LTO 160 valid for Serial NO 728 XXX--XXXX
LTO 250 valid for Serial NO 745 XXX--XXXX
0456 779 041 980902
MECHTIG 160
MECHTIG 250
LTO 160, LTO 250
105107106023104022041
Instruction manual
Betriebsanweisung
Manual d’instructions
Gebruiksaanwijzing
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Rights reserved to alter specifications without notice.
Änderungen vorbehalten.
Sous réserve de modifications sans avis préalable.
Recht op wijzigingen zonder voorafgaande mededeling voorbehouden.
ENGLISH 3..............................................
DEUTSCH 40.............................................
FRANÇAIS 78.............................................
NEDERLANDS 116.........................................
ENGLISH
TOCe
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1 DIRECTIVE 4........................................................
2SAFETY 4..........................................................
3 INTRODUCTION 5...................................................
3.1 General 5..................................................................
3.2 Technical data 6............................................................
4 INSTALLATION 7....................................................
4.1 General 7..................................................................
4.2 Placing 7...................................................................
4.3 Lifting instructions 8.........................................................
4.4 Mains voltage connection 8...................................................
4.5 Connection of a complete welding system 9....................................
5 OPERATION 10.......................................................
5.1 Genral 10...................................................................
5.2 Controls and connections 11...................................................
5.3 Overheating protection 12.....................................................
6 MAINTENANCE 12....................................................
6.1 General 12..................................................................
6.2 Check--up and cleaning 12....................................................
7 CONTROL BOX 13....................................................
7.1 The mode of operation of the control box 13.....................................
7.2 Actual tool codes 14..........................................................
7.3 Division into functional areas 14................................................
7.4 The SEL key 15..............................................................
7.5 The SET key 19..............................................................
7.6 The MEM key 22.............................................................
7.7 The OPE key 25.............................................................
7.8 Control of the process 29......................................................
7.9 The POB, POC tool 30........................................................
7.10 Storing sectors in the course of running 30.......................................
7.11 Associations within a sequential sector 31.......................................
7.12 Setting the memory to aero / basic parameter values 32...........................
7.13 Start/stop over external controls 32.............................................
7.14 The length of a transport sector 33.............................................
7.15 The influence of sector changes on pulsing 33...................................
8 ERROR MESSAGES 34................................................
8.1 Memory errors 34............................................................
8.2 Communictions errors 34......................................................
8.3 Errors in the course of welding 35..............................................
8.4 Errors in the course of sequential running 36....................................
8.5 Blocking messages 36.......................................................
9 ACCESSORIES 37....................................................
10 ORDERING SPARE PARTS 39..........................................
DIAGRAM 154............................................................
LIST OF COMPONENTS 158...............................................
SPARE PARTS LIST 161...................................................
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1 DIRECTIVE
DECLARATION OF CONFORMITY
Esab Welding Equipment AB, 695 81 Laxå, Sweden, gives its unreserved guarantee
that welding power source LTO 160 / LTO 250 from serial number 636 / 745 com-
plies with standard EN 60974-- 1, in accordance with the requirements of directive
73/23/EEA and addendum 93/68/EEA and standard EN 50199 in accordance with
the requirements of directive 89/336/ EEA and addendum 93/68/ EEA .
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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
Users of ESAB welding equipments have ultimate responsibility for ensuring that anyone who works
on or near the equipment observes all the relevant safety precautions.
Safety precautions must meet the requirements that apply to this type of welding equipment.
The following recommendations should be observed in addition to the standard regulations that apply
to the work place.
All work must be carried out by trained personnel who are familiar with the operation of the welding
equipment.
Incorrect operation of the equipment may lead to a hazardous situation which can result in injury to
the operator and damage to the equipment.
1. Anyone who uses the welding equipment must be familiar with:
S its operation
S its function
S relevant safety precautions
S welding
2. The operator must ensure that:
S no unauthorized person is stationed within the working area of the equipment when it is
started up.
S that no--one is unprotected when the arc is struck
3. The work place must:
S be suitable for the purpose
S be free from draughts
4. Personal safety equipment
S Always wear recommended personal safety equipment, such as safety glasses, flame--proof
clothing, safety gloves.
S Do not wear loose--fitting items, such as scarves, bracelets, rings, etc., which could become
trapped or cause burns.
