ESAB LTN 160 User manual

Valid for serial no. 011--xxx--xxxx0468 290 101 GB 041101

Aristotig 160

Aristotig 200

LTN 160, LTN 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 Control panel 8.............................................................

6.2 OTHER FUNCTIONS 10......................................................

6.3 LIFTARC 11.................................................................

6.4 Error Codes 11..............................................................

7 MAINTENANCE 12....................................................

8 ORDERING SPARE PARTS 12..........................................

DIAGRAM 13............................................................

ORDERING NUMBER 15.................................................

SPARE PARTS LIST 16...................................................

ACCESSORIES 17.......................................................

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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 LTN 160/200 from serial number 628 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 1995--09--14

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

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 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

Aristotig 160 and Aristotig 200 are two rectifiers designed using inverter

technology and are intended for TIG -- welding and welding using coated electrodes.

The machines are also called LTN 160 and LTN 200. Inverter technology contributes

towards low power consumption, a low weight and compact dimensions.

The advanced electronics with m icroprocessor control provides, amongst others,

quick regulation and top class welding characteristics.

Arisotig is equipped with ARC PLUS, a new type of control that with MMA welding

provides a m ore intensive, more concentrated and smoother arc. It reacts quicker

after a short circuiting drop transfer, which reduces 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

electrode 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 we ld in g.

Aristotig 160/200 is available in two designs, one with a central connector and one

with an OKC connector for a TIG torch.

Aristotig 160/200 is supplied complete witha5metremainscable,5metrereturn

cable, 1 cable coupling, 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.

ESAB’s accessories for the product can be found on page 17.

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4 TECHNICAL DATA

LTN 160 LTN 200

Permittedloadat

35 % duty cycle, TIG 160 A/16 V 200 A/18 V

35 % duty cycle, MMA 140 A/26 V 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 3--160 A 3--200 A

Setting range, MMA 4--140 A 4--200 A

Slope up 0-- 10 s 0-- 10 s

Slope down 0-- 10 s 0-- 10 s

Gas pre --flow 0-- 25 s 0-- 25 s

Gas post--flow 0-- 25 s 0-- 25 s

Pulse time 0.02--5.0 s

(0.001--5.0 s)

0.02--5.0 s

(0.001--5.0 s)

Pause time 0.02--5.0 s

(0.001--5.0 s)

0.02--5.0 s

(0.001--5.0 s)

Open --circuit voltage 70 V 70 V

Open--circuit power 30 W 50 W

Useful Power, P

at max current MMA

4.8 kW 7.2 kW

Apparent Power, S

at max current MMA

6.9 kVa 11.7 kVa

Power factor, at max current MMA 0.69 0.63

Efficiency, at max current MMA 0.75 0.78

Fuse, slow rupture 16 A 10 A

Mains cable,cross section 3x2.5 mm

4x1.5 mm

Dimensions lxwxh 515x285x415 515x285x415

Weight 23 kg 23 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.

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 be execu ted by a p rofession 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.

LTN 160 LTN 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 mm

4x1.5 mm

Welding cable, cross section 25 mm

25 mm

*) When welding with max 100 A a 10 A slow rupture fuse is sufficient.

Aristotig 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!

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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-

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 m achine there is a control panel for the selection of functions and

setting of parameters. This consists of a display, setting knob, LEDs and

push--buttons.

By using the push--buttons you can move between the different functions. The

selected function is indicated by r espective LEDs coming on.

One line at a time is set. The current line is indicated by a red LED. Movement

between 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 a ctual unit (ampere/volt/seconds). On the lines where only a function is

selected, ”------” is shown on the display.

Description o f the fun ctio n s:

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

For a description of Liftarc ignition, see page 112.

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 m achine slopes down to the pilot current. The

arc is extinguished when the trigger is released ”4”.

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Line 5 Parameter setting

1. Gas pre flow 0--25 s

2. Slope up 0--10 s

3. Pulse current or continuous current 3--160 A alt. 3--200 A

4. Pulse time 0,02--5,0 s (0.001--5.0 s)

5. Pause current 3--160 A alt. 3--200 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

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

machine’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

settings on line 5.

MMA: Welding current

The welding data m emory is changed using the green arrow

keys.

Changes can also be made by quickly pressing the torch trigger,

regardless of whether you are welding or not.

To activate the possibility of jumping between pro grams 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. Th e same thing applies in 2 step

trigger action if you are not welding. During welding, using 2 step

trigger action, you release 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.

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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 m achine is reset

for normal welding again using the same m ethod 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. T he higher the value the harder the arc.

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 on the machine the current can be remotely

regulated in T IG and MMA modes.

If pulsed current is selected in TIG mode, 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.

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6.3 LIFTARC

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.

6.4 Error Codes

Aristotig 160/200 is equipped with integrated error monitoring. If an error should

occur then an error code is displayed. The 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

machine should be taken to an authorized ESAB service workshop to be rectified.

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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, Aristotig 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.

Dismantling the filter.

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8 ORDERING SPARE PARTS

Repair and electrical work should be performed by an authorized ESAB serviceman.

Use only ESAB original spare and wear parts.

LTN 160 / LTN 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.

Edition 041 101

Diagram

LTN 160

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Edition 041 101

LTN 200

-- 1 4 --

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LTN 160, LT N 200

Edition 041 101

Ordering number

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Ordering no. Denomination Type Notes

0468 300 800 Welding power source Aristotig 160 with central connector for TIG welding

0468 300 881 Welding power source Aristotig 160 with OKC connector for TIG welding

0468 300 802 Welding power source Aristotig 200 with central connector for TIG welding

0468 300 883 Welding power source Aristotig 200 with OKC connector for TIG welding

0468 300 884 Welding power source Aristotig 160 with OKC connector for TIG welding,

Only for Denmark

0468 290 990 Spare parts list Aristotig 160,

Aristotig 200

LTN 160, LT N 200

Edition 041 101

Spare parts list

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Item

Qty Ordering no. Denomination

1 2 0441 819 001 Screw

2 1 0468 275 001 Grill

3 1 0468 519 001 Filter

LTN 160, LT N 200

Edition 041 101

Accessories

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Trolley ............................

for 5 l gas cylinder

0468 530 880

Trolley ............................

for 10--50 l gas cylinder

0456 804 880

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Protective handle for connections . . 0458 311 001

LTN 160, LT N 200

Edition 041 101

-- 1 8 --

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bt07t004

Tophandle ....................... 0468 305 880

For LTN 200 & LTN 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 160, LT N 200

Edition 041 101

-- 1 9 --

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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

(state the length when ordering) 0262 613 602...............

LTN 160 & LTN 200: Return cable, 25 mm

(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.

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

ESAB LTN 160, LTN 160, LTN 200, LTN 200 User manual

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