display
5. Setting knob The welding cable and return cable should be con-
t
d
t
1
1
d
1
2
6. Push--buttons
nected to 11 and 12
7. Remote control connection
8.Dustfilter
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. In addition, the error code ”E13” is displayed. When the temperature has
dropped the thermostat automatically resets.
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6.1 Control panel
On the front of the machine there is a control panel for the selection of functions and
setting of parameters. This consists of a display, setting knob, LEDs and push--but-
tons.
By using the push--buttons you can move between the different functions. The se-
lected function is indicated by respective LEDs coming on.
One line at a time is set. T he current line is indicated by a red LED. M ovement be-
tween lines takes place using the red arrow keys.
Movement within each line takes place using the green arrow keys.
All settings are made using the setting knob. The LEDs to the right of the display
indicate the actual unit (ampere/volt/seconds). On the lines where only a function is
selected, ” ------” is shown on the display.
Description o f the functions:
S Line 1
S Line 2
S Line 3
S Line 4
S Line 5
S Line 6
S Line 7
Line 1
TIG welding or MMA welding
If MMA welding is chosen, the current is set here and lines 2--5 are
ignored.
Line 2
TIG/HF ignition or TIG/Liftarc ignition
bt07t001
Place the electrode against the
workpiece.
Press in the torch switch.
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bt07d002
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bt19d12e
Tilt the torch a little, lift and an arc is
produced.
bt07t002
To stop--release
the torch trigger.
Line 3 Continuous current or pulsed current OO--O
Line 4 2 step or 4 step trigger action
2 step trigger action means that the arc is ignited when the torch
trigger is pressed in and is extinguished when the trigger is released.
4 step trigger action means that when the torch trigger is pressed in
”1” the machine starts with the pilot current and then slopes up to the
set current when the trigger is released ”2”. When the trigger is
pressed in again ”3” the machine slopes down to the pilot current. T he
arc is extinguished when the trigger is released ”4”.
bt07d003
Line 5 Parameter setting
1. Gas pre flow 0--25 s
2. Slope up 0--10 s
3. Pulse current or continuous current 3--250 A
4. Pulse time 0,02--5,0 s (0.001--5.0 s)
5. Pause current 3--250 A
6. Pause time 0.02--5.0 s (0.001--5.0 s)
7. Slope down 0--10 s
8. Gas post flow 0--25 s
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Line 6
Measurement instrument
Shows the welding current or arc voltage during the present welding
run.
The measurement instrument has a hold function that locks the
measurement value when the welding run is stopped.
Line 7
Welding data memory OO1O2O1--2O A
Four different sets of welding data settings can be stored in the ma-
chine’s memory, two for TIG mode and two for MMA mode.
The following can be stored:
TIG: selected option from line 3 (continuous or pulsed current) All set-
tings on line 5.
MMA: Welding current
The welding data memory is changed using the green arrow
keys.
Changes can also b e made by quickly pressing the torch trigger, re-
gardless of whether you are welding or not.
To activate the possibility of jumping between programs both the
green arrow keys should be pressed simultaneously.
When the jump function is activated an indicating lamp comes on.
O1--2 If the 4 step trigger action is selected, quickly pressing the
trigger will switch the welding data. The same thing applies in 2 step
trigger action if you are not welding. During welding, using 2 step
trigger action, you r elease the trigger momentarily to change the
welding data.
Aristotig has battery backup so that the settings remain in memory
even when the machine is switched of or disconnected from the
power supply.
6.2 Other functions
Drop welding (MMA)
Drop welding can be used when welding with stainless steel electrodes.
The technique involves the arc switching between igniting and extinguishing to allow
better control over the heat transfer. The electrode only needs to be lifted a little for
the arc to be extinguished.
The machine should be in the current setting mode when the function is activated.
Press both of the green arrow
keys simultaneously for 2 seconds and the
symbol ” --_--” indicates that the function is activated.
This mode remains active even if the machine is switched off. The machine is reset
for normal welding again using the same method and ”------” is then indicated on the
display.
Arc Force (MMA)
The Arc Force setting changes the machine’s dynamic. A softer or harder arc can be
obtained. The machine should be in the current setting mode when activating the
function by pressing the two red arrow keys simultaneously for 2 seconds. The
display shows a value between 0 and 100. The higher the value the harder the arc.