5. General precautions
S Make sure the return cable is connected securely.
S Work on high voltage equipment may only be carried out by a qualified electrician.
S Appropriate fire extinquishing equipment must be clearly marked and close at hand.
S Lubrication and maintenance must not be carried out on the equipment during its operation.
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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 keep fumes and gases 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 ear defenders or other hearing protection.
S Warn bystanders of the risk.
MALFUNCTION -- Call for expert assistance in the event of malfunction.
PROTECT YOURSELF AND OTHERS!
3 INTRODUCTION
3.1 General
LTO 160 / LTO 250 is a transistor--controlled welding power source for TIG welding.
It is programmable and provided with a memory so that different welding programs
can be set and stored by means of a control box. The welding programs can be
divided into sectors with different sets of parameters. T he division into sectors is
time--controlled.
LTO 160 / LTO 250 has battery backup so that the settings remain in memory even
when the machine is switched off or disconnected from the power supply.
LTO 160 / LTO 250 is a machine of inverter type, which means that the mains
voltage first is rectified and then converted back to alternating current of very high
frequency. After this it is transformed to welding current.
Rectifier RectifierInverter T ransformer
Control system
The inverter principle makes it possible to control every sequence of the welding
process by means of electronics, which results in better welding properties.
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The LTO 160 / LTO 250 microcomputer is of type Siemens 805 15. It is programmed
to provide for optimal starting properties. The microcomputer supervises the welding
procedure and provides for the right static and dynamic qualities.
LTO 160 / LTO 250 is designed both for manual and mechanized welding, and as a
result it can drive the ESAB welding tools PRB, PRG, PRI, POB, POC and PRH. For
manual welding a TIG torch for OKC connection is used.
LTO 160 / LTO 250 is co mposed of th e follo win g u n its:
S Power module containing power units and control electronics. Here the
incoming mains voltage is transformed to high--frequency alternating voltage
which is then transformed to welding voltage.
S Control box for the selection of welding procedure (sequence or
non--sequence), HF or LIFTARC start, programming, parameter changes,
memory handling, sector classification, manual gas pre--flow, manual rotation,
manual wire feed, start and stop. The values for current and voltage are
continuously displayed on the control box during the welding process. T he
communication between the control box and the power source is very reliable
from interference point of view as the signals are transmitted via optical fibres.
(L=10m.)
3.2 Technical data
LTO 160 LTO 250
Mains voltage 230 V, 1 400 V, 3
Mains frequency 50--60 Hz 50--60 Hz
Permissible load at
35 % duty cycle
60 % duty cycle
100 % duty cycle
160 A / 16 V
110A/15V
80 A / 13 V
250 A / 20 V
180 A / 17 V
140 A / 16 V
No--load power 55 W 50 W
Power factor 0,68 0,61
Efficiency 0,70 0,80
Primary current at 100% duty
cycle
10 A 15 A
Dimensions L x W x H 515 x 285 x 505 mm 515 x 285 x 505 mm
Weight 32 kg 33 kg
Temperature class F (155 C) F (155 C)
Enclosure type IP 23 IP 23
Application class
Capacity of internal memory,
number of parameter sets
100 100
Battery back--up MECHTIG
160
2 years 2 years
Battery back--up Control box 2 years 2 years
Arc strike for tube welding
t
o
o
l
s
HF HF
t
oo
l
s
Arc strike for manual welding
HF and LIFT ARC HF and LIFT ARC
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Setting range
LTO 160 LTO 250
Pulse, background and cont.
current
3--160 A 3--250 A
Steps of adjustment, current 1A 1A
Wire feed speed 0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
0,10--2,20 m/min (MEI 20/21)
0.15--1.50 m/min (POB, POC)
Rotation speed 5--100 % of max. speed 5--100 % of max. speed
Pulse and background time 0.02--5.0 s 0.02--5.0 s
Pre--heat time 0--99.8 s 0--99.8 s
Gas pre --flow 1--250 s 1--250 s
Gas post--flow 3--250 s 3--250 s
Slope--up and slope down 0-- 25 s 0-- 25 s
Sector time 0.01--33.59 min 0.01--33.59 min
Steps of adjustment, sector
time
0.1 s 0.1 s
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 IP 23 is designed for
indoor and outdoor use.
Duty cycle
The duty cycle refers to the tim e in per cent of a ten--minute period that you can
weld at a certain load without overloading the welding power source.
4 INSTALLATION
4.1 General
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.
Installation must be carried out by a qualified electrician.
4.2 Placing
Place the machine so that there is nothing to prevent the cooling air from passing
through it.
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4.3 Lifting instructions
4.4 Mains voltage connection
The rating plate with production number and connection data is located on the rear
panel of the welding eqipment.
S Make sure the machine is connected for the correct mains voltage and properly
fused. Earth according to applicable directives.
LTO 160 LTO 250
Mains voltage 230 V 400 V
Mains frequency 50--60 Hz 50--60 Hz
Fuse, slow rupture 16 A 16 A
Mains cable, cross section 3x2.5mm
2
4x1.5mm
2
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4.5 Connection of a complete welding system
B--B Motor cable --wire feed
C--C Motor cable -- rotation
G--G Cooling--water hose in
H--H Cooling--water hose out
J--J Welding cable
L--L Torch contact
M--M Gas hose out
N--N Gas hose in
Q--Q Return cable +
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B--B Motor cable --wire feed
C--C Motor cable -- rotation
G--G Cooling--water hose in
H--H Cooling--water hose out
J--J Welding cable
L--L Torch contact
M--M Gas hose out
N--N Gas hose in
Q--Q Return cable +
5OPERATION
5.1 Genral
General safety regulations for the handling of the equipment appear from
page 4. Read through before you start using the equipment!
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WARNING!
Rotating parts can cause injury, take great care.
1. Make sure the welding and return cables and the welding tool are properly
connected.
2. Make sure there are no gas leaks.
3. Set the starting switch to position 1. The indicating lamp goes on to show that
mains voltage is supplied.
4. Set data according to instructions under CONTROL BOX
5.2 Controls and connections
1. Mains power switch
2. Indicating lamp thermostat (yellow)
3. Indicating lamp mains ( white)
4. Control box
5. Connection for return cable (+)
6. Connection for welding cable (--),
cross section 25 mm
2
7. Connection wire feed MEI 21, POC
8. Connection rotation PRB 17--49,
33--90, 60--170, PRH 6--40, 25--90,
POC
9. Connection wire feed MEI 20, POB,
PRI
10. Connection rotation PRB 9--20,
18--40, 36--80, 71--160, 140--220,
PRG, PRI, POB
11 . Connection for cooling unit 230 V,
1.25 A
12. Connection for shielding gas
13. Connection for remote start -- TIG
torch
14. Mains cable
15. Gas nipple, connection of gas bottle
16. Control box cable
17. Fuse, slow rupture 1.25 A
(connection 230 V)
18. Connection for flow--guard
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5.3 Overheating protection
The machine 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.
6 MAINTENANCE
6.1 General
Note:
All su p p lier guarantees will exp ire if the cu sto mer himselft during the
guarantee p eriod takes measures in order to order to remedy an error in the
machine.
6.2 Check--up and cleaning
Generally LTO 160 / LTO 250 does not require any maintenance. Normally, it is
sufficient to blow out the machine using clean, compressed air (reduced pressure)
annually, and the dust filter should be cleaned regularly. If the machine is set up in
dusty or dirty environment the m achine and the dust filter should be cleaned more
often.
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7 CONTROL BOX
7.1 The mode of operation of the control box
The process equipment is continuously updated via the control box.
A central unit in the control box is the working storage where all actual values
regarding methods and parameters are collected.
The working storage always contains a complete set of values for the process.
The whole working storage can be stored in a larger storage area, the library,which
holds up to 100 parameter sets from the working storage.
Each parameter set in the library forms a sector.
(The reason for naming it sector is the following: A parameter set r ecalled to the
working storage supplies the process with data within the geometrical sector
described by the rotation during the time entered.)
The contents of the working storage can be influenced by:
S changing separate parameters
S recalling a sector (the whole working storage will b e o v erwritten)
The contents of the library can be influenced by:
S storing a sector
S erasing a sector
The contents of the working storage and the library normally remain from operation
to operation (owing to battery backup).
A sector can be either of the weld or transport type and they can be mixed
arbitrarily. A transport sector can only cause rotation, according to the entered data
for direction, speed and time, (no welding parameters are available).