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Press one of the buttons and the power source returns to the normal operating
mode. The set Arc Force value remains. Different Arc Force settings can be stored in
the machine’s two sets of welding data memory.
Pulse time/Pause time (TIG)
Normally the setting range for these parameters is 0.02--5.0 s. Through pressing the
two green arrows simultaneously for 2 seconds, times down to 0.001 s can be set.
This extended setting range remains until the machine is reset using the same
method. When activating the function the machine should be in the mode for setting
the pulse time/pause time. Note that times below 0.250 s are displayed without the
decimal point.
Remote control
Using the remote control socket o n the machine the current can be remotely regu-
lated in TIG and MMA modes.
If pulsed current is selected in TIG m ode, it is the pulsed current that is remotely
regulated. T he set value from the remote control is shown on the display by stepping
to the position where the current should be set when not using the remote control.
Switching to the remote mode takes place automatically when the unit is connected.
This is confirmed by the LED coming on. O A
(NOTE! the pins L and M in the remote control’s connecting plug must be strapped
for automatic connection to take place).
NOTE!
When using FS002 the slope--up and slope--down times should be set to 0 sec.
6.3 Fault tracing
Error Codes
LTN 255 is equipped with integrated error m onitoring. If an error should occur then
an error code is displayed. T he error codes are as follows:
E01 Memory error, internal RAM
E02 Memory error, external RAM
E03 Memory error, EPROM
E04 Memory error, random test of battery backed up RAM
E05 Memory error, variable value outside limit in battery backed up RAM
E06 Low battery voltage
E10 Incorrect supply voltage 20 V
E11 Incorrect supply voltage --15 V
E13 High temperature, thermal switch protection
E14 Current --servo error
The error indications are shown if the machine is not able to maintain the set
current, for example, while MMA welding with an extremely long arc. The
indication should disappear after welding for a few seconds under normal
conditions.
If any of these error codes are displayed permanently or recur frequently the ma-
chine should be taken to an authorized ESAB service workshop to be rectified.
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bt19d12e
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, Aristotig 255 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.
bt07d109
Dismantling the filter.
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.
LTN 255 is designed and tested in accordance with the international and European
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.
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Edition 041 101
Diagram
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bt19e11a
LTN 255
Edition 041 101
Ordering number
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bt19o11a
Ordering no. Denomination Type Notes
0468 300 894 Welding power source LTN 255 400V 50/60Hz,
with central connector for TIG welding
0468 300 895 Welding power source LTN 255 400V 50/60Hz,
with OKC connector for TIG welding
0457 328 990 Spare parts list LTN 255
LTN 255
Edition 041 101
Spare parts list
-- 1 5 --
bt19s11a
Item
Qty Ordering no. Denomination
1 2 0441 819 001 Screw
2 1 0468 275 001 Grill
3 1 0468 519 001 Filter
LTN 255
Edition 041 101
Accessories
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bt19a11a
Trolley ............................
for 5 l gas cylinder
0468 530 880
Trolley ............................
for 10--50 l gas cylinder
0456 804 880
bt07t003
Protective handle for connections . . 0458 311 001
LTN 255
Edition 041 101
-- 1 7 --
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bt07t004
Tophandle ....................... 0468 305 880
For L TN 200 & L TN 255
CoolingunitOCF2L ..............
For LTN 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
LTN 255
Edition 041 101
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bt19a11a
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 ...................
MMA and TIG: current
0349 090 886
LTN 255: Return cable, 35 mm
2
(state the length when ordering) 0262 613 602...............
LTN 160 & LTN 200: Return cable, 25 mm
2
(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:
LTN 255 LTN 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 and remote control units can be found in separate brochures.
-- 1 9 --
p
ESAB AB
SE--695 81 LAXÅ
SWEDEN
Phone +46 584 81 000
www.esab.co m
031021
ESAB subsidiaries and representative offices
Europe
AUSTRIA
ESAB Ges.m.b.H
Vienna--Liesing
Tel: +43 1 888 25 11
Fax: +43 1 888 25 11 85
BELGIUM
S.A. ESAB N.V.
Brussels
Tel: +32 2 745 11 00
Fax: +32 2 726 80 05
THE CZECH REPUBLIC
ESAB VAMBERK s.r.o.