Within each sector sequential or non--sequential running is indicated.
Sequential running:
When running a sequential sector, the sector values control the process during the
time entered into the sector. Then the nearest higher sector is automatically recalled
from the library (blanks are permitted). The sequence keeps running till an end
sector is found. When this in other respects quite normal sector has run to its end,
the sequence is terminated and the start sector which started the sequence is
automatically recalled. We have come to the starting--point of a new identical
sequence.
Any sequential sector can serve as a start sector. There is nothing in the contents of
the sector to indicate start sector information. Instead the start sector concept is
associated with the sector where the last sequence started.
The end sectors, however, are pre--defined by the fact that they contain a special
parameter for this.
Any number of end sectors can exist in the library. (In the extreme case 100 different
end sectors are possible, corresponding to an equal number of sequences
consisting of one sector.)
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The concept of welding program can be identical with a sequence of sectors. A
welding program is r e called by manually recalling the sector which is to constitute
the start sector.
Non--sequential running:
The sector values control the process until the running is interrupted manually. A
desired sector change before the next start is executed manually. The concepts of
start and end sector have no significance here.
7.2 Actual tool codes
Welding to ol Size Code
A21 PRB 9--20, 18--40, 36--80,
71--160, 140--220,
17--49, 33--90
PRB
60--170 PRB 60--170
A21 PRH 6--40, 25--90 PRH
A21 PRG 25--45 PRG
A21 PRI 36--80, 71--160, 140--220 PRI
A22 POB 12--60 POB
A22 POC 12--60 POC
7.3 Division into functional areas
All handling of the control box takes place within four functional areas, r epresented
by the main keys SEL (select), SET (set), MEM (memory) and OPE (operate):
METHOD SELECTION SEL S Select welding method in the
working storage.
SETTING SET S Enter weld and transport data into
the working storage.
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MEMORY HANDLING MEM S Store the contents of the working
storage in an empty storage
area.
S Recall previously stored data to the
working area.
S Erase previously stored data in the
working area.
OPERATION OPE S Start welding/transport or manual
functions.
The main keys are described in separate chapters. The function of the other keys
appears from these chapters.
7.4 The SEL key
SEL is one of the four main keys of the control box.
Under SEL the method is selected.
Four different selections are possible, distributed on each one level on the display.
All method selections are available under two pictures:
Level 1, select method: SEQUENCE/NON SE-
QUENCE
Level 2, select type of current: PULSED CURR./
CONT.CURR/. /TRANSP. SECTOR
Level 3, select starting method: HF--START/LIFTARC
Level 4, select tool: POB/PRI/PRB/PRG
The contents on the four lines together determine the actual method (irrespective of
the location o f the square brackets). The brackets mark a line where changes can be
made.
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(In the exemplified method selection above, the start values selected by ESAB have
been used.)
It is not possible to reach the SEL mode when an activity is going on!
Proceedings under SEL
An overview of keys having significance in the SEL mode. T he SEL mode can be
quitted by way of the other three main keys.
The active keys are described below.
Select level by moving the brackets with the level
keys:
(You can step up and down between the four levels.
The pictures change automatically. Nothing regarding
the method can be changed using these keys What
you read is what already applies.)
Select alternative within the respective level using:
(The alternatives come up cyclically within each level.
When an alternative comes up it is also selected.)
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SEL -- Example 1
A non--sequential method is to be selected.
SEL -- Example 2
A transport sector is to be selected.
[
]
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SEL -- Example 3
A POB tool is to be selected.
[
]
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7.5 The SET key
SET is one of the four main keys of the control box.
Under SET the setting of welding and transport parameter values takes place.
Under SET the parameters are shown in pairs, one on each line on the display, for
example
The actual parameter set is the result of the selections made under SEL with regard
to:
S PULSED CURR./CONT.CURR./TRANSP. SECTOR
S SEQUENCE/NON SEQUENCE
Possible sets of parameters are shown later in the text.
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Proceedings under SET
An overview of keys having significance in the SET mode. The SET mode can be
quitted by way of the other three main keys.
The active keys are described below.
Change parameter pictures using the level keys:
(By means of these keys you can r ead all existing
parameters in the actual parameter set.)
Set the values for the parameters shown using the four
increase/decrease keys:
(For + and YES, use the increase key and for -- and
NO the decrease key.)
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