Prague
Tel: +420 2 819 40 885
Fax: +420 2 819 40 120
DENMARK
Aktieselskabet ESAB
Copenhagen--Valby
Tel:+4536300111
Fax:+4536304003
FINLAND
ESAB Oy
Helsinki
Tel: +358 9 547 761
Fax: +358 9 547 77 71
FRANCE
ESAB France S.A.
Cergy Pontoise
Tel:+33130755500
Fax:+33130755524
GERMANY
ESAB GmbH
Solingen
Tel: +49 212 298 0
Fax: +49 212 298 204
GREAT BRITAIN
ESAB 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
HUNGARY
ESAB Kft
Budapest
Tel:+3612044182
Fax:+3612044186
ITALY
ESAB Saldatura S.p.A.
Mesero (Mi)
Tel:+3902979681
Fax:+390297289181
THE NETHERLANDS
ESAB Nederland B.V.
Utrecht
Tel: +31 30 248 59 22
Fax: +31 30 248 52 60
NORWAY
AS ESAB
Larvik
Tel:+4733121000
Fax:+4733115203
POLAND
ESAB Sp.z.o.o
Warszaw
Tel: +48 22 813 99 63
Fax: +48 22 813 98 81
PORTUGAL
ESAB Lda
Lisbon
Tel: +351 1 837 1527
Fax: +351 1 859 1277
SLOVAKIA
ESAB Slovakia s.r.o.
Bratislava
Tel:+421744882426
Fax:+421744888741
SPAIN
ESAB Ibérica S.A.
Alcobendas (Madrid)
Tel: +34 91 623 11 00
Fax: +34 91 661 51 83
SWEDEN
ESAB Sverige AB
Gothenburg
Tel:+4631509500
Fax:+4631509222
ESAB International AB
Gothenburg
Tel:+4631509000
Fax:+4631509360
SWITZERLAND
ESAB AG
Dietikon
Tel: +41 1 741 25 25
Fax: +41 1 740 30 55
North and South America
ARGENTINA
CONARCO
Buenos Aires
Tel: +54 11 4 753 4039
Fax: +54 11 4 753 6313
BRAZIL
ESAB S.A.
Contagem--MG
Tel: +55 31 3369 4333
Fax: +55 31 3369 4440
CANADA
ESAB Group Canada Inc.
Missisauga, Ontario
Tel: +1 905 670 02 20
Fax: +1 905 670 48 79
MEXICO
ESAB Mexico S.A.
Monterrey
Tel: +52 8 350 5959
Fax: +52 8 350 7554
USA
ESAB Welding & Cutting Products
Florence, SC
Tel: +1 843 669 44 11
Fax: +1 843 664 44 58
Asia/Pacific
CHINA
Shanghai ESAB A/P
Shanghai
Tel: +86 21 6539 7124
Fax: +86 21 6543 6622
INDIA
ESAB India Ltd
Calcutta
Tel: +91 33 478 45 17
Fax: +91 33 468 18 80
INDONESIA
P.T. Esabindo Pratama
Jakarta
Tel: +62 21 460 01 88
Fax: +62 21 461 29 29
MALAYSIA
ESAB (Malaysia) Snd Bhd
Selangor
Tel: +60 3 703 36 15
Fax: +60 3 703 35 52
SINGAPORE
ESAB Singapore Pte Ltd
Singapore
Tel: +65 861 43 22
Fax: +65 861 31 95
ESAB Asia/Pacific Pte Ltd
Singapore
Tel: +65 861 74 42
Fax: +65 863 08 39
SOUTH KOREA
ESAB SeAH Corporation
Kyung--Nam
Tel: +82 551 289 81 11
Fax: +82 551 289 88 63
UNITED ARAB EMIRATES
ESAB Middle East
Dubai
Tel: +971 4 338 88 29
Fax: +971 4 338 87 29
Representative offices
BULGARIA
ESAB Representative Office
Sofia
Tel/Fax: +359 2 974 42 88
EGYPT
ESAB Egypt
Dokki--Cairo
Tel: +20 2 390 96 69
Fax: +20 2 393 32 13
ROMANIA
ESAB Representative Office
Bucharest
Tel/Fax: +40 1 322 36 74
RUSSIA--CIS
ESAB Representative Office
Moscow
Tel:+70959379820
Fax: +7 095 937 95 80
ESAB Representative Office
St Petersburg
Tel:+78123254362
Fax: +7 812 325 66 85
Distributors
For addresses and phone
numbers to our distributors in
other countries, please visit our
home page
www.esab.co m
/